SF06.MachineSafetySolutionsOverview
Contents
1. gt POWERED BY WERNER ELECTRIC Om Mumaties Zone Safety https www voutube com watch v x4TAVU20el You can see this technology at work in booths 705 and 804 in the tradeshow area CO Alternative Safety Means mm OO 2 18 6 a 6 6 i ElectroGuard Systems Trapped Key Systems Sometimes tradition safeguarding methods are not enough or cannot meet the environmental requirements so there are additional methods that can be used POWERED BY WERNER ELECTRIC han riaht OO INNO Drrlumall Arttamatinn Inc All riahte racariiatd ElectroGuard System Description amp Uses CO O oJ o ef a a a a What is an ElectroGuard system Itis a energy control and isolation solution that provides a systematic method of control An ElectroGuard system uses safety rated contactors safety rated pneumatic valves and safety rated hydraulic valves to isolate the energy sources Pressure switches and voltage meters are used to verify that the energy sources have been removed and safety relays to verify that the correct actions have been taken Where do you use ElectroGuard systems ElectroGuard systems are used in areas where lock out amp tag out are complex spread out distributed or takes multiple steps POWERED BY WERNER ELECTRIC Canvuriasaht CF JNNAQ Drrlumall Arttamatinann Inc All riahte racariiatd Trapped Key System Description amp2. Machine Safety Solutions Overview SOLUTION EXPO vii A N Welcome During this session we will discuss various types of safety devices available for machinery safety solutions to prevent access to or control a hazard We will include products from Rockwell Automation Numatics and Paletti Rockwell ST TT d Additional discussion is available in these sessions e SFO1 Risk and Hazard Assessment e SFO2 Introduction to ISO 13849 e SFO4 Guard Interlocking Update ref ISO 14119 e SFO5 Configurable Safety Relay Lab with 440R CR30 POWERED BY WERNER ELECTRIC Ga A machine control strategy that includes both safety and production control systems e Purpose of production system is to produce e Purpose of safety system is to protect In the past safety and production control systems shared little if any information Harmonizing your safety and production control systems offer tremendous opportunities to improve productivity Shared diagnostics on common HMI for faster troubleshooting e Safety system that changes parameters based on the state of the production system e Zone control to enable continued production flow when one zone is shut down e Better shut down and restart of production systems after a safety event Control Operating ka Equipment kejt Safety o System 1 A N When do you select hardware 1 Risk Assessment 5 Maintain and Improve ISO 12100 ISO 13849 2 ANS
3. Uses CO What is a trapped key system It is a safety solution that uses keys to ensure a that energy sources and access points are isolated prior to access The trapped key system uses a seguence of captive keys switches valves interlock devices and simple control solutions to isolate energy sources How do trapped key systems work Trapped systems use keys that are captive when the isolation device is in the on position Keys can only be removed when hazardous energy is removed How can trapped key solutions handle complex system reguirements Trapped key solutions use a building block approach POWERED BY WERNER ELECTRIC CAAurioht OO DAOA Drrlumall Arttamatiann Inc All rishte racariiatd Ai Common Terminology e rapped Key Interlock also known as key transfer systems e Primary Keys free at the start of a sequence e Secondary Keys trapped at the start of a M ence UIL Primary A _ _ L SA y oe n JA NE dg 2 TI ed by af SAY 4 m D y R 2 li KS y A gt y GA Primary gt Key POWERED L Copyright 2012 Rockwell Automationy Inc All rights reserved VER ELECTRIC JE s SE SE i a a aa Start Seguence Devices e Start Sequenc Rotary Switches E Solenoid Release an I a I I rosare d Rotary Key Switch i o w Enclosure Panel Mounted laam MRKSE10 20amp 4ni aj yste m J 40T MRPSE10 20
