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EZ-SCREEN® (TYPE 4) EZ-SCREEN® (TYPE 2) GRIDS & POINTS

Safeguarding Basics

Basics of SafeguardingMachine and personnel safeguarding refers to the combination of requirements, methods and solutions used to protect people who come in contact with dangerous machines in the industrial environment.

RequirementsNational and regional governmental bodies have regulations, mandates, standards and recommendations for implementing a safety method or a solution.

Key regulations regarding general machine guarding include the following:• MachineryDirective-EU• OSHAGeneralDutyClause–USA

(see page 512 for an abridged version list of industry safety standards)

Device RequirementsSafetydevicesmustbeabletoconsistentlyandreliablybringamachinehazardto an orderly stop.

To be considered a safety device, the following methods must be used to ensure reliableoperation:faultexclusion,redundancyandself-checking.

Safety Circuit RequirementsAsafetystopcircuittypicallycomprisesof2normally-opencontactfrommechanically-linkedrelays.Thecircuitismonitoredtodetectcertainfailuresthat could lead to the loss of the safety function.

Machine Control

PLC

Machine

Hazard

Safety Interface

FSD

Personnel Protection

Two-Hand Control

Emergency Stopping

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PhotoelectricsSensors

Fiber OpticSensors

Measurement & Inspection Sensors

Special PurposeSensors

Vision

Lighting &Indicators

Wireless

Safety Light Screens

Safety Laser Scanners

Safety Controllers & Modules

Safety Two-Hand Control Modules

Safety Interlock Switches

Emergency Stop & Stop Control

LIGHT SCREENS

LASER SCANNER

CONTROLLERS &MODULES

TWO-HANDCONTROL MODULES

INTERLOCK SWITCHES

E-STOP &CONTROL DEVICES

TheRiskAssessmentProcessinmachinesafeguardingisaprocessusedtoidentifyhazardsthrougheachphaseofthemachine’slifecycleandtominimizedangerstopersonnelandequipment.

The basic steps in a Risk Assessment Process: 1.Identifyhazardsandwheretheyoccur. 2.Assessriskbyseverityofharmandprobabilityofoccurrence. 3.Reducetheriskthroughtheuseofprotectivemeasures. 4. Validate and document results.

Methods: Risk Assessment

Risk Assessment Standards•OSHA3071,JobHazardAnalysis•MIL-STD-8820,USDODSystemSafetyProgram•ANSIB11.0General(Safety)RequirementsandRiskAssessment•ISO12100,GeneralPrinciplesforDesign,RiskAssessmentandRiskReduction•SEMIS10,RiskAssessment,SemiconductorManufacturingEquipment

Methods: SafetyCircuitsDependingonthelevelofriskassociatedwiththemachineoroperations,anappropriatelevelofcontrol circuitry performance must be incorporated into safety device design.

Basic Single Single with Monitoring Dual with Monitoring

Gen

eric

StopCommand ProtectiveCommandProtectiveCommand MonitoringSignal

Redundant(Safety)StopCommands MonitoringSignal

Simple Device

Machine Stop

Machine Stop

Safe-Guarding

Device

Machine Stop

Safe-Guarding

Device

Machine Stop

Safe-Guarding

Device

•Nonsafety-ratedcomponents•Integratedinaccordancewith

relevant standards•Reliabilitydependsonrobust

components•Redundancynotrequired

•Safety-ratedcomponents•Integratedinaccordancewith

safety principles and design•Redundancynotrequired

•Safety-ratedcomponents•Conductsperiodictestofsystem•Normaloperationallowedifnofaults

are found•Ifunsafefaultisfound,systemwill

default to safe state or indicate that unsafe system exists

•Safety-ratedcomponents•Greatestdegreeoffaulttolerance•Redundancyandself-checking•Singlefailurecannotcauselossof

safety function•Faultsdetectedimmediatelyoratnext

demand on system

Faul

t

PossiblelossofsafetyfunctionGreaterreliability,butpossibleloss

of safety functionFaultdetectedateachtest

Safetyfunctionisensuredwithasinglefault.Anaccumulationoffaultsisnot

possible or detected.

