Festo Safety Engineering

Safety engineering guidelines
Your partner in safety
Table of contents
Page
At Festo, quality has many aspects one of these is handling machines safely. This is the reason behind our safety-orientated automation technology. It gives you the certainty that your workplace is as safe as possible.
This brochure is intended as a guide. It covers the core questions relating to safety-orientated pneumatics: Why use safety-orientated pneumatics? How can I identify the risk posed by a system or machine to the operator or user? Which standards and directives apply? What safety measures are derived from these? What are the most common safety measures?
Simple and helpful: In the second part of the brochure, you can find sample circuit diagrams for the most common safety functions related to pneumatic drives and the associated product combinations from Festo. These can be used to solve many safety functions. If you have further requirements, our specialists worldwide will be happy to help.
Directives and standards Time schedule for EC machinery directive and DIN EN ISO 13849-1 Definition and concept of risk Risk assessment Directive-compliant procedure for safe design (as per EN ISO 12100) Control architectures (as per DIN EN ISO 13849-1) 4 operation modes 10 safety functions
Sample circuit diagrams
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Festo products
46
Services
74
Reduce risk think preventively
Simple but safe!
Machines have to be designed in a way that protects people, animals, property and the environment from harm. The goal is to prevent physical damage of any type. Using safetyorientated pneumatics from Festo provides you with the security of implementing safety measures in compliance with the EC machinery directive. You can reliably prevent collisions or uncontrolled restarts after an emergency stop, for example. At the same time, using safetyorientated pneumatics also minimises the risk of liability claims.
The EC machinery directive specifies a risk analysis and assessment for machines. Protection goals are derived and defined from this directive. The protection goals are achieved using various safety functions. Safetyorientated pneumatics from Festo, in the form of Components Circuits Engineering make it easy to achieve your safety objectives. Safe operation of machines should be possible in all modes and stages of their service life.
Safety-orientated pneumatics from Festo provides you with solutions for Commissioning Automatic/manual operation Setting operation Risk situations and emergency functions, such as safe stopping, safe exhausting. Restarting -> protection against unexpected starting up Servicing/maintenance In addition to this, if errors occur, they must not lead to failure of the safety functions, depending on their hazard potential.
In general, the simpler the safety engineering used in the application, the more efficient it is. The complexity of safety engineering is in the variety of state combinations and transitional states. As a result, it would seem almost impossible to implement standardised safety engineering concepts. Due to their flexible application, pneumatic drive systems from Festo need to be included in the risk analysis and assessment for each machine, depending on the application.
Festo provides solutions on the basis of risk analyses and assessments for the most common applications. This ensures that the electrical safety functions for your pneumatic systems controllers are enhanced with the appropriate safety concepts.
Basic safety requirements in the manufacturing industry
Time schedule for EC machinery directive and DIN EN ISO 13849-1
The development of the single European market has led to standardised guidelines for mechanical engineering for the manufacturing industry.
Free movement of goods in Europe
Article 95 of the EU Treaty (free movement of goods)
Article 137 of the EU Treaty (occupational health and safety)
Machine safety requires safe control systems. Important harmonised standards include EN 954-1, which is going to be superseded by EN ISO 13849-1. DIN EN 954-1 will be in force until the end of 2009.
2006
2007
2008
2009
2010
29th December 2009
2011
Old machinery directive

May 2006 EN ratification
Europe
e.g. machines
Health and safety outline directive 89/391/EEC
Incorporation into national law
New machinery directive

extended to 29th December 2009
Low voltage directive 2006/95/EC
Machinery directive 98/37/EC 2006/42/EC
Use of work equipment single directive 86/655/EEC
EN 954-1
8th May 2007 Listing in the Official Journal of the European Communities
Harmonised European standards

Responsibility
National statutory provisions
EN ISO 13849-1
Manufacturers
Operators Germany DIN EN 954-1

2nd October 2006 EN ratification
February 2007 Withdrawn from DIN
Directives are laws. The EC machinery directive applies to mechanical engineering run on. The primary aim of the EC machinery directive is to specify basic health and safety requirements in relation to the design run on and construction of machines. The CE mark identifies a machine as compliant with the EC machinery directive.
One option for complying with the EC machinery directive is to apply harmonised standards. Harmonised standards are listed in the Official Journal of the European Communities. Applying these results in what is known as the presumption of conformity, which reinforces the legal security of operators and manufacturers.
February 2007 DIN ratification
DIN EN ISO 13849-1
EN 954-1 has presumption of conformity according machinery directive 98/37/EC EN ISO 13849-1 has presumption of conformity according machinery directives 2006/42/EC and 98/37/EC
A new machinery directive will apply to the trade in and construction of machines in the EU from the end of 2009. EU member states urgently have to incorporate this directive into their national legislation because, at European level, directives are laws.
Manufacturers have to comply with the laws of their country. Applying standards is an option. Standards reflect the best available technology.
Fundamental standards for designing control functions
Definition and elements of risk
Applying harmonised standards provides legal security in compliance with European law.
Design and risk assessment of machinery EN ISO 12100

Safety of machinery Basic concepts, general principles for design
Electrical safety aspects EN 60204-1

Safety of machinery Electrical equipment of machines, part 1: General requirements
Risks are the result of hazards and relate to the gravity of possible damage and the probability of the damage occurring. The first step is to reduce risk by implementing inherent safety. The second step is to reduce risk by implementing safety measures. The final measure is to reduce risk through instruction.
Low risk Safety Residual risk
High risk
EN 1050 (EN ISO 14121-1)

Safety of machinery Risk assessment, part 1: Principles
Adequately reduced
Danger/hazard Risk before protective measures

Necessary minimum risk reduction
Functional and safety-related requirements for safety-related control systems
Designing and implementing safety-related control systems EN 62061

Safety of machinery Functional safety of safety-related electrical, electronic and programmable control systems
Actual risk reduction
Safety = acceptable residual risk
Any architectures
Safety integrity level (SIL) SIL 1, SIL 2, SIL 3
Risk in terms of the considered hazard
Severity of harm that can result from the considered hazard
Probability of occurrance of that harm
DIN EN ISO 13849-1

Safety of machinery Safety-related parts of control systems, part 1: General principles for design Successor standards to EN 954-1:1996, transition period until 2009
Exposure of person(s) to that hazard
Designated architectures (categories)

Performance level (PL) PL a, PL b, PL c, PL d, PL e
The possibility of avoiding or limiting the harm
Harmonised standards that relate to machine safety serve to reduce safety risks to an acceptable minimum, as per the machinery directive.
The occurrance of a hazardous event
Risk assessment
Risk analysis Source: EN ISO 12100, 3.14
Directives and standards describe the process of risk assessment. Every manufacturer is obliged to carry out a risk assessment. This is followed by a risk evaluation and, if necessary, suitable measures for reducing risk have to be implemented. Focusing on risk reduction This guide is primarily concerned with the area of risk reduction in the form of technical safety measures. We assume that all possible design measures for reducing risk have already been explored.
Risk assessment Source: EN ISO 1050/14121
Start Specification of the machine limits Use limits Space limits Time limits
Source: EN ISO 12100; 5.2
Determination of the limits of the machinery

Source: EN 1050, Section 5 ISO 14121
Design measures e.g. inherent safety Preliminary hazard analysis (PHA) WHAT-IF method Failure mode and effects analysis, failure effects analysis (FMEA) Failure simulation for control systems MOSAR procedure Fault tree analysis (FTA) DELPHI-Technique
Source: EN 1050, Appendix B Source: EN 12100-2, Section 4
Hazard identification
Determining/defining states & transitional states
Technical safety measures and supplementary safety measures Identify the safety function to be performed
When estimating the risk and identifying the required performance level, the degree of risk reduction is established. Whether or not the required risk reduction level has been achieved for technical safety measures depends on the following parameters: 1) Control architecture 2) Mean Time To Failure (MTTFd) 3) Diagnostic coverage (DC) 4) Common Cause Failure (CCF) In all cases, the performance level (PL) must be equivalent to at least the required PLr.
Risk estimation
Determining the required PLr
Risk evaluation Source: EN ISO 12100-1, 5.3
Risk evaluation of safety design measures Is the machine safe? yes Risk evaluation of technical safety measures Is the machine safe? yes
Source: EN ISO 12100; 5.3
For all safety functions
no
Design and technical implementation of the safety function Determining the PL
Category
MTTFd
DC
CCF
no yes PL PLr no
Source: DIN EN ISO 13849-1, 4.2 Figure 3
All possible instructive measures used yes
no
User information on the machine and in the user manual

