Machine Safety Training for Beginners

Machine Safety Training for Beginners
Introduction to Machine Safety

Contents Introduction to Machine Safety Annexes:
Additional Products Info Standards Safety Principles

Introduction to Machine Safety
Safety basics and offer presentation

Danger and Risk Most people have a misunderstanding between danger / hazard and risk. A danger is ever present whereas risk is the possibility of that danger happening. Consider the following two statements: A hungry tiger is dangerous A hungry tiger is risky A hungry tiger is dangerous, but it is only a risk if it is in your vicinity. We can avoid or reduce risk by bounding danger (tiger is locked in the ZOO, so the risk to be attacked is very low) ZOO It is very risky if it is in the same room as yourself! Risks are events or conditions that may occur, and whose occurrence, if it does take place, has a harmful or negative effect

Protect People and Increase Productivity
Investing in machine safety Health & safety for all personnel Cut costs associated with: Physical injuries Insurance premiums Lost production, penalties … Increased productivity due to the prevention of accidents Better failure detection Worker confident at work Improving maintenance efficiency

Safety - Acceptable Risk Level
Risk 0 does not exist but it must be reduced up to an acceptable level Safety is the absence of risks which could cause injury or damage the health of persons. It’s one of the machine designer job to reduce all risks to a value lower than the acceptable risk. Integrated Safety – designed to reduce the risk to people, environment, assets and production in an integrated manner in all industrial settings.

Machine Safety as Global Concept
Design and production Installation and implementation Safety must be taken into account: already in the design phase and must be kept in place throughout all stages of a machine’s life cycle: Transportation Installation Adjustment Operation, Production Maintenance Dismantling Safety is necessary to obtain CE mark Operation Maintenance

Safety Chain Principle
Stop the dangerous machine Signaling Disconnection and locking power supply Safe drive technology Monitor & analyze the information Safety-oriented signal processing Catch the information Safeguarding to protect people from hazard Initializing & control of hazardous machine Emergency stop operations Use devices that comply with safety standards Safe signal transmission Safe connection & communication of functional units or segments Safety function comprises all parts of safety related electrical/electronic control system

Preventa - Your Full Safety Chain Solution
Catch the information Emergency stop/ Trip wire Control of access of hazardous zones Occasional Free to continuous Starting & enabling of dangerous movements

Monitor the information Safety modules Controllers Safety PLC ASi safety at work

Stop the machine Variable drives Vario Contactors Audible and visible warnings

European legislation and the standards
The EU Machinery Directive (98/37/EC), As a European law, defines the targeted levels of Machine Safety. Compliance with machinery directive is necessary to get the CE mark, and to Allow the free circulation of machinery within the European Union. A new version will be effective at the end of 2009 The European harmonised standards Established technical specifications which comply with the requirements of the related directives. Compliance with European Harmonised standard give compliance with the related directive Comply with the European harmonized Standards is the simplest way to comply with the Machinery Directive

The Process to Comply with CE Marking
+info +info +info +info +info +info +info

Safety Switches offer Guard switches Safety switches Limit switches
Additional offer info Guard switches Safety switches with rotary or spindle actuator Limit switches Coded magnetic Heavy Industrial Machines (Metal enclosure) XCS A / B / C / E XCS D / M Light Industrial Machines (Plastic enclosure) XCS MP / PA / TA / TE XCS PL / TL / TR / PR XCS P XCS DM / DM3 / DM4

Safety Mats offer Additional offer info XY-TP1 XY-TP2 XY-TP3 XY-TP4 500x500 mm 500x750 mm 750x750 mm 750x1250 mm All pieces can be electrically interconnected depending on the shape and size needed to protect from accessing danger area

Finger and Hand protection
Light Curtains offer Additional offer info Type 4 Type 2 Finger and Hand protection Body protection Hand protection Body protection NEW NEW XPS-CM XUS-LDS cascadable segments XUS-LB XU2-S XU2-S XUS-LDM XUS-LPZ XUS-LPB XUS-LNG Sn: 0.3…20 m 38 mm X 50 mm 2x PNP + 1x PNP (or NPN) IP65 2 versions are possible: - active (left) receiver Sn: 0,8…70 m - passive (right) rcvr Sn: 0,8…8 m 52 mm X 55 mm 2x PNP + 1x PNP IP67 Sn: 0.3…15 m 28.5 mm X 32 mm 2 solid-state PNP IP65 Sn: 0,75…1,2 m Diam 18 2x N/O + 4x PNP IP67 XUS LPDM Programming and Diagnostic Module NEW Compact model Slim model Modular beam

