SAFI250 Machine Safety. Introduction

SAFI250 Machine Safety Introduction

Course Objectives Participant will: Explain safety categories Define SIL and PL Identify safety opportunities Discuss product options Setup basic operation of products

Module objectives At the end of this module the participant will: Explain the risk management aspects of machine safety Define the role of the standards used for applying machine safety

White paper Unfamiliarity with Standards, Device Integration Tops List of Machine Safety System Concerns for Machine Builders by Dave Collins Over 3000 people responsible for machine safety

66% anticipate using more safety products 55.8% not aware of safety categories 68% not aware of PL 61% did not know they needed to meet SIL

Safety Market Survey

Processes and Machines Linking functional islands and machines Machine/Process Safety Inputs and outputs signal processing Emergency stop by control Disconnection of power supply Initialization and control of hazardous movements Restricted access to hazardous zones Disconnection of power supply

Standards and architecture

Module objectives At the end of this module the participant will: Define the standards involved with machine safety Define terms associated with the standards specifically Safety Integrity Level (SIL) and Performance Level (PL) Explain methods to determine appropriate SIL and PL Outline the process for determining PL

Managing risk Residual risk Tolerable risk EUC risk Necessary risk reduction Increasing risk Actual risk reduction Practical risk covered by other technology safety-related systems Practical risk covered by E/E/PE safety-related systems Practical risk covered by external risk reduction facilities Risk reduction achieved by all safety-related systems and external risk reduction facilities

Functional Safety Sector specific standards for Process Industry and Machines Safety of Systems and Equipment IEC 61508 Functional safety of electrical / electronic / programmable electronic safety-related systems EN 954-1 Safety related parts of control systems Process Machines Software IEC 61511 IEC 61508-3 IEC 62061 EN/ISO 13849-1 Standards highlighted in red are International standards

IEC 61508 Seven part standard for complex subsystems (e.g. products) and systems SIL Systems/devices can be classified as two types Safety of Systems and Equipment IEC 61508 Functional safety of electrical / electronic / programmable electronic safety-related systems Process Software Machines EN 954-1 Safety related parts of control systems IEC 61511 IEC 61508-3 IEC 62061 EN/ISO 13849-1 Low complexity or simple systems: Failure modes are 100% known Complex All failure modes not known Complex equipment must comply with IEC 61508 and is responsibility of the component manufacturer.

EN 954-1 Safety of Systems and Equipment IEC 61508 Functional safety of electrical / electronic / programmable electronic safety-related systems EN 954-1 Safety related parts of control systems Process Machines Software IEC 61511 IEC 61508-3 IEC 62061 EN/ISO 13849-1 Defines Categories Sets method or architecture to accomplish goal More subjective

Standards relating to IEC 61508 Safety of Systems and Equipment IEC 61508 Functional safety of electrical / electronic / programmable electronic safety-related systems EN 954-1 Safety related parts of control systems Process Machines Software IEC 61511 IEC 61508-3 IEC 62061 EN/ISO 13849-1 IEC 61511: Functional safety - Safety instrumented systems for the process industry IEC 61508-3: Functional safety of electrical/electronic/programmable electronic safety-related systems - Software IEC 62061: Machine Safety Safety Integrity Levels (SIL)

EN/ISO 13849-1 Safety of Systems and Equipment IEC 61508 Functional safety of electrical / electronic / programmable electronic safety-related systems EN 954-1 Safety related parts of control systems Process Machines Software IEC 61511 IEC 61508-3 IEC 62061 EN/ISO 13849-1 Specify requirements and implementation for safetyrelated control systems Defines Performance Levels PFHd (Probablility of dangerous Failure per Hour)

Which Standard Should be Used? Safety of Systems and Equipment IEC 61508 Functional safety of electrical / electronic / programmable electronic safety-related systems Process Machines EN 954-1 Safety related parts of control systems Software IEC 61511 IEC 61508-3 IEC 62061 EN/ISO 13849-1 IEC 62061 (SIL) Simple to Complex systems Electrical/electronic/programmable electronic safety systems EN/ISO 13849-1 (PL) Simple to low complexity Electrical, mechanical, pneumatic and hydraulic safety-related systems Machine designers can choose either or both.

