Basic safety design and safety controllers. (Phoenix Contact) Drive for Technology 2010 presentation

1. Sponsored by:
Safety Relays &
Safety Controllers
Presenter: Mike Garrick

2. Agenda
Why Safety? The “Safety bridge” truly Meets the spirit of
the “Drive for Technology” event!
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

3. Phoenix Contact Safety
Why Safety?
• Reason: Machines are dangerous
Force Guided Relays • To protect:
• Man
Basic Safety Design • Machine
• Material
Taking the Mystery
out of Safety
Controllers Avoiding danger
Safety Bridge? Increase availability &
reliability
Increase output (yields)

4. Phoenix Contact Safety
•Machines come in many shapes and forms and
Why Safety?
can potentially expose people to different
hazards:
Force Guided Relays
• Mechanical
• Crushing, cutting, pressing etc.
Basic Safety Design • Electrical
• Contact with high voltages
Taking the Mystery
• Thermal
out of Safety
Controllers • Burns and scolding
• Noise & Vibration
Safety Bridge? • Hazardous Chemical Substances
• Rays
• Microwaves, x-rays
• Biological
• Pressurized Gasses
• Ergonomic (65% of all injuries in the US)

5. Phoenix Contact Safety
Why Safety?
Force Guided Relays • Design
• Training
Basic Safety Design
• Proper installation and startup
Taking the Mystery testing
out of Safety • Maintenance
Controllers
• Accident documentation
Safety Bridge? • Rule enforcement

6. Typical Accidents
Why Safety?
Force Guided Relays • Reaching in to clear equipment
• Bypass loose or missing safe
Basic Safety Design guards
Taking the Mystery • No lockout tag out
out of Safety • Operator errors (training)
Controllers
• Bad design
Safety Bridge?

7. Direct Vs Indirect
• Costs
Why Safety? • Direct
• Workers Comp
Force Guided Relays • Medical Expenses
• Indirect
Basic Safety Design
• Legal settlements /fines
• Time lost by injured employee
Taking the Mystery • Loss of efficiency
out of Safety • Damage to tools & equipment
Controllers • Loss of production
• Failure to fill orders
Safety Bridge? • Damage from accident
• Fire
• Water
• Explosion
• Unknown Factors
• Human Tragedy
• Morale * Reputation

8. Direct Vs Indirect
Who’s directly responsible for an accident?
Why Safety?
Paper Rolled! 10/09 $136,500
Force Guided Relays
Safety Interlocks 2/15/2005 $116,000
Basic Safety Design
Taking the Mystery
out of Safety
Conveyor Accident, 5/19/04 $133,650
Controllers
Lathe Machinery Accident 5/09 $56,250
Safety Bridge?
Then comes the Indirect Costs…..

9. Who does OSHA Target?
Why Safety?
Accidents
Force Guided Relays Nature of the business
Falling
Basic Safety Design Exposure
Taking the Mystery Contruction
out of Safety Trenching
Controllers
Presses
Safety Bridge?
Southern Air Whistle Blower 4/2009

10. Motion Hazard Types
Why Safety?
Force Guided Relays
• Rotating parts
• Reciprocating and transverse motions Recip_Trans
Basic Safety Design
• In-running nip points Nip Points
Taking the Mystery
out of Safety
• Cutting, sanding, and grinding actions
Controllers • Punching
Safety Bridge? • Shearing
• Bending, etc.

11. The Heart of the Safety Relay
Why Safety?
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

12. The Heart of the Safety Relay
• Minimum Definition
Why Safety?
• All contacts are
mechanically linked
Force Guided Relays
• 1 NC & 1 NO contact
set
Basic Safety Design
• If the any of the
Taking the Mystery contacts fail (weld),
out of Safety
Controllers
opposite type contacts
will not close.
Safety Bridge?

13. The Heart of the Safety Relay
• Contacts are pulled
Why Safety? together and pushed
apart by the mechanical
Force Guided Relays
link.
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

14. The Heart of the Safety Relay
“If any of the contacts fail
Why Safety? (weld), opposite type
contacts will not close.”
Force Guided Relays
This is error tolerant behavior
>0.5mm
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

15. The Heart of the Safety Relay
Why Safety?
Standard FGR
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

16. The Heart of the Safety Relay
Why Safety?
Shown not energized
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?
FGR Standard Relay
** Minimum requirement of a FGR is 1
normally closed mechanically linked to 1
normally open contact

17. The Heart of the Safety Relay
Why Safety?
Shown energized
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?
FGR Standard Relay

18. The Heart of the Safety Relay
Why Safety?
Shown not energized
Force Guided Relays
Basic Safety Design
>0,5mm
Taking the Mystery
out of Safety
Controllers
Safety Bridge?
FGR Standard Relay
X = Welded NO Contact

19. The Heart of the Safety Relay
Why Safety?
E-stop Start
Force Guided Relays
K1
Basic Safety Design
K1-1
Taking the Mystery
out of Safety K1-2
Controllers M
Safety Bridge?