Source: EN 12100-2, Section 6
End
Source: Directive 2006/42/EC, Appendix I, 1)
10
Risk reduction Source: EN ISO 12100-1, 5.4
Human interaction during whole life cycle Possible states of the machine Unintended behaviour of the operator or reasonably foreseeable misuse
For each safety function specify the required characteristics
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Evaluating technical safety measures determination of the performance level
Application 13849-1, step 1: Determining the required performance level
Determination the PL = Performance Level
Determination of the SIL = Safety Integrity Level
The figure shows the simplified procedure for determining the performance level (PL) of a safety function. The PL is a function of categories B to 4, diagnostic coverage none to high, various MTTFd areas and the common cause failure. The PL can be assigned to a specific SIL level. However, it is not possible to infer the PL from the SIL. Apart from the average probability of a dangerous failure per hour, other measures are needed to achieve a specific PL.
Determination of the MTTFd = mean time to failure (dangerous)

105 PFHd < 104
b 1 c
3 x 106 PFHd < 105
106 PFHd < 3 x 106
107 PFHd < 106
The graph for determining the required performance level is based on identifying the risk and the resulting necessity for reducing this to an acceptable level. Low risk results in PL = a (minimal measures for risk reduction). High risk results in PL = e (comprehensive measures for risk reduction).
P1 F1 P2 S1 P1 F2 P2 P1 F1 P2 S2 P1 F2 P2
low risk
a b
d e
high risk
Source: DIN EN ISO 13849-1, Appendix 1.2.3
e
DC < 60% none DC < 60% 60% DC 90% DC 60% DC 90% DC 99% DC none < 90% < 99% < 90% < 99% high low medium low medium
108 PFHd < 107
2 5
Cat B
Cat 1
Cat 2
Cat 3 CCF 65%
Cat 4
Technically speaking, PLr (required) is a nominal value, which is the minimum that should be achieved by the real structure. Statements from EN 62061 are also quoted here for a better assessment of risks. The basic principle of risk is always evaluated in the same way: the severity of the possible damage and the probability that the damage will occur.
Statements from other standards DIN EN ISO 13849-1 S Severity of injury S1 S2 Slight (normally reversible injury) Serious (normally irreversible injury, or death) EN 62061 Irreversible injury (4 points) (death, loss of eye or arm) Irreversible injury (3 points) (broken limb, loss of finger) Reversible injury (2 points) (requires further medical attention from a doctor) Reversible injury (1 point) Frequency (with a duration > 10 min) < 1 h (5 points) > 1 h to < 1 day (5 points*) > 1 day to < 2 weeks (4 points*) > 2 weeks to < 1 year (3 points*) > 1 year (2 points*) * if exposure lasts less than 10 min, this can be reduced one level Impossible (5 points) Rare (3 points) Probable (1 point)
CCF not relevant
Risk graph: Which performance level is required? PL a to e Designated architectures: How is the control chain or safety function structured? Cat B to 4 Quality of components in the control chain. Determining the MTTFd for the entire process chain from sensors to actuators Diagnostic coverage: Which dangerous failures are identified?
Evaluation Low Medium High
MTTFd 3 years MTTFd < 10 years 10 years MTTFd < 30 years 30 years MTTFd 100 years
Frequency and/or exposure to hazard F1 F2 Seldom to less often and/or exposed time is short Frequent to continuous and/or exposed time is long
Source: DIN EN ISO 13849-1, Chapter 4.5.2
Possibility of avoiding the hazard P1 Possible under specific conditions Scarcely possible
P2
Common cause failure (CCF): measures to reduce CCF
DIN EN ISO 13849-1 Chapter 4.5.4
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13
Safety function Exhausting
Implementation 13849-1, step 2: Determination of the designated architechture for category B

Category B Summary of requirements Safety-related parts of control systems must comply with the applicable standards Control system must be designed, built, selected, assembled and combined to ensure that they withstand the expected influences System behaviour Fault tolerance: zero. The occurrence of a fault can lead to the loss of the safety function Mainly characterised by selection of components Example Entire control chain = cat. B
Cat. B*
Cat. 1
* Normal PLC control systems (not safety control systems) only achieve category B
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Control architecture of category 1
Category 1
Summary of requirements The requirements of B shall apply Well-tried components and well-tried safety principles shall be used Well-tried component: a) Widely used in the past with successful results in similar applications, or b) Manufactured and verified using principles that demonstrate its suitability and reliability for safety-related applications
System behaviour Fault tolerance: zero, but the probability of occurance is lower than for category B The occurrence of a fault can lead to the loss of the safety function Mainly characterised by selection of components
Example* Entire control chain = cat. 1 Hardware structure

EM
Wiring
ERGEN
CY
S TOP
*The example shows the schematic representation of a specific category. Depending on the safety relay, the wiring may be different and the connections may have different designations. A fault examination has to be carried out for each concrete application.
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Category 2 Summary of requirements Requirements of B and the well-tried safety principles shall apply System behaviour
Fault tolerance: zero, but the loss of the safety function is Safety-related parts of control systems must check safety functions at suitable intervals by the machine control system: when the machi- detected by the check ne starts up and before a hazardous situation arises, e.g. the start of The occurrence of a fault can a new cycle; at the start of other movements and/or periodically lead to the loss of the safety during operation, if the risk assessment and the operation mode function between the checks show that this is necessary. Testing at suitable intervals (test frequency must fulfil one hundred times the requirement rate (safety function)) Mainly characterised by structure

EM
Wiring
ERGEN
CY
S TOP
m i
TE
OTE
*The example shows the schematic representation of a specific category. Depending on the safety relay, the wiring may be different and the connections may have different designations. A fault examination has to be carried out for each concrete application.
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19
Category 3
Summary of requirements Requirements of B and the use of well-tried safety principles shall apply Safety-related parts shall be designed so that a single fault in any one of these parts does not lead to a loss of the safety function, and Whenever reasonably practicable, the single fault is detected
System behaviour Fault tolerance: one When a single fault occurs, the safety function is always performed Some but not all faults are identified Accumulation of undetected faults can lead to the loss of the safety function Mainly characterised by structure

EM
Wiring
ERGEN
CY
S TOP
I1
m
m
L1
O1
c i m
m
I2
L2
O2
*The example shows the schematic representation of a specific category. Depending on the safety relay, the wiring may different and the connections may have different designations. A fault examination has to be carried out for each concrete application. Note: BGIA certification as a category 3 component as per DIN EN ISO 13849-1 has been requested for MS6-SV.
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21
Category 4
Summary of requirements Requirements of B and the use of well-tried safety principles shall apply Safety-related parts shall be designed so that a single fault in any of these parts does not lead to a loss of the safety function, and The single fault is detected at or before the next demand upon the safety function, but that if this detection is not possible, an accumulation of undetected faults shall not lead to the loss of the safety function.
System behaviour Fault tolerance: one When single fault occurs, the safety function is always performed Detection of accumulated faults reduces the probability of the loss of the safety function The faults will be detected in time to prevent the loss of the safety function Mainly characterised by structure

