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Saety Handbook

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Saety handbookContents

Product overview 4

Regulations and StandardsGeneral inormation 8

Machine saety 10

Process industry 21

Furnaces 26

Push buttons

EMERGENCY OFF control devices 28

Signal towers and Signal beacons 30

Position switch LS-Series 31

Advant Controller 31-S

Sae intelligence 34

System data 35

Saety-related input/output modules 36

Saety control devices

Rules or application 38

EMERGENCY OFF control gear and saety door watchdog 41

Two-hand control, Dribbling inspection and test equipment 45Extension device, Monitoring relay 46

Technical data /Certifcations C 57x 47

Selection tables/Accessories C 57x 48

Dimension drawings (C 57x, C 580) 49

Electronic saety relay C 67xx 51

Selection table C 67xx 52

Terminology 53

Circuit examples

Switch saely 58

Saety contactor combinations C 57x 61Relay saety combinations C 57x 62

EMERGENCY OFF (EMERGENCY STOP) circuit 63

Protective door monitoring 67

Press control devices 72

Monitoring underspeed 76

Electronic saety relay 77

Appendix

Certifcates 80

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Saety handbookProduct overview

Saety standards

Again and again, the practical implementation o sae-

ty requirements presents new challenges or plant de-

signers and machine manuacturers. What requently

makes the design and planning stage more di cult is

the act that the saety requirements are continuously

extended and tightened against the background o

the CE label and compliance with the machine guide-

lines. ABB STOTZ-KONTAKT GmbH oers a comprehen-

sive range o saety components or plant and machi-

ne manuacture. Depending on the type used, these

components ensure saety directly at the machine, as

well as in the switchgear cabinet.

But ABB STOTZ KONTAKT also has a suitable product

in stock or the saety o the complete system.

Apart rom ulilling the applicable standards and

requirements, ABB products are state o the art so

that the protection o people, machines and the envi-

ronment can be optimally realised in machines and

plants.

The saety components in ABB STOTZ-KONTAKTs pro-

duct range and their applications are exemplary:

Plant saety,

Machine saety,

Switchgear cabinet saety.

Controland Act

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Saety handbookProduct overview

Evaluate

Detect

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Regulations and Standards

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Regulations and StandardsGeneral inormation

Goal

The goal o saety technology is to keep the potential

hazards or man and the environment as low as possible

by applying and utilizing technology. However, this

should be achieved without imposing unnecessary re-

strictions on industrial production, the use o machines

and the production o chemical products. By applying

internationally harmonized regulations, man and the

environment should be uniormly protected to the

same degree in all countries. At the same time, die-

rences in competitive environments, due to dierent

saety requirements, should be eliminated.

Basic principles o European legislation

Legislation states that we must ocus our eorts at

preserving and protecting the quality o the environ-

ment, and protecting human health through preventive

actions (Council Directive 96/82/EC on the control

o major-accident hazards involving dangerous sub-

stances). It also demands Health and saety at the

workplace (Workplace, health and saety legislation,

). Legislation demands that this and similar goals

are achieved or various areas (Areas which are legis-

lated) in the EC Directives. In order to achieve these

goals, legislation places demands on the operators

and users o plants, and the manuacturers o equip-

ment and machines. It also assigns the responsibility

or possible injury.

The EC Directives

Speciy demands placed on plants and systems

and their operators/users to protect the health

and saety o personnel and the quality o the

environment

Defne product eatures and characteristics to

protect the health and saety o users

Contain regulations about health and saety at the

workplace (minimum requirements).

A new, global concept orms the (new approach,

global approach) basis or the EC Directives:

EC Directives only contain generally valid saety

goals, and defne undamental saety require-

ments

Legislation no longer specifes that specifc stan-

dards have to be met

Standards Committees, which have received the

appropriate mandate rom the EC Commission,

can defne technical details in the Standards.

These Standards are harmonized under a specifc

Directive and are listed in the O cial Journal o

the EC. When the harmonized standards are ul-

flled, then it is assumed that the associated sae-

ty requirements o the Directive are ulflled.

EC Directives speciy that Member States recogni-

ze each others national regulations and laws.

The EC Directives have the same degree o impor-

tance, i.e. i several Directives apply or a specifc piece

o equipment, then the requirements o all o the rele-

vant Directives have to be met (e.g. or a machine with

electrical equipment, the Machinery Directive, Low-

Voltage Directive and EMC Directive apply).

Other regulations apply to equipment where the EC

Directives are not applicable. They include regulations

and criteria or voluntary tests and certifcation.

Workplace health and saety legislation

Health and saety at the workplace is subject to natio-

nal legislation, i.e. the national requirements must be

observed, as other saety requirements can be derived

rom these.

Note: The Directives and laws, mentioned in this Ma-

nual, represent a selection in order to provide inor-mation about the essential goals and principles. This

does not claim to be complete.

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Regulations and StandardsGeneral inormation

Standardization goals

The demand to make plants, machines and other

equipment as sae as possible, in-line with state-o-

the-art technology, comes rom the responsibility

o the manuacturers and users o equipment and

products or their saety. State-o-the-art technolo-

gy regarding all aspects which are o signifcance or

saety, is described in the Standards. State-o-the-art

technology is ensured by ulflling the various relevant

standards. This also ensures that the erector o a plant

or system, or manuacturer o a machine or a piece o

equipment, has ulflled his responsibility or ensuring

saety.

Functional saety

From the perspective o the object to be protected,

saety can not be segregated. As the causes o hazards

and the technical measures applied to avoid them can

dier widely, a dierentiation is now made between

various types o saety, e.g. by speciying the cause o

the potential hazard. For instance, electrical saety is

used i protection has to be provided against hazards

due to electricity, or unctional saety, i the saety is

dependent on the correct unction.

This dierentiation is now reected in the new stan-

dardization in so much that there are special stan-

dards which are involved with unctional saety. Thearea o saety o machinery, EN 954 (or ISO 13489) deals

especially with saety-relevant parts o controls and

thereore concentrates on the unctional saety. IEC

handles, in the pilot standard IEC 61508, the unctio-

nal saety o electrical, electronic and programmable

electronic systems, independent o any special appli-

cation area.

In IEC 61508, unctional saety is defned as part o the

overall saety relating to the EUC* and the EUC control

system which depends on the correct unctioning o

the E/E/PE** saety-related systems, other saety-related

systems and external risk reduction acilities.

In order to achieve unctional saety o a machine or a

plant, the saety-relevant parts o the pro-tective- and

control devices must unction correctly and, when a

ault or ailure occurs, the plant or system must remain

in a sae condition or be brought into a sae state. To

realize this, specifc qualifed technology is required,

which ulflls the requirements specifed in the rele-

vant standards.

The requirements to achieve unctional saety are

based on the basic goals:

avoid systematic aults

control systematic aults

control random aults or ailures.

The measure or the achieved unctional saety is the

probability o dangerous ailures, the ault tole-

rance and the quality which should be guaranteed

by avoiding systematic aults. In the Standards, this is

expressed using various terms. In IEC 61508: Saety

Integrity Level (SIL), in EN 954 (ISO 13489): Categories

and in DIN V 19250 and DIN V VDE 0801: Requirement

class (AK).

* EUC: Equipment under control

** E/E/PE: Electrical, electronical, programmable electronical

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Machinery Directive (98/37/EC)*

With the introduction o a common European market,

eective 01.01.1993, a decision was made to harmoni-ze the national standards and regulations o all o the

EC Member States. This meant that Machinery Direc-

tive, as an internal Directive, had to be implemented

in the domestic legislation o the individual Member

States. (For instance, in Germany, the contents o the

Machinery Directive were implemented as the 9th

Decree o the Equipment Saety Law.) For the Machi-

nery Directive, this was realized with the goal to have

unifed protective goals and to reduce trading barriers.

The application area o the Machinery Directive corre-

sponds to its defnition.

Machinery also means an assembly o machineswhich, in order to achieve the same end, are arranged

and controlled so that they unction as an integral

whole.

The application area o the Machinery Directive thus

ranges rom a basic machine up to a complete plant.

The Machinery Directive has 14 Articles and 7 An-

nexes. The basic health and saety requirements in

Annex I o the Directive are mandatory or the saety

o the machine. The protective goals must be imple-

mented in a responsible ashion in order to ulfll the

requirements or conormance with the Directive. The

manuacturer o a machine must prove that the basic

requirements are ulflled. This proo is made easier by

applying harmonized standards.

A certifcation technique is required or machines li-

sted in Annex IV o the Machinery Directive, which repre-

sent a greater hazard potential.