20. The Heart of the Safety Relay
Why Safety? E-stop Start
Force Guided Relays K1
K1-1
Basic Safety Design
Taking the Mystery
out of Safety
Controllers K2
K2-1
Safety Bridge?
K1-2 K2-2
M

21. The Heart of the Safety Relay
E-stop
K1-1
Why Safety?
K1
K3-1
Force Guided Relays
Basic Safety Design K2-1
K2
Taking the Mystery
out of Safety K3-2
Controllers Start
K1-3 K2-3
Safety Bridge?
K3
K1-2 K2-2 K3-3
M

22. Principles for Risk Assessment, ANSI/RIA R15.06, ANSI
B11.19.TR3, IEC 61508, ISO 13849, ISO 14121, EN 1050
Determine the limits
of the Machine
Consider all life phases.
Hazardous-
analysis
Identify dangerous zones / parts
Identify the hazards
Risk-
Risk estimation
analysis
Risk evaluation
IF RISK MUST BE
REDUCED
Design a safety concept:
• Protective measure Risk-
• Estimate residual risk reduction
• ...
No Yes Document the results
Is the machine safe?
technical documentation

23. Safety of Machinery – Risk Evaluation (EN954-1)
Severity of the Injury
S1 Slight (normally reversible) Injury
S2 Severe (normally irreversible) Injury, including Death
Category
Frequency and/or Duration of the Danger
B 1 2 3 4
F1 Seldom to regular and/or
S1
the duration is short
Start
F2 Frequent to continuous and/or P1
F1
the exposure is long P2
Potential to avoid the Danger P1
S2
P1 Possible under certain conditions
F2 P2
P2 Scarcely possible
Selection of the Category
B, 1 to 4 Categories of safety-related part of control systems
Preferred categories Possible categories requiring Measures which can be
for Reference points additional steps over dimensioned for the
relevant risk

24. Safety of Machinery – Risk Evaluation (EN954-1)
Category
B 1 2 3 4
S1
Start
P1
F1
P2
P1
S2
P2
F2
S: Seriousness of injury? S2 heavy, irreversible
F: Frequency and duration in the danger zone?
F2 permanent
P: Possibility of avoiding the injury? P2 hardly possible

25. Safety Categories
Category B
• One failure can lead to a loss in safety
Category 1
• One failure can lead to a loss in safety Single
(but it‘s not as probable as in category B) Channel
Category 2
• One failure can lead to a loss in safety in
between the test cycle, however, the test
cycle will detect the failure

26. Single Channel
Why Safety? • Components:
• I: Input, sensor
Force Guided Relays • L: Logic, control
• O: Output, (Motor)
Basic Safety Design contactor
Taking the Mystery
out of Safety
Controllers
Im Im
I L O
Safety Bridge?

27. Single Channel
Why Safety? • Components:
• TE: Test equipment
Force Guided Relays • OTE: Output of test equipment
Basic Safety Design
Im Im
Taking the Mystery I L O
out of Safety
Controllers
m
Safety Bridge?
Im
TE OTE

28. Safety Categories
Category 3
• When a single error occurs, the safety is
maintained
• Some – not all – errors are recognized.
(Multiple errors can lead to a loss in
safety.) Dual
Channel
Category 4 (Redundant)
• Safety-relevant components must be
designed in a way, that:
• An error does not lead to the loss of safety
• An error is recognized during or before the
next requirement

29. Dual Channel
Why Safety?
m
Im
I1 L1 Im O1
Force Guided Relays
Basic Safety Design c
Taking the Mystery
out of Safety m
Im
Controllers I2 L2 Im O2
Safety Bridge?

30. Dual Channel
Why Safety?
m
Im
I1 L1 Im O1
Force Guided Relays
Basic Safety Design c
Taking the Mystery
out of Safety m
Im
Controllers I2 L2 Im O2
Safety Bridge?

31. Safety Relay Designs
Why Safety?
Force Guided Relays
Basic Safety Design Inputs Reset Outputs
Taking the Mystery
out of Safety Logic
Controllers
Safety Bridge?

