Safety Relays and Controllers

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

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Safety Relays and Controllers

  1. 1. Sponsored by: Safety Relays & Safety Controllers Presenter: Mike Garrick
  2. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 36. CONTACTRON “4 in 1“ 10x service life A microprocessor-controlled combination of: • robust relay technology • with wear-free solid-state technology
  37. 37. “4 in1” Savings Over Contactors E-stop Contactors Reversing Contactors Overload Relay
  38. 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. 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. 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. 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. 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. 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. 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. 45. Safety Controllers Why Safety? Force Guided Relays Basic Safety Design Taking the Mystery out of Safety Controllers Safety Bridge?
  46. 46. Safety Controllers Vs Safety Relays Why Safety? … Force Guided Relays … Basic Safety Design Taking the Mystery out of Safety Controllers Safety Bridge?
  47. 47. Safety Controllers Vs Safety Relays Why Safety? Force Guided Relays Basic Safety Design Taking the Mystery out of Safety Controllers Safety Bridge?
  48. 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. 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. 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. 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. 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. 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. 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. 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. 56. Safety Controllers Why Safety? Force Guided Relays Basic Safety Design Taking the Mystery out of Safety Controllers Safety Bridge?
  57. 57. Configuration Software Graphic user interface Simple to use for non programmers In 3 steps to a complete and tested project
  58. 58. Configuration Software – 3 Steps
  59. 59. Configuration Software
  60. 60. Configuration Software Demo Simulation Mode
  61. 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. 62. Safety Controllers Why Safety? Force Guided Relays Basic Safety Design Taking the Mystery out of Safety Controllers Safety Bridge?
  63. 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. 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. 65. Safety Bridge Technology – The Concept Why Safety? & Force Guided Relays & Basic Safety Design & Taking the Mystery out of Safety Controllers Safety Bridge?
  66. 66. Safety Bridge Technology – The Concept Why Safety? & Force Guided Relays Basic Safety Design Taking the Mystery out of Safety Controllers Safety Bridge? &
  67. 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. 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. 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. 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. 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. 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

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