basics of safety applications - wtwh media llc · 3/23/2016 · distributed safety systems •...
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usa.siemens.com/controlsUnrestricted © Siemens 2016
Basics of Safety Applications
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03.23.2016Page 2 John Burns/ DF CP
DISCLAIMER/ TERMS OF USE:
THE INFORMATION PROVIDED HEREIN IS PROVIDED AS A GENERAL REFERENCE REGARDING THE USE OF THE APPLICABLE PRODUCTS IN GENERIC APPLICATIONS. THIS INFORMATION IS PROVIDED WITHOUT WARRANTY. IT IS YOUR RESPONSIBILITY TO ENSURE THAT YOU ARE USING ALL SIEMENS PRODUCTS PROPERLY IN YOUR SPECIFIC APPLICATION. ALTHOUGH THIS SITE STRIVES TO MAINTAIN ACCURATE AND RELEVANT INFORMATION, THERE IS NO OFFICIAL GUARANTEE THAT THE INFORMATION PROVIDED HEREIN IS ACCURATE. IF YOU USE THE INFORMATION PROVIDED HEREIN IN YOUR SPECIFIC APPLICATION, PLEASE DOUBLE CHECK ITS APPLICABILITY AND BE ADVISED THAT YOU ARE USING THIS INFORMATION AT YOUR OWN RISK. THE PURCHASER OF THE PRODUCT MUST CONFIRM THE SUITABILITY OF THE PRODUCT FOR THE INTENDED USE, AND ASSUME ALL RISK AND LIABILITY IN CONNECTION WITH THE USE.
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03.23.2016Page 3 John Burns/ DF CP
Why Safety Technology?
Protection of…• People• Environment
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03.23.2016Page 4 John Burns/ DF CP
Why safety technology?
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03.23.2016Page 5 John Burns/ DF CP
What aspects do the safety standards cover
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Cutting disc > Cutting off
Transport rollers > Crushing and shearing
Clamping plates > Crushing
Chips > Cutting, penetrating
Risk Assessment Risk Reduction Proof
The necessary steps towards a safe machine can be illustrated with a process chain.
Safety Process Chain
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03.23.2016Page 7 John Burns/ DF CP
Risk Assessment
Risk Reduction
Proof Document resultsCarry out a validationDocument the measures
Implement a safety concept and put it into operation
Design the architectureof the safety functions
Define and evaluate
the safety measures
Evaluate the risksIdentify the hazardsDescribe the machine
Safety Process Chain
Risk Assessment Risk Reduction Proof
The necessary steps towards a safe machine can be illustrated with a process chain.
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03.23.2016Page 8 John Burns/ DF CP
Risk Assessment
Risk Assessment Risk Reduction Proof
The measure for achieved functional safety is the probability of dangerous failures, the fault tolerance and the quality that is to be guaranteed as a result of freedom from systematic faults. It is expressed in the standards using different terms
• In IEC 62061: “Safety Integrity Level” (SIL)• In ISO 13849-1: “Performance Level” (PL)
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03.23.2016Page 9 John Burns/ DF CP
Risk Reduction
•Technology solutions consist of three main components
DetectionDetection EvaluationEvaluation ReactionReaction
Risk ReductionRisk Assessment Proof
•Mechanical Guarding
•Education
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DetectionEmergency stop and protective area monitoring
DetectionDetection EvaluationEvaluation ReactionReaction
Initiates stopPrevents unauthorized accessDetects dangerous machine functionsPositive opening contacts
Positive opening switches are designed in such a way that actuation of the switch always results in opening the contacts. Welded contacts are opened by actuation (EN 60947-5-5)
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Detection
Standard position switches
Safety switch with separate actuator
Safety switchhinge switch
Safety switches with separate actuator and
interlocking
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03.23.2016Page 12 John Burns/ DF CP
Panel Mounted Configurable Enclosures Distributed Safety
Detection
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Detection