Positioning of the Safety Solutions
Safety System Safety PLC Safety Controllers Centralised I/O Process and Safety Island Safety Devices (Dialogue and Detection) Multiple Safety Functions AS-interface Safety Safety Modules One Safety Function Decentralised I/O Repetitive Machines Simple Machines Batch Process Complex Machines Manufacturing Process Machine Complexity

Safety Processing Devices offer overview
Non-configurable modules Configurable controllers Programmable PLCs No software With software XPS-A/B/C/D/T/V XPS-MP XPS-MC ASISAFEMON XPS-MF 1 safety function 2 independent functions Multiple independent functions 1 or 2 independent Multiple

Central processing unit
Safety PLC offer Additional offer info Compact Solution: 90% of applications - Wiring cost reduction - Network flexibility Safety Remote IO Modular Solution: 10% of applications Speed: Response time Large application memory High network flexibility XPSMF1 Digital Input XPSMF40 Safety PLC XPSMF IO Cards Digital IO XPSMF2 Digital Output Digital: Input; Output; Input & Output Analogue: Input; Output Counter Input XPSMF35 Safety PLC Digital & Analogue IO XPSMF3 Input & output XPSMF30 Safety PLC Digital IO XPSMF31 Safety PLC Rack Digital IO Power supply unit Central processing unit

Safety Controller offer
Additional offer info XPS MC XPS MP Bus connection Modbus Modbus, CANopen Modbus, Profibus DP

Additional safety contacts modules
Safety Modules offer Additional offer info XPSAC XPSAF XPSATE XPSAV XPSAFL XPSAR XPSAK XPSVC XPSBA XPSBC XPSBF XPSECM XPSECP Time Delay fnc 4 or 8 N/O E-stop, Switch, Trip-wire Two-hand control stations Light curtains Enabling switch Additional safety contacts modules XPSLCD XPSLCM XPSCM XPSDMB XPSDME XPSTSA XPSTSW XPSVNE XPSDA XPSPVT XPSPVK XPSOT Type 2 or Type 4 Type 2 Light curtains Single beam sensors Single beam sensors For applications requiring safety time delay Zero speed detection Lifts control Press application

AS-i Safety@Work offer
Additional offer info ASI SSSLB ASI SSLC ASI SSLLS ASI SE ASI SSL ASI SAFEMON.. ASI SA01 Emergency Stop Category 4 monitor M12 entries ISO M16 entry Control stations Analyser Network ASi-Safety at Work on the standard ASi cable ASI TER Slave Monitor Management Safe and logical functions Software Adjustment terminal

Safety Dialogue Solutions
E-stop and Trip wire switches Two-hand control Enabling grip switch Foot switches Authorize starting of a dangerous machine movement once people are outside the danger zone Allow access to a danger zone and stop the machine when it is not actuated Emergency stop function to avoid the accident or reduce it’s consequences Start or Stop the machine

E-stop and Trip wire offer
Additional offer info Emergency Stop pushbuttons for: machine tools, foundries, presses, automobile industry Emergency Stop pushbuttons for: assembly and packaging machines paper, cardboard and woodworking machines food/beverage processing and chemical industries Control stations for: assembly and packaging machines, paper, cardboard and woodworking machines, food/beverage processing, chemical and automobile industries, mechanical presses Metal bezel and fixing collar Plastic bezel and fixing collar Plastic enclosure XB4 B XB5 A XAL K Trip wire switches for: conveyor systems, materials handling, machine tools, electrical testing stations Protection ≤15 m Protection ≤50 m Protection ≤100 m or 2x 100 m XY2 CH XY2 CE XY2 CB

Control and Signaling offer
Two-hand Control Station, Enabling Switch and Foot Switch offer Two-hand Control Station Enabling Switch Additional offer info Additional offer info XY2 SB XY2 AU Single pedal switches - Metal Single pedal switches - Plastic XPE Y XPE A Double pedal switches - Metal XPE R Additional offer info XPE M XPE G XPE B

Mini-Vario and VARIO Switch Disconnectors
Additional offer info Front Mounting Enclosed VCCD / VCCF Backplate mounting in enclosure VCFN / VCF* VCD / VCF Door mounting

Reminder The safety chain protects your personnel, material and increases your productivity Safety must be taken into account from the design stage to end of the life of your installation Schneider Electric offers complete safety chain solutions