EM
Wiring
ERGEN
CY
S TOP
I1
m
m
L1
O1
c i m
m
I2
L2
O2
*The example shows the schematic representation of a specific category. Depending on the safety relay, the wiring may be different and the connections may have different designations. A fault examination has to be carried out for each concrete application. Note: BGIA certification as a category 3 component as per DIN EN ISO 13849-1 has been requested for MS6-SV.
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Implementation 13849-1, step 3: Determination of the Mean Time To Failure (MTTFd)
where:
Input Input signal Logic Control signal Outlet Control signal
Formula for determining the MTTFd value for a mechanical element in a channel
MTTFd =
B10d 0.1 nop
B10d [cycles] = mean number of cycles until 10% of components fail dangerously B10d = 2 x B10
Life time data based on the technical data sheet B10 Application data MTTFd MTTFd MTTFd MTTFd B10
Mean number of annual actuations nop for the mechanical element
nop =
dop hop 3600s/h tcycle
hop [h/d]: mean operating hours/day dop [d/anno]: mean operating days/year tcycle [s]: mean cycle time
Evaluation
MTTF
1 1 ______ = N _______
Low Medium High
3 years MTTFd < 10 years 10 years MTTFd <30 years 30 years MTTFd 100 years
MTTFd
i=1
MTTFd,i
Calculating the total MTTFd for two different channels
MTTFd =
2 3
MTTFdC1 + MTTFdC2
1 1 1 + MTTFdC1 MTTFdC2
Source: DIN EN ISO 13849-1, Chapter 4.5.2
MTTFdC1 and MTTFdC2: values for two different, redundant channels. If the MTTFd for a channel is more than 100 years, 100 years is used in subsequent calculations.
The mean time to failure (MTTFd) is initially determined for each redundant channel. Next, a total MTTFd value is determined for both channels. This value is given in years and is a qualitative statement of the safety function. In line with the applicable standard, the technical safety measure is assessed and given one of three classifications: low, medium or high.
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Implementation 13849-1, step 4: Determination of the diagnostic coverage (DC)
This table shows a summary of sources of fault related to pneumatics, taken from DIN EN ISO 13849-2. Under certain conditions, it is possible to exclude faults. The prerequisites for excluding a fault are described in detail in DIN EN ISO 13849-2. Faults must be examined and evaluated in the context of each application to establish whether the fault has a dangerous effect on the safety function. Depending on the construction principle and the design of components, different results may arise for different applications; in other words, a specific product may be suitable for one application but not for another. The design engineer for the installation is responsible for checking this.
Spontaneous change in the setting device
Change in the flow rate in the case of non-adjustable, circular orifices and nozzles
Spontaneous change of the initial switching position (without an input signal)
Bursting of the valve hosing/ moving component(s)/mounting/ housing screws
Key
Change in the set value without change to the setting device Unintended unscrewing of the operating element of the setting device Failure at the connector (e. g. tearing off, leakage) For proportional flow valves: unintentional change in the setting value Change of the detection or output characteristics Failure of the end position cushioning
Fault list Change of switching times
Change in flow rate without any change in setting device
Change in the leakage flow rate over a long period of use
Loosening of the piston/ piston rod connection
Electrical power failure
Clogging (blockage)
Not relevant for this component Freedom from defects assured to some extent for the component (see DIN ISO 13849-2) Freedom from defects not assured for this component
Non-switching/ not switching back
Products
Directional control valves
Shut-off/non-return/quick exhaust/shuttle valves Flow control valves
Pressure failure
Pressure rise
Bending
Leakage
Pressure limiting valves
DC average
DC2 DCN DC1 + + ... + MTTFd1 MTTFd2 MTTFdN DCavg = 1 1 1 + + ... + MTTFdN MTTFd1 MTTFd2
Pipework
Tubing
Connecting pieces
Pressure intensifier and pressure medium converter Filter DC1 =
(identified dangerous fault) (total dangerous fault)
Lubricator
Silencer
Energy storage device and reservoir Sensors
Logic elements (AND/OR)
Delay elements
Transformers (pressure switch, position switch and amplifier) Cylinder
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Implementation 13849-1, step 5: Determining Common Cause Failures (CCF)
Combination or series connection of SRP/CS to achieve an overall performance level
Common cause failure No. Measures against CCF 1 Separation/ Segregation Physical separation between signal paths, e.g. separation in wiring/piping, sufficient clearances and creep age distances on printed-circuit boards 2 Diversity Different technologies/design or physical principles are used, for example: first channel programmable electronic and second channel hardwired, kind of initiation, pressure and temperature. Measuring of distance and pressure, digital and analog. Components of different manufactures Design/application/experience Protection against overvoltage, over pressure, over-current etc. Components used are well-tried Assessment/analysis Are the results of a failure mode and effect analysis taken into account to avoid commoncausefailures in design. Competence/training Have designers/ maintainers been trained to understand the causes and consequences of common cause failures? Environment Electromagnetic compatibility (EMC) The system was checked for EMC immunity (e.g. as specified in the relevant product norms) Other factors Have the requirements for immunity to all relevant environmental influences such as temperature, shock, vibration, humidity (e.g. as specified in relevant standards) be considered?
Score S
15
20 15 5
3 3.1 3.2 4
Safety functions can be implemented using multiple SRP/CS connected in series. The performance of each SRP/CS is either determined by the user or, ideally, specified by the manufacturer of the component in the technical data for the certified components. To determine the total performance level, the number of the lowest performance level has to be identified and the overall PL is determined using the standard.
Sensors
User design Using certified components User design
Logic
Using certified components
Actuators
User design Using certified components
Architecture selection
MTTF B10 value
d
MTTF B10 value
d
MTTF B10 value
d
Application data n
op
Application data n
op
Application data n
op
Diagnostic coverage 0 ... 99% CCF value common cause failure
PL a, b, c, d or e
PL a, b, c, d or e
PL a, b, c, d or e
PL a, b, c, d or e
PL a, b, c, d or e
PL a, b, c, d or e
5 25
Partial result Sensors Partial result Logic Partial result Actuators
6 6.1
6.2
10
determined by the mechanical engineer specified by the manufacturer
PL
Total Measures for avoiding CCF Meets the requirements Process failed; choose additional measures Which common cause failures can arise? The measures against these failures should be recorded in a grid. Only the complete number of points or no points may be claimed for each listed measure. If a measure is only partially fulfilled, it receives zero points.
[max. possible: 100] Total S score 65% or better less than 65%
Simplified calculation of PL for series allignment of Safeyrelated Part of control Systems In a series connection, the number of the lowest PL is determined. This result can be used to determine the total PL from the table.
Lowest PL PLlow a b c d e
Number of lowest PL Nlow ,3 >3 ,2 >2 ,2 >2 ,3 >3 ,3 >3
Entire system PL not permitted a a b b c c d d e
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4 operation modes 10 safety functions
Pressurising
Maintaining pressure
Reducing pressure and force
Exhausting
During the risk assessment, the hazardous situation also has to be determined and, subsequently, the risks have to be evaluated. This applies to a machines entire service life. The following four operating modes in particular are used for operating a machine: Initial position/standstill Normal operation Set-up and service operation Emergency operation
Specific safety functions can be derived from these operation modes: Pressurising of machines Maintaining pressure Reducing pressure and force Exhausting of machines Two-hand operation Tamper-proof Reducing speed Free of forces Stopping, holding and blocking a movement Reversing a movement
Initial position, standstill
You can find these safety functions both in the suggested circuits and in the products and solutions. The information specified always refers to very specific safety functions. This will enable you to quickly decide whether the information is relevant to your current task, both in the sample circuits and in the products.
Set-up and service operation
Normal operation
Two-hand operation
Emergency operation
Tamper-proof, prevention of unexpected starting up
Reducing speed
Free of forces
Stopping, holding and blocking a movement
Reversing a movement
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Examples of safety-orientated pneumatics
The varying requirements and areas of application for installations mean that the results of risk analyses are very variable as are the solutions for them. Here we present some important examples.
Picking & Placing discrete goods Safety measures 1. Prevention of unexpected start-up, as per EN 1037 2. Two-channel stop, as per EN ISO 13849-1 3. Stop category 1 as per EN 60204-1
Power-driven interlocking guards Safety measures 1. Prevention of unexpected start-up, as per EN 1037 2. Single-channel for safety function exhausting, as per EN ISO 13849-1 3. Stop category 1 as per EN 60204-1
Safety for pressing, joining and setting procedures Safety measures 1. Prevention of unexpected start-up, as per EN 1037 2. Single-channel reversing, as per EN ISO 13849-1 3. Unpowered state using stop category 1 as per EN 60204-1
In progress: safety during setting-up Safety measures 1. Prevention of unexpected start-up, as per EN 1037 2. Single-channel run at reduced speed, as per EN ISO 13849-1
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Safety function Two-hand operation
Safety function Reversing
Sample circuit diagram two-hand control block
Sample circuit diagram double two-hand control block
Control chain
Description The control block for two-hand start ZSB 1/8 is a pneumatic AND gate. If inputs 11 and 12 are pressurised within a max. of 0.5 s of each other, the assembly switches through and there is an output signal at port 2. The system is controlled by two external 3/2-way push-button valves. If both push-button valves are activated, outlet port 2 is pressurised. If one or both pushbuttons are released, outlet port 2 is unpressurised. The system exhausts from 2 to 3.
one-way flow control valve screwed in cylinder
safety relevant
safety relevant
safety relevant
Description If pressure switch DR1 displays the minimum operating pressure and the two pushbuttons WV5 and WV6 are actuated, both two-hand control blocks (WV3 and WV4) switch through. This reverses the WV1 and WV2 power valves and the piston rod extends. If only one of the two power valves reverses, the piston rod remains retracted. If the piston rod extends and one power valve is reset by the integrated spring, the piston rod retracts again. The working lines to the bearing
cap side of the cylinder are safety-related; in other words, they play a decisive role in the function and, by extension, safety. If one of these lines is kinked or clogged, the cylinder does not receive the pressure it requires to travel to its retracted position. This should be noted when laying the working lines, for example, in energy chains. If one of the power valves fails, there is an acoustic fault alarm caused by venting at on one of the silencers.
Part no. 3527 6817 6817 9270
Identifier WV1 WV2 WV3 DR
Type ZSB-1/8 SV-3-M5 SV-3-M5 VD-3-PK-3
Product designation Control block for two-hand start Front panel valve Front panel valve Pressure sequence valve
Function Control architecture Number of channels Diagnostic coverage Performance level CCF
Description (max. possible) Cat. 2 1 Medium d > 65%
Note All the information that relates to standards is identified with max. possible. Whether the values are reached does not only depend on the pneumatics. It is only possible to assess whether a specific function is achieved or not by observing the complete system. The design of the electrical engineering, mechanics, hydraulics and pneumatics all play a role.
1m hose
Part no. 9270
Identifier DR1 KS1 SP1
161061 3527 184135
Product designation Pressure sequence valve Any drive One-way flow control valve SP2 One-way flow control valve WV1, WV2 VL-5/2-D-01-FR 5/2-way valve WV3, WV4 ZSB-1/8 Control block for twohand start WV5, WV6 SV/O-3-PK-3x2 Front panel valve Description (max. possible) Cat. 3 2 Medium d > 65%
Type VD-3-PK-3
Note All the information that relates to standards is identified with max. possible. Whether the values are reached does not depend only on the pneumatics. It is only possible to assess whether a specific function is achieved or not by observing the complete system. The design of the electrical engineering, mechanics, hydraulics and pneumatics all play a role.
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Safety function Stopping, holding and blocking a movement
Sample circuit diagram exhausting via non-return valves
Sample circuit diagram pneumatic holding using stop valves
Description Directional control valves WV1 and WV2 are responsible for the normal operating function. If there is no current, they are in their initial position and exhaust the installation. To make it possible to retract and extend the cylinder, WV3 has to exert pressure on both non-return valves (SP1 and SP2). In this case, the two non-return valves do not affect normal operation. If both non-return valves (SP1 and SP2) are exhausted, cylinder KS1 can also be exhausted via the non-return valves.
These make up the second channel for exhausting the drive. It is important to note that the two non-return valves also need a differential pressure in order to exhaust. This differential is application specific.
Identifier KS1 DS1 SP2, SP1 WV3, WV2, WV1
Type
e.g. HGL, H, HA, HB e.g. CPE, MHE, MFH
Product designation Any drive Any pressure switch Non-return valve Solenoid valve
Description The cylinder can be held pneumatically via two different channels. Channel 1 is created by stop valve WV1. When not actuated (mid-position), the valve is closed; in other words, if the electrical power is switched off, WV1 switches to its spring centred mid-position and the cylinder is held pneumatically. The second channel is created by the two stop valves (WV3 and WV4) and actuating valve WV2. When not actuated, WV2 is exhausted and switches the two stop valves to the closed position. The two stop valves create the second channel for pneumatic holding.
Part no.
910445
Identifier KS1 DS1 DR1, DR2 WV1, WV2 WV3, WV4
Type Any drive Any pressure switch GR... CPE..., MH...,MFH..., VSVA... VL-2-1/4-SA3919
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Safety function Tamper-proof, prevention of unexpected starting up
Sample circuit diagram mechanical and pneumatic holding
Sample circuit diagram servopneumatics
Description The safety function stopping a movement is implemented both pneumatically and mechanically (diversified) in this circuit. Assuming that both the mechanical brake and the pneumatic holding in the application are sufficient to fulfil the stopping a movement safety function, this is a two-channel system. Channel 1 is implemented via WV1. In the mid-position (dead), the valve is closed and the cylinder stops.
The second channel is controlled via the mechanical brake by WV2. When exhausted, the brake is activated and it holds the piston rod. It is important to note that a brake is used here, and not a retaining device.
Description For implementation of the following safety measures: Protection of unexpected start-up, as per EN 1037 (two-channel design) -> possible: performance level d, as per EN ISO 13849-1 Single-channel exhausting safety measure, as per EN ISO 13849-1 -> possible: performance level d, as per EN ISO 13849-1* Stop category 0 as per EN 60204-1
Identifier DS1 ST1, ST2 KS1 WV1, WV2
Product designation Any pressure switch GR... Flow control valve DNCKE.., DNCKE..-S, KEC.., KEC..-S Cylinder CPE.., MH.., VSVA.., MFH.. Directional control valve Description (max. possible) Cat. 3 2 Medium d > 65%
Type
Function Control architecture Number of channels Diagnostic coverage Performance level Max. possible CCF
Part no. 163380 9517 9517 11689 188510 188510 151694 542897
Type DNC-50-500-PPV-A GRU-1/4-B GRU-1/4-B H-1/4-B MFH-5/2-D-1-FR-S-C MFH-5/2-D-1-FR-S-C MPYE-5-1/4-010-B SDE5-D10-FP-Q6E-P-M8
Product designation standard cylinder flow control/silencer flow control/silencer non-return valve solenoid valve solenoid valve proportional directional control valve pressure switch
*Requires appropriate diagnostics (e.g. additional evaluation of the signal change at the pressure switch)
The cylinder can move depending on its position during exhausting.