Regulations and StandardsMachine saety

* substitute 89/392/EC, 91/368/EC, 93/68/EC

Overview o the Machinery Directive (rom 89/392/EC)

Application area, selling/marketing, free transfer of goods, protective clause Art. 1 Art. 7Certification technique Art. 8 Art. 9CE-marking, protection against arbitrary fulfillment Art. 10 Art. 12Coming into force, transitional regulations, cancellation of regulations Art. 13 Art. 14

Essential health and safety requirements relating to the design andconstruction of machinery and safety components

Contents of1. EC Declaration of Conformity for machinery andsafety components

2. Declaration by the manufacturer orhis authorized representatives established in the community

CE conformity marking

Types of machinery andsafety components which the procedure referred to in article 8 (2) (b) and(c) must be applied

EC Declaration of Conformity

EC type examination

Minimum criteria to be taken into account by the Member Statesfor the notification bodies

I

II

III

IV

V

VI

VII

35

10

45

84

10

8

8

8

9

Machinery Directive

Appendix Artikel

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Annex IV o the Machinery Directive

1. Electro-sensitive devices designed specifically to detect persons in order to ensure their safety(non-material barriers, sensor mats, electromagnetic detectors, etc.)

2. Logic units which ensure the safety functions of bimanual controls.

3. Automatic movable screens to protect the presses referred to in 9, 10 and 11

4. Roll-over protection structures (ROPS)

5. Falling-object protective structures (FOPS)

B. Safety components

1. Circular saws (single or multi-blade) for working with wood and analogous materials or for workingwith meat and analogous materials.

1.1. Sawing machines with fixed tool during operation, having a fixed bed with manual feed of the work-piece or with a demountable power feed.

1.2. Sawing machines with fixed tool during operation, having a manually operated reciprocating saw-bench or carriage.

1.3. Sawing machines with fixed tool during operation, having a built-in mechanical feed device for thework-pieces, with manual loading and/or unloading.

1.4. Sawing machines with movable tool during operation, with a mechanical feed device and manualloading and/or unloading.

2. Hand-fed surface planing machines for woodworking.

3. Thicknessers for one-side dressing with manual loading and/or unloading for woodworking.

4. Band-saws with a fixed or mobile bed and band-saws with a mobile carriage, with manual loadingand/or unloading, for working with wood and analogous materials or for working with meat andanalogous materials.

5. Combined machines of the types referred to in 1 to 4 and 7 for working with wood and analogousmaterials.

6. Hand-fed tenoning machines with several tool holders for woodworking.

7. Hand-fed vertical spindle molding machines for working with wood and analogous materials.

8. Portable chainsaws for woodworking.

9. Presses, including press-brakes, for the cold working of metals, with manual loading and/or un-loading, whose movable working parts may have a travel exceeding 6 mm and a speed exceeding30 mm/s.

10. Injection or compression plastics-molding machines with manual loading or unloading.

11. Injection or compression rubber-molding machines with manual loading or unloading.

12. Machinery for underground working or the following types: machinery on rails: locomotives and brake-vans hydraulic-powered roof supports internal combustion engines to be fitted to machinery for underground working.

13. Manually-loaded trucks for the collection of household refuse incorporating a compressionmechanism.

14. Guards and detachable transmission shafts with universal joints as described in Section 3.4.7.

15. Vehicles servicing lifts.

16. Devices for the lifting of persons involving a risk of falling from a vertical height of more than3 meters.

17. Machines for the manufacture of pyrotechnics.

A. Machinery

Types of machinery and safety components for which the procedure referred toin Article 8, Paragraph 2, letters b) and c) must be applied

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Standards

To sell, market or operate/use products, these pro-

ducts must ulfll the basic saety requirements o theEC Directives. Standards can be extremely helpul

when it involves ulflling these saety requirements.

In this case, a dierentiation must be made between

harmonized European standards and other technical

rules and regulations which are known in the Directives

as National Standards.

Generally, all European Standards must be included,

unchanged in the national standards o the Member

States, independent o whether they are hamroni-

zed under the Machinery Directive or not. National

standards handling the same subject must then be

withdrawn.

Thus, within a period o time in Europe, a unifed set o

regulations will be created.

Harmonized European Standards

These are drawn-up by the two standards organiza-

tions CEN (Comit Europen de Normalisation) and

CENELEC (Comit Europen de Normalisation lectro-

technique) as mandate rom the EC Commission in or-

der to ulfll the requirements o the EU Directives or

a specifc product. And they must be published in the

o cial documentation o the European Communities.These Standards (EN Standards) are then transerred

into the national standards unchanged. They are used

to ulfll the basic health- and saety requirements and

the protective goals specifed in the Annex I o the Ma-

chinery Directive.

When using such standards, there is an automatic

presumption o conormity; i.e. the manuacturer can

be trusted to have ulflled all o the saety aspects o the

Directive as long as they are handled in the particular

Standard.

However, not every European Standard is harmoni-zed in this sense. The listing in the European docu-

mentation is decisive. The up-to-date version o these

lists can always be called-up in the Internet (Address:

http://www2.echo.lu/nasd/index.html).

The European Standards o CEN or the saety o ma-

chines are hierarchically structured as ollows

A Standards; also known as Basic Standards.

B Standards; also known as Group Standards.

C Standards; also known as Product Standards.

The diagram above shows the structure.

Type A Standards/Basic Standards

As Standards contain basic terminology and defni-

tions or all machines. This includes EN 292 Saety

o machinery Basic concepts, general principles or

design.

A Standards primarily address the party setting B- and

C Standards. The techniques or minimizing risks, spe-

cifed there, can however, also be helpul or manuac-

turers, i there are no relevant C Standards.

Type B Standards/Group Standards

These include all Standards with saety-related state-

ments, which can involve several types o machines.

The B Standards also primarily address the party set-

ting C Standards. However, they can also be helpul or

manuacturers when designing and building machine i

there are no relevant C Standards.

For B Standards, an additional subdivision was made,

and more precisely in:

Type B1 Standards or higher-level saety aspects,

e.g. ergonomic design principles, saety distances

rom potential sources o danger, minimum

clearances to prevent crushing o body parts.

Type B2 Standards or saety equipment are

specifed or various machine types, e.g.EMERGENCY STOP equipment, two-hand con-

trols,

interlocking/latching, contactless protective devices,

saety-related parts o controls.


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Type C Standards/Product Standards

These involve the Machine-Speciic Standards, e.g.

or machine tools, woodworking machines, elevators,

packaging machines, printing machines etc.

The European Standards are conceived, in order to

avoid repeating general statements, which are alrea-

dy included in type A, or type B standards; as ar as

possible, reerence to these are made in type C Stan-

dards.

In addition to machine-related requirements, Pro-

duct Standards can also include requirements which,

under certain circumstances, deviate rom the Basic-

and Group Standards. For the machine OEM, type C

Standard/Product standards have the highest priority.

It can be assumed that it thereore contains the basic

requirements o Annex I o the Machinery Directive

(automatic presumption o conormity).

I there is no Product Standard or a particular machi-

ne, then type B Standards can be applied as support

when building a machine.

National Standards

I harmonized European Standards are not available,

or they cannot be applied or certain reasons, then the

manuacturer can utilize the National Standards. All o

the other technical rules and regulations and European

Standards, not listed in the European oicial docu-

mentation (non-harmonized), all under this term o

the Machinery Directive. Those not listed in oicial

documentation can include, or example, still valid

DIN Standards and VDE Regulations and are declared,

also rom the German government as helpul to ulfll

the Machinery Directive.

However, when such standards are applied, the above

mentioned automatic presumption o conormity

does not apply. This means, that a risk analysis must

be carried-out and proven and i necessary, risk re-

duction measures applied which makes the whole

procedure more costly. These national standards are

or example, used by notifed bodies in order to iden-

tiy whether a specifc product ulflls the goals o the

Machinery Directive.


European Standards or saety o machinery

Basic safety

standards

Basic design principles and

terminology for machines

Group safetystandards

General higher-level safetyaspects standards

Reference to special protectivedevicesGenerally handled safety-relateddevices

Specialist Standards Special safety features forindividual machine groups

TypB

TypB-1

TypB-2

TypA

TypC

Elevators: prEN 81-1 Woodworking machines: prEN 691 Presses + shears: prEN 692, prEN963 Injection molding machines: EN 201 Food preparation machines: prEN 1672-1 Printing and paper machines: pr EN 1010 Machining centers: prEN 12417

Cable railways: prEN 1709 Automated production systems: prEN 1921 etc.