Ris

k Very LowMinor bump or bruise with

no lost time

LowMinor first aid, infrequent exposure

orhighlikelihoodofavoiding thehazard

Mid RangeInjuries that are slight or normally

reversible, requiring normal healing or only first aid

High or Very HighNormallyreservedforhand-fed

applications where injuries could be severe to irreversible

AN

SI /

B11

— — —

ControlReliableANSIB11.19(Clause6.1andAnnexC)

Category3or4and/orPLdorPLe perISO13849-1

satisfyControlReliabilityrequirements

AN

SI /

RIA

Simple SingleChannel SingleChannelwithMonitoring

ControlReliableANSI/RIAR15.06(1999Clause4.5)

ControlreliabilityforrobotstypicallyexceedsaCat3butisnotnecessarily

intendedtobeaCat4

ISO

/ EN CategoryB

ISO13849-1/EN954-1Category1

ISO13849-1/EN954-1Category2

ISO13849-1/EN954-1Category3&4

ISO13849-1/EN954-1

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EZ-SCREEN® (TYPE 4) EZ-SCREEN® (TYPE 2) GRIDS & POINTS

Solutions: Comparing Guards and Devices*Type Safety Function Advantages Limitations Requirements Standards

Guards: protective physical barrier used to prevent access.

FixedGuard Providesafixedbarriertothehazard

•Lowmaintenance•Longlife•Lowcostforsmallareas•Protectsallindividuals•Cancontainejectedmaterials

•Poorergonomics•Limitedvisibility•Limitedaccess•Costlyforlargeareas•Maintenancemayrequireremoval

of guard

•Protectfromidentifiedhazard•Preventuserfromreaching

over, under, around or through the barrier

•Providesafeopenings

•ANSIB11.19•ISO14120•ISO13857

InterlockedGuard

Interrupts power to machine when guard is opened

•Lowinitialinvestment•Canbeplacedclosetohazard•Protectsallindividuals•Cancontainejectedmaterials

•Costlyforlargeareas•Increasedmaintenance

•Mustbedifficulttodefeat•Guardmayopenonlyaftermachinehasstopped–ormustbe installed at a safe distance

•ANSIB11.19•NFPA79•ISO14119•ISO14120•IEC60204-1•ISO13857•ISO13855

Safeguarding Devices: components, attachments or mechanisms designed to perform a specific safeguarding function.

SafetyLightScreen

Arrestspowertomachinewhen sensing field is interrupted

•Excellentergonomics•Allowsfrequentaccess•Protectsallindividuals•Costeffectiveforlargeareas•Allowsforgoodvisibility

•Limitedtomachinesthatcanbestoppedquickly

•Noprotectionfromejectedparts•Mayrequiretheuseofadditional

guards•Maycreateapass-throughhazard

•Initiateimmediatestopwhensensing field is interrupted

•Appropriateresolutionrequiredtodetectobjectsthesizeofatorso,ankle,handorfinger

•ANSIB11.19•IEC61496•ISO13855

Multiple-BeamSystem:•Grids•Points

Arrestspowertomachinewhen sensing field is interrupted

•Lowinitialinvestment•Allowsfrequentaccess•Allowsforgoodvisibility•Protectsallindividuals

•Limitedtomachinesthatcanbestoppedquickly

•Noprotectionfromejectedparts•Largesafetydistance•Maycreateapass-throughhazard

•Initiateimmediatestopwhensensing field is interrupted

•Appropriateresolutionrequiredtodetectobjectsthesizeofa torso

•ANSIB11.19•IEC61496•ISO13855

Two-HandControl

Operatormustusebothhands to actuate machine motion hereby preventing operator access to hazardousarea

•Operator’shandsareawayfromhazardousarea

•Lowinitialinvestment•Lowmaintenance

•Potentialergonomicimpact•Providesprotectiononlyforoperator•Noprotectionfromejectedparts

•Concurrentactuationwithin 1/2second

•Releaseandreactivationrequired before machine motion may be reinitiated

•ANSIB11.19•NFPA79•ISO13851•IEC60204-1•ISO13855

SafetyMatMonitor

Interrupts power to machine when a minimum pressure is applied

•Excellentergonomics•Protectsallindividuals•Allowsforgoodvisibility

•Costlyforlargeareas•Maintenanceintensive•Largesafetydistance

Minimum object sensitivityof66lbsonand3-1/8"surfaceto detect a foot

•ANSIB11.19•ISO13855•ISO13856

Complementary Safety Devices: used to supplement a primary safeguard.