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Safety function Stopping a movement
Description For implementation of the following safety measures: Prevention of unexpected start-up, as per EN 1037 (two-channel design) > possible: performance level d, as per EN ISO 13849-1 Single-channel exhausting safety measure, as per EN ISO 13849-1 -> possible: performance level d, as per EN ISO 13849-1* Stop category 0 as per EN 60204-1
Description For implementation of the following safety measures: Prevention of unexpected start-up, as per EN 1037 (two-channel design) -> possible: performance level d, as per EN ISO 13849-1 Single-channel exhausting safety measure, as per EN ISO 13849-1-> possible: performance level d, as per EN ISO 13849-1* Stop category 1 as per EN 60204-1
Part no. 163380 151694 542897 7802 161082 161082 9517 9517 11689
Type DNC-50-500-PPV-A MPYE-5-1/4-010-B SDE5-D10-FP-Q6E-P-M8 MFH-3-1/8 VL-5/2-D-02-FR VL-5/2-D-02-FR GRU-1/4-B GRU-1/4-B H-1/4-B
Product designation standard cylinder proportional directional control valve pressure switch solenoid valve pneumatic valve pneumatic valve flow control/silencer flow control/silencer non-return valve
Part no. 163380 151694 542897 11689 188510 188510
Type DNC-50-500-PPV-A MPYE-5-1/4-010-B SDE5-D10-FP-Q6E-P-M8 H-1/4-B MFH-5/2-D-1-FR-S-C MFH-5/2-D-1-FR-S-C
Product designation standard cylinder proportional directional control valve pressure switch non-return valve solenoid valve solenoid valve
The cylinder can move depending on its position during exhausting.
Pneumatic residual energy in the system.