Evolution of improvement Categories (EN954-1) Safety Integrity Levels - SIL Performance Levels - PL

EN954-1 - Categories S F Severity of injury S1 - Slight (normally reversible injury) S2 - Serious (normally irreversible) injury including death Frequency and/or exposure time to the hazard F1 - Seldom to less often and/or the exposure time is short F2 - Frequent to continuous and/or the exposure time is long P Possibility of avoiding the hazard or limiting the harm P1 - Possible under specific conditions P2 - Virtually impossible

EN954-1: Risk Assessment Safety Category B 1 2 3 4 Control System Requirements Control per basic specifications Use of well tried and tested components and principles Safety functions shall be checked at suitable intervals (frequency to be determined to application) A single fault must not cause the loss of the safety function. The single fault shall be detected when ever reasonably practical. A single fault must not cause loss of safety function. This fault be detected at or before the next demand shall of the safety function. An accumulation of faults must not cause loss of safety function. Control System Behavior (in the event of a fault) Possible loss of safety function Greater reliability but possible loss of safety function Fault detected at each test Safety function ensured except in the case o an accumulation or faults. Safety function always ensured, an accumulation of faults is not possible.

Examples of products by Category Use of basic control components Use of well tried and tested components and principles Periodically tested Redundancy Redundancy + continuous self checking B 1 2 3 4

Evolution of improvement Categories Safety Integrity Levels SIL (IEC 61508 and IEC 62061) Performance Levels PL

Safety Standards IEC 61508 Electrical / Electronic / Programmable Systems Functional Safety Passive protection Total life cycle of system\ IEC 62061 Simpler more functional

Categories (per EN954-1) S F Severity of injury S1 - Slight (normally reversible injury) S2 - Serious (normally irreversible) injury including death Frequency and/or exposure time to the hazard F1 - Seldom to less often and/or the exposure time is short F2 - Frequent to continuous and/or the exposure time is long P Possibility of avoiding the hazard or limiting the harm P1 - Possible under specific conditions P2 - Virtually impossible

Safety Integrity Level per IEC 62061 Class of Probability of Harm (CL) CL = Fr + Pr + AV Fr = Frequency of Exposure Pr = Probability of Occurrence AV= Probability of Avoiding harm Se = Severity of Injury

Safety Integrity Level Consequences Death, loosing an eye or arm Permanent, loosing fingers Reversible, medical attention Reversible, first aid G ey a ea Sa ety esu es eco e ded Severity Class Cl (Se) 3-4 5-7 8-10 11-13 14-15 4 SIL 2 SIL 2 SIL 2 SIL 3 SIL 3 3 OM SIL 1 SIL 2 SIL 3 2 OM SIL 1 SIL 2 1 OM SIL 1

Safety of Machinery and Functional Safety Machinery: Determination of the required SIL. (Example according to IEC/EN 62061) Consequences Severity (Se) Irreversible: death, losing an eye or arm 4 Irreversible: broken limb(s), losing a finger(s) 3 Reversible: requiring attention from a medical practitioner 2 Reversible: requiring first aid 1 Frequency and duration of exposure (Fr) Frequency of exposure Duration > 10 min <= 1 h 5 > 1 h to <= 1 day 5 > 1 day to <= 2 weeks 4 > 2 weeks to <= 1 year 3 > 1 year 2 Probability of occurrence Probability (Pr) Very high 5 Likely 4 Possible 3 Rarely 2 Negligible 1 Serial no. Hazard Se Fr Pr Av Cl 1 hazard x 4 5 + 4 + 3 = 12 2 Probability of avoiding or limiting harm (Av) Impossible 5 Rarely 3 Probable 1 Consequences Death, loosing an eye or arm Permanent, loosing fingers Reversible, medical attention Reversible, first aid G ey a ea Sa ety esu es eco e ded Severity Class Cl (Se) 3-4 5-7 8-10 11-13 14-15 4 SIL 2 SIL 2 SIL 2 SIL 3 SIL 3 3 OM SIL 1 SIL 2 SIL 3 2 OM SIL 1 SIL 2 1 OM SIL 1

Safety of Machinery and Functional Safety Machinery: Risk assessment form (given as an example in IEC 62061) Risk assessment and safety measures Product: Issued by: Date: Consequences Death, losing an eye or arm Permanent, losing fingers Reversible, medical attention Reversible, first aid Black area = Safetymeasures required Grey area = Safety mesures recommended Severity Class Cl Frequency and duration Probability of hzd. Event Avoidance (Se) 3-4 5-7 8-10 11-13 14-15 Fr Pr Av 4 SIL 2 SIL 2 SIL 2 SIL 3 SIL 3 <= 1 hour 5 Common 5 3 OM SIL 1 SIL 2 SIL 3 > 1 h to <= 1 day 5 Likely 4 2 OM SIL 1 SIL 2 > 1 day to <= 2 wks 4 Possible 3 Impossible 5 1 OM SIL 1 > 2 wks to <= 1 year 3 Rarely 2 Possible 3 > 1 year 2 Negligible 1 Likely 1 No. Hazard Se Fr Pr Av Cl Safety Measure Safe Comments

