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Basics of Safety Applications Unrestricted © Siemens 2016 usa.siemens.com/controls
Basics of Safety Applications Unrestricted © Siemens 2016 usa.siemens.com/controls
Basics of Safety Applications
Basics of Safety
Applications
Unrestricted © Siemens 2016 usa.siemens.com/controls
Unrestricted © Siemens 2016
usa.siemens.com/controls

DISCLAIMER/ TERMS OF USE:

DISCLAIMER/ TERMS OF USE: THE INFORMATION PROVIDED HEREIN IS PROVIDED AS A GENERAL REFERENCE REGARDING THE

THE INFORMATION PROVIDED HEREIN IS PROVIDED AS A GENERAL REFERENCE REGARDING THE USE OF THE APPLICABLE PRODUCTS IN GENERIC APPLICATIONS. THIS INFORMATION IS PROVIDED WITHOUT WARRANTY. IT IS YOUR RESPONSIBILITY TO ENSURE THAT YOU ARE USING ALL SIEMENS PRODUCTS PROPERLY IN YOUR SPECIFIC APPLICATION. ALTHOUGH THIS SITE STRIVES TO MAINTAIN ACCURATE AND RELEVANT INFORMATION, THERE IS NO OFFICIAL GUARANTEE THAT THE INFORMATION PROVIDED HEREIN IS ACCURATE. IF YOU USE THE INFORMATION PROVIDED HEREIN IN YOUR SPECIFIC APPLICATION, PLEASE DOUBLE CHECK ITS APPLICABILITY AND BE ADVISED THAT YOU ARE USING THIS INFORMATION AT YOUR OWN RISK. THE PURCHASER OF THE PRODUCT MUST CONFIRM THE SUITABILITY OF THE PRODUCT FOR THE INTENDED USE, AND ASSUME ALL RISK AND LIABILITY IN CONNECTION WITH THE USE.

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John Burns/ DF CP

Why Safety Technology?

Why Safety Technology? Page 3 03.23.2016 Protection of… • People • Environment John Burns/ DF CP

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Why Safety Technology? Page 3 03.23.2016 Protection of… • People • Environment John Burns/ DF CP

Protection of…

• People

• Environment

Why Safety Technology? Page 3 03.23.2016 Protection of… • People • Environment John Burns/ DF CP
Why Safety Technology? Page 3 03.23.2016 Protection of… • People • Environment John Burns/ DF CP

John Burns/ DF CP

Why safety technology?

Why safety technology? Page 4 03.23.2016 John Burns/ DF CP
Why safety technology? Page 4 03.23.2016 John Burns/ DF CP

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What aspects do the safety standards cover

What aspects do the safety standards cover Page 5 03.23.2016 John Burns/ DF CP
What aspects do the safety standards cover Page 5 03.23.2016 John Burns/ DF CP

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Safety Process Chain

Safety Process Chain The necessary steps towards a safe machi ne can be illustrated with a

The necessary steps towards a safe machine can be illustrated with a process chain.

Risk Assessment Risk Reduction Proof
Risk Assessment
Risk Reduction
Proof
with a process chain. Risk Assessment Risk Reduction Proof Cutting disc > Cutting off Chips >
Cutting disc > Cutting off Chips > Cutting, penetrating Clamping plates > Crushing
Cutting disc > Cutting off
Chips > Cutting, penetrating
Clamping plates > Crushing

Transport rollers > Crushing and shearing

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Safety Process Chain

Safety Process Chain The necessary steps towards a safe machi ne can be illustrated with a

The necessary steps towards a safe machine can be illustrated with a process chain.

