safety — key to the machine solution

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2011 Schneider Electric. All Rights Reserved. Safety-Key to the Machine Solution Dave Collins Schneider Electric Industry NOW Express

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This presentation covers international and local safety standards. In addition, it explains how Schneider Electric tested, validated, and documented approach helps machine building OEMs design safe, more energy efficient machines.

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Page 1: Safety — Key to the Machine Solution

2011 Schneider Electric. All Rights Reserved.

Safety-Key to the Machine Solution

Dave CollinsSchneider Electric Industry NOW Express

Page 2: Safety — Key to the Machine Solution

2Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Confused about safety?

You are not alone

Almost 60% are not aware of Safety Categories

68% not familiar with Performance Levels

Most have difficulty in applying safety products

Page 3: Safety — Key to the Machine Solution

3Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Standards

Safety is driven by standards

Standards determine devices to use, how to use them, and sometimes how safety products are constructed

Some US standards are similar to IEC standards

Page 4: Safety — Key to the Machine Solution

4Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

US Standards

A few of the most important US Standards are:●

OSHA 29 CFR1910

NFPA 79, 2007 Edition, Electrical Standard for Industrial Machinery

ANSI B11.19, Performance Criteria for Safeguarding

ANSI/RIA R15.06, Industrial Robots and Robot Systems, Safety Requirements

Locally●

UL and CSA (in Canada)●

UL is mandatory in most US cities in their codes and requirements. ●

Customers and users demand these approvals even if local codes do not require it.

Canada●

CSA is mandatory in Canada

Page 5: Safety — Key to the Machine Solution

5Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

European / International Standards

Safety categories (B, 1, 2, 3, 4) per EN 954-1 are no longer valid since December 31, 2011

Performance Levels (a, b, c, d, e) per EN/ISO 13849-1 replaced safety categories on January 1, 2012

SIL (Safety Integrity Levels) are designed for use primarily for

more complex systems or microprocessor and software based systems

SIL can be determined by either IEC 61508 or IEC 62061

Page 6: Safety — Key to the Machine Solution

6Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Starting pointfor the

evaluation ofthe risk

a

b

c

d

e

P1

P2

P1

P2

P2

P2

P1

P1

F2

F1

F1

F2

S1

S2

Requiredperformance

level (PLr)

Low contributionto risk reduction

High contributionto risk reduction

S Severity of injuryS1 Slight (normally reversible injury)S2 Serious (normally irreversible) injury including death

F Frequency and/or exposure time to the hazardF1 Seldom to less often and/or the exposure time is shortF2 Frequent to continuous and/or the exposure time is long

P Possibility of avoiding the hazard or limiting the harmP1 Possible under specific conditionsP2 Virtually impossible

EN/ISO 13849-1 Risk graph and parameters

Uses the same criteria as EN 954-1

Page 7: Safety — Key to the Machine Solution

7Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

EN/ISO 13849-1

EN/ISO 13849-1 adds new parameters to the requirements of the categories of EN 954-1 in order to determine the Performance Level (PL):

MTTFd = mean time to dangerous failure Three levels of MTTFd

are defined in this standard in order to classify the requirements of the categories and the performance levels (PL):

DC = diagnostic coverage DC = dd / d total

Denotation of mean time to dangerous failure Range of MTTFd

low 3 years <= MTTFd < 10 yearsmedium 10 years <= MTTFd < 30 years

high 30 years <= MTTFd < 100 years

Denotation of diagnostic coverage Range of DCnone DC < 60%low 60% <= DC < 90%

medium 90% <= DC < 99%high 99% <= DC

ldd / ld totaltotal failures Dangerous

detected failures Dangerous

total d

dd

Page 8: Safety — Key to the Machine Solution

8Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

EN/ISO 13849-1 Relationship between categories, DC, MTTFd

and PL

MTTFd

of each channel = lowMTTFd

of each channel = mediumMTTFd

of each channel = high

*

In many applications the realization of performance level c by category 1 may not be sufficient. In this case a higher category e.g. 2 or 3 should be

chosen.

a *

b 1

c 1

d 2

e 3

Cat. BDC avg =

0

Cat. 1DC avg =

0

Cat. 2DC avg =

low

Cat. 2DC avg =medium

Cat. 3DC avg =

low

Cat. 3DC avg =medium

Cat. 4DC avg =

high

Perf

orm

ance

leve

l

Saf

ety

Inte

grity

Lev

el

*

DC = Diagnostic CoverageMTTFd

= Mean Time To Failure -

DangerousPL = Performance Level

Page 9: Safety — Key to the Machine Solution

9Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

100 % of flexibility and optimization with Flexible Machine Control

1 software environmentSimplify machine programming & commissioning with SoMachine suite

Multiple hardware Control PlatformsEmbedded Intelligencewhere it is needed

Logiccontrollers

Motioncontrollers

HMIcontrollers

Drivecontrollers I/Os

Safety is at the center of it all

Page 10: Safety — Key to the Machine Solution

11Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Ready-to-use architectures: TVDA

● Predetermined equipment lists

●Tested●

our experts tested each application to ensure that they work in all possible configurations.

●Validated●

Full functional compatibility of devices.