Safety Integrity Level Probability of a Hazardous Failure per hour (PFH d ) Average probability of a dangerous failure per hour PFHd SIL IEC 61508, EN 62061 >= 10-5 to < 10-4 No special safety requirements >= 3 x 10-6 to < 10-5 1 >= 10-6 to < 3 x 10-6 1 >= 10-7 to < 10-6 2 >= 10-8 to < 10-7 3

Safety Integrity Level High Demand on Machine Safety System SIL 3 10-8 to < 10-7 (per chart in ISO/EN13849-1) 10-7 PFHd < 10-8 (mathematically) Between.00000010 and.00000001 Dangerous failures per HOUR

SIL 4 Yes, it exists but don t worry about it UNLESS the results of failure leaves a crater!

Evolution of improvement Categories Safety Integrity Levels - SIL Performance Levels PL (EN/ISO 13849-1)

Performance Level (PL) EN/ISO 13849-1 Required performance level (PL r ) Low contribution to risk reduction S1 S2 F1 F2 F1 F2 P1 P2 P1 P2 P1 P2 P1 P2 a b c d e Safety-related system High contribution to risk reduction

Performance Levels Probability of Dangerous Failure per Hour Performance level EN/ISO 13849-1 PL Average probability of a dangerous failure per hour PFHd SIL IEC 61508, EN 62061 a >= 10-5 to < 10-4 No special safety requirements b >= 3 x 10-6 to < 10-5 1 c >= 10-6 to < 3 x 10-6 1 d >= 10-7 to < 10-6 2 e >= 10-8 to < 10-7 3

Category Architecture Behavior B 1 2 3 4 i m i m Input Logic Output i m i m Input Logic Output i m i m Input Logic Output i Test m Test equipment output m i m Input 1 Logic 1 i m Output 1 cross monitoring m i m Input 2 Logic 2 i m Output 2 m i m Input 1 Logic 1 i m Output 1 cross monitoring m i m Input 2 Logic 2 i m Output 2 Fault can lead to loss of safety function Fault can lead to loss of safety function but high MTFFd reduces chance of function loss Fault can lead to loss of safety function between checks; check detects loss of safety function Fault does not lead to loss of safety function, detect single fault before next demand of safety function Fault does not lead to loss of safety function, detect fault before next demand (switch off at end of next operating cycle)

Performance Levels Safety Related Parts of Control System (SRP/CS) Identifies the parts and pieces in the system Terms introduced for PL Mean Time To Dangerous Failure (MTTFd) Diagnostic Coverage (DC) Common Cause Failures (CCF)

Performance Levels Mean Time to dangerous Failure (MTTFd) Denotation of mean time to dangerous failure Low Medium High Range of MTTFd 3 years MTTFd < 10 years 10 years MTTFd < 30 years 30 years MTTFd < 100 years

Performance Levels Diagnostic Coverage Denotation of diagnostic coverage Range None DC < 60% Low 60% DC < 90% Medium 90% DC< 99% High 99% DC

Performance Levels Common Cause Failure Fuse Relay Device Relay Fuse

Performance Levels 1. 2. 3. 4. 5. 6. Risk assessment Determine Required PL (Performance Level) Determine Architecture Evaluate PL Verify PL Validate

Performance Levels 1. 2. 3. 4. 5. 6. Risk assessment Determine Required PL Determine Architecture Evaluate PL Verify PL Validate S1 S2 F1 F2 F1 F2 P1 P2 P1 P2 P1 P2 P1 P2 Required performance level (PL r ) a b c d e Low contribution to risk reduction High contribution to risk reduction

Performance Levels 1. 2. 3. 4. 5. 6. Risk assessment Determine Required PL Determine Architecture Evaluate PL Verify PL Validate S1 S2 F1 F2 F1 F2 P1 P2 P1 P2 P1 P2 P1 P2 Required Low contribution performance to risk reduction level (PL r ) a b c d e High contribution to risk reduction