Two-hand circuit: prEN 81-1 Emergency stop equipment, functional aspects

design guidelines EN 418 Light barriers: prEN 61496

Minimum clearances to prevent parts of the bodybeing crushed: EN 349

Safety-relevant parts of control systems:EN 954-1

Safety clearances against accessing dangerouslocations with the upper limbs: EN 294

Electrical equipment of machines: EN 60204-1 Safety of machines inter-latching devices with and

without tumbler: prEN 1088

Safety of machines: DIN EN 292-1

Safety of machinery; basic terminology, generalprinciples for design; technical principles andspecifications: EN 292-2

Noteforusers:

Ifharm

onizedC

Standardsexistfortheparticularproduct,thentheassociatedB-

andifrelevant,alsotheAStandardscanbeconsideredassecondary

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Risk analysis/evaluation

As a result o their general design and unctionality, ma-

chines and plants represent potential risks. Thus, theMachinery Directive requires a risk assessment or

every machine and, i relevant, risk reduction, so that

the remaining risk is less than the tolerable risk. The

ollowing Standards should be applied or the techni-

que to assess these risks:

EN 292 Saety o machinery Basic concepts,

general principles or design

EN 1050 Saety o machinery Principles or risk

assessment

EN 292 mainly handles the risks to be evaluated and

design principles to reduce risks. EN 1050 basically

handles the iterative process with risk assessment and

risk reduction to achieve saety.

Risk assessment

Risk assessment is a sequence o steps, which allows

hazards, which are caused by machines, to be systema-

tically investigated. Where necessary, the risk assess-

ment phase is ollowed by risk reduction. The iterative

process (reer to Graphic) is obtained by repeating

this procedure. This allows potential hazards to be

removed as ar as possible, and allows the appropriate

protective measures to be made.

The risk assessment includes:

Risk analysis

Determining the limits o the machine

(EN 292, EN 1050 Paragraph 5)

Identifcation o hazards

(EN 292, EN 1050, Paragraph 6)

Techniques to estimate risks

(EN 1050, Paragraph 7)

Risk evaluation (EN 1050, Paragraph 8)

Ater risk have been estimated, a risk evaluation is

made as part o an iterative process to achieve saety.

In this case, a decision has to be made whether it is

necessary to reduce a risk. I the risk is to be urther

reduced, suitable protective measures must be selec-

ted and applied. The risk evaluation must then be

repeated.

I the required degree o saety has still not been re-

ached, measures are required to reduce the risk. Risk

reduction and the selection o suitable protective

measures are not part o the risk evaluation. Suitable

protective measures must be used to reduce risks. I

the protective measures involve interlocking/latching-

control unctions, then these must be confgured inaccordance with EN 954.

Standard EN 1050 calls this operation an iterative pro-

cess to achieve saety.

Risk elements are defned as a support tool to evalu-

ate risks. Graphic shows the inter-relationship o these

risks elements.


Iterative process to achieve saety in accordance with EN 1050

NO

YES

EN D

Risk reduction and the selection of appropriate safety measuresare not part of the risk assessment. For a further explanation, referto Section 5 of EN 292-1 (1991) and EN 292-2.

START

Determine the machine limits

Identify the hazard

Risk estimation

Risk evaluation

Reduce risk

Is the machine safe

RISKANALYSIS

RISKASSESSM

ENT

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Residual risk (EN 1050)

Saety is a relative term in our technical environment.

Unortunately, it is not possible to implement the so-

called zero risk guarantee where nothing can happen

under any circumstance. The residual risk is defned

as: Risk, which remains ater the protective measures

have been implemented.

In this case, protective measures represent all o the

measures to reduce risks.

Reducing risks

In addition to applying structural measures, risk re-

duction or a machine can also be realized using saety-

relevant control unctions. For these control unctions,

special requirements must be observed, which are de-

scribed in EN 954-1, graduated according to the level

o risk.

The requirements placed on saety-relevant parts o

control systems are sub-divided into categories, gra-

duated according to the level o risk. Techniques to

select the suitable category as reerence point or con-

fguring the various saety-related parts o a control,

are recommended in Annex B o EN 954-1.


Risk elements

Possible selection o the categories in accordance with EN 954-1

Risk

related to theconsidered hazard

Severity

of the possible harm forthe considered hazard

= +is a

function

of

and

Probability of OCCURRENCE of

that harm

Frequency and duration ofexposure

Probability of occurrence ofhazardous event

Possibility to avoid or limit theharm

S Severity of the injury

S1 Slight (normally reversible) injuryS2 Severe (normally irreversible) injury including

death

F Frequency and/or exposure time to the

hazardous condition

F1 Seldom up to quite often and/or the exposuretime is short

F2 Frequent up to continuous and/or the exposuretime is long

P Possibility of avoiding the hazard

P1 Possible under specific conditionsP2 Scarcely possible

Selecting the category

B, 1 to 4 Categories for safety-related parts ofcontrol systems

Preferred categories for reference points

Possible categories requiring furthersteps

Measures which can be over-dimen-sioned for the relevant risk

Starting point forestimating the riskof the safety-relatedpart of the control

Category

B 1 2 3 4

S1

S2

F1

F2

P1

P2

P1

P2

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The adjacent table indicates a brie summary o the

requirements or the various categories. The complete

text or the requirements is contained in EN 954-1,

Section 6.

Basic requirements to confgure control systems are

defned in the various categories. These are intended

to make the systems tolerant to hardware aults. Ad-

ditional aspects must be observed or more complex

control systems, especially programmable electronic

systems, so that

random hardware ailures can be controlled,

systematic errors/aults in the hardware and sot-

ware are avoided, and

systematic errors/aults in the hardware and sot-

ware can be controlled,

so that su cient unctional saety is achieved or sa-

ety-critical tasks. The necessary requirements are de-

scribed in the German Drat Standard DIN V VDE 0801

and the International Standard IEC 61508. The scope o

the required measures is also graduated corresponding

to the risk reduction required.

Saety Integrated

The measures which are required to make a complex

control adequately unctionally sae or saety tasks are

extremely comprehensive and involve the complete

development- and manuacturing process. Thus, con-

trols such as these are specifcally developed as ail-

sae devices. Advant Controller CS 31-S with AC 31

Saety Fieldbus are examples o such control systems.


Description o the requirements or the Categories in accordance with EN 954-1

Principles toachieve safety

System behaviour 2)Summary of requirementsCategory 1)

B Safety- related parts of control systems and/or theirprotective equipment, as well as their components,shall be designed, constructed, selected, assembledand combined in accordance with relevant standards sothat they can withstand the expected influence.

The occurrence of a fault can lead to theloss of the safety function.

Mainly characterized

by selectionof components.

Mainly characterizedby structure.

1 Requirements of B shall apply. Well- tried componentsand well-tried safety principles shall be used.

The occurrence of a fault can lead to theloss of the safety function but the probabilityof occurrence is lower than for category B.

2 Requirements of B and the use of well- tried safety prin-ciples shall apply. Safety function shall be checked atsuitable intervals by the machine control system.

The occurrence of a fault can lead tothe loss of the safety function between thechecks. The loss of safety function is detected bythe check.

3 Requirements of B and the use of well- tried safety prin-ciples shall apply. Safety-related parts shall be designed,so that:

a single fault in any of these parts does not lead tothe loss of the safety function; and whenever reasonably practicable the single fault isdetected.

When the single fault occurs the safetyfunction is always performed. Some but not all faults will be detected.

Accumulation of undetected faults canlead to the loss of the safety function.

4

1) The categories are not intended to be used in any given order or in any given hierarchy in respect of safety requirements.2) The risk assessment will indicate whether the total or partial loss of the safety function(s) arising from faults is acceptable.

Requirements of B and the use of well-tried safety prin-ciples shall apply. Safety-related parts shall be designed,so that: a single fault in any of these parts does not lead to aloss of the safety function; and the single fault is detected at or before the nextdemand upon the safety function. If this is not possible,then an accumulation of faults shall not lead to a loss ofthe safety function.

When the faults occur the safety functionis always performed. The faults will be detected in time to pre-vent the loss of the safety function.

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Saety-related unctions

The saety-related unctions include, in addition to the

classic unctions

stop

actions in an emergency situation

in the meantime, also more complex unctions such

as

speed limiting

position limiting

speed deviation etc.

The classic unctions are defned in EN 60204-1 and

are generally implemented using basic electromecha-nical components. Electronic programmable systems

can also be used to implement more complex unc-

tions, i they ulfll the relevant standards (IEC 61508,

EN 954 or DIN V VDE 0801).