T hanks for your attention

Additional Products Info

Safety Switches Working principle: Advantages: Disadvantage:
The start command for the machine can only be initiated following correct operation of the guard switch. On its release, the N/C safety contacts are opened by positive action or, for coded magnetic switches, change state (must be monitored using a PREVENTA safety module) Advantages: The guard only has to move a small distance for the switch to be activated. Ideal for: Guards without hinges or guides connecting them to the machine Guards that can be disassembled without tools Disadvantage: Can be bypassed if an actuator key not attached to the guard is used Open Closed Guard Key

Functionality Actuator Key
Common to all metal or plastic case safety switches Square turret head which can be rotated through 360° in 90° steps Contact states remain unchanged when loosening the fixing screw (head remains attached to the body) Safety of operation 3-pole contacts for metal cases and 2-pole or 3-pole for plastic cases Without or with intelocking and locking of actuator by solenoid Manual locking/unlocking by pushbutton or key operated lock Correspondence to environment XCS metal for heavy duty environment XCS plastic for light and normal environment

Functionality - Lever or Spindle
Application Immediate stopping of the dangerous movement as soon as the lever or spindle reaches an angle of +5° or -5° from the home point 0° Degrees of freedom Lever-operated XCSPL and XCSTL: +180°, +/-90° or -180° depending on the product reference Spindle-operated XCSPR and XCSTR: +/-270° Levers – Straight or elbowed, making the lever switches suitable for use with all types of hinged guards: flush with the machine framework (use a switch with an elbowed flush lever) overhanging in relation to the machine framework (use a switch with a straight lever) Spindle operators 2 spindle lengths: 30 or 80 mm

Coded magnetic Switches and Systems
Plastic case system for use on machines with low inertia (quick rundown times) Coded Magnetic Switches 2-pole (XCS DMC/XCS DMR/XCS DMP) or 3-pole (XCS DMP) contacts In safety circuits must always be used in conjunction with a Preventa safety module Coded Magnetic Systems Self-contained range: category 3 (SIL 2) XCS DM3 and category 4 (SIL 3) XCS DM4 Integrated self-monitoring using micro-processors, no need to use external safety module

Mounting and Directions of Approach
XCS-DM3 /4 3 options for transmitter/receiver mounting: face to face, side to side, face to side 2 directions of approach for each type of mounting (except XCS-DMR)

Functionality – Coded Magnetics 1
Working principle – Reed Switch: Use Reed technology: contact activated by magnetic field Composition: A pair of ferromagnetic blades encapsulated in a hermetically sealed glass tube containing inert gas which prevents any oxidation/corrosion of the blades S N Safety output contacts Coded magnets =

Functionality – Coded Magnetics 2
Working principle – Hall Effect: The receiver part has a conductor (Hall element) with an established current flow The presence of a perpendicular magnetic field will cause a difference of potential on opposite edges of the hall element, this is what is known as the Hall Effect In the absence of a magnetic field, the measured voltage is insignificant The hall voltage is directly proportional to the strength of the magnetic field Image source = Wikipedia Hall Voltage 1 – Electrons 2 – Conductor (Hall sensor) 3 – Magnet 4 – Magnetic field 5 – Power supply

Miniature Safety Limit Switches
With head for linear movement (plunger) or rotary movement (lever) narrow metal miniature case XCS M compact metal XCS D or plastic XCS P case With protective plate, preventing both access to the fixing screws or adjustment of the head by no authorised personnel. Torx fixing screws. Used for machines without or with low inertia: Used in pairs, with one switch in positive mode, and the other in negative mode In combined mode, they can, when connected to Preventa modules, provide a Category 4 safety control system back

Safety Mats The safety mats function is to protect operator in front of the dangerous machines in the harsh environnent (where optical solution can‘t be used) Features Detect of people or objects weighing more than 20Kg crossing or falling on the mats surface Modular surface – electrically interconnectable, without loss of sensitivity “Protect Area Design” software configuration tool is available for simplification of installation Simple wiring Insensitive to dusty environment

Safety Mats Characteristics
A safety mat comprises: a sensing zone 1 a border comprising aluminium rails 2 and rail corners which secure the assembly 3 Working principle: Two stainless steel plates separated by polyurethane foam On activation (object on mat) short-circuit between plates will be detected Advantages Rigidity for transport Detection at any point Disadvantage Too heavy objects can damage plates and they will short-circuit permanently (max. load 800N/cm2) However, the short-circuit guarantees tripping safety

