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Fault detection must consider for each part of the safety system, as
well as the connections (i.e., the system). What are the failure
modes of a dual channel tongue switch? What are the failure modes
of the MSR? What are the failure modes of the contactors K1 and
K2? What are the failure modes of the wiring?
Category 3
Input
Output
Logic
Reasonably Practical
Fault Detection
Input
Wiring
Output
Logic
Wiring
Figure 127: Category 3 Block Diagram
SCP
Ch2
L1 L2 L3
SCP
K2
Aux
Start
Stop
K1
Ch1
Guard
Closed
Monitoring Ch1
Safety
Ch2
Relay
K2
OP
Tongue
Switch
TS
Gnd
K1
K2
Contactors
TS
A failure could occur where the head mounting screws are not
torqued properly. With this condition, the expected vibration of the
machine may cause the head mounting screws to back out. The
operating head, under spring pressure, removes the pressure from
the safety contacts, and the safety contacts close. Subsequently,
opening the guard does not open the safety contacts, and a failure
to danger occurs.
Similarly, the operating mechanism within the switch must be
reviewed. What is the probability that a failure of a single
component will lead to the loss of the safety function? These
questions will be answered in the near future as mean time to
dangerous failure, diagnostic coverage and safe failure fraction must
be provided to meet the increasing knowledge required to assure
the performance of the safety function.
Wiring
Wiring
Motor
(Hazard)
Undetected Faults
As stated earlier, some faults cannot be detected. These faults, by
themselves, do not lead to the loss of the safety function. When
evaluating faults, a series of questions must be asked. The answer
to the first question will lead to different follow-up questions:
Opening Question: Can the fault be detected?
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L1 L2 L3
+V
SCP
If no, did the fault lead to the loss off the safety function? Would a
subsequent fault lead to the loss of the safety function?
Figure 129 shows a widely used approach for connecting multiple
devices to a monitoring safety relay. Each device contains two
normally closed direct opening action contacts. These devices can
be a mix of interlocks or e-stop buttons. This approach saves wiring
costs as the input devices are daisy-chained. Assume a short circuit
fault occurs across one of the contacts. Can this fault be detected?
Wiring Fault in
the System
K1
Aux
Sw1
Sw2
Sw3
Ch2
Gate
Control
Power
Monitoring Ch1
Safety
Relay Ch2
L1 L2 L3
Ch1
Comm
Enable
SCP
K2
Aux
Start
Start
Stop
+V
SCP
24VDC
E-Stop
Ch2
Gate
Control
Circuit
Gnd
Stop
K1
Safety Rated
Variable Frequency
Drive
Ch1
Monitoring Ch1
Safety
Relay Ch2
K2
Motor
(Hazard)
OP
K1
K2
TS
Motor
(Hazard)
Contactors
When switches Sw1 and Sw3 are opened, the MSR successfully
removes power from the hazard. When Sw1 and Sw3 are closed the
hazard can be restarted by pressing the start button. During these
actions, the fault was not detected but did not lead to the loss of
the safety function. What about when Sw2 is opened?
When Sw2 opens, Ch1 opens and Ch2 remains closed. The MSR
de-energizes the hazard because Ch1 opened. When Sw2 closes,
the motor cannot be started when the Start button is pressed,
because Ch2 did not open. The fault is detected. The weakness to
this design is that switch Sw1 or Sw3 can be opened and closed
and mask the fault. A subsequent fault (a short circuit across the
second contact or Sw2) will lead to the loss of the safety function.
The series connection of mechanical contacts is limited to Category
3 as it may lead to the loss of the safety function due to an
accumulation of faults.
Figure 130 shows a category 3 circuit using a safety rated variable
frequency drive. Recent developments in drive technology coupled
with the updating of the electrical standards allow safety rated
drives to be used in e-stop circuits without the need for a electromechanical disconnect of the actuator (e.g., the motor). Pressing the
E-Stop opens the outputs of the MSR. This sends a stop signal to
the drive, removes the enable signal and opens the gate control
power. The drive executes a Category 0 Stop immediate removal
of power to the motor. The drive achieves category 3 because it has
redundant signals to remove power to the motor: the enable and a
positive guided relay. The positive guided relay provides reasonably
practical feedback to the actuator. The drive itself is analyzed to
determine that a single fault does not lead to the loss of the safety
function.
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SCP
SCP
K2
Aux
Start
Ch2
L1 L2 L3
Stop
K1
Ch1
Guard
Closed
Monitoring Ch1
Safety
Ch2
Relay
K2
OP
Tongue
Switch
TS
Gnd
K1
K2
TS
Motor
(Hazard)
Contactors
Wiring Fault in
the System
SCP
Ch2
Stop
Ch2
K1
Stop
K1
Ch1
Monitoring Ch1
Safety
Relay Ch2
K2
OP
Tongue
Switch
TS
Gnd
K1
K2
TS
Guard
Closed
Monitoring Ch1
Safety
Relay Ch2
OP
TS
K1
Gnd
Ch2
L1 L2 L3
SCP
K2
Aux
Start
Motor
(Hazard)
Figure 133 shows another wiring fault example. This fault occurs
from the mechanically linked contact of K2 to the monitoring input
of the MSR. Can this fault be detected?