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Detection
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Reaction
DetectionDetection EvaluationEvaluation ReactionReaction
Safety-rated contactors must include positively driven (mirror) contacts
A component with positive-driven contacts guarantees that the NC and NO contacts are never closed simultaneously (EN 60947-5-1)A mirror contact is an NC contact that is guaranteed not to be closed at the same time as a main contact (EN60947-4-1)
Siemens 3RT contactors comply with this requirement
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Programmable Safety Relays• Moderate inputs and outputs• Simple to semi-complex logic• Multiple Zone
Safety Relays• Limited inputs and outputs• Simple logic• Single Zone
EvaluationMonitors Inputs / Initiates Reaction
Distributed Safety Systems• Distributed multiple inputs and
outputs• Complex Logic• Multiple Zone
DetectionDetection EvaluationEvaluation ReactionReaction
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03.23.2016Page 17 John Burns/ DF CP
Siemens Safety IntegratedMachine safety solution selection
Safety RelaysSafety Relays
Without PC
3 Safety Functions
Fail-Safe ControllersFail-Safe Controllers Fail-Safe ControllersFail-Safe Controllers
In-Cabinet(IP 20)
Cabinet-Free(IP 65/67)
Programming Programming Language
e.g., LAD/F-LAD
>25 Safety Functions25 Safety Functions
ASI-SafeASI-SafeModular Safety SystemModular Safety System
Cabinet-Free(IP 65/67)
Graphical Editor
In-Cabinet(IP 20)
8 Safety Functions
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Functionality of a Safety Circuit A review
24V or 115VACPower Supply
0V
SensorsInitiate machine shut down
Positive OpeningGuarantees that all NC contacts are in the open position when actuated
Redundancyensures safety functionality even if a failure disables one channel
EvaluationFault detection and evaluation; opens the circuit in case of a failure.
Positive Driven (Mirror)Guarantees that NC contacts are not to be closed at the same time as the main contact
Feedback LoopMonitors the correct operation of the contactor coils
ResetReactivates the safety circuit
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Standard Switch and ContactorStandard Switch and Contactor
Safety Levels PL a
L1 L2 L3
PL a allows• NO contacts for
• Enabling• Two-hand control• Restart
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24 VDC
0 VDC
Ope
n
Clo
sed
Safety Levels PL b
L1 L2 L3
PL b requires• Sensors with positive
opening contacts
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03.23.2016Page 21 John Burns/ DF CP
AndAnd
• Sensors with positive opening contacts
• Safety evaluation unit rated to SIL 1
• Feedback loop from contactor’s NC contacts
24 VDC
0 VDC
Ope
n
Clo
sed
Safety Levels PL c / SIL 1
ON
L1 L2 L3
Q1
PL c / SIL 1 requires
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03.23.2016Page 22 John Burns/ DF CP
AndAnd
• Sensors with positive opening contacts
• Safety evaluation unit rated to SIL 2
• Feedback loop from contactor’s NC contacts
• Redundancy in sensor contacts
• Redundancy in contactors
24 VDC
0 VDC
Ope
n
Clo
sed
Safety Levels PL d / SIL 2
ON
L1 L2 L3
Q1
Q2
PL d / SIL 2 requires
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03.23.2016Page 23 John Burns/ DF CP
AndAnd
24 VDC
0 VDC
Ope
n
Clo
sed
ON
L1 L2 L3
Q1
Q2
• Sensors with positive opening contacts
• Safety evaluation unit rated to SIL 3
• Feedback loop from contactor’s NC contacts
• Redundancy in sensor contacts
• Redundancy in contactors
• Separate channels of evaluation for sensors
Safety Levels PL e / SIL 3
PL e / SIL 3 requires
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03.23.2016Page 24 John Burns/ DF CP
Siemens Safety Evaluation Portfolio
MSS 3RK3
3SK1
Safety device Safety RelaysSIRIUS 3SK
Modular Safety SystemSIRIUS 3RK3
FailsafeSIMATIC
PLCs and distributed I/O
Engineering Hardware-parameterized Software-parameterized Software-programed