Risk Assessment
Risk Assessment

Risk Assessment

Risk Reduction Proof Describe the machine Identify the hazards Evaluate the risks Define and evaluate
Risk Reduction
Proof
Describe the machine
Identify the hazards
Evaluate the risks
Define and
evaluate
the safety measures
Design the architecture
of the safety functions
Implement a safety concept and
put it into operation
Document the
Carry out a validation
Document results
measures

Risk Reduction

Proof

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Risk Assessment

Risk Assessment Risk Assessment Risk Reduction Proof The measure for achieved functional safety is the probability
Risk Assessment Risk Reduction Proof
Risk Assessment
Risk Reduction
Proof

The measure for achieved functional safety is the probability of dangerous failures, the fault tolerance and the quality that is to be guaranteed as a result of freedom from systematic faults. It is expressed in the standards using different terms

• In IEC 62061: “Safety Integrity Level” (SIL)

• In ISO 13849-1: “Performance Level” (PL)

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“Safety Integrity Level” (SIL) • In ISO 13849-1: “Performance Level” (PL) Page 8 03.23.2016 John Burns/

John Burns/ DF CP

Risk Reduction

Risk Reduction Risk Assessment Risk Reduction Proof •Mechanical Guarding • Technology • Education solutions
Risk Assessment Risk Reduction Proof •Mechanical Guarding
Risk Assessment
Risk Reduction
Proof
•Mechanical
Guarding

Technology

Education

solutions consist of three

main components

DetectionDetection EvaluationEvaluation ReactionReaction
DetectionDetection
EvaluationEvaluation
ReactionReaction

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Detection Emergency stop and protective area monitoring

Detection Emergency stop and protective area monitoring EvaluationEvaluation ReactionReaction Initiates stop Prevents
EvaluationEvaluation ReactionReaction
EvaluationEvaluation
ReactionReaction

Initiates stop Prevents unauthorized access Detects dangerous machine functions Positive opening contacts

Positive opening switches are designed in such a way that actuation of the switch always results in opening the contacts. Welded contacts are opened by actuation (EN 60947-5-5)

DetectionDetection
DetectionDetection

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Detection

Detection Standard position switches Safety switch with separate actuator Safety switch hinge switch Safety switches
Standard position switches Safety switch with separate actuator Safety switch hinge switch Safety switches with
Standard position switches Safety switch with separate actuator Safety switch hinge switch Safety switches with

Standard position switches

Standard position switches Safety switch with separate actuator Safety switch hinge switch Safety switches with separate
Standard position switches Safety switch with separate actuator Safety switch hinge switch Safety switches with separate

Safety switch with separate actuator

position switches Safety switch with separate actuator Safety switch hinge switch Safety switches with separate

Safety switch hinge switch

Safety switch with separate actuator Safety switch hinge switch Safety switches with separate actuator and interlocking
Safety switch with separate actuator Safety switch hinge switch Safety switches with separate actuator and interlocking

Safety switches with separate actuator and interlocking

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Detection

Panel Mounted

Detection Panel Mounted Page 12 03.23.2016 Configurable Enclosures D i s t r i b u

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Configurable Enclosures

Panel Mounted Page 12 03.23.2016 Configurable Enclosures D i s t r i b u t
Panel Mounted Page 12 03.23.2016 Configurable Enclosures D i s t r i b u t
Panel Mounted Page 12 03.23.2016 Configurable Enclosures D i s t r i b u t

Distributed Safety

Mounted Page 12 03.23.2016 Configurable Enclosures D i s t r i b u t e

John Burns/ DF CP

Detection

Detection Page 13 03.23.2016 John Burns/ DF CP
Detection Page 13 03.23.2016 John Burns/ DF CP

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Detection

Detection Page 14 03.23.2016 John Burns/ DF CP
Detection Page 14 03.23.2016 John Burns/ DF CP

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Reaction ReactionReaction Safety-rated contactors must include positively driven (mirror) contacts A component with

Reaction

ReactionReaction
ReactionReaction

Safety-rated contactors must include positively driven (mirror) contacts

A component with positive-driven contacts guarantees that the NC and NO contacts are never closed simultaneously (EN 60947-5-1) A mirror contact is an NC contact that is guaranteed not to be closed at the same time as a main contact

(EN60947-4-1)

Siemens 3RT contactors comply with this requirement

Siemens 3RT contactors comply with this requirement DetectionDetection EvaluationEvaluation Page 15 03.23.2016
Siemens 3RT contactors comply with this requirement DetectionDetection EvaluationEvaluation Page 15 03.23.2016
DetectionDetection
DetectionDetection
3RT contactors comply with this requirement DetectionDetection EvaluationEvaluation Page 15 03.23.2016 John Burns/ DF CP