Performance Levels 1. 2. Risk assessment Determine Required PL I1 I2 L1 L2 O1 O2 3. 4. 5. Determine Architecture Evaluate PL Verify PL INPUT Interlocking Switch 1 SW1 (XCS) Interlocking Switch 2 SW2 (XCS) SRP/CS a LOGIC Safety Relay SR1 (XPS) SRP/CS b OUTPUT Contactor 1 CON1 Contactor 2 CON2 SRP/CS c 6. Validate

Performance Levels 1. 2. 3. 4. 5. 6. Risk assessment Determine Required PL Determine Architecture Evaluate PL Verify PL Validate Consult Table K1 of the standard Category or Structure MTTFd of all components DC (Diagnostic Coverage) CCF (Common Cause Failure) DC avg 1 MTTF = d DC1 MTTF 1 MTTF d1 d1 = ~ N i = 1 DC2 + MTTF 1 + MTTF 1 MTTF d2 d2 +... + +... + di DCN MTTF 1 MTTF dn dn

Performance Levels 1. 2. 3. 4. 5. 6. Risk assessment Determine Required PL Determine Architecture Evaluate PL Verify PL Validate Performance level a * b 1 c 1 d 2 e 3 Cat. B DC avg = 0 Cat. 1 DC avg = 0 * Cat. 2 DC avg = low Cat. 2 DC avg = medium Cat. 3 DC avg = low Cat. 3 DC avg = medium DC = Diagnostic Coverage MTTF d = Mean Time To Failure - Dangerous PL = Performance Level Cat. 4 DC avg = high Safety Integrity Level

Performance Levels 1. 2. 3. 4. 5. 6. Risk assessment Determine Required PL Determine Architecture Evaluate PL Verify PL Validate User documents the: Procedure used Assumption list Calculations Refer to ISO 13849-2

Performance Levels 1. 2. 3. 4. 5. 6. Risk assessment Determine Required PL Determine Architecture Evaluate PL Verify PL Validate Questions?

SISTEMA Safety Integrity Software Tool for the Evaluation of Machine Applications From IFA: Institut für Arbeitsschutz der Deutschen Gesetzlichen Unfallversicherung Helps calculate the PL Free download User must understand how to do calculations manually Schneider Electric makes no recommendations regarding the use of this tool. Website: http://www.dguv.de/ifa/en/pra/softwa/sistema/index.jsp

Other considerations and terms

Module objectives At the end of this module the participant will Define terms specific to contact configurations used in machine safety circuit Explain operating modes for machine safety components Define access time in terms of machine safety

Contact terms Slow make and break Speed of contact action dependent on speed of operator 9001 KA1 for example

Contact terms Snap Action Action of contacts not fully dependent on motion of operator Contacts move to pretravel position then continue action

Contact terms

Operating modes Negative mode relies on device to open contacts properly Hazard potential

Operating modes Positive mode forces switch to open contacts Hazard potential If only one switch, must be positive mode.

Operating modes Best practice: combine modes

Contact terms Positive Opening Contacts will open period. EN60947-5-1 and NFPA 79

Contact terms Mechanically linked Link between contacts Min. distance between contacts in case of weld

Contact terms Linked Contacts a.k.a. mechanical guided, forced guided NC contact welds, impossible to close NO contacts (energized coil) If NO contacts welds, impossible to open NC contact (de-energized coil)

Contact terms Mirrored contacts NC aux contact linked to NO power poles Never closed at same time as power poles If power pole welds, link prevents NC aux contact from closing when de-energized TeSys D and TeSys K meet this requirement!

Access time Access time of personnel vs. the stopping time of the machine Hazard Stopping time is less than access time: guard does not need to be locked Hazard Stopping time is greater than access time: guard must be locked until the hazard poses no threat 63 inches per second for movement of hand

Access time Machinery with instant stopping (Stopping time < access time) Standard non-locking safety interlock switches or locking switches

Access time High inertia machines; Long stopping time (Stopping time > access time) Interlocking with actuating key Use solenoid locking safety interlocks.