4. 4 LEDs both sides G Global approvals Slim clean design sealed body IP69K POWERED BY WERNER ELECTRIC AA LA N Solid state safety design e With the solid state design these can be connected in series with other devices such as Light Curtains and SensaGuard switches while maintaining a PLe rating Exceeds requirements of ISO TR 24119 referenced in the new EN ISO 14119 2013 standard Short circuit protection e Overload protection e Cross fault channel to channel detection e Designed to switch DC powered devices Supports switching of up to 200 mA POWERED BY WERNER ELECTRIC AN A N Hinge Operated Interlocks Bulletin 440H e Connect directly to a guard door hinge and allow immediate opening of the guard e Provides good clearance due to unobtrusive mounting e Well suited for machines where product is loaded through a hinged guard e Ideal for machines with misaligned guards or applications with contaminants POWERED BY WERNER ELECTRIC N Limit Switch Interlocks Bulletin 440P Available in four different body styles with a broad selection of operators circuit arrangements and connection options 30 mm metal 22 mm metal and plastic and 15 mm plastic body styles Positive opening action contacts making them ideal for safety related applications POWERED BY WERNER ELECTRIC 7 d Safety Interlock Guidance Type of Guard Recommended Switch Type Pr L
5. high costs of rewiring e Innovative safety logic editor reduces the friction involved in setting up a safety system b minimizing manual input for a best in class configuration experience Safety 8 Productivity e Embedded serial port for direct diagnostic communications to PanelView Component terminals or Micro800 controllers e 16 user configured status LEDs allow you to tailor indication to best suit your a p pl icat I O A File Edit View Debug Tools Communications Window Help i JI Id 4 I pi As MS Optimize Panel Space SELF N lai GUARDMASTER CRIO Logic x Rea e Quick Tips e 22 Safety I O in a compact 110mm wide housing e e Expand by up to 16 standard I O using front mounted plug in slots that allow i di 4 i D you to maintain the 110mm horizontal footprint sm Part of the Connected Components Workbench Bundle A e Preferred compatibility within the bundle E 0 a O Emerg f a lee e e Reduced supply chain costs e One software supports Guardmaster 440C CR30 Micro800 controllers PovverFlex drives Kinetix 3 servo drives and PanelView Component terminals POWERED BY WERNER ELECTRIC Guardmaster 440C CR30 e Easy to Use e Single Wire Safety support Innovative rapid configuration editor A single wire to expand safety IO e 2080 Plug in support Expansion of standard I O Serial Port for Diagnostics Muting Sensors Esedback Monitoring PanelView Component
6. or on M Micro800 a on POWERED BY WERNER ELECTRIC 4 N When do use Safety PAC s Where a safety relay or controller isn t quite enough Some complex logic required Light curtain muting plus enable pendant for a zone Multiple safety zones 3 or more Distributed safety I O required Where a new machine is being built Safety Motion and standard I O can be controlled by one controller When a modular amp scalable system is needed When the system has complex needs When a large area footprint is to be safe guarded poweRED BY WERNER ELECTRIC GuardLogix Safety Integration Logix Integrated Safety Dual Processor Solution 1002 Architecture 1002 is recognized as the best safety architecture SIL 3 Certification per IEC 61508 ISO 13849 Performance Level e Category 4 Programs with RSLogix5000 e Extensive suite of certified safety application instructions Simplifies design validation maintenance Dual Channel Suite Muting amp Press Suite CIP Safety for safety rated interlocking or safety I O on Ethernet POWERED BY WERNER ELECTRIC What type of device needs to be isolated What type of power needs to be isolated What is the current requirements of the output device Where are the outputs located Is speed control needed Is position control needed Is signal control needed Hardwired or network control Oo NAM PF WN bb On machine quick disconect s
7. E pili a m meid amry Tongue J i Va Guard Locking s kaari V V V Hing V r Depending on mounting POWERED BY WERNER ELECTRIC A N Non Separating Methods Pressure Sensitive safety systems This includes safety mats and safe edges Chequer pattern side 1 Straight rib pattem side 2 for maximum anti slip for ease of cleaning in i SM Heavy Duty Ribbed Vinyl e Upper Conductive Plate amp f Non condurtive Compressible Separ Lower Conductive Plate hygiene applications Heavy Duty Ribbed Vinyl Flexible Sealing Bead Electro Sensitive safety systems This includes light curtains area scanners and Safety cameras INI POWERED BY WERNER ELECTRIC Pressure Sensitive Devices Safedge Safety Edges Specially hardened steel plate construction Active sensing over entire mat surface Four wire system for fault detection Minimum detection weight of 66 Ibs Variety of aluminum trim options Special sizes and shapes are possible IP67 Conductive rubber profiles 5mm 19 mm or 41 mm 0 19 in 0 74 in or 1 61 in cushion factors available 50 m 164 04 ft maximum lengths Variety of profile shapes IP65 poweRED BY WERNER ELECTRIC CO GuardShield Type 4 Light Gurtains SH La cali 14 Md 2 3 Ss aM pT nea Sodi PIOAIUS DIPTIED hier pare pa Advanced features and functionality e Range 16