32. Machine Safeguarding Input
Safety Sensors (Input)
Why Safety?
Force Guided Relays
Basic Safety Design
Taking the Mystery
E-Stop Magnetic Door
out of Safety
Controllers
Switches
Safety Bridge?
Two-Hand Control Light Curtain

33. Machine Safeguarding Logic
Safety Controls (Logic)
Why Safety?
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?
Safety
Relays
AX Bus Solutions

34. Machine Safeguarding Output
Power Control Elements (Output)
Why Safety?
Force Guided Relays
Door Interlocks
Basic Safety Design Contactor
Taking the Mystery
out of Safety
Controllers
Safety Bridge?
AC Drive Contactron
4 in 1

35. CONTACTRON- “4 in 1”
• “Star” of the family
• Reversing solid state starter
• The “star”
• Reverse running
TOP highlight
75% less space
• Forward running forward
75% less wiring reverse
time
protect
• Motor protection (overload 10x service life
relay)
Safety rated
• Emergency stop

36. CONTACTRON “4 in 1“
10x service life
A microprocessor-controlled combination of:
• robust relay technology
• with wear-free solid-state technology

37. “4 in1” Savings Over Contactors
E-stop Contactors
Reversing Contactors
Overload Relay

38. Machine Safety Functions
Safety control system
Why Safety? Logic, Processing:
Analyses signals,
monitors sensors and
Force Guided Relays actors
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?
Sensor: Output / Power
Receives signals, Control Elements:
recognizes danger Stops movement,
removes danger

39. Safety Relay Designs
Reset and
Power Input Feed Back Connection
Supply +Channel 2
Why Safety?
A1 S21 S22 S33 S34 13 23 31
Force Guided Relays
~ +
Basic Safety Design _
K1
Taking the Mystery
out of Safety LOGIC
Controllers
K2
Safety Bridge?
Power A2 S11 S12 14 24 32
Supply -
Input
Channel 1

40. Safety Relay Designs
S1
K4
Start
Why Safety?
A1 S21 S22 S33 S34 13 23 31
Force Guided Relays
~ +
_
Basic Safety Design K1
K4
LOGIC
Taking the Mystery
out of Safety K2
Controllers
Safety Bridge? A2 S11 S12 14 24 32
K4
S2

41. Safety Relay Designs
K4
Why Safety? Start
K5
A1 S21 S22 S33 S34 13 23 31
Force Guided Relays
~ + K4
Basic Safety Design _
K1
Taking the Mystery LOGIC
out of Safety K5
K2
Controllers
Safety Bridge?
A2 S11 S12 14 24 32
K4 K5

42. Safety Relay Designs
S1
Why Safety? Start
A1 S21 S22 S33 S34 13 23 31
Force Guided Relays
~ + K4
Basic Safety Design _
K1
Taking the Mystery LOGIC
out of Safety K5
Controllers K2
Safety Bridge?
A2 S11 S12 14 24 32
K4 K5
S2

43. Safety Relay Designs
S1 K4
Start
Why Safety? K5
A1 S21S22 S33 S34 13 23 31
Force Guided Relays
~ + K4
_
Basic Safety Design K1
Taking the Mystery LOGIC
K5
out of Safety K2
Controllers
Safety Bridge? A2 S11 S12 14 24 32
K4 K5
S2

44. Safety Relay Designs
Start K4
Why Safety?
K5
Force Guided Relays A1 S33 S34 13 23
K4
Basic Safety Design PSR-SCP-24UC/ESM4/2X1/1X2
Taking the Mystery K5
out of Safety A2 S11 S12 S21 S22 14 24
Controllers
K4 K5
Safety Bridge? E-stop 1
E-stop 2

45. Safety Controllers
Why Safety?
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

46. Safety Controllers Vs Safety Relays
Why Safety?
…
Force Guided Relays
…
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

47. Safety Controllers Vs Safety Relays
Why Safety?
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

48. Safety Controllers Vs Safety Relays
I/Os
Why Safety? high
(>64) fixed function configurable programmable
Force Guided Relays
Basic Safety Design middle
Safe PLC
(16 to 64)
Taking the Mystery Safety Controller
out of Safety
Controllers
PSR Safety Relays
Safety Bridge? few Functionality
(1 to 16)
complex

49. Safety Controllers Vs Safety Relays
Why Safety?
Force Guided Relays
Becomes cost and space effective when a
Basic Safety Design
customer is using 3 to 5 standard safety
Taking the Mystery relays
out of Safety
Controllers
Safety Bridge?