Why know these terms? An e-stop would require what type of contact? Monitoring for welded contacts requires what? To insure that two sets of contacts never close at the same time we d use what? To monitor for welded power contacts use

Terms - Stop Categories In addition to Safety Categories (per ISO 13849-1), there are categories that identify the stopping characteristics of the machine or process. Do not get these confused with Safety Categories. Three categories of emergency stop function: Category 0: Immediate removal of power (all machines must have a category 0 or 1 emergency stop) Category 1: Power to machine actuators to achieve the stop, then the removal of power (all machines must have a Category 0 or 1 emergency stop) Category 2: Power to machine actuators to achieve the stop; power remains on the circuit These stop categories are identified in EN 60204-1 and NFPA 79

Machine Safety Products

Module objectives At the end of this module the participant will Identify various components associated with machine safety Define operating platforms available Locate specific catalog items from the machine safety catalog Perform basic set of E-stop with monitoring Safety interlock schemes with gate protection

Machine Safety Solutions E-Stop Inputs Guarding & Positioning Machine Safety Products Logic Output

Machine Safety Related Contactors and relays Only certain ones Based on category levels (not SIL or PL) Catalog page: 6/22 E-Stop push buttons Required per other applications and codes Catalog page: 7/9 Limit Switches, Cable Pull, Palm Switches Be aware of other products related to machine safety

E-stop specifics Visible and readily accessible Red actuator with Yellow background Initiated by single human action Continuously operable, clearly indentified

E-stop specifics Absolute priority over all other functions Capability at each work station, location Category 0 or 1 must have e-stop NOT flat panel Mechanical latch (pull or rotate to release) Reset will not restart machine

Machine Safety Products Safety interlocks With and without locking With locking solenoid Lever arm and rotary Non-contact Control platforms Relays Controllers PLCs Light curtains

Safety Interlocks Limit access to areas while machine operates Stops machine when guards are opened Monitored to prevent starting machine

XCSA, XCSB and XCSC Catalog pg: 3/24 Metal body Unlocking means Without locking - XCSA Tubular key - XCSC Pushbutton - XCSB Location of key or pushbutton easily changed from left to right side of switch Easy to rotate non-removable head Actuating key approach from top or side

XCSE Catalog pg: 3/25 Rugged metal switch with locking solenoid Locking without power (preferred) Locking with power Rotatable non-removable head IP67 Actuating key approach from top or side

XSCLE / XCSLF Slim profile Plastic (E) or metal (F) Locking with solenoid Locking without power (preferred) Locking with power Rotatable head

XCSMP Safety Interlock Switch Catalog pg: 3/40 Miniature safety interlock - only 0.6 wide 2 directions of actuation, top and side 3 types of actuating keys IP67 Pre-cabled, several lengths

Non-Locking Safety Interlock Catalog pg: 3/44 Used where stopping time is less than access time XCSPA - slim plastic body XCSTA - wide plastic body Easy to rotate non-removable head Actuating key approach from top or side IP67

XCSTE Catalog pg: 3/45 Compact plastic switch with locking solenoid Locking without power (preferred) Locking with power Easy to rotate nonremovable head

Lever Type Safety Interlocks Catalog pg: 3/52 Two lever types available XCSPL - slim plastic body XCSTL - wide plastic body Used on hinged doors or guards Head can be rotated in 4 directions Easy to rotate non-removable head No actuating key to align or attach to the guard, eliminating alignment issues Straight or offset levers

Rotary Shaft Interlock Catalog pg: 3/52 Two rotary types available XCSPR - slim plastic body XCSTR - wide plastic body Used on hinged doors or guards Head can be rotated in 4 directions No actuating key to align or attach to the guard Can be used on narrow doors or guards

Rotary Shaft Interlock Shaft fits over hinge pin and is secured to the hinge pin When the door is opened, switch operates When the shaft is operated 5, switch contacts change state Available in two shaft lengths: Standard: 1.18 (30mm) Extended: 3.15 (80mm)

Non Contact Interlocks Catalog pg: 3/56 XCSDMR XCSDMP XCSDMC

Non Contact Interlocks Suitable for Category 4 XCSDMP Face to face, side to side and face to side actuation* With or without LED indicator XCSDMC Face to face, side to side and face to side actuation. With or without LED indicator XCSDMP XCSDMC

Non Contact Interlocks XCSDMR Face to face, side to side actuation. With or without LED indicator XCSDMR

Machine Safety Platforms Type Safety Relay Safety Controller Safety PLC AS-I Safety Card Family XPS XPSMC XPSMF ASISAFE Lexium 32 Function Solution for monitoring one function Solution for monitoring several functions simultaneously Solution for monitoring many functions simultaneously and communication over Safe Ethernet Solutions using a safety related communications bus Solutions using a motion controller Schneider Electric Preventa Machine Safety Products 86

Safety Relays Monitor status of guards and interlocks Prevent and stop machine operation Won t allow machine start until conditions are met