Protect Area Design software
Main function: Creation of an application based on light curtains and/or safety mats Benefits: Quick chose of the products needed for the application Huge winning time compare to the application manage without PAD* software Allow, with the “SysQuote” software associated in option to quote the complete applications Results: Component selection (products description) Graphical representation of the configuration List of selected components (references and quantities) Configuration of products back

Light Curtains This is an electro-sensitive optical safety device used to protect people working near dangerous machines. When the light curtain senses entry into the protected zone by an object, it sends a stop signal to the guarded machine Light curtains can replace mechanical guards IF the operating environment is not polluted (splashing, spattering etc. ) Facilitate operator’s work if frequent access to the danger zone is needed Easier access for maintenance operations Applicable for machines where dangerous movement can be stopped quickly Mechanical and hydraulic presses Molding presses Stamping, forming and automated assembly machinery

Light Curtains System Components

Light Curtains Characteristics
Detection Capacity (d) is the smallest object (diameter) that safety light curtain is capable of detecting with absolute certainty (finger, hand or body detection) d = P + e P - distance between the axis of 2 adjacent beams e - diameter of the beams Protected Height (Hp) is the zone (or height) within which an object of equal diameter to the detection capacity d is detected with absolute certainty d  14 mm – finger d  30 mm – hand d  70 mm – body

Light Curtains Standard Functions – 1/2
Automatic/Manual protection mode is what standard EN/IEC calls start (or restart) interlock of the safety light curtain in AUTO mode: on power-up or after the beams have been cleared, the light curtain resets itself automatically in MANUAL mode: on power-up or after the beams have been cleared, the light curtain keeps its output safety circuits in the “open” position. Pressing (and releasing) the reset button will cause actual resetting of the light curtain Monitoring of external switching device (EDM - External Devices Monitoring) consists of monitoring the function (open or closed), together with the time taken to reach that condition, of the machines power switching components (contactors) Note: in all cases, a general start instruction for the machine will trigger its actual start-up. Additionally, if the EDM connectors are incorrectly wired, the XUS-LT system will enter an alarm state. On power-up, the XUS-L system looks for an EDM closed condition. If this is found, it will enter a state consistent with the selected operating mode. When the XUS-L system enables its safety outputs, it monitors the EDM for a closed-to-open transition. This transition must occur within 300 ms or the XUS-L system considers the EDM alarmed and will then enter an alarm state.

Light Curtains Standard Functions – 2/2
Test function is a feature that allows a machine controller to simulate an interruption of the sensing field. The order to start the test is given by the machine during a non-hazardous phase in which it performs a self-test of the entire safety system including the light curtain (ex., on power-up) If the result of the test is not conclusive, the light curtain controller sends a stop signal to the connected machine Response time – the maximum time between detection of the beam being interrupted and the change in state of the OSSD of the light curtain OSSD – Output Switching Safety Device

Light Curtains Specific Functions – 1/3
Muting is the temporary automatic disabling of the light curtain’s detection function, which allows objects to access the hazardous zones during the process without stopping the machine Activation (or deactivation) is achieved by means of standard sensors (photo-electric or other) When activated, a signal is sent to the automation system and signaling informs the operator that they are not protected The three-sensor muting system is an uni-directional system. In a three sensor system, the following conditions must be met for the system to enter the muting state: • Sensor 3 is used as a direction detector, and must transition to the On state prior to the activation of sensor pair 2 and 1. • Sensor pair 2 and 1 must activate within 3 seconds of each other. • Sensor 3 must turn Off before Sensor 2 or 1. Signalling: important fct that requires a system verifying that the lamp is not burned (=> fct integrated in the muting module)

Blanking is the disabling of a selected group of light beams in the light curtain (and not all the beams as with muting) This function allows the presence of objects during process operations Caution when using: The detection capacity changes  This imposes a greater safety distance Additional protection is necessary on each side of the "blanked" zone, in order to prevent any intrusion into the free areas

Floating Blanking – is the inhibition of one or two light beams (adjacent or otherwise), anywhere in the light curtain An obstruction can move or "float" inside the sensing zone without generating a stop signal Blanking plus floating blanking functions can be combined. This prevents the light curtain from being accidentally tripped if the part blanking the beam starts to vibrate (making it interrupt or trigger the signal) This function turns OFF the output when the total number of interrupted beams inside the sensing area exceeds the number of set beams (1 or 2). back