E-Stop•Button•RopePull

Operatoractivatesbuttonin emergency situation to shut off power to machine

•Immediateresponse•Safeshutdownofmachine

process

•Notconsideredasafeguard•Requiresconsciousactofoperator•Limitsinjuryormachinedamage

but typically does not prevent it

•Overridesallotherfunctionsand operations

•ResetofE-stopdoesn’tinitiatemachine motion

•Buttonmustberedwithyellowbackground

•Shouldbelocatedateachoperation station

•Finalremovalofpowerdonebyelectromechanical components

•ANSIB11.19•NFPA79•ISO12100•IEC60204-1•ISO13850

*Thisrepresentsapartiallistofavailablesafeguards&devices.

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PhotoelectricsSensors

Fiber OpticSensors

Measurement & Inspection Sensors

Special PurposeSensors

Vision

Lighting &Indicators

Wireless

Safety Light Screens

Safety Laser Scanners

Safety Controllers & Modules

Safety Two-Hand Control Modules

Safety Interlock Switches

Emergency Stop & Stop Control

LIGHT SCREENS

LASER SCANNER

CONTROLLERS &MODULES

TWO-HANDCONTROL MODULES

INTERLOCK SWITCHES

E-STOP &CONTROL DEVICES

Locating a Safety Product

Solutions: Choosing and Locating a SafeguardWhen choosing a safeguard, ask yourself the following questions: 1)isitsafe,2)isitlegaland3)doesitmakesensefortheapplication.

Choosing a Safety Product

□ Who will use it?

□Howwilltheyuseit?

□Whathazardsareassociatedwithwhichtask?

□ What are the types of hazards?

□ Where will the safeguard be located?

E=Excellent A=Acceptable P=Poor X=NotAcceptable

Guarding Solutions M

aint

enan

ce $

Freq

uent

Acc

ess

Infre

quen

t Acc

ess

Loca

te C

lose

to H

azar

d

Long

Mac

hine

Sto

p Ti

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Ergo

nom

ic

Visi

bilit

y

Mul

tiple

Ope

rato

rs

Gua

rds

Agai

nst E

ject

ed

Mat

eria

l

Comments

FixedHardGuard P P E E E P P E E•Limitedaccess•Limitedvisibilitytothemachine•Costlyforlargeareas •Costlytomaintainandfix

LockingGuard P P E E E P P E E

InterlockGuard P P A E A P P E E

Two-HandControl A A A A A A A P P •Onlyprotectsoperator(s)

High-ResolutionSLS E E P E P E E E X •Locateclosertohazard

Low-ResolutionSLS E E P E P E E E X •CostslessthanhighresolutionSLS

3-or4-BeamPerimeter E A A P A E E E X •Takeslessspacethan2-beam

2-BeamPerimeter E A A P A E E E X •Costslessthan3-or4-beam

SafetyMats P A A P A E E E X •Maintenance-intensive

Safety DistanceDs = K (Ts + Tr) + Dpf

Ds =SafetyDistance(inches) K =OSHAHand-SpeedConstant Ts =MachineResponse(sec) Dpf =DepthPenetrationFactor(inches)

Low-resolution two-beam safety grid(48"Dpf)

Low-resolution three- or four-beam safety grid(36"Dpf)

Standard-resolution safety light screen(3"to8"Dpf)

Horizontal sensing fields, including safety mats, horizontalsafetylightscreensandareascanningdevices(48"Dpf)

Hard guard or solenoid-locking guard

Standard or magnetic interlock hard guard interlockedguard opens away or laterally

fromthehazard(+/-Dpf)

Two-hand control (0"Dpf)

High-resolution safety light screen (1"to2"Dpf)

+ DpfDs

K * Ttotal

NOTE:Illustrationexamplesarebaseduponthedescribedsafeguardsbeingusedastheprimarysafeguardingdevice,allexampleshavingidenticalstoppingtime, andfollowinggenerallyacceptedindustrialengineeringpracticesthatarefoundwithinANSIB11.19safetystandard.