8. ED BY WERNER ELECTRIC 7 d Other Non Separating Devices Localized safety systems such as emergency stop pushbuttons pull cords two hand control stations and emergency switching off devices v Movable safety systems such as enabling switches and pendants POWERED BY WERNER ELECTRIC NEW Mobile Vlevv A new portable tethered EOI device e HMI Applications with line of sight requirements e Setup calibration activities where an operator needs to be in close proximity to application with access to HMI e Applications requiring local safety functionality through E STOP or enabling switch Maintenance applications POWERED BY WERNER ELECTRIC HA f x Identify Component 8 Block Diagram Typical safety function diagram j I Koela OUTPUT SOLVING i Sensing element Control element Final element or actuator e The designer shall select an architecture that will meet the needs of the safety function Category B 1 2 30r4 POWERED BY WERNER ELECTRIC Performance Level Category or SIL level reguirement Functional Reguirements Control reguirements System size footprint System complexity Logic Reguirements Process complexity Zoning requirements Safety Monitoring Diagnostics Information Needs SHA 0 Te Documentation Validation Reporting 10 Cost Ga Goal The process of specifying and selection of safety systems to deliver compliant machiner
9. I B11 0 ANSI B11 0 4 Installation Verification l l 2 Functional Requirements and Validation M ISO 13849 2 Specification ANSI B11 19 ISO 12100 3 Design and Design Verification ANSI B11 0 ISO 13849 1 ANSI B11 19 POWERED BY WERNER ELECTRIC AA N Risk Assessment Overvievv Refer to SFO1 Risk and Hazard Assessment for more information on this process POWERED BY WERNER ELECTRIC AA N Risk Reduction Overvievv titan d Refer to SFO1 Risk and Hazard Assessment for more information on this process POWERED BY WERNER ELECTRIC LA d SRP CS Design Overview e m O Validation POWERED BY WERNER ELECTRIC 7 Ga The Safety Reguirements Specification SRS is a formal document which describes the various safety functions and provides all of the required information an engineer vvill need to design the control system to perform the safety functions The SRS is considered a living document and shall have provisions for revision control and document management The validation protocols for testing the safety functions are derived from the SRS The SRS should include the follovving Description of the function environmental requirements response times operating modes fault handling reguirements diagnostics safe parameters fault exclusion failure modes etc Ga Once the Safety Functions have been identified and defined there are six basic steps required to determine t
10. amp Anto IT MRKSE11 20amp 2n 0 2 2rjfe e Key Control Element rea pesa Key Exchange Units gn e Guarded Area Access Devi Ces Key Control Element Bolt Lock a fo enable gate to be opened single key unit for partial body access only Access Locks a Guarded Area 440T MEEXE11 3 Way Exchange unit 1 key in 2 keys out 440T MEEXE 12 4 Way Exchange unit 1 key in 3 keys out Slam Locks Access Devices 440TMKEXE13 5 Way Exchange unit 1 key in 4 keys out e Specialty Devices Electronic Timed Delay Unit Stopped Motion Unit na eS Mini Valve Locke TT Switchgear Adaptors Rotate amp Remove Gafe Key sm to enable gate to be opened dual key unit for full body access Dual Key mi Lock or Ghain Lock 440T MDALE10 Dual Key Access Interlock 440T HDGLE10 Key Chain Interlock Single Key RIS Lock o r Chain i T Rotate Remove Personnel Key to be taken into hazardous area to prevent accidental machine start up n e el a ee J Alternative Gate Lock I I I I I I I aso ERA BO Kby Boltlock Omm procen Single Key Slambock shown with std actuator Dual Key Boltlock rr SSOT NDELE14 Dual Key L Dm Projaction 1 Copyright 0 2012 R an Application Example e Customer has two gates that need to be accessed On occasion both gates will need to be accessed at the sam