EvaluationEvaluation

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Evaluation Monitors Inputs / Initiates Reaction

Evaluation Monitors Inputs / Initiates Reaction Safety Relays Programmable Safety Relays • Limited inputs and outputs
Safety Relays Programmable Safety Relays • Limited inputs and outputs • Moderate inputs and outputs
Safety Relays
Programmable Safety Relays
• Limited inputs and outputs
• Moderate inputs and outputs
• Simple logic
• Simple to semi-complex logic
• Single Zone
• Multiple Zone
DetectionDetection
EvaluationEvaluation

Distributed Safety Systems

Distributed multiple inputs and outputs

Complex Logic

Multiple Zone

ReactionReaction

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Siemens Safety Integrated Machine safety solution selection

Siemens Safety Integrated Machine safety solution selection 3 Safety Functions Without PC 8 Safety Functions Graphical
3 Safety Functions Without PC
3 Safety Functions
Without PC
8 Safety Functions Graphical Editor Cabinet-Free (IP 65/67) (IP 20)
8 Safety Functions
Graphical
Editor
Cabinet-Free
(IP 65/67)
(IP 20)
25 Safety Functions
25 Safety Functions
Cabinet-Free (IP 65/67) (IP 20) 25 Safety Functions >25 Safety Functions ProgrammingProgramming Language

>25 Safety Functions

ProgrammingProgramming

Language

e.g., LAD/F-LAD

ProgrammingProgramming Language e.g., LAD/F-LAD Cabinet-Free (IP 65/67) In-Cabinet In-Cabinet (IP 20)
Cabinet-Free (IP 65/67)
Cabinet-Free
(IP 65/67)
In-Cabinet
In-Cabinet
In-Cabinet (IP 20)
In-Cabinet
(IP 20)
SafetySafety RelaysRelays

SafetySafety RelaysRelays

ASI-SafeASI-Safe

ASI-SafeASI-Safe

Modular Safety Modular Safety
Modular Safety
Modular Safety

System

System

Fail-SafeFail-Safe ControllersControllers

Fail-SafeFail-Safe ControllersControllers

Fail-SafeFail-Safe ControllersControllers

Fail-SafeFail-Safe ControllersControllers

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Functionality of a Safety Circuit A review

Functionality of a Safety Circuit A review 24V or 115VAC Power Supply Evaluation Fault detection and

24V or 115VAC Power Supply

Evaluation Fault detection and evaluation; opens the circuit in case of a failure. 0V
Evaluation
Fault detection and
evaluation; opens the
circuit in case of a
failure.
0V

are in

or 115VAC Power Supply Evaluation Fault detection and evaluation; opens the circuit in case of a
or 115VAC Power Supply Evaluation Fault detection and evaluation; opens the circuit in case of a
or 115VAC Power Supply Evaluation Fault detection and evaluation; opens the circuit in case of a
or 115VAC Power Supply Evaluation Fault detection and evaluation; opens the circuit in case of a
Redundancy ensures safety functionality even if a failure disables one channel
Redundancy
ensures safety
functionality even if a
failure disables one
channel
Reset Reactivates the safety circuit
Reset
Reactivates the
safety circuit
disables one channel Reset Reactivates the safety circuit Feedback Loop Monitors the correct operation of the

Feedback Loop

Monitors the correct operation of the contactor coils

Sensors Initiate machine shut down
Sensors
Initiate machine shut
down
Positive Opening Guarantees that all NC contacts the open position when actuated
Positive Opening
Guarantees that all
NC contacts
the open position
when actuated

Positive Driven (Mirror)

Guarantees that NC contacts are not to be closed at the same time as the main contact

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Safety Levels PL a

StandardStandard SwitchSwitch andand ContactorContactor

StandardStandard SwitchSwitch andand ContactorContactor
L1 L2 L3
L1
L2
L3
SwitchSwitch andand ContactorContactor L1 L2 L3 Page 19 03.23.2016 PL a allows • NO contacts for