K1
Aux
TS
SCP
K2
Contactors
+V
K2
Tongue
Switch
Motor
(Hazard)
Contactors
Stop
Figure 135 shows a cross channel input fault. A fault occurs from
Channel 1 to Channel 2 at the input of the MSR. With 8 connections
for the two channels, there are 8 potential ways to create the cross
channel fault. Can this fault be detected?
Detection of this fault is dependent upon the MSR. MSRs designed
for two normally closed contacts utilize diverse inputs. One input is
pulled up to +V, and the second input is pulled down to ground. A
wiring short will be detected immediately, and the safety input of the
MSR will turn off, removing energy from the hazard.
K1
Ch1
+V
K2
K1
Aux
OP
K2
Aux
SCP
Guard
Closed
SCP
K2
Aux
Start
Ch1
Guard
Closed
K1
Aux
SCP
SCP
K2
Aux
Start
Monitored Manual
Reset Button
L1 L2 L3
+V
L1 L2 L3
Monitoring Ch1
Safety
Relay Ch2
Tongue
Switch
Start
Ch2
TS
Gnd
K1
K2
TS
Motor
(Hazard)
SCP
Stop
K1
Ch1
Contactors
One Wiring Fault
in the System
L1 L2 L3
Guard
Closed
Monitoring
Ch1
Safety
Relay Ch2
K2
OP
Tongue
Switch
TS
Gnd
K1
K2
TS
Motor
(Hazard)
Contactors
One Cross Channel Wiring
Fault in the System
Some MSRs are designed to interface with input devices like light
curtains and laser scanners. These devices have OSSD (Output
Solid State Switching Devices) that have built in cross fault
detection.
Figure 136 shows an example safety system with light curtains
(OSSD outputs). Can the safety system detect this fault?
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+V
SCP
SCP
+V
OSSD1
OSSD2
L1 L2 L3
Stop
SCP
K2
Aux
Start
TS
Start
K1
Aux
SCP
K1 K2
SW1
Stop
K1
Safety Rated
Input Logic Output
TS
K1
K2
Sender Receiver
Monitoring Ch1
Safety
Ch2
Relay
Pulse
Test
Outputs
SW2
K2
OP
TS
K1
K2
TS
Gnd
Motor
(Hazard)
Contactors
The MSR cannot detect this fault, because both inputs are pulled up
to +V. In this example, the wiring fault is detected by the light
curtain. Some light curtains use a fault detection technique called
pulse testing. With these light curtains, the detection of the fault is
immediate, and the light curtain turns off its output. In others, the
detection is made when the light curtain is cleared. When the light
curtain attempts to energize its output, the fault is detected and the
output remains off. In either case, the hazard remains off in the
presence of the fault.
Gnd
Figure 138: Safety PLC using Pulse Testing for Fault Detection
The faults described above are only a subset of all the faults that
must be considered. Short circuits to +V, to Ground, shorts to other
circuits, and open circuit conditions must be evaluated. In addition,
the component ratings and performance must be considered.
Figure 139 shows a variation of a Safety PLC arrangement. In some
cases, connecting a non safety rated device to a safety system is
needed and beneficial. If the outputs are sourcing type, they can be
connected directly to the input of the safety PLC. If they are dual
channel, they can be considered to meet Category 3s reasonable
requirements.
Another consideration for Safety PLC modules is the number of
inputs. Occasionally, one or two additional inputs may be needed,
but panel space does not allow for an additional block. In this case,
input devices may be connected in series (e.g., SW1 and SW2) and
still meet the requirements of Category 3. The tradeoff is the loss of
information as to which switch is actuated, unless an additional
contact is used and connected to the machine control system.
+V
SCP
SCP
Start
Stop
K1 K2
Safety Rated
Input Logic Output
TS
TS
K1
K2
Nonsafety
Rated
Channel 1
SW1 SW2
Pulse
Test
Outputs
Channel 2
Gnd
Cross
Channel
Fault
Category 4
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Input
Wiring
Wiring
Output
Logic
Mandatory Monitorng
for Fault Detection
Input
Wiring
Output
Logic
Wiring
Negative Mode
+V
K1
Aux
SCP
Figure 141 shows the same circuit as was shown in Figure 128,
which was declared a category 3 circuit. Again, using fault exclusion
to eliminate the failure of the tongue interlocks to open due to a
failure of the operating head, this circuit also meets the
requirements of Category 4.