50. Safety Controllers Major Features
Major Benefits
Flexibility
• Easy configurable logic
Simulation
• Test at your desk
Approvals
• Maximum safety level achieved
Hardware
• High performance / small size
“Look and Feel”
• Housing and connectors in a
“Phoenix”- form factor

51. Safety Controllers Major Features
Major Benefits
Flexibility
• Easy configurable logic
Simulation
• Test at your desk
Approvals
• Maximum safety level achieved
Hardware
• High performance / small size
“Look and Feel”
• Housing and connectors in a
“Phoenix”- form factor

52. Safety Controllers Major Features
Major Benefits
Flexibility
• Easy configurable logic
Simulation
• Test at your desk
Approvals
SIL3 • Maximum safety level achieved
Hardware
PLe
• High performance / small size
SIL CL 3
“Look and Feel”
UL/CSA • Housing and connectors in a
Safety Cat. 4 “Phoenix”- form factor

53. Safety Controllers Major Features
67,5 mm
Major Benefits
Flexibility
20 Inputs
• Easy configurable logic
Simulation
4 Safe Outputs • Test at your desk
Approvals
4 Auxiliary Outputs • Maximum safety level achieved
Hardware
Ground Switching • High performance / small size
Out’s “Look and Feel”
4 test pulse outputs • Housing and connectors in a
“Phoenix”- form factor

54. Safety Controllers Major Features
Major Benefits
Pluggable Connectors
Flexibility
• Easy configurable logic
Screw- and
Simulation
Spring technology
• Test at your desk
Plug-in, Keyed and Approvals
Marked • Maximum safety level achieved
Hardware
Twin- Spring cage • High performance / small size
“Look and Feel”
USB- Connection • Housing and connectors in a
“Phoenix”- form factor
Removable Memory stick

55. Safety Controllers – Application Example
Why Safety?
Force Guided Relays
Basic Safety Design
Safety-Functions:
Taking the Mystery
out of Safety • 2 Emergency Stops
Controllers • 3 Safety Doors
Safety Bridge? Safety Relays 1 safety Controller
5 Modules
Width Width
180 mm 67.5 mm

56. Safety Controllers
Why Safety?
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

57. Configuration Software
Graphic user interface
Simple to use for non
programmers
In 3 steps to a complete
and tested project

58. Configuration Software – 3 Steps

59. Configuration Software

60. Configuration Software
Demo Simulation Mode

61. Safety Controllers New!
Why Safety?
Force Guided Relays PLC
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?
Order No. 2692720

62. Safety Controllers
Why Safety?
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

63. Safety Controllers – Make the best choice
• Software
Why Safety? • Fully functional package is a free
download
• No licensing fees
Force Guided Relays • Easy drag and drop!!
• Simulation Mode!!
• Complexity
Basic Safety Design • Programming methods
• Supported functionality
Taking the Mystery • Password protected
out of Safety
Controllers • Hardware
• Size
• Plug-in, keyed and printed terminals
Safety Bridge?
• Proper approvals
• Modular, I/O
• Network
• Memory included
• Use standard USB cable

64. Safety Bridge Technology New!
Why Safety?
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?
Safety Bridge Input Modules Safety Bridge Logic Module
Safety Bridge Logic Module
• Creates and monitors the safety safety protocol
• Creates and monitors the protocol
• Distributed acquisition of safety signals
• Processes all safety safety functions
• Processes all functions
• 24 safe inputs (8 per module)
• 8 safe 8 safe outputs onboard
• outputs onboard

65. Safety Bridge Technology – The Concept
Why Safety?
&
Force Guided Relays
&
Basic Safety Design &
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

66. Safety Bridge Technology – The Concept
Why Safety?
&
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?
&

67. Safety Bridge Technology – Components
PSDI
8
Why Safety? Inputs SAFECONF
Force Guided Relays
Project
Basic Safety Design 8
Inputs Network LPSDO
Taking the Mystery 8 Outputs
out of Safety
Controllers
Safety Bridge? 8
Inputs

68. Safety Bridge Technology – Addressing
Why Safety? PSDI PSDI
Force Guided Relays
LPSDO LPSDO
Basic Safety Design
…
Taking the Mystery
out of Safety
Controllers
Safety Bridge?
Island # 1 Island # 31

69. Safety Bridge Technology – Requirements
Why Safety?
PL or SIL rating is
Force Guided Relays independent of machine
PLC or bus system
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
Safety Bridge?

70. Safety Bridge Technology – Software
Why Safety?
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
V2.5
Safety Bridge?
Available
Now

71. Safety Bridge Technology – Approvals
Why Safety?
Force Guided Relays
Functional Safety
Basic Safety Design EN 954 Category 4
EN ISO 13849 PL e
Taking the Mystery
out of Safety EN 62061 SIL CL3
Controllers
IEC 61508 SIL 3
Safety Bridge?

72. Phoenix Contact Safety – Q&A
Why Safety?
Force Guided Relays
Basic Safety Design
Taking the Mystery
out of Safety
Controllers
PSR Safety Safety Safety PLCs
Safety Bridge? Relays Controllers