SF08 - Safety System Functional Design Considerations

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PUBLIC INFORMATION

Safety System Functional Design Considerations


Agenda

Output Technologies

Logic Technologies

Safeguarding Technologies & Considerations

Function Safety and it’s importance

Why is Safety Important

Closing


Why Safety is important.

Every 15 seconds, somewhere in the world: 160 workers have a work-related accident

Someone dies from a work-related accident or disease

Source: International Labor Organization

The cost to the global economy is a staggering $1.25 trillion which equals 4% of the world GDP.


Safety Systems are evolving with new technologies that

enhance productivity and system performance.

4Copyright © Rockwell Automation, Inc. All rights reserved.

1960 1970 2000 Future1980 1990

Safety products and solutions can be combined to create flexibleautomation solutions that enhance system performance.

2010

Legacy• Hard Guarding

Solutions that

limited access.

Initial Safety• Basic safety products

that allowed access

but resulted in a stop

condition.

Modern Safety• Advanced safety

products and

solutions that result

in options to stopping

the machinery.

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Safety as a Core System Function

Safety continues to emerge as a core contributor to overall system performance.

Safety has become a Key Differentiator:

Global & Company Compliance

Common Designs

Reduced Costs

Increased Efficiency – Systematic MTTR Reduction

Improved Competitiveness

Reduced Floor Space; Reduced Labor

Improved Ergonomics; Reduced Injuries


Agenda

Output Technologies

Logic Technologies




Closing


Functional Safety –Do we have a Problem?

Are Safety Procedures Ever Bypassed?

Do People take the “Short Cuts” to expedite

procedures?

Is LOTO (Lock Out Tag Out) always

followed?

Safety must be Easy and Intuitive or it will be bypassed.

Are Safety Systems or Technologies ever Bypassed?

Are people using a “Cheater Key”?

Some systems are so poorly designed and integrated that people

are forced to bypass the safety system just to get their jobs done!

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The Functional Safety Lifecycle helps to confirm

that we are following the right steps.

5. Maintain & Improve

1. Risk Assessment

4. Installation & Validation 2. Functional RequirementsSpecification

3. Design, Selection & Verification

The Machinery Functional Safety Lifecycle is a defined process to confirm Compliance.

Functional Safety Life-cycle

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ght ©

What is an

assessment and how

do I do it? Machine Characteristics/Limits

Risk Evaluation

Task & Hazard Identification

Risk Estimation

Risk Reduction

Risk

Tolerable

OK

Too High

Risk Assessment Process according

to ISO12100 & ANSI B11.0

The Risk Assessment is the Foundation


Evaluate the risk associated with each Task/Hazard Pair to understand the required system performance.

10

Risk Estimation - ANSI TR306 Method


11

There are a number of Risk Reduction Measures

and we have to decide which one/ones are best.

Design it out

Fixed enclosing guard

Monitoring Access /

Interlocked Gates

Awareness Means, Training and

Procedures (Administrative)

Personal protective equipment

Most Effective

Least Effective

Hierarchy of Protective Measures


Agenda

Output Technologies

Logic Technologies




Closing


Safeguarding Considerations

Risk reduction Requirement? (PLr,SIL/Cat)

Frequency of Access & machine cycle time?

Access Tasks - Maintenance or Production or both?

Type of Access? (Full Body, Arm, Hand, Finger Access)

Stop Time of the Machine? (For Safe Distance Calculation)

Machine or Hazard Containment Requirements? (Ejected Material)

Environment? (Wet, Dusty, Explosive, etc.)


These considerations are used to develop the Functional Specification.

The Functional Specification should…

Outline the Machine’s operational needs.

Identify the number of safety functions that are needed.

Identify the characteristics of each safety function.

Identify how the safety functions work together to form an effective

solution.


The Functional Specification is used in the design and selection

phase to achieve proper selection of devices/products.

Design & selection considerations:

What input device are needed to meet the

functionality requirements?

What logic devices are needed to meet the


What output devices are needed to meet the


Where are they? (Local or distributed)

Are there any special system needs?

(Safe-speed/Safe-position/Zone control, etc.)

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Types of Guarding according to the standards.

Each type has its benefits and draw backs depending on the requirements of the application.


Fixed Guarding Requirements.

Standards Requirements

• Fixed guards must be install to prevent contact with body parts and clothing.

• Fixed guard must be firmly secured.

• Fixed guards must be installed with fasteners that require a tool for removal.

• Fixed guard must prevent objects from falling into moving parts.

• Fixed guards should not create additional hazards .


Movable Guarding requirements.

• Moveable guards should be installed with an interlocking device to prevent machinery operation when open.