Ch1
L1 L2 L3
SCP
K2
Aux
Start
Stop
K1
+V
K1
Aux
SCP
Ch2
SCP
K2
Aux
Start
Guard
Closed
OP
Ch2
K1
TS
Gnd
Monitoring Ch1
Safety
Relay Ch2
TS
K1
K1
K2
TS
Motor
(Hazard)
Contactors
K2
Tongue
Switch
Gnd
K2
Tongue
Switches
Stop
Ch1
Guard
Closed
Monitoring Ch1
Safety
Relay Ch2
L1 L2 L3
K2
TS
Motor
(Hazard)
Contactors
+V
SCP
Ch1
SCP
K1
Ch1
Monitoring Ch1
Safety
Relay Ch2
K2
OP
Guard
Closed
Gnd
K1
K2
TS
Motor
(Hazard)
Contactors
Monitoring Ch1
Safety
Relay Ch2
K2
Figure 145 shows a modular monitoring safety relay with one device
connected to each input module. If the safety relay is rated for
category 4, this arrangement of input devices meets Category 4.
OP
Tongue
Switches
Ch2
Gnd
SCP
Stop
TS
Stop
Guard
Closed
Ch2
L1 L2 L3
K2
Aux
Start
Noncontact
Interlock
L1 L2 L3
K2
Aux
Start
K1
Aux
SCP
TS
K1
K2
TS
Motor
(Hazard)
Contactors
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+V
SCP
Ch2
Ch1
K1
Aux
L1 L2 L3
SCP
K2
Aux
Start
Stop
K1
Modular Monitoring
Safety Relay
Ch1
K2
Ch2
OP
TS
Gnd
K1
K2
TS
Motor
(Hazard)
Contactors
Figure 146 shows a system that has the high integrity level of hard
wiring and also allows a correctly sequenced shut-down which
protects the machine and program.
Minotaur
MSR138DP
Guard
Interlock
Switch
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PLC
Normal Machine
Control
Figure 146: Delayed Outputs for Orderly Shutdown
Some components, on the other hand, perform continuous selfchecking. Light curtains, for example, sequentially turn on and off
their LEDs. If a fault occurs, the light curtain turns off its outputs,
before a demand is place on the safety system, as it continuously
checks itself. Microprocessor based relays and safety PLCs are
other components that perform continuous self-checking.
The control system requirement for continuous self checking is not
intended to limit the selection of components to light curtains and
microprocessor based logic units. The checking should be
performed at startup and after every demand on the safety system.
This level of risk reduction is intended to align with Category 4 of
ISO13849-1.
Contactor
PLC
Solenoid Locking
Interlock Switch
Simple
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A New Direction
At the time of publication of this catalog there is an increasing
awareness of the implications of a new generation of standards that
cover the functional safety of safety related control systems and
devices.
Functional safety is the part of the overall safety that depends on
the correct functioning of the process or equipment.
Therefore the functional safety of an electrical control system is
highly relevant to the control of hazards arising from moving parts of
machinery.
Three of the most significant control system functional safety
standards for machinery are:
IEC/EN 61508 Functional safety of safety related electrical,
electronic and programmable electronic control systems
This standard contains the requirements and provisions that are
applicable to the design of complex electronic and programmable
systems and subsystems. The standard is generic so it is not
restricted to the machinery sector.
IEC/EN 62061Safety of machinery - Functional safety of safety
related electrical, electronic and programmable electronic control
systems
It is the machinery specific implementation of IEC/EN 61508. It
provides requirements that are applicable to the system level design
of all types of machinery safety related electrical control systems
and also for the design of non-complex subsystems or devices. It
requires that complex or programmable subsystems should satisfy
IEC/EN 61508
ISO/EN 13849-1:2006 Safety of machinery Safety related parts of
control systems
Intended to provide a functional safety transition path from the use
of Categories.
The functional safety standards represent a significant step beyond
the familiar existing requirements such as Control Reliable and the
Categories system of ISO 13849-1 (EN 954-1). Categories are not
disappearing yet, the original standard will remain valid until 2010 to
provide a period for transition to its new revised version. This new
version of ISO/EN 13849-1 uses the functional safety concept and
has introduced new terminology and requirements. In this section
we will refer to the new version as ISO/EN 13849-1:2006.
Interest in the functional safety standards will grow because they are
the future and they facilitate more flexibility and the use of new
technology for machinery safety.
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ISO 13849-1:2006 will not use the term SIL, instead it will use the
term PL (Performance Level). In many respects PL can be related to
SIL. There will be five performance levels, PLa is the lowest and PLe
is the highest.
PL (Performance Level)
PFHD (Probability of
Dangerous Failure per
Hour)
SIL
105 to <104
None
3 x 106 to <105
107 to <106
108 to <107
1-67
EN/ISO13849-1:2006
IEC62061:2005
Position
Sensing
Logic
Solving
Output
Actuation
Note: This should take account of all tasks required at the machine and it is very important to also give full
consideration to production and maintenance requirements when deciding on the safety function concept.
Logic
subsystem
Output
subsytem
Logic
Output
Input
Logic
Output
Additional detailed requirements are given in the texts of the standards. A review and explanation of some of the new terminology used in
both standards is given in the following chapters.
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