Safety Processing Devices
The safety processing devices contains one or two safety circuit(s) for processing input signals provided by Detection or/and Control units and forming safety or/and signaling outputs. They provide safety solutions for each safety function. The Schneider Electric range of safety control solutions comprises four product families: dedicated safety modules with one or two safety functions configurable controllers managing several safety functions safety PLCs used within complex and distributed over SafeEthernet safety system safety monitors and interfaces dedicated to the AS-Interface system, allowing use of a single medium for control and safety AS-interface Safety Monitor is also a configurable controller that manages several safety fcts and controls 1 or 2 actuators. => between Controller and Safety PLC

Programmable Safety PLC
The XPS-MF range of Safety PLCs and I/O are Programmable Electronic Systems (PES) that can be interfaced to safety and non-safety devices to carry out safety or non-safety related tasks for machinery and equipment XPS-MF safety PLCs and Distributed I/O modules are tested and certified by TÜV for functional safety in accordance to CE and standards: IEC up to SIL 3, EN up to category 4 SafeEthernet protocol over Ethernet is certified for safety-related communication between XPS-MF products XPSMFWIN is the project management software used to: Configure the safety PLCs, Develop the user applications using FBD and SFC languages (IEC ), Carry out on-line tests and diagnostics… back

Safety Controllers XPS-MP – safety controller module with 15 preprogrammed (only 2 independent fncts can be chosen) safety functions provide a solution for the majority of safety applications up to category 4 conforming to the standard EN 954-1/ISO 6 safety outputs (3 N/O per function) 3 solid-state outputs (for signaling to the process PLC) XPS-MC – configurable safety controller designed to provide a safety solution with conformity up to category 4 of standard EN 954-1/ISO and up to SIL3 requirement of standard IEC 61508 Safety inputs: 16 or 32 Safety outputs: 6 solid-state + 2 x 2 relay outputs (4 relay outputs with guided contacts) NON-safety communication via: CANopen, Profibus and Modbus XPSMCWIN configuration software for XPS-MC Free of charge “Service version” is available for customers back

Safety Modules Safety Modules – designed to provide a safety solution for the majority of safety applications. Each safety module performs one or few preprogrammed safety functions (emergency stop, switch, light curtains, two-hand control station, etc. monitoring) Modules enclosed into housings of width: 22,5 mm – 2 to 3 safety outputs + 1 to 2 additional outputs 45 mm – 3 to 6 safety outputs + 2 to 5 additional outputs 90 mm – 6 to 8 safety outputs + 2 to 6 additional outputs Up to the Category 4 max depends on the structure and other products used in the solution back

AS-i Safety@Work Concept
SAFETY AT WORK The Actuator/Sensor Interface or AS-Interface is the only worldwide standardized bit-oriented fieldbus: Power supply, standard data and safety-oriented data transfers on the same 2-wire yellow cable The AS-i Safety at Work system can be used to create safety functions up to Category 4 AS-interface "Safety at Work" allows direct safety components connection on the cable: Emergency stops Limit switches Light curtains Contact less sensors, etc.

AS-i Cabling - Maximum security
AS-i significantly improves machine’s reliability, availability and safety: Cabling errors are eliminated: A rubberized 2-wire cable (2 x 1.5 mm2) The profile section prevents stations being connected with incorrect polarity Risk of electrical connection failure greatly reduced High immunity to electromagnetic interference (EMC) The machine’s safety function is fully integrated with AS-Interface Safety at Work. Connecting modules: Contact blades penetrate the rubber jacket and make contact with the two wires Removing blades from cable causes no problems - cable is “self-healing”. holes made in the rubber jacket of the cable close themselves and revert to the type of protection IP67 AS-interface Safety Monitor is also a configurable controller that manages several safety fcts and controls 1 or 2 actuators. => between Controller and Safety PLC

AS-i Modules This diagram illustrates an active AS-i module for four connections back

Emergency stop & Emergency switching off
the emergency stop device is part of the emergency stop function system of the machine

Machinery EN/IEC Safety of machinery EN/ISO 13850 Emergency Stop Equipment TRIGGER Emergency Switching Off Emergency Stop Eliminate the risk of electrical shock by switching off the electrical supply Eliminate the risk induced by the machine operation - Safety risk assessment -

What is an emergency stop operation Is « an emergency operation intended to stop a process or a movement that has become hazardous »  is part of the emergency stop function system of the machine What is an emergency switching off operation Is « an emergency operation intended to switch off the supply of electrical energy to all or part of an installation where a risk of electric shock or another risk of electrical origin is involved »  is directly linked to risk of electrical origin, related to the machine or not