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andand ContactorContactor L1 L2 L3 Page 19 03.23.2016 PL a allows • NO contacts for •

PL a allows NO contacts for

Enabling

Two-hand control

Restart

John Burns/ DF CP

Safety Levels PL b

24 VDC

L1 L2 L3 0 VDC Open Closed
L1
L2
L3
0 VDC
Open
Closed

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b 24 VDC L1 L2 L3 0 VDC Open Closed Page 20 03.23.2016 PL b requires

PL b requires Sensors with positive opening contacts

John Burns/ DF CP

Safety Levels PL c / SIL 1

Safety Levels PL c / SIL 1 24 VDC PL c / SIL 1 requires •

24 VDC

PL c / SIL 1 requires

• ON Sensors with positive opening contacts AndAnd • Safety evaluation unit rated to SIL
ON
Sensors with positive
opening contacts
AndAnd
Safety evaluation unit rated
to SIL 1
L1
L2
L3
Feedback loop from
contactor’s NC contacts
Q1
0 VDC
Open
Closed

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Safety Levels PL d / SIL 2

Safety Levels PL d / SIL 2 24 VDC PL d / SIL 2 requires ON

24 VDC

PL d / SIL 2 requires

ON • Sensors with positive opening contacts • Safety evaluation unit rated to SIL 2
ON
• Sensors with positive
opening contacts
• Safety evaluation unit rated
to SIL 2
L1
L2
L3
• Feedback loop from
contactor’s NC contacts
AndAnd
• Redundancy in sensor
contacts
Q1
• Redundancy in contactors
Q2
0 VDC
Open
Closed

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Safety Levels PL e / SIL 3

Safety Levels PL e / SIL 3 24 VDC PL e / SIL 3 requires ON

24 VDC

PL e / SIL 3 requires

ON • Sensors with positive opening contacts • Safety evaluation unit rated to SIL 3
ON
• Sensors with positive
opening contacts
• Safety evaluation unit rated
to SIL 3
L1
L2
L3
• Feedback loop from
contactor’s NC contacts
• Redundancy in sensor
contacts
Q1
• Redundancy in contactors
AndAnd
Q2
Separate channels of
evaluation for sensors
0 VDC
Open
Closed

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Siemens Safety Evaluation Portfolio

Siemens Safety Evaluation Portfolio F-CPU: S7-1200 / S7-1500 / ET 200SP MSS 3RK3 MSS ASIsafe 3SK2
F-CPU: S7-1200 / S7-1500 / ET 200SP
F-CPU: S7-1200 /
S7-1500 / ET 200SP

MSS 3RK3

Portfolio F-CPU: S7-1200 / S7-1500 / ET 200SP MSS 3RK3 MSS ASIsafe 3SK2 3SK1 Safety device

MSS ASIsafe

3SK2 3SK1
3SK2
3SK1
/ S7-1500 / ET 200SP MSS 3RK3 MSS ASIsafe 3SK2 3SK1 Safety device Engineering Number of

Safety device

Engineering

Number of

safety functions

Communication

Safety Relays

SIRIUS 3SK

Modular Safety System SIRIUS 3RK3

Failsafe SIMATIC PLCs and distributed I/O

Hardware-

parameterized

Software-parameterized

Software-programed

Up to 3*

Up to 6

Up to 20

From 10

none

AS-i and PROFIBUS

AS-i, PROFIBUS, PROFINET, PROFIsafe, I-WLAN

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Online Configurator

Online Configurator l www.siemens.com/industrymall Page 25 03.23.2016 John Burns/ DF CP
l
l

www.siemens.com/industrymall

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Evaluation - Safety Relay

3SK1 Standard

Evaluation - Safety Relay 3SK1 Standard Page 26 Output Expansion 03.23.2016 4 RO 3 RO 5