11. e POWERED BY WERNER ELECTRIC Ga Mechanical and design engineers are integral to the safety process and often the most capable to prevent a hazard Selection of technology Is the technologyf device inherently dangerous or safe Can an alternative technology be used Placement or orientation vvithin the machine Can the hazard be mitigated by redesign Physical characteristics Can a hazard be mitigated through the design of parts CO Design it out Fixed enclosing guard Controlling Limiting or Monitoring Access Awareness Means Training and Procedures Administrative Personal protective equipment Risk Reduction Hierarchy Most Effective gt Least Effective POWERED BY WERNER ELECTRIC 7 N Safeguard Requirements e Prevent contact Prevent worker s body or clothing from contacting hazardous moving parts e Secure Safeguards are firmly secured to machine and not easily removed require use of tools e Protect from falling objects No objects can fall into moving parts POWERED BY WERNER ELECTRIC Ga Separating e Non Separating Fixed fences 8 barriers Mechanical detection devices require a tool for removal e Safety Mats Moveable guarding types e Pressure Sensitive Edges Electro Sensitive Devices reguire interlock switches e Light Curtains e Area Scanners require safe distance calculation Localized protection devices e Em
12. e time e One gate will allow full body access e One gate will only allow top body access reach in with hands e Power must be removed from the hazards prior to opening either gate i Sh Sh ah DN M a a n co E A i a e s lt N x n n M AN n Di gt e n M Ma n n Lo gt POWERED BY WERNER ELECTRIC Copyright 2012 Rockwell Automationy inc All rights reserved
13. ergency Stops Two Hand Control Moveable protection devices e Enabling Switches LA N Separating Guarding Examples Fixed H SUNAINA Separating guards provide a physical separation from machine hazards Moveable Guarding POWERED BY WERNER ELECTRIC Separating Guard Criteria e Is access needed to the protected area e How often is access needed e Vhat is the hazard e How long does it take the hazard to stop e Vho needs access to the hazardous area e Vhy is access needed POWERED BY WERNER ELECTRIC Paletti Guarding Solutions POWERED BY WERNER ELECTRIC J Bulletin 440K Tongue Operated Interlocks Provide electrical interlocking of a machine s control circuit to the guard door Offering flexible keys for enhanced tolerance to misalignment to meet a wide range of applications Available in a variety of packages contact configurations and degrees of holding force Easy to install and cost effective POWERED BY WERNER ELECTRIC Bulletin 440N Non Contact Interlocks Requires no physical contact with the actuator No contact between sensor and actuator helps reduce risk of debris contamination Large sensing field helps compensate for door misalignment Types RFID coded standard amp unique and magnetically coded POWERED BY WERNER ELECTRIC A N SensaGuard The next generation of non contact switches using RFID technology for coding and inductive
14. he Performance Level Step 1 Determine the required performance level PLr 4 N Performance Level Required The Risk Assessment determines the Performance Level required PLr Creates the Foundation of the Safety System Functional Requirements System Design and Validation Protocol Shows Due Diligence and compliance to standards Performance Contribution to Level PLr Risk Reduction P1 F1 so Low Si Pi Task Hazard F2 P2 P1 F1 P2 P1 S2 F2 P2 S Severity F Frequency or Duration of Exposure P Avoidance Probability High POWERED BY WERNER ELECTRIC Ga Once the Safety Functions have been identified and defined there are six basic steps required to determine the Performance Level Step 2 Identify the SRP CS Components 8 Design Block Diagram f x Identify Component 8 Block Diagram Typical safety function diagram i i LOGIC output A i SO AV I ME I i _ Sensing element Control element Final element or actuator The designer shall select an architecture that will meet the needs of the safety function Category B 1 2 30r4 POWERED BY WERNER ELECTRIC CO Design it out Fixed enclosing guard Controlling Limiting or Monitoring Access Awareness Means Training and Procedures Administrative Personal protective equipment Risk Reduction Hierarchy Most Effective gt Least Effectiv
15. m e Integrated laser alignment e Finger 14 mm or hand 30 mm detection e Cascadeable e IP65 standard IP67 kits available i it E ON OFF functionality standard Range 9 m to 30m Integrated laser alignment Finger 14 mm or hand 30mm detection IP65 poweRED BY WERNER ELECTRIC NEW 5C300 Safety Camera e Compact Safety Camera Up to 2 meters e Expansion of safety light curtain portfolio e One size fits all solution e No software needed e Easy commissioning with teaching e 24Vdc 20ms response time IP54 e Performance Level d PLd ISO 13849 e SIL 2 IEC 61508 e Type 3 IEC 61496 POWERED BY WERNER ELECTRIC Presence Sensing Guidance Hr 4 broj Ej a if Capita SS Ss RT H Tee Png Senne M Ne af ve KN Uu 1 di A GJEJ E S P SS JES N Pa SaO Na S OESE RE LEI F SES EE ES ES SJ SI amp ETRE SAI ATG Finger Detection Hand Detection y T Whole Body Detection Simple On Off Point of Operation Control POC Point of Access Control PAC Area Access Control AAC cui Blanking MI Floating Blanking el Je f Integrated Laser Alignment CNN nm Beam Coding ii N SH I External Device Monitoring EDM e e Lej jetet el Manual Restart Si M Auxiliary Output elel Cascading Single Light Curtain can safeguard two adjacent points of entry Muting eal an external module MSR42 or MSR22LM POWER