• Interlock devices must create a stop command.

• The machine should not restart when the guard is closed. A secondary action should be used to re-start the

machine cycle.

• Moveable guards should be evaluated to ensure that the machinery has time to stop before access is

achieved.

• Guard locking switches should be used machine application that take time to stop.


Movable Guarding Technologies

Interlocking Technologies according to ISO14119

Tongue/Key Interlocks

Non-contact Magnetic Interlocks

Non-contact RFID

Interlocks

Hinge Interlocks

Guard-locking Interlocks


Moveable Guarding Considerations

What type of moveable guard is being used? (Hinged/Lift-off/Sliding)

Is the guard in the same position every time? (Regularly aligned or not)

What is the environment that the moveable guard is being used in?

(Wet/dry/Hazardous location/etc.)

What is the hazard and how long does it take to stop?

Which type of interlock switch should be used? (Standard interlock or

Guard-locking)

What category/type of switch is required? (Type 1,2, 3 or 4 according

to ISO14119)


Standard Tongue Interlock Switches and

Rotary Hinge Switches

Mechanical Technology that:

Has Limited PL depending on the wiring

method/structure that is utilized.

Has limited alignment and adjustment capability.

Especially suited to simple guard door solutions but has

limitations.

Limited IP ratings.

Ideal for moveable guards that have consistent alignment.

Per ISO14119

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SensaGuard™ Technology - Series connection, Diagnostics, Ple non contact, with standard or unique RFID coding

Combination device - Replaces separately mounted interlock and door latch.

Adjustable latch force - Magnetic latch adjustable (15-45N holding force)

Especially suited to aluminum profile guard door construction systems -Can be used on framed or unframed guard doors

RFID Coded - Standard and unique coded versions

Rated to IP69K suitable for high pressure, high temperature wash-down. No food traps, sealed unit.

Ideal for moveable guards that do not have consistent alignment.

Ideal for lift off guarding applications.

SensaGuard & SensaGaurd with Magnetic Latch

Per ISO14119


Per ISO14119plus

Guard-locking Technology - Several types (Tongue, Pin & Magnetic)

Combination device – Door monitoring and locking in 1 device.

Adjustable holding forces – Depending on the type and model of switch.

Especially suited to aluminum profile guard door construction systems - Can used on framed or unframed guard doors

RFID Coded – Some models.

Rated to IP69K – Some models.

Guard Locking Switches


Non-Separating Guarding Solutions

24

All non-separating guards require the use of safe-distance calculations to determine the position/location of the guarding.


Mechanically Actuated Technologies.

25

Mechanically Actuated Non-Separating Technologies according to ISO13856-1

Safety Mats Pressure Sensitive Edges


Safety Mats

Safety Mat Technology - Several technologies

Performance Limitations – Can only be used up to Cat3/PLd

Environmental Limitation – Can only be used on flat surfaces.

Especially suited for protecting areas.


Electro-Sensitive Non-Separating Guarding

27

Electro-sensitive Non-Separating Technologies according to IEC61496-1

Light Curtains Area Scanners Safety Camera


Per IEC61496

Opto-electronic Technology - Several types (Type2 not for safety and Type4)

Uses infrared beams in a send & receive manner – Multiple beam spacing to meet varying application needs.

(14mm for finger detection/30mm for hand detection/70mm for leg detection)

Varying sensing distances – Depending on the manufacturers & model.

Especially suited for POC & PAC applications

POC – Point of Operation Control

PAC – Perimeter Access Control

Varying IP ratings depending on the manufacturer, model & installation method..

Light Curtains

Point Operation Control

Perimeter Access Control


Per IEC61496

Opto-electronic Technology - Utilizes lasers and time of flight technology. (Limited to Cat3 due to the technology that is used)

Software Programmable Configuration – Flexible and programmable to fit simple and complex needs.

Varying sensing distances – Depending on the manufacturer & model. (Typical ranges from 2M to 10M)

Can be used in POC & PAC applications

POC – Point of Operation

PAC – Perimeter Access Control

Single zone or multi-zone capabilities – Depending on the manufacturer and model number.

Area Scanner

Horizontal Applications

Vertical Applications


SafeZone™ Typical Applications

30


Per IEC61496

Opto-electronic Technology - Uses reflective technology

(Limited to Cat3 due to the technology that is used)

Uses a reflective tape with a defined pattern.

2 meter sensing distance.

Suitable for POC applications

POC – Point of Operation

Programming by a simple pushbutton.

Safety Camera

Horizontal Applications

Vertical Applications


SafeZone Mini - Vertical Applications

32

Vertical Mounting –

2 meter (6.6 ft) safety field set at 70 mm (2.76 in) resolution

for maximum safety field range

Must be configured with contour as a reference

No warning field required.

