Hands On: Introduction to Safety Workshop Presented by Robert Jones Manufacturing in America March 14-15, 2018
Before we start A Penny for Your Thoughts At the end of the session, share your feedback via MiA App - and get a chance to win tickets to the Detroit Tigers baseball game!
Machine Safety Safety Process Chain The necessary steps towards a safe machine can be illustrated with a process chain. Risk assessment Risk reduction Proof Cutting disc > Cutting off Chips > Cutting, penetrating Transport rollers > Crushing and shearing Clamping plates > Crushing
Machine Safety Are Risk Assessments Required? Risk assessment Risk reduction Proof European Union : USA: DIRECTIVE 2006/42/EC (Machinery Directive) NFPA 79 ANSI B11.19 ANSI / RIA 15.06 ANSI ASSE Z244.1 YES! All new & revised machine safety standards state that a Risk assessment MUST be performed
Machine Safety Methods of Risk Mitigation Safety Implementations Physical safety measures Barriers (e.g. guards, enclosures), protective clothing and equipment, floor markings Safety awareness General safety education courses, proper equipment training, regular internal safety evaluation Safety controls Input devices (e.g. sensors, pilot devices), safety evaluation devices, Output devices (e.g. contactors, motor starter protection)
Machine Safety Risk Assessment Process The following standards should be applied for the techniques to evaluate and assess these risks: For USA: ANSI B11.0-2010, Safety of Machinery; General Requirements And Risk Assessment. For Europe: EN ISO 12100 "Safety of machinery basic terminology, general principles for design risk assessment & risk reduction
Machine Safety Quantifying Risk Risk Risk assessment Risk reduction Proof
Machine Safety Determination of required SIL Risk Risk assessment Risk reduction Proof
Machine Safety Determination of required PL Risk Risk Risk assessment Risk reduction Proof
Machine Safety Typical Safety Circuit example SIL 3 / PL e wiring 24V or 115VAC Power Supply Redundancy ensures safety functionality even if a failure disables one channel Safety Controller Evaluation Fault detection and evaluation; opens the circuit in case of a failure. Reset Reactivates the safety circuit Sensors Initiate machine shut down OR Feedback Loop Monitors the correct operation of the contactor coils Positive Opening Guarantees that all NC contacts are in the open position when actuated Positive Driven (Mirror) Guarantees that NC contacts are not to be closed at the same time as the main contact 0V The Complete Safety Solution
Machine Safety Understanding Safety Levels - PL a Standard Switch and Contactor PL a allows NO contacts for Enabling Two-hand control Restart L1 L2 L3 The Complete Safety Solution
Open Closed Machine Safety Understanding Safety Levels - PL b 24 VDC PL b requires Sensors with positive opening contacts L1 L2 L3 0 VDC The Complete Safety Solution
Open Closed Machine Safety Understanding Safety Levels - PL c / SIL 1 24 VDC ON PL c / SIL 1 requires Sensors with positive opening contacts And Safety evaluation unit rated to SIL 1 L1 L2 L3 Feedback loop from contactor s NC contacts Q1 0 VDC The Complete Safety Solution
Open Closed Machine Safety Understanding Safety Levels - PL d / SIL 2 24 VDC ON PL d / SIL 2 requires Sensors with positive opening contacts Q1 L1 L2 L3 Safety evaluation unit rated to SIL 2 Feedback loop from contactor s NC contacts And Redundancy in sensor contacts Redundancy in contactors 0 VDC Q2 The Complete Safety Solution