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EZ-SCREEN® (TYPE 4) EZ-SCREEN® (TYPE 2) GRIDS & POINTS

Requirements: Standards

Safety Standards Acronyms

ANSI: AmericanNationalStandardsInstitute

CE: MarkofEuropeanConformity

CEN: EuropeanCommitteeforStandardization

CENELEC:EuropeanCommitteeforElectrotechnical

Standardization

CSA: CanadianStandardsAssociation

EN: EuropeanNorm

IEC: InternationalElectrotechnicalCommission

ISO: InternationalOrganizationforStandardization

OSHA: OccupationSafetyandHealthAdministration

SEMI: SemiconductorEquipmentandMaterialsInternational

UL: UnderwritersLaboratory

SafetyandSafeguardingstandardsareminimumrequirements for product and machine design, manufacture, use and evaluation that guide the methods used to improve safety. Note: The following is not all inclusive and is provided for informationonly.Supersededdesignationsarecontained in parentheses.

General Requirements (A & B standards)

U.S.OSHA29CFR1910.212GeneralRequirementsforAllMachinesOSHA3071JobHazardAnalysisANSIB11.0(ANSIB11.TR3)GeneralRequirementsandRiskAssessmentOSHA29CFR1910.147TheControlofHazardousEnergy(lockout/tagout)ANSIZ244.1Lockout/TagoutofEnergySourcesANSI/NFPA79ElectricalStandardforIndustrialMachinery

International/EuropeanISO12100(ISO12100-1/-2andISO14121)GeneralPrinciplesforDesign-RiskAssessmentand

RiskReductionISO14118(EN1037)PreventionofUnexpectedStartUpIEC60204-1ElectricalEquipment ofMachines:GeneralRequirements

Safety and Safeguarding Design

U.S.ANSIB11.19PerformanceCriteriaforSafeguardingANSIB11.20IntegratedManufacturingSystemsANSIB11.24Transfer MachinesANSIB11.TR1ErgonomicGuidelinesANSIB11.TR5SoundLevelMeasurementGuidelinesANSIB11.TR6SafetyControlSystemsANSIZ535seriesSafetySigns,Tags/Labels,Symbols,ColorCodesandManuals/Instructions

International/EuropeanISO11161IntegratedManufacturingSystemsISO14119(EN1088)InterlockingDevicesAssociatedwithGuardsISO14120(EN953)Guards

ISO13849-1(EN954-1)SafetyRelatedPartsofControlSystemsISO13850(EN418)EmergencyStopDevicesISO13851(EN574)Two-HandControlDevicesISO13854(EN349)Minimum gaps to avoid crushing of parts of the human bodyISO13855(EN999)ThePositioningofProtectiveEquipmentISO13857(ISO13852/EN294,ISO13853/EN811)SafetyDistances[openings]-UpperandLowerLimbsIEC61508FunctionalSafetyofelectrical/electronic/programmableelectronicsafety-relatedsystemsISO62061FunctionalSafetyofSafety-RelatedElectrical, ElectronicandProgrammableControlSystems

Machine Specific Applications, Grouped by Type (C Standards) Mechanical Power Transmission ApparatusOSHA29CFR1910.219Note:ANSI/ASMEB15.1MechanicalPowerTrans-missionApparatushasbeenincorporatedintoANSIB11.0&ANSIB11.19.

Machine Tools- Mechanical Power Presses(Note:RefertotheANSIB11.xxseriesforadditionalMachine Tool standards)OSHA29CFR1910.217ANSIB11.1EN692

ConveyorsANSI/ASMEB20.1ISO9851

Industrial RobotsANSI/RIAR15.06ISO10218(EN775)

Injection Molding / Extruding (Rubber & Plastics)ANSIB151.xxseriesEN201EN1114-1EN289EN422EN1612

Mills and CalendersOSHA29CFR1910.261OSHA29CFR1910.216ANSIB28.1EN1417

PackagingANSI/PMMIB155.1EN415series

SemiconductorSEMISxxseriesSEMIS2SEMIS10

LasersANSIZ136.1ANSIB11.21

Turning Machines / Machining CentersANSIB11.22ANSIB11.23

These and other standards are available from:OSHADocuments:http://www.osha.gov AmericanNationalStandardsInstitute(ANSI): http://www.ansi.org NSSNNationalResourceforGlobalStandards:http://www.nssn.org/