Can connect the SafeZone™ Mini’s OSSD’s to the MSR22LM or the MSR42 muting modules


Simplicity of Installation and Start Up

• One size fits all openings from 400mm X 400mm (1.3 ft.)

up to 1500m X 1500m (4.9 ft.)

• Simple Installation and Commissioning;

1. Mount the SC300 to the frame

2. Adhere the reflective strips to the machine frame

3. Attach power cable

4. Teach the SC300 the reflective tape area

5. Confirm the sensing field boundaries by using the supplied test rod

Verify protected area

using test rod

Install the SC300

at corner of

opening

Attach

Reflective

Tape to

Frame

Simple Installation And Commissioning

Press teach

button Or

use external

key switch

Reflective tape can be positioned in a variety of ways to

accommodate many application configurations

Positioning of tape allows

an opening in bottom corner

of machine frame

Positioning of tape allows the SC300 to

have a protective field that accommodates

Irregular shapes of machine frame


Emergency Stop & Non-Separating Guarding.

34

Emergency stop Non-Separating Technologies according to ISO13850

Emergency Stop Buttons

Pull-cordsEmergency

Switching-off Devices


Two Hand Control Non-Separating Guarding

35

2 hand control Non-Separating Technologies according to ISO13851

Two Hand Control Stations


Enabling Device - Non-Separating Guarding

36

Enabling Devices

Enabling device Non-Separating Technologies according to EN60947


Agenda

Output Technologies

Logic Technologies




Closing


Safety Market Segmentation of Yesterday!

Source: Control Design Magazine Survey, June 2009

30%

• The market was dominated by simple safety relay solutions in the past but

is changing quickly and will continue to change as people recognized the

benefits of smart safety solutions!

70%use hard-wired relay-based safety systems.

30% of respondents use contemporary/integrated

safety solutions.

70%


Safety Market Segmentation of Today!

30% of the market

Low end safety relay market

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Integrated safetySimple safety Semi-complex safety

40% of the market

30% of the market

Mid level safety relay & controller market

High level safety controller market

Cutting & slicing

Machines

Shrink

Wrappers

Form Fill & Seal

MachinesPalletizer s &

De-palletizers

Case Packer

Systems

Food ‘n’ Beverage

Bottle labeling

Integrated

Bottling Lines

The fastest growing area of safety in the semi-complex area!


Safety Input devices have a variety of output types

depending on the selected device.

We need to make sure that we select a logic device that

can handle these different types of signals.

Our new Guardmaster® series relays have configuration

capability for multiple signal types.

These new relays are also expandable via a single wire.

These new relay also have advanced communication

abilities.

40

Configurability, expandability and networkability.


Universal Input Capabilities

Universal Input

All sensor types go to same terminals

Automatic cross-loop monitoring – no configuration

by switch setting or hardwired-jumper required

Supports both single-channel and two dual-channel

safety inputs

Two dual-channel inputs on DI models configured by

logic switch

All Faults including Cross-Loop are detected by test

outputs S11 and S21

Laser

Scanners

Safety

MatsContact

Interlocks

Grip

Switches

Hinge

Switches

Cable Pull

Switches Non Contact InterlocksE-StopsLight

Curtains

S12 S22 S32 S42

A1 A2 S11 S21

IN1 IN2

Safety Inputs

PWR

Test Out

S11 (CH1)

S21 (CH2)

Cross fault

CH1 CH2

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Networkability – EtherNetcommunications module for diagnostics.

42

• 2-port embedded switch supports linear, star, and ring EtherNet/IP™

network topology.

• Add-on-instructions (AOI’s) for quick communications to a

ControlLogix® PLC.

Ring Topology

Linear Topology


Guardmaster® 440C-CR30 & the new EtherNet Communications Adapter

Configurable LED

Indicators

RS232 Serial Port

(non-isolated)

USB Programming

Port

Verification ID Display Switch

Two Plug-in Slots

DIN Rail or Panel

Mount

2 Single-Wire Safety or

Safety N.C. Inputs

2 Single-Wire Safety or

Safety Outputs

10 Dedicated N.C. Safety Inputs

6 Configurable Safety Terminals

(N.C. Inputs, N.O. Inputs, Test

Sources, or Outputs)

2 Safety Outputs

The New EtherNet plug-in module with 2 ports to

comply with DLR requirements/needs.

Add-on-instructions (AOI’s) for

quick communications to a

ControlLogix PLC.


Guardmaster® 440C-CR30 Key Features

Keeps safety simple, separate and flexible.