Page 26

Output Expansion

03.23.2016

- Safety Relay 3SK1 Standard Page 26 Output Expansion 03.23.2016 4 RO 3 RO 5 Amp

4 RO

3 RO

5 Amp

10 Amp

- Safety Relay 3SK1 Standard Page 26 Output Expansion 03.23.2016 4 RO 3 RO 5 Amp

John Burns/ DF CP

Evaluation - Safety Relay

Evaluation - Safety Relay Device Connector 3SK1 Advanced Power Supply Input Expansion Output Expansion Page 27
Device Connector
Device Connector
Evaluation - Safety Relay Device Connector 3SK1 Advanced Power Supply Input Expansion Output Expansion Page 27

3SK1 Advanced

Power Supply

- Safety Relay Device Connector 3SK1 Advanced Power Supply Input Expansion Output Expansion Page 27 03.23.2016

Input Expansion

Output Expansion

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Traditional Safety Relay

Traditional Safety Relay Page 28 03.23.2016 John Burns/ DF CP
Traditional Safety Relay Page 28 03.23.2016 John Burns/ DF CP

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New 3SK1 Safety Relay

New 3SK1 Safety Relay Page 29 03.23.2016 John Burns/ DF CP
New 3SK1 Safety Relay Page 29 03.23.2016 John Burns/ DF CP

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Safety Relay Application Example

Safety Relay Application Example Page 30 03.23.2016 John Burns/ DF CP

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Safety Relay Application Example Page 30 03.23.2016 John Burns/ DF CP
Safety Relay Application Example Page 30 03.23.2016 John Burns/ DF CP

John Burns/ DF CP

Evaluation – Programmable Safety Relay

Evaluation – Programmable Safety Relay 3SK2 Device Connector Power Supply Page 31 03.23.2016 Output Expansion John
3SK2 Device Connector Power Supply
3SK2
Device Connector
Power Supply

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Output Expansion

John Burns/ DF CP

Evaluation – Programmable Safety Relay Zone Estop Area Estop Zone Estop Page 32 03.23.2016 John

Evaluation – Programmable Safety Relay

Evaluation – Programmable Safety Relay Zone Estop Area Estop Zone Estop Page 32 03.23.2016 John Burns/
Evaluation – Programmable Safety Relay Zone Estop Area Estop Zone Estop Page 32 03.23.2016 John Burns/
Zone Estop Area Estop Zone Estop
Zone Estop
Zone Estop

Zone Estop

Area Estop

Zone Estop
Zone Estop

Zone Estop

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SIRIUS Innovations Motor starter 3RM1 Failsafe

SIRIUS Innovations Motor starter 3RM1 Failsafe • Contactor and Overload Direct / reversing start Same Size

Contactor

and Overload

Direct / reversing start Same Size Enclosure

and Overload Direct / reversing start Same Size Enclosure With Safety functionality • Suitable for safety

With Safety functionality Suitable for safety applications up to PL e / SIL 3

With overload protection ATEX certified up to SIL 2

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Evaluation SIL 3 application with a safety relay

Emergency Stop Start
Emergency
Stop
Start
Emergency Stop Start
Emergency Stop Start
SIL 3 application with a safety relay Emergency Stop Start Page 34 03.23.2016 6 Wires /
SIL 3 application with a safety relay Emergency Stop Start Page 34 03.23.2016 6 Wires /

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a safety relay Emergency Stop Start Page 34 03.23.2016 6 Wires / starter • 4 wires

6 Wires / starter

4 wires for 2 coils

2 wires for feedback

John Burns/ DF CP

SIRIUS 3SK1 and 3RM1 Failsafe Application

SIRIUS 3SK1 and 3RM1 Failsafe Application 3RM1 Failsafe Motor Starters Emergency Stop 3SK1 Safety Start Relay
3RM1 Failsafe Motor Starters Emergency Stop 3SK1 Safety Start Relay Motor Starter
3RM1 Failsafe
Motor Starters
Emergency
Stop
3SK1
Safety
Start
Relay
Motor Starter
Failsafe Motor Starters Emergency Stop 3SK1 Safety Start Relay Motor Starter Page 35 03.23.2016 John Burns/

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Distributed Safety

SIMATIC AS-i F-Link with TIA Portal
SIMATIC AS-i F-Link with TIA Portal

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SIMATIC AS-i F-Link with TIA Portal Page 36 03.23.2016 Standard data PROFINET / PROFIsafe SIMATIC PN
SIMATIC AS-i F-Link with TIA Portal Page 36 03.23.2016 Standard data PROFINET / PROFIsafe SIMATIC PN
Standard data PROFINET / PROFIsafe
Standard data
PROFINET / PROFIsafe