Safety Relays, How Do They Work? L1 (+) F1 (+) S1 ( ) K3 K4 A1 S11 S12 S21 S22 B1 Y1 Y2 13 23 115 V 230 V T + XPS K1 Logic K1 K2 K2 K3 K3 K3 K3 A2 PE S33 S34 14 24 K4 K4 K4 K4 S2 Start K3 K4 N ( ) Schneider Electric Preventa Machine Safety Products 88

Safety Relays, How Do They Work? L1 (+) F1 (+) S1 ( ) K3 K4 Safety Outputs: 13-14 23-24 A1 S11 S12 S21 S22 B1 Y1 Y2 13 23 115 V 230 V T + XPS K1 Logic K1 K2 A2 PE S33 S34 14 24 K2 Aux K3 K3 K4 K4 Power K3 K3 K4 K4 N ( ) S2 Start K3 K4 K3 & K4 are external relays/contactors Schneider Electric Preventa Machine Safety Products 89

Safety Relays, How Do They Work? L1 (+) F1 (+) S1 ( ) K3 K4 Safety Outputs: 13-14 23-24 A1 S11 S12 S21 S22 B1 Y1 Y2 13 23 115 V 230 V T + XPS K1 Logic K1 K2 A2 PE S33 S34 14 24 K2 Aux K3 K3 K4 K4 Power K3 K3 K4 K4 N ( ) S2 Start K3 K4 K3 & K4 are external relays/contactors Schneider Electric Preventa Machine Safety Products 90

Safety Relays, How Do They Work? L1 (+) F1 (+) S1 ( ) K3 K4 Safety Outputs: 13-14 23-24 A1 S11 S12 S21 S22 B1 Y1 Y2 13 23 115 V 230 V T + XPS K1 Logic K1 K2 A2 PE S33 S34 14 24 K2 Aux K3 K3 K4 K4 Power K3 K3 K4 K4 N ( ) S2 Start K3 K4 K3 & K4 are external relays/contactors Schneider Electric Preventa Machine Safety Products 91

XPSAF and XPSAFL Catalog pg: 2/187 & 2/191 For E- stop and switch monitoring Removable and non-removable terminals 22.5mm wide 3 N.O. safety outputs 3 LED s for easier set-up and troubleshooting 24V AC/DC XPS-AF Category 4 E-stop, interlock switches XPS-AFL Category 3 with e-stop and interlock switches Designed for Type 4 light curtain inputs for category 4

XPSAK Catalog pg: 2/201 For emergency stop and interlock switch monitoring Removable and non-removable terminals Category 4 45mm wide 3 N.O. safety outputs 1 N.C. auxiliary output 4 S.S. outputs for PLC signaling 4 LED s for set-up and troubleshooting Dual voltage devices available - 120VAC & 24 VDC, 230V AC & 24 VDC, as well as 24VAC/DC

XPSBF Catalog pg: 2/209 For Two Hand Control Applications Removable and non-removable terminals Category 4 22.5mm wide 2 N.O. safety outputs. 2 S.S. outputs for PLC signaling 3 LED s for set-up and troubleshooting 24V DC

Safety Controller XPSMCWIN XPS MC16Z XPS MC16ZC XPS MC16ZP XPS MC32Z XPS MC32ZC XPS MC32ZP

Solutions inside firmware Emergency stop with single and dual channel buttons Guard with single or dual channel and with interlock Light curtains (type 4) with solid state and relay outputs Light curtains (type 4) with solid state and relay outputs with muting Magnetic non-contact safety interlocks Two-hand control device (EN 574:Type IIIC) Safety mat Zero speed detection Injection moulding machine Hydraulic press valve monitoring (3 valves) Eccentric press control with optional valve monitoring (XPS-PVK/OT) Seat valve monitoring (1 valve) Enabling device OR logic Timing functions Optional stop cat.0 and stop cat.1 for all outputs Plus many more

Machine Safety Controller XPSMCWIN Drag and Drop interface Part of Safety Suite Certified Safety Functions

Machine Safety Controller Diagnostic Window Yellow arrow = error message Green = ON state Red = OFF state Text message in bottom yellow frame Grey = not used

Machine Safety Controller PLC Modbus CANopen Profibus

AS-Interface Safety at Work Catalog pg: 2/262

AS-Interface Safety at Work PLC and standard ASi master AS-i power supply Standard interface Safety monitor Emergency - stop pushbutton with safety interface Safety light curtain Standard Interface Safety monitor Safety interlock switch with attached safety interface