Stop

Stop categories according to EN 60204-1

There are three stop categories, which are defned in EN

60204-1, independent o an emergency situation:

Stop Category 0

Uncontrolled stop; stopping by immediate removal opower to the machine actuators (e.g. motor).

Stop Category 1

Controlled stop; the power is only removed when the

machine has come to a standstill.

Stop Category 2

Controlled stop, where power is still ed to the ma-

chine when it is at a standstill.

Emergency operations

The new EN 60204-1/11.98 (IEC 60204-1), harmonized

with HD 384 (IEC 60364), has defned the ollowing pos-sible actions or emergency situations (EN 60204-1

Annex D):

Action in an emergency situation includes individu-

ally, or a combination o:

EMERGENCY STOP

EMERGENCY START

EMERGENCY OFF

EMERGENCY SWITCHING ON.

According to EN 60204-1 and EN 418, these unctions

are exclusively initiated by a conscious manual inter-

vention. In the ollowing text, only EMERGENCY OFF

and EMERGENCY STOP will be discussed.

The latter ully corresponds to the same terminology

in the EC Machinery Directive.

EMERGENCY OFF

This is an intervention (action) in an emergency situa-

tion, which disconnects the electrical power to a com-

plete system or installation or part o it i there is a risk

o electric shock or another risk caused by electricity

(rom EN 60204-1 Annex D).

Further, the ollowing is deined in 9.2.5.4.3 o EN

60204-1:

Functional aspects to disconnect the power in an

emergency situation are deined in IEC 60364-4-46

(identical to HD 384-4-46).

Power must be disconnected in an emergency situa-

tion, where

protection against direct contact (e.g. with con-

tact cables, slip ring assemblies, switch-gear in

electrical rooms) is only achieved by maintaining

a clearance or barriers;

other hazard or damage could occur as a result o

electric power.

In an emergency situation, the power supply is dis-

connected rom the machine which results in a Cate-

gory 0 Stop.

I a Category 0 Stop is not permissible or a machine,

then it may be necessary to provide other protection,

e.g. against direct contact, so that power does not

have to be disconnected in an emergency situation.

This means, that EMERGENCY OFF should be usedwhere the risk analysis indicates a hazard due to elec-

tric voltage/power and thereore requires that the

electric voltage is immediately disconnected rom the

complete machine.


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In the application area o the EC, EMERGENCY OFF de-

vices all under the Low-voltage Directive 73/23/EEC,

i they are not used in conjunction with machines. I

they are used in conjunction with machines, then they

come under the Machinery Directive 98/37/EC, as is

true or all o the other electrical equipment.

EMERGENCY STOP

This is an action, in an emergency situation, which

is defned to stop a process or movement which has

become hazardous (rom EN 60204-1 Annex D).

Further, in 9.2.5.4.2 o EN 60204-1 the ollowing is de-

fned:

Stop

In addition to the requirements or stop (reer to

9.2.5.3), the ollowing requirements apply or an emer-

gency stop:

It must have priority over all other unctions and

actions in all operating modes;

The power to the machine actuators, which could

cause hazardous conditions, must be disconnec-

ted as quickly as possible without creating other

hazards (e.g. using mechanical stopping/ braking

devices, which do not require an external supply

by using counter-current braking) or Stop Cate-

gory 1;

Resetting may not initiate a restart.

Stopping in an emergency situation must either be

eective as a Stop, Category 0 or Category 1 (reer to

9.2.2). The Stop Category in an emergency situation

must be defned as a result o the risk evaluation or

the machine.

To technically implement the EMERGENCY STOP, cor-

responding to the application recommendation in the

oreword o EN 60204-1, the requirements o either EN

60204-1 or EN 954 and IEC 61508 can be applied. EN

60204-1 primarily requires that this is implemented

using electromechanical components, as basic (pro-

grammable) electronic systems are not sae enough.

By correctly applying EN 954 and, i required, IEC

61508, electronic- and programmable electronic com-

ponents become unctionally sae enough, that they

can also be used to implement EMERGENCY STOP or

all Categories.

Devices or EMERGENCY OFF and EMERGENCY STOP

In order to ulill the protective goals, both o EN

60204-1 as well as EN 418, the ollowing require-

ments are valid or both unctions (also reer to 10.7

in EN 60204-1):

When contacts switch, even with just a brie ac-

tuation, the control device must positively latch.

It is not permissible that the machine can be re-

started rom a remote main operator control sta-

tion without the hazard or danger frst having

been removed. The emergency stop device must

be consciously released again locally.

Other saety-related unctions

For all other saety-related unctions, EN 60204-1 re-

commends that electromechanical components are

used. With the argument that it is presently di cult

to be able to secure the reliability o ault-ree opera-

tion o a single-channel programmable electronic unit

with su cient confdence. This expressly reers to the

time at which the associated text o the standard was

drawn-up.

The application recommendation in the oreword o

the new EN 60204-1 or this Chapter takes into ac-

count the progress which has been made in develo-ping saety-relevant technology. It recommends that

the dierent requirements o other relevant stan-

dards, e.g. IEC 61508, should be taken into conside-

ration. When taking into account the requirements

o these standards, it is possible to use electronic and

programmable electronics, or example, a ail-sae Ad-

vant Controller 31-S in a saety-related ashion, even

or complex unctions.


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Man Machine

In order to simpliy the interaction between man and

machines, reerence is made to Standards EN 60073an DIN EN 60204.

Switches, pushbuttons and signaling lamps are, in the

frst instance, the machine components which are used

as the interace between man and machine. These

operator control elements are clearly and uniormly

identifed using color coding which has a very spe-

cifc signifcance. This guarantees that the saety o

operating personnel is increased and it is easier to

handle and maintain the operating resources/plants

and systems.

The colors or pushbuttons, the signiicance o thecolors, explanations and application examples are

shown in Graphic.

According to DIN EN 60204-1 (VDE 0113 Part 1) the

ollowing inormation has to be observed:

The preerred colors or START/ON operator con-

trol devices should be White, Grey or Black, pre-

erably White, Green can be used, Red may not be

used.

Red must be used or EMERGENCY OFF operator

control devices. The colors or STOP/OFF operator

control devices should be Black, Gray or White,

preerably Black. Red is also permitted. It is not

permissible to use Green.

White, Grey and Black are the preerred colors or

pushbuttons, which can be used alternating as

START/ON- and STOP/OFF pushbuttons. It is not

permissible to use Red, Yellow or Green.

White, Grey and Black are the preerred colors or

pushbutton control elements which initiate an

operation while they are pressed, and end that

operation when they are released (e.g. jogging).

Green is reserved or unctions, which display a

sae or normal operating condition.

Yellow is reserved or unctions, which display an

alarm or a non-standard (abnormal) condition.

Blue is reserved or unctions which require a spe-

cifc action.

Reset pushbuttons must be Blue, White, Grey or

Black; i they also act as STOP/OFF pushbuttons,

White, Green or Black are preerred, but preeraly

Black. It is not permissible to use Green.

The colors or the indicating lamps, their signifcance

with reerence to the status o the machine as well as

their handling and application examples, are listed in

Graphic (Page 18).

For illuminated pushbuttons, the inormation in Gra-

phics (Page 17 and 18) applies. I problems are en-

countered when assigning suitable colors, White must

be used. For EMERGENCY OFF devices, the color Red

must not be dependent on the illumination status o

the device.

Coding cables

The color coding o switches, pushbuttons and indica-

tor lamps has been discussed in the previous Section.

EN 60204 oers a higher degree o exibility when

coding cables. It specifes that cables at every con-

nection must be able to be identifed in conormance

with the technical documentation .

It is su cient i terminals are numbered, correspon-

ding to the inormation in the circuit diagram, i the

cable can be easily visually tracked. For complex con-

trols, it is recommended that the internal wiring cables

as well as the outgoing cables are coded so that aterthe cable has been disconnected rom the terminal,

it can be easily re-connected later to the same termi-

nal. This is also recommended, or terminal locations


Colors or pushbuttons and their signifcance in accordance with EN 60204-1 (VDE 0113 Part 1): 06.93

ExplanationMeaningColour

Red Emergency Actuate in the eventof a hazardous con-dition or emergency

Yellow Abnormal Actuate in the eventof an abnormal con-dition

Green Normal Actuate to initiate

normal conditions

Blue Mandatory Actuate for a con-dition requiringmandatory action

Black

Grey

White

Note Where a supplemental means of coding (e.g. shape, position, texture) is used for the identification of push-button actuators, then the same colour White, Grey or Black may be used for various functions (e.g. White forSTART/ON and for STOP/OFF actuators).

