safety relays and controllers

Safety Relays & Safety Controllers

Sponsored by:

Presenter: Mike Garrick

Agenda

Safety Bridge?

Taking the Mystery out of Safety Controllers

Basic Safety Design

Force Guided Relays

Why Safety? The “Safety bridge” truly Meets the spirit of the “Drive for Technology” event!

Phoenix Contact Safety

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

• Reason: Machines are dangerous• To protect:

• Man• Machine• Material

Avoiding danger

Increase availability & reliability

Increase output (yields)


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety? •Machines come in many shapes and forms and can potentially expose people to different hazards:

• Mechanical• Crushing, cutting, pressing etc.

• Electrical• Contact with high voltages

• Thermal• Burns and scolding

• Noise & Vibration• Hazardous Chemical Substances• Rays

• Microwaves, x-rays • Biological • Pressurized Gasses• Ergonomic (65% of all injuries in the US)


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

• Design• Training• Proper installation and startup

testing• Maintenance• Accident documentation• Rule enforcement

Typical Accidents

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

• Reaching in to clear equipment• Bypass loose or missing safe

guards • No lockout tag out• Operator errors (training)• Bad design

Direct Vs Indirect

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

• Costs• Direct

• Workers Comp• Medical Expenses

• Indirect• Legal settlements /fines• Time lost by injured employee• Loss of efficiency • Damage to tools & equipment• Loss of production• Failure to fill orders• Damage from accident

• Fire• Water • Explosion

• Unknown Factors• Human Tragedy• Morale * Reputation

Direct Vs Indirect

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

Conveyor Accident, 5/19/04

Then comes the Indirect Costs…..

Who’s directly responsible for an accident?

Safety Interlocks 2/15/2005

$133,650

$116,000

Lathe Machinery Accident 5/09 $56,250

Paper Rolled! 10/09 $136,500

Who does OSHA Target?

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety? Accidents

Nature of the businessFallingExposureContructionTrenchingPresses

Southern Air Whistle Blower 4/2009

Motion Hazard Types

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

• Rotating parts• Reciprocating and transverse motions• In-running nip points • Cutting, sanding, and grinding actions • Punching • Shearing • Bending, etc.

Recip_Trans

Nip Points

The Heart of the Safety Relay

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?• Minimum Definition

• All contacts are mechanically linked

• 1 NC & 1 NO contact set

• If the any of the contacts fail (weld), opposite type contacts will not close.


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?• Contacts are pulled

together and pushed apart by the mechanical link.


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?“If any of the contacts fail

(weld), opposite type contacts will not close.”

This is error tolerant behavior>0.5mm


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

FGRStandard


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

** Minimum requirement of a FGR is 1 normally closed mechanically linked to 1 normally open contact

FGR Standard Relay

Shown not energized


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

FGR Standard Relay

Shown energized


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

X = Welded NO Contact

>0,5mm

FGR Standard Relay

Shown not energized


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

K1

M

K1-2

StartE-stop

K1-1


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

K1

M

K1-2

StartE-stop

K1-1

K2

K2-1

K2-2


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?K1

M

K1-2

E-stop

K3-1

K2

K3-2

K2-2

K1-1

K2-1

K1-3

Start

K2-3

K3

K3-3

Determine the limits of the Machine

Identify the hazards

Risk estimation

Design a safety concept:• Protective measure• Estimate residual risk• ...

Is the machine safe?No Document the resultstechnical documentation

Yes

Hazardous-analysis

Risk-analysis

Consider all life phases.

Identify dangerous zones / parts

Risk evaluationIF RISK MUST BE

REDUCED

Risk-reduction

Principles for Risk Assessment, ANSI/RIA R15.06, ANSI B11.19.TR3, IEC 61508, ISO 13849, ISO 14121, EN 1050

Severity of the Injury

S1 Slight (normally reversible) Injury

S2 Severe (normally irreversible) Injury, including Death

Frequency and/or Duration of the Danger

F1 Seldom to regular and/or

the duration is short

F2 Frequent to continuous and/or

the exposure is long

Potential to avoid the Danger

P1 Possible under certain conditions

P2 Scarcely possibleSelection 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

B 1 2 3 4

Start

S1

S2

F1

F2

P1

P2

P1

P2

Category

Safety of Machinery – Risk Evaluation (EN954-1)

B 1 2 3 4

Start

S1

S2

F1

F2

P1

P2

P1

P2

Category

S: Seriousness of injury? F: Frequency and duration in the danger zone?

P: Possibility of avoiding the injury?

S2 heavy, irreversible

F2 permanentP2 hardly possible

Safety of Machinery – Risk Evaluation (EN954-1)

Safety Categories

Category B• One failure can lead to a loss in safety

Category 1• One failure can lead to a loss in safety

(but it‘s not as probable as in category B)

Category 2• One failure can lead to a loss in safety in

between the test cycle, however, the test cycle will detect the failure

Single Channel

Single Channel

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety? • Components:• I: Input, sensor• L: Logic, control• O: Output, (Motor)

contactor

I L OIm Im

Single Channel

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety? • Components:• TE: Test equipment• OTE: Output of test equipment

I L OIm Im

TE OTEIm

m

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.)