Open Closed Machine Safety Understanding Safety Levels - PL e / SIL 3 24 VDC PL e / SIL 3 requires Sensors with positive opening contacts 0 VDC Q1 Q2 ON L1 L2 L3 Safety evaluation unit rated to SIL 3 Feedback loop from contactor s NC contacts Redundancy in sensor contacts Redundancy in contactors And Separate channels of evaluation for sensors The Complete Safety Solution
Machine Safety Risk Reduction Risk assessment Risk reduction Proof Solutions consist of three main components Detection Evaluation Reaction Very Important as this is how the safety function is defined when doing the calculations for SIL/PL levels
Detection Input Devices May Include Several or Just One of the Following: (Depending Upon Safety Category Desired) Mechanical Input Devices Emergency Stop (with or without enable or resets) Position Switch Interlock Switch
Detection Input Devices May Include Several or Just One of the Following: (Depending Upon Safety Category Desired) Electronic Input Devices Solenoid Interlock Gate Switches Magnet or RFID Position Switches Light Grids / Area Laser Scanners Encoder Position Switches Safety Mats
Detection Input Devices with Safety Protocol using Networks Mixed Safety Non-Safety Devices same Network AS-I Safe Profi Safe
Detection Flowchart - Guides you to the right Siemens Safety Solution To fit your applications safety functionality, as per your comfort level
Evaluation Safety Relay & Programmable Controllers May Include One, Several, or a Combination of the Following: (Depending Upon Safety Category Desired and Complexity) Safety Relays Configurable Safety Relays MSS (Modular Safety System)
Evaluation 3SK, Universal Functionality Simple Slim portfolio + Flexible + Extendable through modular product concept Combinable With motor starter SIRIUS 3RM1 Failsafe Multifunctional Parameterization via DIP switch or software + + Economic Simple and reduced wiring with usage of innovative device connector +
Evaluation Modular expandability of SIRIUS Safety Relays 3SK1 Reduction of wiring outlay and space saving despite higher functionality
Evaluation 3SK1 compared with 3SK2 3SK1 customer s requirement 3SK2 most simple logic more complex logic additional functions (e.g. Muting/Interlock) only wiring allowed time off delay complex time functions powerful outputs enhanced diagnostics simplification of commissioning less space consumption
Evaluation Parameterization, Configuration, Visualization Safety ES Software Allows for comprehensive documentation thanks to graphical Drag&Drop code interface Easy-to-use configuration tools turn complex wiring parameterization into straightforward software solutions Makes implementing advanced functions easy: Muting functionality Protective door monitoring Independent output functions
Evaluation Modular Safety System (3RK3) Designed to minimize the number of modules needed when multiple safety functions must be evaluated. 3RK3111/3RK3131 (Basic/Advanced central unit) 3RK3121/3RK3122 (Basic/Advanced central unit with ASI safe integration) Expansion modules, DP interface module, and diagnostic display available
Evaluation SIMATIC Failsafe CPUs Failsafe versions of the SIMATIC automation system integrate additional safety-related functions S7-1200F: High level functionality and flexibility. ET200SP F: Distributed controller for compact systems. S7-1500F: Greatest performance, flexibility and networking capability.