AS-Interface Safety at Work ASISAFEMON1B 1 output group ASISAFEMON2B 2 output groups

AS-Interface Safety at Work Monitors devices Emergency stop buttons Safety guards Light curtains Logic functions OR (up to 6 devices) On delay/off delay/pulse, etc EDM

AS-Interface Safety at Work Interfaces for emergency stop buttons M16 thread M12 connectors IDC (Vampire pin)

Safety PLC s Catalog pg: 2/4 XPSMF safety PLCs

Safety PLC s XPSMF Safety PLCs SafeEthernet Distributed Safety I/O SIL 3 per IEC 61508 PL e per ISO 13849-1

LAB EXERCISES

Light curtains

Module objectives At the end of this module the participant will Determine when to use safety interlocks vs light curtains Explain various terms associated specifically with light curtains Perform basic set up of light curtains Select components necessary to meet light curtain applications

Safety Interlocks vs. Light Curtains Safety Interlocks where: Access not desired or needs to be limited Large areas or multiple points of access Flying debris, fluids or coolants, or other materials to keep away from personnel Lower cost is a primary concern Light Curtains where: Easy physical access to hazardous areas Clear visibility of the operation is desired Gates and guards may not be practical Cannot be used where potential for flying debris exists

Requirements for use Must be able to stop anywhere in its cycle. Must not present a hazard from flying parts or debris Must have consistent response and stopping times Satisfy all governmental and local rules, codes, and regulations including (but not limited to) ANSI and OSHA Responsibility of user and/or employer Severe smoke, particulate matter, and corrosives may degrade the efficiency of a light curtain Additional guarding may be required

Light Curtains - XUSL Where gates or guards are impractical or undesired Excellent visibility of the machine or process Provides free access to work area Point of operation or perimeter guarding Floating blanking and fixed blanking functions Will not protect operators or personnel from flying projectiles or debris

Specialized terms Minimum Object Sensitivity (MOS) Minimum Safety Distance Blanking Floating Exact Muting Alignment system Type 2 and Type 4 curtains

Minimum Object Sensitivity Affects minimum safety distance Smallest diameter of object sensed Finger protection: 14 mm Hand protection: 30 mm

Minimum Safety Distance (Ds) Based on movement of 63 in/sec for hand Depends on which entity OSHA ANSI CE Calculate all and largest separation distance

Blanking & Muting Any blanking increases the MOS and minimum safety distance Floating: allows a specific number which floats (entry location varies) Exact channel: fixed group to allow for machine parts (supports, fixtures) Muting: temporary time to allow passing of material (not hands)

Alignment system Individual Blocked Beam Indicators illuminate whenever a beam is not detected by the receiver A A Beam Indicator A Receiver Channel

Blocked Beam Indicators (BBI) Illuminate whenever a beam is not detected by the receiver, Illuminate if exact channel select blanked beam is detected when it should be blocked. One for each light beam in the light curtain. Aid in installation, adjustment and troubleshooting C Standard on all Schneider Electric Light Curtains BBI LED s B A Infrared Receivers

Floating Blanking The synchronizing beam must always be present and cannot be floated. One or two beams can be blocked without opening light curtain outputs Typical applications: Sheet metal Conveyors Paper

Exact channel blanking An object programmed to be in the field must remain in the field for the light curtain to operate Beams blanked are inverse (light curtain looks for dark) Typical applications Brackets Conveyors The synchronizing beam must always be present and cannot be blocked

Muting Beams temporarily ignore missing signals while material in field for specific time The synchronizing beam must always be present and cannot be blocked Temporary suspension of beams as material moves in or out time sensitive Typical applications Assembly Conveyor

Type 2 vs Type 4 light curtains Type 2 Perimeter guard Periodic self-checking (power up and reset) Type 4 Point of operation (serious injury) Pinch points, areas where shearing or punching Continuous self-checking

Type 2 applications Packaging Conveyors Warehouse/storage Robot areas

Type 4 applications Presses, shears, trimmers Hoisting equipment Saws Machine and wood working Textiles

Two and three box configurations Two box Emitter Transmitter No control box required Three box Emitter Transmitter Control box Early design of curtains Fading usage

Light curtains catalog

How to Select the Right Light Curtain 1 - What light curtain type is required? 2 - What is the MOS? 3 - What is the protected height? 4 - Is blanking going to be used? 5 - Is customer aware of the proper use of minimum safety distance formulas?