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Safety function Stopping a movement
Safety function Reducing the speed
Description For implementation of the following safety measures: Prevention of unexpected start-up, as per EN 1037 (two-channel design) -> possible: performance level d, as per EN ISO 13849-1 Two-channel stop safety measure, as per EN ISO 13849-11* -> possible: performance level d, as per EN ISO 13849-1
Description For implementation of the following safety measures: Prevention of unexpected start-up, as per EN 1037 (two-channel design) -> possible: performance level d, as per EN ISO 13849-1 Single-channel reversing safety measure, as per EN ISO 13849-1 -> possible: performance level d, as per EN ISO 13849-1*
Single-channel reduced speed safety measure, as per EN ISO 13849-1 -> possible: performance level "d", as per EN ISO 13849-1*
Part no. 163380 542897 151694 7802 161082 161082 11689
Type DNC-50-500-PPV-A SDE5-D10-FP-Q6E-P-M8 MPYE-5-1/4-010-B MFH-3-1/8 VL-5/2-D-02-FR VL-5/2-D-02-FR H-1/4-B
Product designation standard cylinder pressure switch proportional directional control valve solenoid valve pneumatic valve pneumatic valve non-return valve
Part no. 163380 175042 11689 11689 188510 188510 151694 542897
Type DNC-50-500-PPV-A GRLO-M3-QS-3 H-1/4-B H-1/4-B MFH-5/2-D-1-FR-S-C MFH-5/2-D-1-FR-S-C MPYE-5-1/4-010-B SDE5-D10-FP-Q6E-P-M8
Product designation standard cylinder flow control valve non-return valve non-return valve solenoid valve solenoid valve proportional directional control valve pressure switch
Pneumatic residual energy in the system.
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Safety function Reducing speed
Servopneumatics key features at a glance
Description For implementation of the following safety measures: Prevention of unexpected start-up, as per EN 1037 (two-channel design) -> possible: performance level d, as per EN ISO 13849-1 * Single-channel reversing safety measure, as per EN ISO 13849-1 -> possible: performance level d, as per EN ISO 13849-1*
Single-channel reduced speed safety measure, as per EN ISO 13849-1 -> possible: performance level d, as per EN ISO 13849-1 Stop category 1, as per EN 60204-1 (however, no sensing of speed 0, instead the reduced speed starts after a set time)
Servopneumatics a drive technology with its own areas of application. Servopneumatics differs from standard pneumatics in that it supports travel to any desired position with maximum dynamic response and the ability to cope with high forces safely. It permits innovative and cost-effective drive solutions. Free positioning using servopneumatics is particularly useful in scenarios that demand com-
pact and cost-effective solutions where the loads to be moved are typically in excess of 10 kg and accuracy of a few tenths of a millimetre is sufficient. Rule of thumb: the overall costeffectiveness of a servopneumatic solution is higher the heavier the load to be moved (however there is a limit after which the dynamic response will be affected).
Part no. 163380 175042 11689 11689 151016 151694 542897 161082 161082
Type DNC-50-500-PPV-A GRLO-M3-QS-3 H-1/4-B H-1/4-B MFH-5/2-D-1-FR-C MPYE-5-1/4-010-B SDE5-D10-FP-Q6E-P-M8 VL-5/2-D-02-FR VL-5/2-D-02-FR
Product designation standard cylinder flow control valve non-return valve non-return valve solenoid valve proportional directional control valve pressure switch pneumatic valve pneumatic valve
Electrical terminal CPX with positioning module CMAX
Pneumatic linear drive unit with integrated displacement encoder DGCI
Proportional valve VPWP
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Products for safety engineering
Braking units DNCKE-S, KEC-S
Complete safety products Everything from a single source: our aim in the field of safety technology as elsewhere is to provide and implement solutions for every safety task in the form of components or systems. Technical data On the following pages you will find our range of products, together with brief descriptions of their function and application ranges. For additional information, consult the electronic catalogue on CD-ROM or online at www.festo.com/catalogue If you have any further questions, please consult your Festo sales engineer, who will be happy to help.
NDiameter
40, 63, 100 mm
NDiameter
TStroke length
of the round material to be clamped 16 ... 25 mm
10 ... 2000 mm
OHolding force
Function
OHolding force
1300 ... 8000 N
Description Holding force of the clamp is larger than the cylinders max. permissible feed force For use in category 1 control systems, as per DIN EN 954-1 (reliable component) If used in higher categories, further technical control measures need to be taken Certified by the Institute for Occupational. Safety and Health (BGIA) for use in safetyoriented control systems CE mark as per EU machinery directive
1300 ... 8000 N
Use As a holding device (static application) Holding and clamping in the event of power failure Protection against pressure failure and pressure drop Holding the piston rod during intermediate stops, for operative procedures in a process As braking device (dynamic application) Braking or stopping movements Suspension of a movement if a danger area is entered
Order code Part no. 526482 526483 526484 538239 538240 538241 527492 527493 527494 538242 538243 538244
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Type DNCKE-40--PPV-A DNCKE-63--PPV-A DNCKE-100--PPV-A DNCKE-40--PPV-A-S DNCKE-63--PPV-A-S DNCKE-100--PPV-A-S KEC-16 KEC-20 KEC-25 KEC-16-S KEC-20-S KEC-25-S
Certification
BGIA certified BGIA certified BGIA certified
BGIA certified BGIA certified BGIA certified

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Clamping unit KP, KPE
Clamping unit for short-stroke cylinders
Selection Clamping cartridge KP Clamping unit KPE DNC-...-KP
Technical data
Diameter of the round material to be clamped 4 ... 32 mm
Description For customer-built clamping units Ready-to-install combination of clamping cartridge KP and housing Various mounting options Holding or clamping the piston rod in any position Holding the piston rod for long periods of time, even under changing loads, fluctuations or leakage
Description Holding or clamping the piston rod in any position Holding the piston rod for long periods of time, even under changing loads, pressure fluctuations or leakages
Technical data
Function
N Diameter
20 ... 100 mm
O Static holding force

80 ... 7500 N Function

80 ... 7500 N

80 ... 7500 N
T Stroke length
10 ... 500 mm

350 ... 5000 N
Order code Order code Part no. 178455 178456 178457 178458 178459 178460 178461 178452 178453 178454
Type KP-10-350 KP-12-600 KP-16-1000 KP-20-1400 KP-20-2000 KP-25-5000 KP-32-7500 KP-4-80 KP-6-180 KP-8-350
Part no. 178465 178466 178467 178468 178469 178470 178462 178463 178464
Type KPE-10 KPE-12 KPE-16 KPE-20 KPE-25 KPE-32 KPE-4 KPE-6 KPE-8
Part no. 163302 163334 163366 163398 163430 163462 163494
DNC-KP Stroke [mm] 32 10-2000 40 10-2000 50 10-2000 63 10-2000 80 10-2000 100 10-2000 125 10-2000
Part no. 548206 548207 548208 548209 548210 548211 548212 548213
Type ADN-20-...-KP ADN-25-...-KP ADN-32-...-KP ADN-40-...-KP ADN-50-...-KP ADN-63-...-KP ADN-80-...-KP ADN-100-...-KP
KP type KP-10-350 KP-10-350 KP-12-1000 KP-16-1400 KP-20-1400 KP-20-2000 KP-25-5000 KP-25-5000
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Mini slide DGSL unit with clamping unit or end position locking
End position locking -EL
Use Clamping unit Mechanical clamping For fixing the slide in any position Frictional locking Clamps with frictional locking at any position Clamping via spring force, released via compressed air
End position locking Mechanical locking when the end position is reached For fixing the slide in the unpressurised, retracted state Positive locking Locks with positive locking in the retracted end position only Locking via spring, unlocked via compressed air
DNC-...-A-...-EL
ADN-...-EL
Description Mechanical locking when the end position is reached Locking is automatically released only when pressure is applied to the cylinder End position locking at one or both ends Order code Part no. 163302 163334 163366 163398 163430 163462
Technical data
Diameter 32 ... 100 mm
Diameter 20 ... 100 mm
Technical data
Function C clamping unit E3 end position locking
NDiameter
T Stroke length
10 ... 2000 mm
TStroke length
10 ... 500 mm
6 ... 25 mm Function
Type DNC-32-EL DNC-40-EL DNC-50-EL DNC-63-EL DNC-80-EL DNC-100-EL
Stroke [mm] 10-2000 10-2000 10-2000 10-2000 10-2000 10-2000