No specificmeaningassigned

for general initiationof functions exceptfor emergency stop(see note)

Examples of application

EMERGENCY OFF; Initiation ofemergency function

Intervention to suppress abnormalcondition; Intervention to restart aninterrupted automatic cycle

START/ON; however white should

be preferably used

Reset function

START/ON, STOP/OFF (preferred)

START/ON, STOP/OFF

START/ON (preferred), STOP/OFF

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which have to be disconnected when the equipment

is transported.

Using the wording in IEC 60204-1 1997, Paragraph

14.2.1 conductor core coding/identifcation, the Stan-

dards Committee wanted to make the ollowing state-

ment:

1. Each individual cable must be able to be iden-

tifed, however, only in correspondence with the do-

cumentation. It is not necessary that every cable must

be able to be identifed without the documentation

2. The type o coding and also the identiicat ion

technique should be agreed between the manuactu-

rer and operator.

It is not the intention o the Standard to speciy a spe-cifc coding type worldwide. For instance, or saety

reasons, actory-internal speciications may have a

higher priority in order to avoid conusion in specifc

areas which are handled by the same personnel. These

defnitions cannot be generalized due to the wide ap-

plication range o the Standard, rom small individual

machines (high unit volume standard products) up to

large, complex machinery plants (unique equipment

and systems).

Primarily, the avoidance o installation/assembly

aults must be guaranteed using appropriate testing.

Instead o many dierent colors, a single color can be

used or the internal wiring. It should be color-coded

as ollows:

Black or main AC and DC circuits

Red or AC control circuits

Blue or DC control circuits

Orange or interlocking circuits, which are sup-

plied rom an external power source.

The above color assignment is recommended i a deci-

sion is made to just use color coding. The only manda-

tory specifcation is the color coding o the protective

conductor and the neutral conductor. For all other

cabling and wiring, one o the methods, listed in 14.2.4

can be selected (color, numbers or letters; or a combi-

nation o colors and numbers or colors and letters).

Protective conductor marking

The protective conductor must be uniquely identi-

fable as a result o its shape, location, coding or color.

I it is only identiied as a result o its color, then a

two-color combination o green/yellow must be used

along the whole length o the cable. The green/yellow

color combination is exclusively reserved or protecti-

ve conductors.

Neutral conductor marking

I a circuit has a color-coded neutral conductor, thenlight blue must be used. Light blue may not be used

to code other cables i there is a danger o accidentally

interchanging them.

I there is no neutral conductor, a light-blue conductor

may be used or other purposes, but not as protective

conductor.


Colors or indicator lamps and their signifcance in accordance with EN 60204-1 (VDE 0113 Part 1): 06.93

ExplanationMeaningColour

Red Emergency Hazardous con-dition

Yellow Abnormal Abnormal condi-tion Impendingcritical condition

Green Normal Normal condit ion

Blue Mandatory Indication of acondition thatrequires actionby the operator

White Neutral Other condit ions;may be usedwhenever doubtexists about theapplication ofRed, Yellow,Green, Blue

Action by operator

Immediate actionto deal with hazar-dous condition(e. g. by operatingemergency stop)

Monitoring and/orintervention (e.g. byre-establishing theintended function)

Optional

Mandatory action

Monitoring

Examplesof application

Pressure/tempera-ture outside safelimits, voltagedrop, voltage in-terruption, passing

through a stopposition

Pressure/tempera-ture outside nor-mal operating ran-ges; Tripping aprotective device

Pressure/tempera-ture within the nor-mal operating ran-ges, permissivesignal to continue

Prompt to enter,specified values

Generalinformation

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Regulations and StandardsProcess industry

Legislation Requirementsin Europe

For the process industry, essentially the ollowing ECDirectives must be applied:

Council Directive 96/82/EC o 9th o Dec. 1996 on

the control major-accident hazards involving dan-

gerous substances (Seveso Directive II).

Low-Voltage Directive

Machinery Directive (98/37/EC)

Pressure Equipment Directive (97/23/EC).

The latter is only relevant in so much that the devi-ces used must ulfll this Directive. The Directive on

the other hand is not valid or assembling pressured

devices at the users plant, or example, in industrial

system under his responsibility.

At the same time, the health and saety at work laws

(Reer to Page 1/2, Workplace Health and Saety Le-

gislation) and accident prevention regulations must

always be observed.

Seveso Directive

This EC Directive specifes, corresponding to the prin-ciples explained in the introduction, the saety goal.

preserving and protecting the quality o the en-

vironment, and protecting human health through

preventive action;

In order to achieve this goal, the ollowing basic re-

quirements have been drawn-up, which the Member

States must ensure are ulflled.

Concept to prevent severe accidents

The owner/operating company is responsible in dra-

wing up a document setting out his major-accidentprevention policy and to ensure that it is properly

implemented. The major-accident prevention policy

established by the owner/operating company shall

be designed to guarantee a high level o protection

or man and the environment by appropriate means,

structures and management systems (Article 7 Para-

graph 1).

The document must take into account the ollowing

basic principles.

The concept to prevent severe accidents must be

in written orm.

A saety management system, in which, among

others, the ollowing issues are regulated:

Determining and evaluating the risks defning

and applying techniques to systematically deter-

mine hazards

Operation monitoring defning and applying

techniques or sae operation, including the

maintenance and service o the plants and

systems.

Quality assurance defning and applying techni-

ques to continuously ensure that the goals are

achieved.

Saety report

The owner/operating company is responsible in ge-

nerating a saety report, in which the ollowing is de-

fned,

that the concept to prevent severe accidents has

been implemented,

that the hazards have been identifed and all o

the required measures to prevent these types o

accidents and limiting the results or man and the

environment, have been put in place, and

the implementation, erection and installation and

operation o all plants and systems is adequately

sae and reliable.

Inspection

The regulatory bodies must set-up a system o inspec-

tions to systematically check the operational-, orga-

nizational and management-specifc systems o the

operation which will allow these regulatory bodies to

confrm that the user can prove,

that he has undertaken measures to prevent se-

vere accidents, and

he has provided adequate measures to limit the

results o any accident

This EC Directive must be implemented on a national

basis.

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Technical measures toulfll the legislative goals

The frst priority is to design the process so that it isintrinsically sae. Where this is not possible, then ad-

ditional measures are required in order to reduce the

remaining risk, as a result o the process, to a tolerable

level. This can be realized using electronic controllers

i these are suitable or the particular task. Electronic

controllers are then suitable or securing the saety o

the plant, i they have been especially designed or this

purpose. The requirements are described in Standards.

Relevant standards or saety measuresusing process control technology

For saety measures using process control technology,e.g. in Germany, presently the ollowing national stan-

dards must be applied:

DIN V 19250 Basic saety issues or control and

instrumentation protective devices

DIN V 19251 Instrumentation and control protec-

tive devices requirements and measures or sa-

ety-related unctioning

DIN V VDE 0801 Basic rules or computers in sys-

tems with saety-related tasks. The standards

are also recognized in other European countriesand appropriately applied, but however, this

must be clarifed on a case-or-case basis. The in-

ternational standards or this application area are:

IEC 61508 Functional saety o electrical/electro-

nic/programmable electronic saety-related sys-

tems

Drat IEC 61511 Functional saety: saety instru-

mented systems or the process industry sector.

IEC 61508 is a basic standard, primarily or developing

sector-specifc standards. It can be directly applied, ithere is no specifc standard or the associated appli-

cation area.

Presently, in Germany, the above specifed national

standards are still valid. Today, instead o DIN V VDE

0801, IEC 61508 can be used. DIN V 19250 and 19251

are scheduled to be replaced by IEC 61511.

The national standard in the US is

ISA S 84 Application o Saety Instrumented Sys-

tems or the Process Industries with Technical

Report TR 84.

The process industry in the US and Canada is not inten-

ding to replace ISA S 84 by IEC 61508, but only with IEC

61511 (the principles o ISA S 84 correspond to those

o IEC 61508).

Further, or the equipment and deviced used, there

are additional standards which apply which are invol-

ved with specifc saety requirements. Also reer to the

Section on Machine Saety.

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Announcement o process control systems in saetyrelated/non-saety related confgurations

Principle o risk reduction (acc. to IEC 61508)

Reducing risks usingprocess control technology

Measures are required to reduce risks, i a ailure o

the basic process control system can lead to a dan-

gerous event or can cause the plant or system to go

into a hazardous condition and i the resulting risk is

unacceptably high. In this case, suitable protection

measures must be taken either to su ciently reduce

the probability o a hazardous event occurring, or to

reduce the extent o the damage. This can be realized

using electronic controller-based saety instrumented

systems, i these ulfll the saety requirements.