The Product Range Type 4 Type Compact Compact Compact Compact Family XUSLB XUSLD XUSLPZ XUSLPB MOS 14 mm and 30 mm 0.55 in and 1.18 in 14 mm and 30 mm 0.55 in and 1.18 in 300, 400,500,600 mm 11.8, 15.7, 19.7, 23.6 in. 500 and 600 mm 19.7 and 23.6 in Sensing Distance SN 1 to 22.9 ft, or 1 to 65.6 ft with PDM 1 to 22.9 ft, or 1 to 65.6 ft with PDM 2.6 to 65.5 ft or 2.6 to 229.7 ft 2.6 to 26.3 ft

The Product Range Type 2 Type Single Beam Compact Family XPSCM and XU2S XUSLN XPSCM XU2S XU2S MOS Single Beam 30 mm, 1.18 in Sensing Distance SN 26.2 ft 0.89 to 49.21 ft

XUSLB Light Curtain pg 3/92 Optimum range Manual and auto start External Device Monitoring by wiring or terminal, MTS (test) Sensing distance: 22.9 ft (7m) (Φ14mm) 26.2 or 65.6 ft (8m or 20m) (Φ30mm) 14 mm and 30 mm (0.55 and 1.18 in) MOS

XUSLDM Light Curtain pg 3/93 Universal range configurable by PDM terminal Manual start, auto start, manual start 1 st cycle. External Device Monitoring, MTS (test) Sensing distance: 22.9 ft (7m) (Φ14 mm) 26.2 or 65.6 ft (8 m or 20 m)* (Φ30 mm) 14 mm and 30 mm (0.55 and 1.18 in) MOS

Cascadable light curtains pg3/94 & 3/95 Finger detection Up to 4 segments (256 beams maximum) Available with the XUSLDM light curtains Each section can be configured for blanking or floating blanking Functionality for each segment is set by the PDM Hand detection

Muting module for light curtains pg 3/106 Muting module for XUSLD light curtains External Mute module XPS-LCM1. Up to 4 muting sensors 1 muting monitoring lamp XPSLCM1 Diagnostics by LED or directly by PDM Terminal Functions setting by PDM Terminal in the XUSLD 2,3 or 4 sensors or dual 4 sensors forward or 2 X sensors forward. Time out: 2 minutes or unlimited Mute Bypass: yes or no. XPSLPDM

XUSLP Type 4 Light Curtain start pg 3/119 Body Detection 1 to 6 beams Minimum Object Sensitivity of 11.8, 15.8, 19.7, and 23.6 in. (300, 400, 500, and 600 m) Type 4 Designed for perimeter guarding Range up to 230 feet (70 M)

Single type 2 beams XU2S (Φ 30 x 80 mm) start pg 3/140 XPSCM XU2S XU2S XU2S + XPSCM body detection single beam Sensing distance (Sn) 26.2 ft (8 m) Up to four beams. Basic functions of XPSCM: Automatic Start, manual start, muting with 3s or 60s de-activation of time.

Compact type 2 XUSLN pg 3/127 Basic function, low cost. 30 mm (1.18 in) MOS Range: 0.89 to 49.21 ft Top and bottom alignment by BBI indicator. Automatic and manual start version Simple to use - no setting up required Used on lighter duty applications Not for use on machinery such as presses

Safety module for light curtains pg 2/215 Safety module for monitoring 2 to 4 independent light curtains - ranges XUSL B/D/P/N Basic functions: Automatic start, 4 light curtains monitoring Selectable functions by DIP switches: Start interlock and start restart interlock, safety external relays EDM/MPCE monitoring. XPS-LCD1141 Built-in Diagnostics and LEDs

Safety module for light curtains pg 2/220 Mute module for 1 to 2 light curtains XUSL B/D/P/N Basic functions: automatic start, safety external relays EDM/MPCE monitoring, muting time 2 minutes, alarm output, N.O. start push button. Selectable functions by DIP switches Built-in Diagnostics and LEDs XPS-LCM1150

Light curtain accessories Laser alignment tool (XUSLAT1) For use with all current XUSL light curtains Used primarily for very long sensing distances between emitters and receivers Programming and Diagnostic module (XUSLPDM) Used to program and troubleshoot XUSLD and XUSLB Powered up by connection to the light curtain Configures Blanking Floating blanking Muting Range Response time

Other Accessories 1. Mirrors 2. Lexan covers 3. IP67 Covers 1. 2. 3.

Light curtain lab