●Documented●

a full user manual contains all the required information for installation and assembly, including CAD and wiring diagrams

Page 11: Safety — Key to the Machine Solution

12Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

The ‘Safety Chain’

approach

Acquire the information Monitor and processing Stop the machine

Safe signal transmission

One provider for the complete safety chain:●

Reduce cost on the machine safety application through a single automation and complete safety chain provider

Page 12: Safety — Key to the Machine Solution

13Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Fully aligned with our TVDA approach:●

Answers the machine customer’s needs, complementary with our automation architectures

Safety Chain Solution

Safe Stop 1 - servoTVD Architecture

Safety Chain Solution

Page 13: Safety — Key to the Machine Solution

14Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012

●Optimized implementation for increased levels of protection●

A cost optimized solution that reaches a very low probability of dangerous failure (PFHd

), which corresponds to PL e and SIL 3

●Typical applications:●

Assembling, machining centers or similar machines tools

Safe Stop 0, High performance

Safety Chain Solutions

Page 14: Safety — Key to the Machine Solution

15Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012

Safety Chain Solutions

●Safety integrated devices for an easier safety chain configuration●

The drive (ATV32) features an integrated safety torque off function (STO), which meets the requirements of PL e and SIL 3

●Typical applications:●

Textile, wood-working or simple packaging machines

Safe Stop 1, Drive - high performance

Page 15: Safety — Key to the Machine Solution

16Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012

● Improved accuracy through safety integrated devices●

Stopping the machine with the Safe Stop 2 (SS2) function by using the enhanced safety module (eSM) integrated on the servo-drive; it meets the requirements of PL e and SIL 3

●Typical applications:●

Packaging, printing, conversion, or similar machines with long freewheel stopping times (high inertia or low resistive torque)

Safety Chain Solutions

Safe Stop 2, Servo - enhanced safety

Page 16: Safety — Key to the Machine Solution

17Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

What can we do for our customers?

Schneider Electric provides a wide variety of scalable and cost effective solutions from simple electromechanical to programmable systems with safety communications, to meet Performance Level “e”, and SIL 3 as well as local and international safety requirements, to help maximize productivity.

Page 17: Safety — Key to the Machine Solution

18Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Monitor and processingType Safety

RelaySafety

ControllerSafety 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

Page 18: Safety — Key to the Machine Solution

19Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Lexium

eSM

and Adapter Hardware

Optional eSM

Terminal Adaptor

for LXM32 M

Accessories:

-

eSM

Terminal adapter

(Connection of up to 5 Lxm)

-

eSM

Cable

AC

Page 19: Safety — Key to the Machine Solution

20Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Acquire the InformationType Safety Interlock Safety Interlock Safety Interlock

Family XCSA XCSB XCSC

Enclosure Metal Metal Metal

Function Non-Locking Locking by Push Button Locking by Key

Page 20: Safety — Key to the Machine Solution

21Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Acquire the InformationType Safety Interlock Safety Interlock Safety Interlock Safety Interlock

Family XCSE XCSL XCSLE & XCSLF XCSTE

Enclosure Metal Metal Metal - XCSLFPlastic - XCSLE

Plastic

Function Solenoid Locking Solenoid Locking Solenoid Locking Solenoid Locking

Page 21: Safety — Key to the Machine Solution

22Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Acquire the InformationType Safety Interlock Safety Interlock Safety Interlock Safety Interlock

Family XCSPA XCSPL XCSPR XCSMP

Enclosure Plastic Plastic Plastic Plastic

Function Non-Locking Non-Locking Non-Locking Non-Locking

Page 22: Safety — Key to the Machine Solution

23Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Acquire the InformationType Non-Contact Non-Contact Non-Contact Non-Contact

Family XCSDMC XCSDMP XCSDMR XCSDM3/4

Operating Zone

Sao: 0.20 in (5 mm)Sar: 0.59 in (15 mm)

Sao: 0.31 in (8 mm)Sar: 0.79 in (20 mm)

Sao: 0.31 in (8 mm)Sar: 0.79 in (20 mm)

Sao: 0.39 in (10 mm)Sar: 0.79 in (20 mm)

Wiring Cable or connector Cable or connector Cable or connector Cable or connector

Size 2.01 x 0.63 x 0.28 in 3.56 x 0.98 x 0.51 in 30 mm dia. 1.51 in 3.94 x 1.34 x 1.26 in

Page 23: Safety — Key to the Machine Solution

24Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Acquire the InformationType Compact Compact Compact Compact

Family XUSLB XUSLD XUSLPZ XUSLPB

MOS 14 mm and 30 mm0.55 in and 1.18 in

14 mm and 30 mm0.55 in and 1.18 in

300, 400,500,600 mm11.8, 15.7, 19.7, 23.6 in.

500 and 600 mm19.7 and 23.6 in

Sensing Distance

SN

1 to 22.9 ft, or1 to 65.6 ft with PDM

1 to 22.9 ft, or1 to 65.6 ft with PDM

2.6 to 65.5 ft or2.6 to 229.7 ft

2.6 to 26.3 ft

Page 24: Safety — Key to the Machine Solution

25Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Acquire the InformationType Cable Pull Switch Cable Pull Switch Emergency Stop

Family XY2 XY2 XB4 – XB5

Feature Adjustable tripping force Viewing windows to aid in adjusting cable tension

Conforms to ISO 13850

Cable Length 165 ft (50 m) 50 ft (15 m)

Page 25: Safety — Key to the Machine Solution

26Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

In addition to all of the previous products, we offer complete lines of other devices for use in safety related applications:● E-Stop buttons, EMO● Indicating banks● Control Relays and Contactors● Drives● Motion

Other Products for the Safety Chain

Page 26: Safety — Key to the Machine Solution

27Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012

Thank You!