Risk reduction

As it is not possible to completely exclude certain risks,

both rom a technical and cost-eective standpoint, it

is necessary not only to determine the existing risk,

but also to defne and speciy a risk which can be tole-

rated. The measure or the saety integrity o the risk-

reducing unctions is then derived rom the dierence

between these two actors.

IEC 61508 defnes Saety Integrity Level (SIL) as a

target measure or the probability o ailure or

executing risk-reducing unctions.

Drat IEC 61511 uses the Saety Integrity Level

(SIL), defned in IEC 61508 as a target measure

or the probability o ailure o the execution o

the risk-reducing unctions.

Actual risk reduction

Partial risk coveredby other technologysafety-related systems

Partial risk coveredby E/E/PE safety-related systems

Risk reduction achieved by all safety-related systems andexternal risk reduction facilities

Partial risk coveredby external riskreduction facilities

Necessary risk reduction

Increasing risk

EUC riskResidual risk Tolerable risk

Prevention

Safety instrumented prevention system

Mitigation

Safety instrumented mitigation system

Basic Process Monitoring systems

Basic Process Control systems

Safety-related

Non-safety relevant

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Saety integrity levels according to IEC 61508: Target ailure measure or a saety unction, allocated toa saety-related system.

Comparison o the requirement categories(This comparison is or inormation purposes only, as the classi-fcations cannot be transerred one to one.

Evaluation unit, e.g. saety PLC

Risk graph and requirement classifcations to DIN V 19250

Selecting the equipment and basicso the required eatures

Saety unction

Risk reduction using electronic controllers is realized by

defning unctions or each possible hazardous event

or each possible dangerous condition o the plant or

system, which prevents the dangerous event occur-

ring. These so-called saety unctions are to maintain

the plant or system in a sae state or to re-establish

this sae state i a dangerous event could occur due to

a ailure or a disturbance in the plant or system. The

saety unction can also be used to reduce the extent

o damage due to a hazardous event.

The defnition o a saety unction always includes the

specifcation o the unction itsel (e.g. inhibiting the

eed to a container, i the level has reached the upper

limit), and the saety integrity, derived rom the risk

analysis.

Implementing the saety unctions

Every saety unction always includes the complete

chain, rom inormation acquisition, through inorma-

tion evaluation up to executing the required action.

Equipment involved, or example, ailsae PLCs, sen-

sors and actuators etc. must ulfll, as a total, the de-

termined SIL rom the risk evaluation. I a unit is used

at the same time or various saety unctions, it mustulfll the highest SIL o the individual unctions.

Safetyintegritylevel

High demand or continuous modeof operation(Probability of a dangerous failureper hour)

Low demand mode of operation(Average probability of failure toperform its design function ondemand)

4

3

2

1

109 to < 108

108 to < 107

107 to < 106

106 to < 105

105 to < 104

104 to < 103

103 to < 102

102 to < 101

Category(EN 954-1)

Safety class(SIL)(IEC 61508)

B1 22 334

01123344

Requirementcategories(DIN V 19250)

12345678

Acquireinformation

Evaluateinformation

Executeaction

Safety function

SensorEvaluation

unitActuator

Extent of loss

Injury1

Duration of stay Risk avoidance Probability

relativelyhigh

low verylow

2

3

4

5

6

7

8

1

2

3

4

5

6

7

1

1

2

3

4

5

6

Several fatalities

Fatality

Catastrophe

Riskparameters

possible

not possible

possible

not possible

seldom

frequent

seldom

frequent

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Maximum permissible SIL or a non-complex sub-systems dependent on its ault tolerance N and the achievedsae ailure raction (acc. to IEC 61508-2 FDIS)

Device characteristics and eatures

I PLCs are used or inormation processing, these

must ulill as Saety-PLC the requirements o the

relevant standards and ulfll the specifed SIL. They

must also be certifed by an independent tester. This

is also valid or other complex devices where not all

o the potential ault/ailure modes can be specifed,

because they use microprocessor technology. The es-

sential characteristics and eatures o a ail-sae PLC,

which are requested in the standards with various

graduated levels, are:

When developing, manuacturing and servicing,

specifc measures and techniques must be applied so

that systematic aults can be avoided.

The PLC must be able to control systematic ailu-

res which occur during operation.

The PLC must detect random hardware ailures

during operation and be able to control them.

To be able to control a ailure means that when

the system detects a ault or ailure, the saety unc-

tion, defned or this case (e.g. shutdown the plant), is

reliably executed.

Application

When using a ail-sae PLC, only the conditions, de-

ined in the associated Saety Manual, and i rele-

vant, additional conditions o the certifcate, must be

maintained. For the peripheral devices which are to

be connected (e.g. sensors and actuators), in addition,

the requirements in the standards (IEC 61508 and IEC

61511) must also be taken into account regarding the

ollowing aspects:

Systematic aults must be avoided, e.g. confgu-

ring-, installations- and handling aults

Random aults or ailures must be detected and

controlled.

Necessary ault tolerance. This is dependent on

the possibilities available to detect aults and

ailures.

Required service/maintenance.

IEC 61508 defnes the maximum permissible SIL o a

system or subsystem dependent on its ault tolerance

and the sae ailure raction over the total possible

ailures (reer to Graphic). Dangerous ailures must be

detected and a required response must be perormed

within a suitably short time. These time requirements

are defned in IEC 61508-2.

In order to detect aults or ailures in peripheral devi-

ces, test- and monitoring unctions can be integrated

into the saety PLC.

When using complex peripheral devices (e.g. trans-

mitters with microprocessor), it must be ensured that

these devices themselves ulfll the relevant standards

(e.g. IEC 61508 or IEC 61511).

The complete saety instrumented system must be

confgured, so that it ulflls the relevant standards or

all o its saety-relevant unctions. IEC 61508 and Drat

IEC 61511 are relevant regarding unctional saety.

Safe failure fract ion

< 60 %

6090%

9099%

99 %

SIL 1

SIL 2

SIL 3

SIL 4

SIL 2

SIL 3

SIL 4

SIL 4

SIL 3

SIL 4

SIL 4

SIL 4

Hardware fault tolerance (see note 2)

0 (see note 1) 1 2

NOTE 1: See IEC 61508-2 for details on interpreting this tableNOTE 2: A hardware fault tolerance of N means that N + 1 faults could cause a loss of the safety function.

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Regulations and StandardsFurnaces

EC Directives

Furnaces and burners are subject to the relevant direc-

tives due to their application and the devices which areused. There are no specifc EC Directives or urnaces.

Furnaces are subject, where relevant, to applicati-

on-specifc directives. Industrial thermo-processing

equipment are, or example, classiied as machines

under the Machinery Directive.

Standards

Industrial thermo-processing equipment

There is a European drat standard or these systems,

which was drawn-up under a mandate o the Machin-

ery Directive, and more precisely, prEN 746 Industrial

thermo-processing equipment with

Part 1: General saety requirements o industrial

thermo-processing equipment

Part 2: Saety requirements or combustion and

uel handling systems.

prEN 746 can be applied to industrial thermo-proces-

sing equipment, or example

Metal producing and processing

Glassworks,

Ceramic plants,

Cement-, lime-, and gypsum plants,

Chemical plants,

Incinerators etc.

This reers to EN 60204-1 and EN 654-1 as well as, or

saety-relevant electronic systems, also to IEC 61508.

Furnaces

For urnaces, which do not belong to industrial ther-

mo-processing equipment, and are not used to heat

process liquids and gases in the chemical industry,

there are the ollowing general standards or electrical

equipment the European Drat Standard

prEN 50156 Electrical equipment or urnaces

Part 1: Requirements or application design and

installation

and the German Standard

DIN VDE 0116

The ollowing Standards are available or burners:

prEN 676 gas burners;

EN 230 oil-vapor burner in a mono-block design;

EN 267 oil burners;

EN 298 automation equipment or urnaces or

gas burners and gas units with and without blower.

EMERGENCY OFF or urnaces

For equipping urnaces with devices to switch-o in

an emergency situation, prEN 50156 specifes that EN

60204-1 and EN 954-1 must be observed so that the

appropriate EC Directives are ulflled.

The regulations are also involved with the associated

equipment or storage, preparation and pumping

uels.