80 ... 600 N
L Pressure
Order code Part no. 543903 543904 543905 543906 543907 543908 543909
3 ... 8 bar
Type DGSL-6 DGSL-8 DGSL-10 DGSL-12 DGSL-16 DGSL-20 DGSL-25
Part no. 548214 548215 548216 548217 548218 548219 548220 548221
Type ADN-20-EL ADN-25-EL ADN-32-EL ADN-40-EL ADN-50-EL ADN-63-EL ADN-80-EL ADN-100-EL
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Two-hand control block ZSB
SV/O front panel valve
Description Category 3 as per DIN EN ISO 13849-1 can be reached with a suitable control architecture. Max. possible performance level = d As intended, the control block for two-hand start enables triggering of a control signal with both hands simultaneously (synchronous) over two separate push-button valves.
This ensures that both of the operators hands are outside the machines danger area. The product is a safety component in line with the EC machinery directive. The ZSB 1/8 control block for two-hand start corresponds to type IIIA, according to DIN EN 574, and category 1, according to DIN EN ISO 13849-1.
Description Use: two-channel directional control valve for use in front panels Suitable for higher category control systems Can be combined with various actuator attachments Mushroom actuator PS The actuator is unlocked by turning the detent ring on the mushroom head. Technical data Function Function
Mushroom pushbutton with detent PRS After pressing the pushbutton, it can only be unlocked using a key. The key can be removed in both switching positions. Key actuator Q with key The key actuator can only be operated with the key. The key can be removed in both switching positions.
Technical data
Function
2
Sample circuit
Control chain
3
MFlow rate
LPressure
up to 50 l/min
1 1
MFlow rate LPressure
0 ... 70 l/min
3 ... 8 bar
0 ... 8 bar
QTemperature range
-10 ... 60 C
QTemperature range
-10 ... +60 C Order code Part no. 184135
Order code Part no. 3527
Type ZSB-1/8
Certification CE certified
Type SV/O-3-PK-3x2
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Tamper-proof flow control valve GRLA--SA
Stop valve VL-2-1/4-SA
Description Setting a defined flow rate A spring pin protects against unauthorised resetting of the volumetric flow rate Impossible to change the flow control valves setting with standard tools thanks to the spring pin protection Six different sizes from M5 to 3/4"
Surface for additional safety label from the systems manufacturer or fitting company
Description Stop valve for blocking the flow in a cylinder (supply/ exhaust air) in both directions. A control signal opens the closed ports Design: poppet valve controlled via a swivel connection Tube fitting (thread G1/4) Port G1/4 Nominal diameter 4 mm
Technical data
Function
Technical data
Function
MFlow rate L Pressure
L Pressure
0 ... 10 bar
0 ... 2500 l/min
0.2 ... 10 bar
Q Temperature range
1
-20 ... 80 C Order code Part no. 25025 Type GRLA-M5-B-SA218543 GRLA-1/8-B-SA218543 GRLA-1/4-B-SA218536 GRLA-3/8-B-SA18541 GRLA-1/2-B-SA218540 GRLA-3/4-B-SA218542
QTemperature range
-10 ... +60 C Order code Part no. 539717 539661 539662 539715 539716 539714
Type VL-2-1/4-SA3919
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Shut-off valves: European version
Shut-off valve HE-LO: US standard
Description Shut-off valve for shutting off and exhausting pneumatic systems. Can be shut off a max. of 6 times in the closed (exhausted) state Padlocks prevent unauthorised starts For systems that require pneumatic shut-off, e.g. during maintenance or repair work. The valve is integrated into the air supply lines Any mounting position
Use Shutting off the compressed air supply whilst simultaneously exhausting systems powered by compressed air. Pressing the actuating button closes the passage from 1 to 2 and opens the passage from 2 to 3. The maximum exhaust flow is achieved by holding the actuating button in its end position until the downstream system is completely exhausted. Greater safety: lockable When closed, the valve can be locked using a padlock. This makes it impossible to supply an inoperative system (e.g. during maintenance work) with air without authorisation.
Description Valve for shutting off the compressed air supply whilst simultaneously exhausting systems powered by compressed air Pneumatic shut-off during maintenance or repair work Fulfils the US Department of Labors requirements The valve is installed in the air supply lines and fulfils the requirements set out in OSHA 29 CFR 147 Control of
Hazardous Energy from the US Department of Labor. Pressing the actuating button closes the passage from 1 to 2 and opens the passage from 2 to 3. The maximum exhaust flow is achieved by holding the actuating button in its end position until the downstream system is completely exhausted. Greater safety: lockable When closed, the valve can be locked using a padlock. This makes it impossible to supply an inoperative system (e.g. during maintenance work) with air without authorisation.
Technical data
Function
Technical data
Function
M Flow rate L Pressure
3100 ... 6000 l/min
MFlow rate
5200 ... 12000 l/min
0 ... 16 bar
L Operating pressure
1 ... 10 bar Note The shut-off valve cannot be used as an emergency-stop valve.
Q Temperature range
-10 ... +60 C
QTemperature range
-10 ... +60 C
O Max. actuating force

90 N PWIS-free
OMax. actuating force

90 N Type HE-3/8-D-MIDI-NOT-SA HE-1/2-D-MIDI-NOT-SA HE-3/4-D-MIDI-NOT-SA HE-3/4-D-MAXI-SA HE-1-D-MAXI-SA
Note The shut-off valve cannot be used as an emergency-stop valve.
Order code Part no. 187026 187027 187028 186688 186689
Order code Part no. 197136 197135 197134 197133 197132 197131 197130 197129
Type HE-G1-LO HE-G3/4-LO HE-G1/2-LO HE-G3/8-LO HE-N1-LO HE-N3/4-LO HE-N1/2-LO HE-N3/8-LO

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Safety function Pressurising
On-off valve with piston position sensing
Pressure build-up and exhaust valve, type MS 6-SV
Description Electric on-off valve for pressurising and exhausting pneumatic systems With solenoid coil, without plug socket 3 voltage ranges can be selected Direct position sensing for the piston spool Can be used in circuits with a higher diagnostic coverage Senses position, not pressure Single-channel
Sensors from Festo Standard sensors with reed contacts for T-slots can be used: type SME-8M, SMT-8M, SME-8, SMT-8 Switching output non-contacting or with reed contact Various mounting and connection options Heat resistant and corrosion resistant designs Versions free of copper or PTFE Please note: sensors are ordered separately. Function Technical data
Description Exhaust reliably quickly in safety-critical areas of the system, e.g. during an emergency stop Provides greatest possible machine availability thanks to reliable processes Institute for Occupational Safety and Health (BGIA) certification as per DIN EN 13849-1, Category 4 Quick exhaust for fast pressure reduction Exhaust rate is one and a half times the pressurising rate
Continuous sensing of the function for fast exhausting at any time Switch-on and pressure buildup functions integrated into the exhaust valve Prevention of unexpected start-up (two-channel control) Compact design Internal evaluation of the piston position sensing
Technical data
Function
P L
Voltage 24 V DC Pressure 2.5 ... 16 bar Temperature range

12 2
PVoltage
24 V DC
3
MFlow (exhaust)
-10 ... +50 C
up to 9000 l/min
12
L Pressure
3,5 ... 10 bar
QTemperature range
Q-10 ... +60 C

Order code Part no. 533537 548535
MFlow (pressurise)
up to 6000 l/min Order code Part no. 548713 548714 548715 548717
Type HEE-D-MIDI-...-SA207255 HEE-D-MAXI-...-SA217173
Type MS6-SV-D MS6N-SV-D MS6-SV-D-1/2-10V24-AG MS6-SV-D-1/2-10V24-SO-AG
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Safety silencer, type UOS-1
Valve block for reliable exhausting of sub-systems
Description The UOS silencer combines the advantages of a standard silencer and those of an open silencer: large flow with low noise level and a compact design For reliable exhausting as per DIN EN ISO 13849-1 Suitable for use with the MS6-SV valve Design: open Port: 1 PWIS free
Contamination in the system can block standard cylinders. The consequence: increased back pressure, which leads to increased exhaust times in the system. This is prevented with this silencer, due to its special design. Dangerous cylinder movements can lead to injury to people and machines.
Description Pre-installed, operationally integrated tested solution Number of channels: 2 Diagnostic coverage DC = medium (integrated fault diagnostics) PLmax = e Air quality: 40 m unlubricated Protected against unintentional start-up (two-channel). If the two solenoid coils are activated simultaneously, the compressed air is switched on
Technical data
Function
Technical data
Function
L Pressure
0 ... 10 bar
PVoltage
24 V DC
12
Ports ISO 1: QS8 Ports ISO 3: QS12 Optional extension of the permissible time window for electric actuation (approx. 10 ms) by connecting additional volumes (for each 0.5 l -> approx. 0.5 sec.) Safe exhausting (two-channel) of pneumatic port A when one of the two coils is turned off Switching position sensing of the directional control valves in their initial position using auxiliary pilot air for the other directional control valve protects against an uncontrolled restart and prevents a dangerous state
Q Temperature range
-10 ... +50 C
LPressure
3 ... 8 bar
QTemperature range
0 ... +40 C Order code
MFlow rate ISO 1:

Type UOS-1 500 Nl/min
Part no. 552252
MFlow rate for ISO 3:

1500 Nl/min Order code Part no. 549146 550521
Type ISO 1 valves ISO 3 valves
Flow rate 500 Nl/min 1500 Nl/min
submitted
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ISO valves in accordance with 5599-1 with position sensing of the piston spool
ISO valves in accordance with 15407-2 with switching position sensing
Description The position of the piston spool is sensed directly Senses position, not pressure Suitable for circuits with a higher diagnostic coverage Suitable for higher category circuits as per DIN EN ISO 13849-1
Sensors from Festo Standard sensors with reed contacts for T-slots can be used: type SME-8M, SMT-8M, SME-8, SMT-8 Switching output contactless or via reed contacts Various mounting and connection options Heat resistant and corrosion resistant designs Versions free of copper or PTFE Please note: sensors are ordered separately.
Description Solenoid valve as per ISO 15407-1, plug form C, for individual electrical connection Solenoid valve as per ISO 15407-2, for use with valve terminal VTSA Valve function: 5/2-way valve ISO size 01, other sizes on request Width 26 mm
The piston spools initial position is monitored by a proximity sensor For higher category control architectures Proximity sensor with M8 port
Technical data
Function
Technical data
MFlow rate LPressure
1200 ... 4500 l/min
14
PVoltage
24 V DC
3
Type VSVA-B-M52-MZD-A1-1T1L-APC VSVA-B-M52-MZD-A1-1T1L-APP VSVA-B-M52-MZH-A1-1C1-APC VSVA-B-M52-MZH-A1-1C1-APP VSVA-B-M52-MZD-A1-1T1L-ANC VSVA-B-M52-MZD-A1-1T1L-ANP VSVA-B-M52-MZ-A1-1C1-ANC VSVA-B-M52-MZ-A1-1C1-ANP
5 1
3 ... 10 bar
Pressure 3 ... 10 bar
560725 560726 560742 560743 560744
QTemperature range
-10 ... +50 C
QTemperature range
-5 ... +50 C Flow rate 1100 l/min
PVoltage
Order code Part no. 185994 188005 188006
24 V DC
Function Type MDH-5/2-D1-FR-S-C-A-SA27102 MDH-5/2-D2-FR-S-C-A-SA23711 MDH-5/2-D3-FR-S-C-A-SA23712 560745

14 4 2
Version Size 01, 5/2RF, plug-in valve, with PNP sensor and cable Size 01, 5/2RF, plug-in valve, with PNP sensor and M8 plug Size 01, 5/2RF, CNOMO valve, with PNP sensor and cable Size 01, 5/2RF, CNOMO valve, with PNP sensor and M8 plug Size 01, 5/2RF, plug-in valve, with NPN sensor and cable Size 01, 5/2RF, plug-in valve, with NPN sensor and M8 plug Size 01, 5/2RF, CNOMO valve, with NPN sensor and cable Size 01, 5/2RF, CNOMO valve, with NPN sensor and M8 plug
5 1
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Safety function Stopping, holding and blocking a movement (mechanically)
ISO terminal for controlling presses
ISO valve for lifting and semi-rotary cylinders
Technical data
Description Valve terminal with multiple connector plate/fieldbus connection as per ISO 15407-2 Vertical stacking plus two sensor valves Pressurising/exhausting via linked standard VTSA valves Valve terminal, consisting of 24 V DC multi-pin plug connector with cable, a series manifold, right-hand end block, double vertical stacking and 2 VSVA plug-in valves, width 26 mm, with piston position sensing by inductive PNP proximity sensor, size M8, and plain cable end and covered manual override. The valves are pneumatically interlinked via the vertical stacking plate using two channels (port 2 is connected in parallel, port 4 inline).
Valve manifold with individual electrical connection as per ISO 15407-1 Double connecting plate plus two sensor valves with C shape plug pattern Valve block comprising a double sub-base and two VSVA valves, width 26 mm, with piston position sensing via inductive PNP proximity sensor, size M8, and plain cable end. 24 V DC pilot valve with electrical interface, C shape, and covered manual override. The valves are pneumatically interlinked via two channels in the connecting plate (port 2 is connected in parallel, port 4 inline).
Technical data
PVoltage
24 V DC
Description For lifting and semi-rotary cylinders in the automotive industry Use Self-holding and subsequent pressure supply in both end positions During the stroke, the cylinder needs to be held under pressure in the event of an emergency (e.g. if someone steps on a safety shut-off mat) Function Type VSVA-B-P53AD-H-A1-1T1L Size 01, 5/3 mid-position 3 1 port pressurised and 1 port exhausted, switching position 14 detenting
L Pressure
3 ... 10 bar
QTemperature range -5 ... +50 C MFlow rate

Order code Part no. 560728 1000 l/min
14
12
Expected to be available from mid 2008
Function
Function Retract clamping device
Normal operation The clamping device is retracted via the 5/2 WV
PVoltage
24 V DC
QTemperature range
-5 ... +50 C
L Pressure
3 ... 10 bar
MFlow rate
1100 l/min Order code Part no. 569819 569820 Code letter Code letter
Valve function: 5/2-way valve ISO size 01 Position sensor with M8 port Valve width 26 mm
Extend clamping device
The clamping device is extended via the 5/2 WV
submitted
64
Version Complete 2x5/2-control block, individual electrical connector, PNP sensor VOFA-L26-T52-M-G14-1C1-ANP Complete 2x5/2-control block, individual electrical connector, NPN sensor SP in order code Complete 2x5/2-control block, integration on valve terminal VTSA, PNP sensor SN in order code Complete 2x5/2-control block, integration on valve terminal VTSA, NPN sensor
Type VOFA-L26-T52-M-G14-1C1-APP
Clamping device in end position
The end positions remain pressurised
After an emergency stop (electrical power switched off ) The clamping device remains pressurised in both chambers 5/3 WV 14 initial position 5/2 WV 12 switched The clamping device remains pressurised in both chambers 5/3 WV 14 initial position 5/2 WV 14 switched The pressure is sustained in the end positions 5/3 WV 12 automatic locking 5/2 WV 14 or 12 switched
Control 5/3 WV 12 switched (no automatic locking) 5/2 WV 12 switched 5/3 WV 12 switched (no automatic locking) 5/2 WV 14 switched 5/3 WV switched to 12 (automatic locking) 5/2 WV switched to 14 or 12
65
Safety function (3 stages) Free of forces
ISO valve for pneumatic manual clamping device
HEL soft-start valve
Description Pneumatic manual clamping device for facilities in car body construction work (insert locations)
Function
14
12
Technical data
PVoltage
24 V DC
L Pressure
3 ... 10 bar
Description Gradual pressure build-up The drives travel slowly into their initial positions Sudden and unpredictable movements are avoided Main seat opens at approx. 50% of the supply pressure Adjustable time delay for pressure response To be used with HE and HEE on-off valves
QTemperature range
-5 ... +50 C Order code Part no. 560727 Type VSVA-B-P53ED-H-A1-1T1L Size 01, 5/3 mid-position exhausted, switching position 14 detenting
Technical data
Function
MFlow rate
1000 l/min
MFlow rate
1000 ... 6500 l/min
L Pressure
3 ... 16 bar
Expected to be available from mid 2008
QTemperature range
-10 ... +60 C Order code Part no. 170690 170691 170692 165076 165077 165078 186521 165079 165080 165081 186522 165082 165083
Function Clamping device is closed Clamping device is in the end position (panel is clamped) Clamping device opens automatically
Normal operation Unpressurised Force supported by air pressure
After an emergency stop (electrical power switched off ) Unpressurised Force supported by air pressure (self-locking) Valve remains in position 12 Valve returns to the mid-position
Control Valve is in the mid-position Coil 12 is switched
Pneumatically operated
Coil 14 is switched
Type HEL-D-MINI HEL-D-MIDI HEL-D-MAXI HEL-1/8-D-MINI HEL-1/4-D-MINI HEL-3/8-D-MINI HEL-1/4-D-MIDI HEL-3/8-D-MIDI HEL-1/2-D-MIDI HEL-3/4-D-MIDI HEL-1/2-D-MAXI HEL-3/4-D-MAXI HEL-1-D-MAXI
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Safety function Reducing pressure and force
Dual-pressure regulator
Soft-start/quick exhaust valve for ISO valve terminal type VTSA
Description Diaphragm pressure regulating valve with secondary venting for setting two different initial pressures in one device. The lower value of p2 (p21) can be set mechanically (SW10 on the adjusting screw). The higher value of p2 (p22) can be set with the rotary knob. Switching from the lower to the higher value occurs electronically.
Description Solenoid actuated on-off and exhaust valve for gradual pressure build-up in pneumatic systems. This protects start-up of pneumatic systems. A small quantity of air flows into the system through an adjustable flow control valve. The initial pressure is built up gradually. Downstream cylinders and devices gradually reach their initial position.
Once the initial pressure reaches the adjustable switch-over pressure, the valve switches to full flow. Use Adjustable switch-over pressure (2, 3, 4, 5 bar) Adjustable filling time 24 V DC or 110 V AC solenoid G1/2 or NPT 1/2 ports Built-in piston position sensing Flow rate (QNn): pressurising 3000 l/min exhausting 3400 l/min
Technical data
Function Key Switch-over pressure