Trigger action & non trigger action
What is a « Trigger action » product When the operator is pushing the mushroom head (actuator), the head is translating to a position where, even if the action on the actuator is discontinued, the mechanism will continue automatically its translation, switch the associated contacts and generate the emergency stop command + the latching-in of the device.  as soon as the NC contact starts to become open, the product will latch in the open position even if you stop to push on the head, or pull the cable. What is a « non-trigger action » product When the operator is pushing on the mushroom head (actuator) up to the mechanical stop (over travel), switch the associated contacts and automatically latch-in.  when the contact is open and the head is not in its « latching » position, the fact to stop to push on the head or pull on the cable will close the NC contact again. it is consequently necessary to push on the head up to its latching point to guarantee and maintain the opening status of the NC contact.

Zoom on solutions = + + Building Machinery
Emergency Switching off function In Machinery it is obligatory to use an Emergency Stop with Trigger function and circular yellow legend However, in Building sector there are no restrictions on use of the trigger or non-trigger E-stops Emergency Stop or Emergency Switching off function = TRIGGER or Non-TRIGGER TRIGGER Non-trigger e-stop cheaper in price – advance in competition. + + EMERGENCY SWITCHING OFF EMERGENCY STOP

Emergency Stop Trip-wire
An e-stop trip wire switch is designed to be triggered by a single human action when a normal e-stop function cannot be used This applies to: Long installations Situations where operations are necessary around the machine It is used to transmit a stop command: At any point in the work zone Regardless of the direction in which the wire is activated These components conform with standard EN/ISO 13850:2006 Three essential principles: Positive operation Latching Resetting

XY2 CH Simple to install Simple to use
Direct mounting of cable with integral tensioner Mechanical indication of the cable tension Only 2 screws to attach the cover Simple to use Visual indication of safety contact 24V 48V 130V 230V ON OFF Option: Yellow beacon with incandescent bulb Low operating force

XY2 CE Simple to install Anchor point to the left
Anchor point to the right Reset device Optional window for cable tension indication Optional indicator light with incorporated incandescent bulb to show state of contacts Polychloroprene or silicon (for low temperatures) bellows back

Two-hand Control Station
It requires simultaneous operation by both hands in order to start and maintain operation of a machine. It therefore provides protection exclusively for the person operating it. The control station can be mounted: directly on the machine housing on a pedestal, enabling 3 directional adjustment: height rake skew Two-hand control station can be operated differently back

Enabling Switch Enabling switches, allow authorised personnel to carry out maintenance, adjustment or programming operations within hazardous zones of machines, provided certain conditions are met Operating principle - The three possible states are: position 0: contact open (control operator at rest) position 1: contact closed (control operator depressed to normal enabling position) position 2: contact open (control operator fully depressed) back

Foot Switch Foot switches are an ideal solution for providing start and stop instructions for many types of industrial machines, running in various operating modes Additional protection and safety possibilities: The cover avoids the risk of accidental starting resulting from a human action or falling object Positive action is required on the toe plate 1 before the pedal 2 can be depressed to start the machine Can be mounted directly on the baseplate of the pedestal XY2 for two-hand control stations back

Switch Disconnectors Mini-Vario and Vario rotary switch disconnectors from 12 to 175A Used for equipment isolation from electrical supply and disconnection (interrupt current running through equipment) Can be safely used for «on-load» making and braking of circuits Pad-lockable handle in the Open position They does not include any protection mechanism May be used as an Emergency Stop button (with yellow cover and red handle) back

How to obtain CE marking?!
Standards How to obtain CE marking?!

Directives and Standards
European Directives are mandatory must be translated locally and applied within two years from publication; define the "essential requirements", e.g. protection of health and safety requirements, that product must meet before placed on the European market Standards are not mandatory, unless they are mentioned in a legislative text on the country level The European standards bodies are mandated to draw up the technical specifications (Harmonized Standards) meeting the requirements of the Directives Comply with the Harmonized Standards is the simplest way to comply with the Machinery Directive

Standardization Institutes
IEC (electrical standards) ISO (other standards: mechanical parts...) CEN (mechanical standards) CENELEC (electrical standards) SIS CSA BS GOST DIN ANSI NF UNE CEI UL JIS OSHA SAA (PCB making machines) ISO: International Organization for Standardization IEC: International Electrotechnical Commission CEN: Comité Européen de Normalisation CENELEC: Comité Européen de Normalisation Electrotechnique

Standardization Bodies
All countries use IEC and ISO standards or adapt them locally. All the main institutes work jointly with other international organizations.