Reaction Output Devices May Include Several or Just One of the Following: (Depending Upon Safety Category Required & Operation Desired) Safety Contactors (Positively Driven Mirror Contacts) Safety Relays (Positively Driven Mirror Contacts) Safety Motor Starters (3RM1 / ET200S / ET200SP) Safety VFDs (G120 / S120)
Siemens Safety Integrated Safety Design Compliance - Safety Evaluation Tool The Safety Evaluation tool A free Internet-based tool for calculating safety functions ISO 13849-1 (successor standard of EN 954-1) IEC 62061 For documenting the results by a report Offers easy, identical handling for both standards Optimum support when using the Siemens products Safety Evaluation Tool Online Access SET Getting Started Document SET Tutorial (YouTube) Risk assessment Risk reduction Proof
Siemens Safety Integrated Machine Safety Services Risk Assessments Partners GP Strategies White Horse Safety Safety Validation Partner TÜV Rheinland of North America White Horse Safety The Complete Safety Solution
Wheat mill with variable feeding Requirements Alternating monitoring of cone or vessel manipulation-proof switches door interlock of service door (crushing mill) door interlock of service door (vessel) nearly no space in cabinet
Wheat mill with variable feeding Solution Solution with HW-parameterized Safety relays Solution with SW-parameterized Safety relays 3SK2
Wheat mill with variable feeding Solution Required 3SK1 Wiring Required 3SK2 Configuration
Material Feeding System: 3SK2 Example Tool Change/Access Inspection Station
Safety Controls Components: 3SK2 Example Detection Devices Emergency Stop - Global Evaluation Devices Programmable Safety Relay Reset Button Reaction Devices RFID Gate switch - Safety Motor Starter Light Curtain - Contactors Safety Motor Starter - Conveyor Contactor - Robot
Evaluating SIL Level: 3SK2 Example Hazard 1: Conveyor Severity: 3, Loss of fingers Frequency: 5, 1 Hr Occurrence: 2, Rarely Preventability: 1, Probable Total: 8 SIL Level: 1 Hazard 2: Robotic Arm Severity: 4, Loss of life Frequency: 3, > 2 Weeks to 1 Year Occurrence: 3, Possible Preventability: 5, Impossible Total: 11 SIL Level: 3
Safety ES Software: 3SK2 Example E-Stop and pushbutton inputs Cross-circuit detection with monitored start E-Stop global output Outputs to 3RM1 through backplane and to contactors 3SE6 Inputs Cross-circuit detection, automatic start 3SE6 Ouput to 3RM1 Wired output to 3RM1
Safety ES Software: 3SK2 Example Inputs from E-stop output block (M1, M2) and Light curtain (M3) Mirror E-stop condition output to LED (QM1) and E- stop and light curtain must not be tripped for contactor LED (QM2) to be on Red E-stop LED (QM1) Green contactor LED (QM2) Light curtain inputs and push button inputs, Input from E- stop output (Q5-C) Output to Contactors Light curtain and E-stop must not be tripped, controls contactors Contactor Feedback Contactors (Q1, Q3) and Auxiliary to LED (M3)
Hands On Demo Unit Layout: 3SK1 3SK1 Basic Unit Contactor Q1 E-Stop, Monitored Contacts Red Status LED Contactor Q2 Reset Button 5SJ4 2A Circuit Breaker
Task #1: 3SK1 SIL 1 Wiring Goal: Demonstrate the ease of setup and flexibility of the 3SK1 series with a SIL 1 configuration. Main take away items: Understand the application of SIL 1 safety measures in system design. Integrate the 3SK1 into a safety system to satisfy SIL 1 standards. The Complete Safety Solution
Task #1: 3SK1 SIL 1 wiring Technical Diagram The Complete Safety Solution
Task #1: 3SK1 SIL 1 wiring Recap Sensor with positive opening contacts Lower rate of failed detection from shorts and welds Safety evaluation unit rated to SIL 1 More reliability and higher level safety functions Picture of demo in SIL 1 configuration Feedback loop from contactor s NC contacts Provides feedback if contactor contacts weld The Complete Safety Solution
Task #2: 3SK1 SIL 3 wiring Goal: Demonstrate the ease of setup and flexibility of the 3SK1 series with a SIL 3 configuration. Main take away items: Understand the application of SIL 3 safety measures in system design. Integrate the 3SK1 into an existing system to satisfy SIL 3 standards.
Task #3: 3SK1 SIL 3 wiring Technical diagram The Complete Safety Solution
Task #3: 3SK1 SIL 3 wiring Recap Safety evaluation unit rated to SIL 3 More reliability and higher level safety functions Separate channels for each set of sensor contacts Failure of a single channel does not disable safety functionality Picture of demo in SIL 3 configuration The Complete Safety Solution
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Seminar Slides After MiA, seminar slides will be available at: http://www.usa.siemens.com/mia-seminars
Questions? Robert Jones 6750 Arnold Miller Pkwy Solon, OH Phone: (330) 980-1133 E-mail: rajones@electro-matic.com