Number of safety functions Up to 3* Up to 6 Up to 20 From 10
Communicationnone AS-i and PROFIBUS
AS-i, PROFIBUS, PROFINET, PROFIsafe,
I-WLAN
MSS ASIsafe
F-CPU: S7-1200 /S7-1500 / ET 200SP
3SK2
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03.23.2016Page 25 John Burns/ DF CP
Online Configurator
www.siemens.com/industrymall
l
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3SK1 Standard
Output Expansion
4 RO5 Amp
3 RO10 Amp
Evaluation - Safety Relay
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3SK1 Advanced
Output ExpansionInput Expansion
Device ConnectorPower Supply
Evaluation - Safety Relay
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03.23.2016Page 28 John Burns/ DF CP
Traditional Safety Relay
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03.23.2016Page 29 John Burns/ DF CP
New 3SK1 Safety Relay
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Safety Relay Application Example
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3SK2
Output Expansion
Device ConnectorPower Supply
Evaluation – Programmable Safety Relay
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Area Estop
Zone Estop Zone Estop
Evaluation – Programmable Safety Relay
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SIRIUS InnovationsMotor starter 3RM1 Failsafe
•Contactor and Overload
Direct / reversing startSame Size Enclosure
With Safety functionality• Suitable for safety applications up to PL e / SIL 3
With overload protection• ATEX certified up to SIL 2
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EvaluationSIL 3 application with a safety relay
EmergencyStop
Start
6 Wires / starter• 4 wires for 2 coils• 2 wires for feedback
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03.23.2016Page 35 John Burns/ DF CP
SIRIUS 3SK1 and 3RM1 FailsafeApplication
EmergencyStop
Start
3RM1 FailsafeMotor Starters
Motor Starter
3SK1 Safety Relay
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Distributed Safety
SIMATIC AS-i F-Link with TIA Portal
AS-i / ASIsafe
PROFINET / PROFIsafe
Safety cell Safety cell
SIMATIC PN / AS-i F-LinkAS-i double master and
F-DI module
Standard data
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03.23.2016Page 37 John Burns/ DF CP
Motor Management System
Distributed Safety
SIMOCODE pro
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03.23.2016Page 40 John Burns/ DF CP
Safety Application Manual
https://support.industry.siemens.com/
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03.23.2016Page 41 John Burns/ DF CP
Safety Application Manual
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03.23.2016Page 42 John Burns/ DF CP
Safety Application Manual
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03.23.2016Page 43 John Burns/ DF CP
Safety Application Manual
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03.23.2016Page 44 John Burns/ DF CP
Siemens Safety IntegratedMachine Safety Life-Cycle Support — USA
►Siemens provides competent support throughout the entire machine safety lifecycle
►Support
►Safety Consultants►Safety Core Team►Safety Validation
► Implementation
►Siemens Solution Partners– Safety
►Safety Functional Examples►Safety Training►Risk Assessment Training
Products and Solutions• Safety Products• Safety Software• Wireless Safety• PC-Based Safety• BMS
Safety Education• Machine Safety Standards• Safety Webinars• Newsletter• Safety White Papers• Siemens Safety Website
Compliance• OSHA Website• Consensus Standards• Risk Assessment Standard• Safety Evaluation Tool - SET
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03.23.2016Page 45 John Burns/ DF CP
Questions
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03.23.2016Page 46 John Burns/ DF CP
Basics of Safety Applications
John BurnsLead Application ConsultantSII DF CP
5300 Triangle Parkway
Norcross, GA 30092
Tel.: +1 (770) 625-5726
Fax: +1 (678) 297-7250
Cell: +1 (678) 575-3086
E-mail:[email protected]
siemens.com
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Basics of Safety Applications