European Standard’s Subordination
A basic std EN ISO 12100 Fundamental notions, Design main principles EN 693 hydraulic Presses EN 692 Mechanical presses C specific class of machines EN 1088 Locking devices EN 953 Fixed and mobile protectors EN/ISO 13850:2006 Emergency Stop equipment EN 574 Bi-manual command devices B2 safety devices EN = EN/ISO 14121 Risk assessment EN = ISO :1999  EN ISO 13849 Safety of machinery Safety-related part of ctrl sys EN Machines electrical equipment EN 294 and 999 Safety distances B1 specific safety aspect

European Machinery Directive 98/37/EC
European Machinery Directive, an early example of the “New Approach” to technical harmonisation and standardisation for products, relies on: mandatory essential health and safety requirements (which must be met before machinery is placed on the market) voluntary harmonised standards drawn up by the European Committees for Standardisation (CEN) and Electro-technical Standardisation (Cenelec) conformity assessment procedures tailored to the type and level of risks associated with machinery and, the CE marking, affixed by manufacturers to signify compliance with all relevant directives. Machinery bearing this marking may circulate freely within the European Economic Area A new version of the Machinery Directive 2006/42/EC will be effective in November 2009 At the moment both versions are valid The directive has greatly simplified the national laws that preceded it and thus removed many barriers to trade within the EU. It has also reduced the social cost of accidents. New Approach directives apply only to products which are intended to be placed (or put into service) on the EU market for the first time. back

Basic concepts According to the requirements of standard EN/ISO , the machine designer’s job is to reduce all risks to a value lower than the acceptable risk It gives guidelines for the selection and installation of devices which can be used to protect persons and identifies those measures that are implemented by the machine designer and those dependent on its user This standard recognises two sources of hazardous phenomena: moving parts of machines moving tools and/or workpieces back +info

Risk Assessment Principles
Machines are sources of potential risk and the Machinery Directive requires a risk assessment to ensure that any potential risk is reduced to less than the acceptable risk Risk assessment consists of a series of logic steps which make it possible to systematically analyse and evaluate machinery-related risks Risk assessment steps: Identification of the potential hazard Risk estimation Risk evaluation EN/ISO => Performance Level (PL) EN/IEC => Safety Integrity Level (SIL) Risk reduction back

Risk Evaluation On the basis of the risk assessment, the designer has to define the safety related control system. To achieve that, the designer will chose one of the two standards appropriate to the application: either standard EN/ISO , which defines performance levels (PL) or standard EN/IEC 62061, which defines safety integrity levels (SIL) The table below gives relations between these two definitions To select the applicable standard, a common table in both standards gives indications: - For building specific complex sub-systems or for higher level requirements including software, standard EN/IEC relating to systems must be used. d (1) For designated architectures only

Remark: Change of Standards
The qualitative approach of the EN is no longer sufficient for modern controls based on new technologies (Electronic and Programmable Electronic systems): insufficient requirements for programmable products, The reliability of the components is not taken into account, too deterministic orientation (designated architectures). Standard EN ISO will totally replace the EN in November 2009, and will upgrade the qualitative approach by the new quantitative (probabilistic) approach and is consistent with safety standards in general. At the moment both standards EN and EN/ISO are valid For complex machines using programmable systems for safety-related control, the sector specific standard EN/IEC has to be considered EN/IEC based on EN/IEC 61508

Standard EN/IEC 62061 Specific to the machine sector within the framework of EN/IEC 61508: gives rules for the integration of safety-related electrical, electronic and electronic programmable control systems (SRECS) does not specify the operating requirements of non-electrical control components in machine (ex.: hydraulic, pneumatic) The probability of failure associated to the required SIL (Safety Integrity Level) depends on the frequency of usage of the safety function to be performed the table only shows High Demand / Continuous mode (because Safety of Machinery only considers SIL 1 to 3 of this mode). The other mode (Low Demand) is normally a second column of this table for Low Demand mode with probability values x (approx. nb of hours in a year!). Safety of Machinery application EN/IEC 62061 back

Standard EN/ISO The Standard gives safety requirements for the design and integration of safety-related parts of control systems, including software design. The Risk Graph helps to determine the required PL (Performance Level) of each safety function S - Severity of injury S1 Slight injury S2 Serious or permanent injury or death F - Frequency and / or exposure to a hazard F1 Seldom to less often and / or short time F2 Frequent to continuous and / or long time P - Possibility of avoiding the hazard or limiting the harm P1 Possible under specific conditions P2 Scarcely possible For combinations of several safety relevant parts into a common system the standard specifies the calculation of the resulting PL PL: from a to e, an associated probability of dangerous failures per hour