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Push buttons

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Push buttonsEMERGENCY OFF control devices

Relevant standards

IEC 60947-5-5 (Requirements or ulflling the ma-

chine guidelines)

EN 60204-1 (Saety o machines Electrical equip-

ment o machines)

EN 60947-5-1 (Low-voltage switchgear with posi-

tive opening contacts)

EN 999 (Approach speed)

EN 292-1 (Saety o machines General design

guidelines)

EN 954-1 (Saety o machines Saety-related parts

o control systems)

Product saety through new standards

The EMERGENCY OFF operating devices rom ABB are

tested according to the new standard or electrical

EMERGENCY OFF devices with mechanical latching,

IEC 60947-5-5 (1997-11), and the corresponding gui-

delines EN 60204.

The ollowing tests have to be passed in order or the

standard to be ulflled:

Category B, 1, 2: acc. to EN 954-1

Using a contact block

Use o two switching elements. A dual-channel control

is absolutely necessary or this category when used or

ail-sae evaluation and diagnostics equipment.

Continuous 6,050 cycles. This is not a test oftest: the mechanical service life, which

is 100,000 operations.

Robustness: A force of 113 N on three axes.

Environmen- Heat and cold, high air humiditytal test: and 5 % NaCl solution

High voltagetest: 2,500 V

Reset test: Tensile force 50 N

Shock test: 15 g

Vibration

test: 2 h at 50 m/s2

Positiveopeningcontacts: according to IEC 947-5-1, K.2.2

Using with a fail-safe Advant 31-S

evaluation unitAdvant 31-S07 EB 91 S

EmergencyOFF

Using with safety combination C 57x

safety combinationC 57x (Cat.2)

EmergencyOFF

Using with a fail-safe Advant 31-S

evaluation unitAdvant 31-S07 EB 91 S

EmergencyOFF

Using with safety combination C 57x

safety combinationC 57x (Cat. 3, 4)

EmergencyOFF

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Push buttonsEMERGENCY OFF control devices

Assembled stations

ABB has two enclosure systems or the installation o

pushbuttons in situ:

Insulated enclosure providing protection-rating IP65

Metal enclosure providing protection-rating IP67

While the insulated enclosure can withstand all nor-

mal internal and external loads, the metal enclosure

made o lightweight metal provides increased loa-

ding capacity with respect to leaks and mechanical

stresses.

Apart rom the individual enclosures, ABB also oers

a range o the most common combinations o in-situ

controls ready assembled ex stock. Furthermore, it is

also possible or customer specifc, tailor made and

pre-assembled in-situ controls to be produced to or-

der.

Accessories

ABBs comprehensive range o accessories enables

virtually all the combinations o pushbuttons ound in

practice to be simply and inexpensively realised.

The ollowing in-situ controls are available pre-assem-

bled ex stock:

Insulated enclosure with 1 control (grey/black

enclosure)

1x pushbutton with 1NO or 2NO

1x mushroom button 2NC

EMERGENCY OFF controls 2NC (yellow/black

enclosure)

Insulated enclosure with 2 controls (grey/black

enclosure)


Insulated enclosure with 3 controls (grey/black

enclosure)


2x pushbutton with 1x indicator light

Metal enclosure with 1 control (grey enclosure)

EMERGENCY OFF pushbutton 2NC

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Push buttonsSignal towers and signal beacons

Signal Tower K 70

Rapid assembly o the signal elements due to

bayonet system

Simple replacement o deective bulbs in every

stage

Flexible composition o the signal elements pos-

sible

Up to 5 elements possible max. 10 elements

with double angle

Lightening elements can be ftted at every stage

Use o up to 5 lightening elements

High protection rating, IP54 or all optical and

acoustic signal elements

LED elements or long service lie

Colour selection to IEC 73, Version 4, 1991 Descrip-

tion and colours or pushbuttons/Signal beacons and

inormation with respect to use o the colours (extract

rom the standard):

Signal Beacons K SB

Tamper-proo design withstands all mechanical

and natural conditions both indoors and out-doors

High protection rating IP65

Cap consists made o high-impact polycarbonate

(up to 20 yrs)

Rapid bulb change rom the inside o the switch-

gear cabinet

Colour Pushbutton/Significance Indicator light/Significance

Serious risk: Dangerous condition

Attention/Imminentcritical state

Normal condition or safe

Status, which requires a definedaction

No special significance

Risk: Act urgently

Attention: Measures necessary

Normal condition, Measures fornormalisation or securing

Predetermined significance

No special significance

Red

Amber

Green

Blue

White, grey, b lack

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Push buttonsPosition switches LS-Serie

Relevant standards

EN 1088 (Latching devices in conjunction with

isolating protective devices)

EN 60947-5-1 (Low-voltage switchgear with posi-

tive opening contacts)

prEN 999 (Approach speed)

EN 292-1 (Saety o machines General design

guidelines)

EN 954-1 (Saety o machines Saety-related

parts o control systems)

EN 60204-1 (Saety o machines Electrical equip-

ment o machines)

Product spectrum

Position switches LS-Series can be used or:

Monitoring protective equipment with hinges,

such as hinged doors, aps, covers etc.

Monitoring protective equipment which can be

moved sideways, or example, sliding doors, pro-

tective screens etc.

Detecting hazardous movements o machine

parts.

Every category can be achieved by using

ABB position switches LS-Series are optimally harmo-

nized with the requirements or the highest degree o

saety and oer the ollowing advantages:

Positive opening o the NC contacts

Version with/without separate actuator

Increased saety using additional latching

(tumbler mechanism)

High degree o protection IP 65/67

Standard enclosure, also in accordance withDIN EN 50047 and 50041

Dierent actuators

Electrically insulated contacts with moving doub-

le contacts.

Position switches LS-Series are supplied with

separate actuators or without actuator. The actuator

elements are shown or the particular switch types.

Positive opening operation o the contacts

(EN 60947-5-1)

Positive opening operation is specifed in accordance

with DIN VDE 0660 Part 200 and is the same as IEC

947-5-1-3 and EN 60947-5-1.

For the electrical equipment o machines, the positive

opening o NC contacts is expressively speciied in

all saety circuits. It is designated according to IEC

947-5-1-3 by the ollowing character (personnel

protective unktion).

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Push buttonsPosition switches

Product spectrum

Plastic casing

Double casing

IP 65 protection degree

Complying with:

EN 50047 standard or 30 mm width 1 cable

conduit Pg11

EN 50041 standard or 40 mm width 1 cabel

conduit Pg13.5

Metal casing


Complying width

EN 50041 standard or 40 mm width 1 cableconduit Pg 13.5

Without normalisation or 60 mm width 3

cable conduits Pg 13.5

Actuators

Saety key, plunger, roller plunger, roller lever,

adjustable lever, or spring rod

Contact blocks

Two electrically separated moving contacts,

Zb shape Snap action or slow contact dependent action

Positive opening operation o N.C. contact(s)

The limit switches are delivered completely as-

sembled, ready or installation.

Many variants (Casing, actuators or contact blocks) are

available on request.

Foot switches

Foot switches with cover

Double insulation


Actuation: ree movement; locked in normal posi-

tion; latched in low position

Mini oot switches


Free movement

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Advant Controller 31-S

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Advant Controller 31-SSave intelligence

A control or saety and restart unctions

The Advant Controller 31-S can be used to design and

standardise small, decentralised control units. With

a control centre, the saety and restart unctions are

supported simultaneously. Saety signals are locally

linked with the saety control centre via the AC31 sa-

ety feld bus.

Certifcation

The Advant Controller 31-S is certifed to international

standards:

DIN V 19250: Basic saety issues or control and

instrumentation protective devices Requirements

category (AK) 1-4

EN 954-1: Saety o machines, Category 3

DIN VDE 0116: Electrical equipment or burner

systems. Requirements or saety-oriented elec-

tronic components, Item 8.7

DIN EN 298: Automation equipment or urnaces

or gas burners and gas units with and without

blower, Items 8, 9 ,10

NFPA 8501: Standard or boiler unctions with a

burner

NFPA 8502: Standard or the prevention o urnace

explosions/implosions in boilers with several

burners

Areas o application

The Advant Controller 31-S is a saety-orientated con-

trol system which is suitable or a diverse range o uses

in plant and machines. Typical applications are e.g.:

Burner and boiler controls

Fuel engineering, gas consumption equipment

Storage and conveying equipment, mixing tech-

nology

Machine manuacture, e.g. or printing and pac-

kaging machines

Construction and container cranes

Plant manuacture, environmental engineering

Road tra c signal systems, tunnel construction

Process locks and saety devices

System topology with modular construction

AC31 Safety Fieldbus

AC31-S Controller

E/A Module

0 V +24 V +

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Advant Controller 31-SSystem data