Category 4• 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

Dual Channel(Redundant)

Dual Channel

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

I1 L1 O1Im

c

I2 L2 O2ImIm

m

Im

m

Safety Relay Designs

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

LogicLogic

InputsInputs ResetReset OutputsOutputs

Machine SafeguardingSafety Sensors (Input)

E-Stop Magnetic Door Switches

Two-Hand Control Light Curtain

Input

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

Machine SafeguardingSafety Controls (Logic)

Safety Relays

AX Bus Solutions

Logic

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

Machine SafeguardingPower Control Elements (Output)

Door InterlocksContactor

AC Drive Contactron4 in 1

Output

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

• “Star” of the family• Reversing solid state starter• The “star”

CONTACTRON- “4 in 1”

• Reverse running

• Forward running

• Motor protection (overload relay)

• Emergency stop

75% less space

75% less wiring time

Safety rated

TOP highlight

forwardreverseprotect

10x service life

CONTACTRON “4 in 1“

10x service life

A microprocessor-controlled combination of: • robust relay technology• with wear-free solid-state technology

“4 in1” Savings Over Contactors

E-stop Contactors

Reversing Contactors

Overload Relay

Safety control system

Machine Safety Functions

Sensor:Receives signals,recognizes danger

Output / Power Control Elements:Stops movement,removes danger

Logic, Processing:Analyses signals,monitors sensors and actors

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?A1

14A2

~ +_

S11 S12

LOGIC

K1

K2

24 32

13 23 31S34S33S22S21

PowerSupply +

PowerSupply -

Input Channel 1

Input Channel 2

Reset andFeed Back Connection


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

S1

S2

StartK4

K4

K4

A1

14A2

~ +_

S11 S12

LOGIC

K1

K2

24 32

13 23 31S34S33S22S21


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety? StartK4

K5K4

K5

K4

K5

A1

14A2

~ +_

S11 S12

LOGIC

K1

K2

24 32

13 23 31S34S33S22S21


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?S1

S2

Start

K5K4

K4

K5

A1

14A2

~ +_

S11 S12

LOGIC

K1

K2

24 32

13 23 31S34S33S22S21


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?S1

S2

StartK4

K5K4

K5

K4

K5

A1

14A2

~ +_

S11 S12

LOGIC

K1

K2

24 32

13 23 31S34S33S22S21


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

A1

A2

S33 S34 13 23

14 24

K5

K5

Start

K4

K4

S22S21S11 S12

PSR-SCP-24UC/ESM4/2X1/1X2

E-stop 1

E-stop 2

K4

K5

Safety Controllers

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

Safety Controllers Vs Safety Relays

…

…

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?


Safe PLCmiddle(16 to 64)

complex

few(1 to 16)

I/Osprogrammablefixed function configurable

high(>64)

FunctionalityPSR Safety Relays

Safety Controller


Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

Becomes cost and space effective when a customer is using 3 to 5 standard safety relays

Safety Controllers Major Features

“Look and Feel”• Housing and connectors in a “Phoenix”- form factor

Hardware• High performance / small size

Approvals• Maximum safety level achieved

Simulation• Test at your desk

Flexibility• Easy configurable logic

Major Benefits






Major Benefits







Major Benefits

SIL3PLe

SIL CL 3UL/CSA

Safety Cat. 4







Major Benefits

20 Inputs

4 Safe Outputs

4 Auxiliary Outputs

Ground Switching Out’s4 test pulse outputs

67,5 mm







Major BenefitsPluggable Connectors

Screw- and Spring technology

Plug-in, Keyed and Marked

Twin- Spring cage

USB- Connection

Removable Memory stick


Safety Controllers – Application Example

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

Safety-Functions:• 2 Emergency Stops• 3 Safety Doors

Width180 mm

Safety Relays5 Modules

1 safety Controller

Width67.5 mm

Safety Controllers

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

Graphic user interface

Simple to use for non programmers

In 3 steps to a complete and tested project

Configuration Software

Configuration Software – 3 Steps

Demo Simulation Mode


Safety Controllers

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

New!

PLC

Order No. 2692720

Safety Controllers

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

Safety Controllers – Make the best choice

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?• Software

• Fully functional package is a free download

• No licensing fees• Easy drag and drop!!• Simulation Mode!!• Complexity• Programming methods• Supported functionality• Password protected

• Hardware• Size • Plug-in, keyed and printed terminals• Proper approvals• Modular, I/O• Network• Memory included• Use standard USB cable

Safety Bridge Technology

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

New!

• Distributed acquisition of safety signals

• 24 safe inputs (8 per module)

Safety Bridge Input Modules Safety Bridge Logic Module• Creates and monitors the safety protocol

• Processes all safety functions

• 8 safe outputs onboard

Safety Bridge Logic Module• Creates and monitors the safety protocol

• Processes all safety functions

• 8 safe outputs onboard

Safety Bridge Technology – The Concept

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

&

&

&

Safety Bridge Technology – The Concept

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?&

&

Safety Bridge Technology – Components

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

LPSDO

PSDI

Network

8 Inputs

8 Inputs

8 Inputs

8 Outputs

SAFECONF

Project

Safety Bridge Technology – Addressing

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

LPSDOLPSDO

PSDIPSDI

LPSDOLPSDO

PSDIPSDI

…

Island # 1 Island # 31

Safety Bridge Technology – Requirements

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety? PL or SIL rating is independent of machine

PLC or bus system

Safety Bridge Technology – Software

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

V2.5

AvailableNow

Safety Bridge Technology – Approvals

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

Functional Safety

EN 954 Category 4EN ISO 13849 PL e EN 62061 SIL CL3 IEC 61508 SIL 3

Phoenix Contact Safety – Q&A

Safety Bridge?


Basic Safety Design

Force Guided Relays

Why Safety?

Safety PLCsSafety Controllers

PSR Safety Relays

safety relays and controllers

Health & Medicine