SIMATIC PN / AS-i F-Link AS-i double master and F-DI module

AS-i / ASIsafe
AS-i / ASIsafe

Safety cell

Safety cell

John Burns/ DF CP

Distributed Safety

Distributed Safety Motor Management System SIMOCODE pro Page 37 03.23.2016 John Burns/ DF CP

Motor Management System

SIMOCODE pro

Distributed Safety Motor Management System SIMOCODE pro Page 37 03.23.2016 John Burns/ DF CP

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Distributed Safety Motor Management System SIMOCODE pro Page 37 03.23.2016 John Burns/ DF CP
Distributed Safety Motor Management System SIMOCODE pro Page 37 03.23.2016 John Burns/ DF CP
Distributed Safety Motor Management System SIMOCODE pro Page 37 03.23.2016 John Burns/ DF CP

John Burns/ DF CP

Safety Application Manual

Safety Application Manual https:// support .industry. siemens .com/ Page 40 03.23.2016 John Burns/ DF CP
Safety Application Manual https:// support .industry. siemens .com/ Page 40 03.23.2016 John Burns/ DF CP

https://support.industry.siemens.com/

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Safety Application Manual https:// support .industry. siemens .com/ Page 40 03.23.2016 John Burns/ DF CP

John Burns/ DF CP

Safety Application Manual

Safety Application Manual Page 41 03.23.2016 John Burns/ DF CP
Safety Application Manual Page 41 03.23.2016 John Burns/ DF CP

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Safety Application Manual Page 41 03.23.2016 John Burns/ DF CP
Safety Application Manual Page 41 03.23.2016 John Burns/ DF CP

John Burns/ DF CP

Safety Application Manual

Safety Application Manual Page 42 03.23.2016 John Burns/ DF CP
Safety Application Manual Page 42 03.23.2016 John Burns/ DF CP

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Safety Application Manual

Safety Application Manual Page 43 03.23.2016 John Burns/ DF CP
Safety Application Manual Page 43 03.23.2016 John Burns/ DF CP

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Siemens Safety Integrated Machine Safety Life-Cycle Support — USA

Safety Integrated Machine Safety Life-Cycle Support — USA • • • • ► Siemens provides competent
• • • •

Siemens provides competent support throughout the entire machine safety lifecycle

Support

Safety Consultants

Safety Core Team

Safety Validation

Safety Education

Machine Safety Standards

Safety Webinars

Newsletter

Safety White Papers

Siemens Safety Website

Compliance

OSHA Website

Consensus Standards

Risk Assessment Standard

Safety Evaluation Tool - SET

Implementation

Siemens Solution Partners – Safety

Safety Functional Examples

Safety Training

Risk Assessment Training

Products and Solutions

Safety Products

Safety Software

Wireless Safety

PC-Based Safety

BMS

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Questions

Questions Page 45 03.23.2016 John Burns/ DF CP
Questions Page 45 03.23.2016 John Burns/ DF CP

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Basics of Safety Applications

John Burns Lead Application Consultant SII DF CP

5300 Triangle Parkway

Norcross, GA 30092

Tel.: +1 (770) 625-5726

Fax: +1 (678) 297-7250

Cell: +1 (678) 575-3086

E-mail:

john.burns@siemens.com

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siemens.com

+1 (678) 297-7250 Cell: +1 (678) 575-3086 E-mail: john.burns@siemens.com Page 46 03.23.2016 siemens.com John Burns/ DF

John Burns/ DF CP

Basics of Safety Applications Unrestricted © Siemens 2016 usa.siemens.com/controls
Basics of Safety Applications Unrestricted © Siemens 2016 usa.siemens.com/controls
Basics of Safety Applications
Basics of Safety
Applications
Unrestricted © Siemens 2016 usa.siemens.com/controls
Unrestricted © Siemens 2016
usa.siemens.com/controls