Easy to Use:

Innovative rapid configuration editor

2080 Plug-in support:

Expansion of standard I/O

Single Wire Safety support:

A single wire to expand safety I/O

Serial Port for Diagnostics

PanelView™ Component or

Micro800®


Guardmaster® 440C-CR30 Ease of Use

4545

Assigned safety function via Drag ’n’ Drop

Ease of configuration – No previous programming skills required

DONE!

Configure Safety Function Validate and VerifyConfigure Device

Logic configured with Simple

Drag and Drop Function

Block Editor

Checklist to walk

through validation and

verification process

Configured in CCW


Today there is a better way! It is called integrated safety.

Integrated safety is a controls strategy that combines standard control, motion control and safety control into 1 common platform.

In the past, safety and production control systems shared little, if any information

Harmonizing your safety and production control systems offer tremendous opportunities to improve productivity

Shared diagnostics on common HMI for faster troubleshooting

Safety system that changes parameters based on the state of the production system

Zone control to enable continued production flow when one zone is shut down

Better shut down and restart of production systems after a safety event

Operating

Equipment

Control

System

Safety

System


Let’s look at how integrated solutions help!

ControlLogix® chassis

PowerFlex® 755

Armor

Block® I/O

EtherNet/IP™

PV+ EOI

Safety

RelaySafety

Relay

Stratix 8000

E

T

A

P

POINT I/O™

Safety System

An ethernet

switch may

not be

required.

Safety

functionality

can now be

integrated

into

GuardLogix.

Data &

diagnostics

can be

displayed on

one HMI.

Benefits

Information enabled.

Fewer components.

Less training.

Streamlinedmaintenance.

Optimalconnectivity with multiple networks.

Kinetix®

6000

DeviceNet™

Safety relays

& contactors

may not be

required.


Safety Relay/Safety Controller/Safety PLC Selection Matrix

Copyri

ght ©

48

Safety Relays

• 1-25 standard I/O

• 1 zone of safety control

• 1 to 3 safety functions

• Little to no motion control Safety Controllers & Expandable

Relays

• 25 to 100 standard I/O

• 2 to 3 zones of safety control

• 3 to 10 safety functions

• 2 to 6 axes of motion control

• 2 types of hazardous energy

• 1 to 5 screens of

visualizationSafety PLC’s

• More than 100 standard I/O

• Networked I/O

• 3 or more zones of safety control

• More than 10 safety functions

• More than 6 axes of motion

• 2 + sources of hazardous energy

• Multiple screens of visualization


Agenda

Output Technologies

Logic Technologies




Closing


The Most Complete Offering of Safety Output Devices in the Market!

Safety

contactors

• Mechanically linked, positively guided and Mirrored contacts

• Feedback circuit for safety integrity

• Range of power ratings

• Used when simple on-off control is needed.

• Used when simple on-off control is needed for signal switching.

• PowerFlex® AC drives with optional integrated safety functions

• Advanced safety functions in PowerFlex750 series AC drives

• Remove torque without powering down machine

• Used when the machine needs speed control or safe-speed control.

• Kinetix® 6000 with optional integrated safety functions

• Safe Torque Off and advanced safety

• Remove torque without powering down machine

• Used when the machine needs advanced features like safe limited acceleration, safe position, safe direction and safe speed.

PowerFlex

AC drives

Kinetix

Servo drives


Simple Safety Output Selection Matrix and …

Safety Contactors & Relays

• Simple on/off control

• Power control

• Signal control

Safety Variable Frequency Drives

• On/off control with the ability

to control & monitor speed

Safety Servo Systems

• On/off control

• Speed control

• Direction control

• Position control

• Location control

• Acceleration control

• Deceleration control


Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Let’s not forget Safety for Pneumatic and Hydraulic control.

These valves meet Cat3

and Cat4 requirements

and are used in safety

solutions to control

pneumatic & hydraulic

hazards.


Agenda

Output Technologies

Logic Technologies




Closing


As you can see there are a lot of things to consider!

Connectivity ConnectivityInputs Logic Outputs

S c a l e d

That is why the functional specification is so important!

54

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Rockwell Automation –

Global Leader of Safety Products and Services.

(Confidential – For Internal Use

Only) Copyright © 2011 Rockwell

55

#1 in Machine Safety Electrical Safety# 2 in Process Safety

We can help you develop any size solution for your machine needs!

Rockwell has the broadest safety portfolio in the world!

www.rockwellautomationteched.com

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Questions

CIP, CIP Safety, DeviceNet and EtherNet/IP are trademarks of the ODVA.

Date post:	16-Aug-2015
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