Saety-oriented automation device or programming sotware 907 PC 33/331/338

Type 07 KT 94-S 07 KT 93-S

Order number GJR 525 2100 R 2161 GJR 525 1300 R 2171

Weight per item 0.25 kg 0.25 kg

Programm memory 480 kbyte 56 kbyte

Processing time 0.2 ms 0.7 ms(35% word, 65% bit)

Integrated digital I/O 24/16/8 24/16

Decentralised digital I/O max. 992 max. 992

Integrated Al (not-S) 8 (10 V, 5 V 0 10 V, 0 5 V0 20 mA, 4 20 mA

50 C + 400C30C + 70Cor as DI)

Integrated AO (not-S) 4 (10 V, 0 20 mA 4 20 mA or as DO)

Decentralised analogue I/O max. 96/96 max. 96/96

MODBUS connection 2 x integrated via coupler

ARCNET connection integrated integrated

Integrated safety field bus AC31 safety field bus AC31 safety field bus

Smart Media Card Secures user program and data

Sequencers per 16 steps 128 128

Number of times free via software free via software

Number of counters free via software free via software

Real time clock 1 1

Supply voltage 24 V DC 24 V DC

Safety field bus AC31 safety field bus, RS 485-BUS, 2 wire cable (twisted, screened)max. 31 in-situ modules, max. cable length 500 m (2000 m with Re-peater), also via optical fibre (via converter) Cycle time for 31 modu-les with 8 digital inputs or outputs: 12 ms

Mechanical construction Modules in plastic enclosure, fixing via top-hat rail 35 mm to DINEN 50 022 or using screws on assembly panel

Diagnostics Cycle monitoring, battery monitoring, identification of syntax errors,check sum monitoring

Dimensions (W x H x D) 240 x 140 x 85 mm 240 x 140 x 85 mm

COM1

COM2

5

230

230240

65

130

140

65

170

111

Depth of device: 85 mmCOM 1 interface jack isplaced lower so that therequired installation depthdoesnt increase even forplugged in interfacecables. If top-hat rails areused the installationdepth increases by theoverall depth of the rails.

(Dimensions for assemblydrill holes are printed inbold type.)

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Advant Controller 31-SSaety-related input/output modules

Programming and test sotware, additional package

Type 07 DI 90-S 07 DO 90-S 07 Al 90-SSafe inputs Safe outputs Safe analogue inputs

Order number GJR 525 0900 R 0202 GJR 525 0800 R 0202 GJR 525 1200 R 0202Weight kg 0.25 0.25 0.25

Number of digital channels 8 8

Number of analogue inputs 4

Supply voltage 24 V DC 24 V DC 24 V DC

Signal level/Measuring range Short circuit after ZP: 0-Signal: 0 3 V 4 20 mA0 15 % of UP 1-Signal: > UP 2.5 V Error message Range -(0 3.6 V at UP = 24 V) Monitoring 0-Signal: underflow: if input current0-Signal: 1535% of UP Output level > 8 V (5 V typical) < 3.6 mA(+ 3.6 8.4 V at UP = 24 V) at starting state 0 (0-Signal) Error message overrange:undefined level: lead to internal error if input current > 20.4 mA35 65 % of UP (device switches off)(+ 8.4 15.6 V at UP = 24 V)

1-Signal: 65 85% of UP(+ 15.6 20.4 V at UP = 24 V)Short circuit after UP:85 100 % of UP(+ 20.4 24,0 V at UP = 24 V)

Potential separationagainst system bus yes yes yes

Number of modules per line max. 8 max. 16 max. 6

max. switching currentof the transistor outputs 0.5 A, short-circuit proof

Resolution 12 bit

Dimensions 120 x 140 x 85 mm 120 x 140 x 85 mm 120 x 140 x 85 mm

65

130

65

140

94

120

20

85

25

111

75

5

94

Depth of device: 85 mmIf top hat rails are used,the installation depthincreases by the overalldepth of the rails.

(Dimensions for assemblydrill holes are printed inbold type.)

Type 907 PC 33 907 PC 331 907 PC 338 907 PC 339

Order No. German GJP 520 3900 R 0302 GJP 520 4500 R 0402 GJP 520 6700 R 0102 GJP 520 7500 R 0102

English GJP 520 4000 R 0302 GJP 520 4600 R 0402 GJP 520 6800 R 0102 GJP 520 7600 R 0102

Description Programming and test Programming and test Additional package of Additional package of

software General des- software in AWL, FBS, safety functions for safety functions forcription of the program- KOP, system-specific 07 KT93-S incl. 07 KT94-S incl.ming interface exc l. soft - part inc l. software on safety manual safety manualware disc, documentation(SW s. 907 PC 331)

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Saety control devices

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Saety control devicesRules or application

Saety Combinations types C 57x und C 581

The complete program o saety combinations has been

especially designed or the requirements o state-o-

the as saety technology. Saety combinations can be

simply used to confgure saety circuits, as the devices

ulfll EN 60204-1 (VDE 0113 Part 1) and are certifed

by the German Trade Association (BG), German Sta-

tutory Industrial Accident Insurance Association (BIA)

and the Swiss Accident Insurance Institution (SUVA).

Applications

Saety combinations cover wide range o possible

applications. These include monitoring EMERGENCY-

STOP and protective door devices. It is also possible to

monitor press control systems.

Saety Combinations tend to be used or some-what

less complex saety circuits as conventional switching

technology used with electromechanical contacts. Sa-

ety circuits using PLC technology (Advant Controller

31-S) can be used or more complex plants and sy-

stems with a high unctional scope (e.g. with a diagno-

stics unction when an EMERGENCY OFF is initiated). A

ail-sae Advant Controller 31-S is requently used i a

Advant Controller is used or the non-saety-relevant

control o the plant or system.

Positively-driven contacts, a plus or saety

Relays are oten used or saety circuits. The special

eature o ABB saety combinations is the act that con-

tactors or saety relays use positively driven contacts. In

this case, ABB oer two Versions o saety combinati-

ons, and more specifcally, using contactors (CC 570) or

relays (C 571C 581).

Contactor-type saety combinations (C 570)

Contactors have a high switching capacity. For sa-

ety combinations, rated operating currents o

6 A are possible or AC-1, and or DC-13, up to6 A, and a thermal continuous current up to 10 A.

This is also valid up to 55C when mounted in a ca-

binet without having to derate the devices. With this

perormance data, you can optimally confgure every

saety circuit, and it is even possible to switch smaller

drives directly using a saety combination. With a

saety combination, additional main contactors are

not required to switch higher ratings. That naturally

saves costs.

Furthermore, high switching currents also mean more

saety and saety combinations use auxiliary contactors

with an extremely high contact reliability. Statistically,only 1 contact ault occurs every 100 million switching

operations. These low ault statistics signifcantly in-

crease the plant availability.

Relay-type saety combinations(C 571C 581)

In recent years, the trend in low-voltage technology

has been towards miniaturization o the switching de-

vices. With newly-developed, smaller devices, it was

possible to increasingly accommodate more unc-

tionality in a cabinet. It was thereore a logical step

that when it came to saety technology, that there

would also be demand or smaller, more compact sa-

ety combinations. ABB ulflled this enhanced saety

demand by using space-saving saety relays with po-

sitively-driven contacts. These saety relays switch so

that they are intrinsically ail-sae. In this case, 2 con-

tacts, which are independent o one another, have to

be switched in series; normally so-called NO contacts

o monostable relays are used. I a contact was to weld,

then the 2nd contact, connected in series, is used to

disconnect the circuit. A positively-driven NC contact

is used to signal the ault, in this case the welded NO

contact. This NC contact is actuated in synchronism

with the NO contact. For example, i the NO contact

is closed, then the NC contact, which is provided or

monitoring, must be open and vice versa. Using these

paired, positively-driven contacts, it is ensured that

the saety relay also drops-out, i all o the contacts o

the circuit to be protected are welded.

With this new-type o contact arrangement, the saety

relay has positively-driven contacts, which are testedand recognized by SUVA and which ully conorm to

Standard ZH1/457.

The relay saety combinations C57x and 581 can be

used in ambient temperatures o up to 60C, up to

70C with some restrictions when mounted in-line.

Many switching unctions can be implemented using

the series o C 57x and 581 saety combination. The

ollowing program overview shows the spectrum o

devices available:

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Saety control devicesRules or application

The saety combinations Series C 57x and C 581 con-

sist o:

Basic units Expansion units, and

Press-control units.

Basic units

These are used to saely monitor EMERGENCY OFF

devices and protective doors. The basic units have,

in addition to instantaneous enabling contacts, also

o-delayed enabling contact

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