16. olution 10 Cost Safeguarding Output Solutions e Safety output devices include a number different technologies amp solutions that include Safety Contactors Safety Variable Frequency Drives VFD s Safety Servo Systems e Safety output devices could also include several wiring methods Hardwired safety systems Networked safety systems On machine quick connect systems POWERED BY WERNER ELECTRIC Safety Contactors lt OR io E DELI e Mechanically linked positively guided and Mirrored contacts e Feedback circuit for safety integrity Range of power ratings dt resa t E i Rehana PowerFlex AC drives rl PowerFlex AC drives with optional integrated safety functions Advanced safety functions in PowerFlex 750 series AC drives May replace the need for safety contactors Remove torque without powering down machine Restart machines faster Kinetix Servo drives Kinetix 6000 with optional integrated safety functions Safe Torgue Off and advanced safety Remove torque without powering down machine Restart machines faster Pneumatic and Hydraulic Systems These valves meet Cat3 and Cat4 requirements and are used in safety solutions to control pneumatic amp hydraulic hazards POWERED BY WERNER ELECTRIC 4 N Numaitcs Zone Safety Series 503 valves with G3 communications gt LI TUMATICG ze
17. technology for sensing e Safety certified to PLe and Cat 4 e EN ISO 13849 1 e EN ISO 14119 2013 Solid state design and monitored outputs allows series connections e Scalable protection with Unique or Standard coded RFID actuators e Plastic or stainless steel housing IP69K washdown rating e High tolerance to misalignment e Output Diagnostic LED on the sensor POWERED BY WERNER ELECTRIC A 7 LA N Guard Locking interlocks Bulletin 440G Provide electrical interlocking of a machine s control circuit to the guard door Ideal for applications that require a guard door to remain closed and locked until potential hazards have stopped or come to a predetermined safe state Cost effective solution for protecting machines from interruptions in production POWERED BY WERNER ELECTRIC CO Safety certified to PLe and Cat 4 EN ISO 13849 1 EN ISO 14119 2013 r Solid state design and monitored outputs Scalable protection with Unique or Standard coded RFID actuators High holding force of 1300N Fzh Energy Efficient Device only uses 2 5W IP69K rated housing design Power to Release and Power to Lock versions Compact design optimized for ease of mounting Diagnostic info provided with 2 bright 270 LEDs Guardmaster 440G LZ L Actuator Metal holding bolt inserts into the metal bracket and sensor assembly Bar code with URL link to User Manual LEDs both sides
18. y to meet safety standards Challenge Deliver a compliant system vvithout compromising the production capability and flexibility of the overall system Deliver a system vvith capability for expansion and upgrading Deliver a system vvith global support capability Deliver a system vvith adaptability and scalability Design for Recovery Minimize MTTR Downtime or Service time 7 N Guardmaster Safety Relays Universal Input e Asingle catalog number to support all types of safety components including e stops switches mats and light curtains e Six part numbers will cover a majority of safety applications with consistent wiring Single Wire Safety Connection e T V approved concept of one wire connection to expand and cascade safety functions to SIL3 e Simplifies wiring e Maintains PLe SIL3 rating EtherNet IP Interface Dual Input Modules Provides status communication with Logix e Twice the functionality of a standard relay PAC eliminating multiple wiring ina 22 5mm housing terminations Scalable platform to address single and multi zone applications for a variety of standard and special functional reguirements POWERED BY WERNER ELECTRIC Guardmaster 440C CR30 Safety made Simple amp Flexible PR s e Supports four to nine dual channel input circuits and up to five safety output zones e Flexible configuration allows you to re engineer and rapidly integrate application withou having to incur
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SF06.MachineSafetySolutionsOverview