Relationship Between Different Criteria
Relationship between Categories, DCavg, MTTFd and PL *In several application the realisation of performance level c by category 1 may not be sufficient. In this case a higher category e.g. 2 or 3 should be chosen. DC – Diagnostic Coverage MTTFd – Mean Time To Failure (d- Dangerous) PL – Performance Level SIL – Safety Integrity Level back

Electrical Equipment of Machines
Standard EN/IEC completes the safety standards by giving setting-up rules for each component of a machine’s electrical functions. It specifies, amongst other things: the type of connection terminals and disconnection and breaking devices, the type of electric shock protection, the type of control circuits, the type of conductors and wiring rules, the type of motor protection. back

Summary: 6 steps to get the “passport”
Schneider Electric wants to support the customers of PREVENTA safety products in order to achieve easily the certification of their machines. There are 6 steps in the process of certification and CE marking of machines: Applying all relevant directives and standards Complying to the essential health and safety requirements Draw up the technical documentation CE-Type-examination (if applicable proceed with the conformity examination) Draw up the Declaration of Conformity Affix the CE marking Anyway for all machines listed in annex IV the customer needs a document from the notified body before affixing the CE mark on the machine List of dangerous machines for which passing an examination by notified body is mandatory. For other machines, self-certification is possible.

Recommendations Today there are 575 harmonised standards under the machinery directive, and out of that we find about 350 standards for machines. Nevertheless there are only a few harmonised standards for the machines listed in annex IV. In order to ensure the adequate consideration of all applicable standards it is advisable to have made a CE Type-Examination. Specially in all cases where an CE Type-Examination is made, the Notified Body should be involved from the beginning of the project in order to detect discrepancies as early as possible during the development phase and also in order to achieve the certification as soon as possible at the end of the project. back

Focus on basic safety concept
Safety Principles Focus on basic safety concept

Positive Opening Operation
The achievement of contact separation as the direct result of a specified movement of the switch actuator through non-resilient members Safety switches employ a rigid mechanical link from the actuator to open Normally Closed contacts. The normal operation of the switch will force apart contacts, even those that are welded shut. For more information see ISO14119 and IEC

Operation in Negative Mode
In case of welded contacts or broken spring contacts stays in the closed position, which may result on the safety of machine and personnel

Combined Mode To clear faults due to positive mode, use combined mode
Combined mode makes it possible to clear faults due to use of positive mode only. Negative mode is only acceptable if it is combined with a sensor in positive mode; combination of the two modes by means of a positive mode sensor used in conjunction with a negative mode sensor avoids the risk of common mode failures (same failure on both sensors)

Mechanically Linked Electrical Contacts
Mechanical guiding (forced guiding) makes it impossible to close the normally closed and normally open contacts simultaneously If a failure occurs: contact A welded; then contact B stays open.

Locking and Interlocking Devices
Monitoring device Normal approach Danger zone S Access time = Time to cover distance S Interlocking devices Stops the machine and allow immediate access as soon as the access request is detected XCS-MP, XCS-M, XCS-TA, XCS-PA, etc. Allow access to the machine only after it’s complete stop XCS-TE, XCS-E, XCS-B /C, etc. Stopping time < access time Interlocking devices with locking function Stopping time > access time

Mirror Contacts An electrical auxiliary contact mechanically linked to the power poles is an N/C auxiliary contact which can never be closed at the same time as the power poles If one of the power pole contacts becomes welded, the mechanical link prevents the N/C auxiliary contact from closing when the coil is de-energised

Redundancy and Self-monitoring
Cause of the first fault: - break, - crushing, - disconnection, - shorting, - failure of a component. If an initial fault is not noticed, there is no incentive to make repairs and a second fault may eventually occur, jeopardizing safety. 2. Self-monitoring: Consequence: the next cycle may be inhibited or allowed Consists of compensating for the failure of one component by correct operation of another, based on the assumption that both will not fail simultaneously Consists of automatically checking the operation of each of the components which change state at each cycle

Redundancy + Self-monitoring
= the risk of not operating safely is hardly reduced down to an acceptable level compared to the consequences An initial fault in the safety circuit is detected before a second fault occurs (next cycle inhibited) back

T hanks for your attention

Machine Safety Training for Beginners

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