1 2
Pressure
MFlow rate Q
Function
up to 1300 l/min Temperature range -10 ... +60 C
Filling time Examples Fast filling time, switch-over pressure at 6 bar
Working pressure
Technical data p2 regulator pressure regulation range p1 supply pressure 1 Hymax max. pressure hysteresis p1max P2max PWIS-free Corrosion resistance class Ports
0.5 <= 7 bar 1.5 bar <= 12 bar 0.5 bar p1max: 12bar p2max: 7bar CRC2 G1/4
Slow filling time, switchover pressure at 4 bar
Order code Part no. 557377
Type VABF-S6-1-P5A4-G12-4S-1R3P

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Type LR-D-MINI-ZD-V24-SA234223A LR-D-MINI-ZD-V24-UK-SA236138A
submitted
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Pressure zones for valve terminal type 44 VTSA
Pressure zones for valve terminal type 32 MPA
Zone 1
Zone 2
Zone 3
Creating pressure zones and separating exhaust air With the VTSA, pressure zones can be introduced in many ways for different working pressures Pressure zones can be created by separating the internal supply ducts between the series sub-bases with a corresponding channel separator Pressure supply and exhausting via supply plate Free positioning of the supply plates and separating seals in VTSA Channel separator integrated ex works as per the order, differences can be indicated via the coding system for assembling valve terminals
P3
Further examples of pressure supply and pilot air supply via an end plate Internal pilot air supply, ducted exhaust air/silencer External pilot air supply, silencer/ducted exhaust air Reliable exhausting of valves or pressure zones If used together with the MS6-SV valve, specific areas can be exhausted safely whilst the pressure is retained for specific valves or pressure zones. This is a common requirement for protective circuits.
Zone 1
Zone 2
Zone 3
P1
P2
The illustration shows an example of how three pressure zones are built up and connected with channel separation with internal pilot air supply.
VTSA with CPX terminal connection Up to 16 pressure zones possible with VTSA (if only size 1, ISO 5599-2, is used, up to 32 pressure zones are possible)
P1
P2
P3
Creating pressure zones and separating exhaust air With the MPA pressure zones can be introduced in many ways for different working pressures A pressure zone can be created by separating the internal supply ducts between the subbases, with a corresponding separating seal or via a separator integrated into the subbase (code I) Pressure supply and exhausting via supply plate Free positioning of the supply plates and separating seals in MPA with CPX and MPM (multiple connector plate) Separating seals integrated ex works as per the order, differences can be indicated via the coding system for assembling valve terminals MPA with CPX terminal connection Example of pressure zones Up to 8 pressure zones possible with MPA and CPX
Further examples of pressure supply and pilot air supply External pilot air supply, flat plate silencer Internal pilot air supply, ducted exhaust air External pilot air supply, ducted exhaust air Reliable exhausting of valves or pressure zones If used together with the MS6-SV valve, specific areas can be exhausted safely whilst the pressure is retained for specific valves or pressure zones. This is a common requirement for protective circuits.
The illustration shows an example of how three pressure zones are built up and connected with separating seals with external pilot air supply.
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CPX terminal power supply concept
Description The use of decentralised devices on the fieldbus particularly those with a high protection class for direct machine assembly requires a flexible power supply concept. A valve terminal with CPX can generally be supplied via a socket for all voltages. Here, we distinguish between supplying the Electronics plus sensors Valves plus actuators. The following connecting threads are possible - M18 - 7/8
Together with all the supply lines, interlinking blocks make up the backbone of the CPX terminal. They provide the power supply for the modules mounted on them, as well as their bus connection. Many applications require the CPX terminal to be separated into voltage zones. This is particularly true for switching off the solenoid coils and the ports separately. The interlinking blocks can either be designed as a centralised power supply for the entire CPX terminal (which saves on installation work), or they can be designed as galvanically separated, all-pin disconnectable potential groups/voltage segments.
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Knowledge provides greater safety
New machinery directive 2006/42/EC new standard EN ISO 13 849-1 for pneumatics/electro-pneumatics (FOKUS)
Are you a plant operator or engineer? If the answer is Yes, then the new machinery directive applies to you. Are you prepared for the changeover in safety engineering? Are you familiar with the performance level of the safety functions? The new machinery directive 2006/42/EC will come into force on December 29, 2009. The standard DIN EN 954-1 Safety-related parts of control systems General principles for design has already been withdrawn. The successor standard DIN EN ISO 13 849-1 is now valid. In future it will be necessary to define a performance level and degree of diagnostic coverage. Be informed with the aid of this compact and intensive 1-day course. Content New machinery directive 2006/42/EC Changes compared with the old machinery directive 98/37/EC Risk assessment to EN ISO 13 849-1 Differences compared with DIN EN 954-1 EN ISO 13 849-1 concepts: Performance Level PL - Degree of diagnostic coverage DC - Common cause failure CCF - Mean time to failure MTTF Determining the individual values using selected pneumatic and electro-pneumatic circuits Course participants will receive A USB stick containing the course documents, design software for the performance level and additional information A Safety engineering guidelines manual A certificate confirming course participation An option to purchase the web-based training Safety engineering at a 50% discount. Target group Design engineers from mechanical, electrical and control engineering. Duration 1 day For further information, see the www.festo-tac.com
Safety is always more than just the hardware and the corresponding circuit diagrams. Safety starts at the concept stage, for example by identifying necessary performance levels. For comprehensive qualification on the subject of safety, Festo Didactic provides numerous seminars on various topics. More than 40 years of experience in training and consulting and 30,000 participants at more than 2,900 events each year speak for themselves: our instructors provide you with their own experience and give you the best possible preparation for your own specific safety tasks. When it comes to self-structured and flexible modular learning, our web-based training course Safety engineering is ideal.
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Safety in pneumatics and electro-pneumatics for design engineers (SAFETY2)

The European machinery directive is law and requires that design engineers incorporate safety functions into machinery and system designs. This is certified with the CE mark. The previous standard for risk assessment DIN EN 954-1 has already been withdrawn and replaced by the new standard EN ISO 13 849-1. Design engineers will have to conduct their risk assessments in accordance with the new standards. Specific pneumatic and electro-pneumatic circuits for the Safety measures for safety-related pneumatic components will be presented. These sample circuits will be examined with respect to their failure behaviour. This course aims to enable design engineers to design safety-related circuits up to controller category 4, to understand the interaction between pneumatic and electrical components and to assess the behaviour of pneumatic cylinders. The course will teach design engineers what needs to be taken into account when developing these circuits. The seminar focuses on circuit technology. Content Design and function of safetyrelated circuits to EN ISO 13 849-1 Identification of safety categories of circuits Selection of spare parts Power failure and recovery Safe pressurisation and exhausting Safe opening of brakes and clamps Basic and proven safety principles of pneumatics to EN ISO 13 849-2 Selected safety measures for safety-related pneumatic components - Unexpected restart - Blocking, braking and rever sing of movements - Force isolation and freedom of movement - Reduced force and reduced speed - Two-hand operation Error analysis and error elimination to EN ISO 13 849-2 Performance testing of safetyrelevant components Influence of tube length, diameter and fittings on the speed of cylinders Preventing manipulation of protective devices Information on operating instructions and maintenance Target group Design engineers from mechanical, electrical and control engineering. Duration 2 days For further information, see the Festo Didactic homepage: www.festo-tac.com
Reliable design of machinery and systems (SEP-PILZ)
The European directives and standards describe the safety requirements for machines and systems. These frequently include the use of both electrical and pneumatic drives and/or control systems. In this seminar, you will learn about both aspects and will be in a position to design them for optimal interaction in the future. Take advantage of the combined expert knowledge of specialists from Pilz GmbH & Co. KG and Festo Didactic GmbH & Co. KG in one seminar. Demonstrations take place using an actual machine model. After the seminar, you will know what requirements and options are available for safe and reliable electrical engineering and pneumatics. You will be familiar with and able to use DIN EN 954-1/DIN EN ISO 13849-1 Safety-related parts of control systems General principles for design and associated norms.
Contents Introduction, machine directives and standards: laws, machinery directives and their implementation, safe control technology in accordance with DIN EN 954-1, perspective on the new DIN EN ISO 13849-1 Safety-orientated electrical engineering, safety engineering design of control systems, reliable locking; attaching light grids; scanners and safety shut-off mats and their test cycles; emergency-stop classifications; stop categories and operating modes; safe drives; frequency converters; speed monitoring; axis area monitoring; discussion on sample applications and circuits Safety-orientated pneumatics, selected safety measures in safety-oriented pneumatics, characteristics of pneumatic drives and controlling them, power failure, power recovery and restarting, two-hand circuits, sample circuits
Target group Design engineers from mechanical, electrical and control engineering and control engineers Duration 2 days For more information, see the Festo Didactic homepage: www.festo-tac.de
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Safe machines in operation (SMB) in cooperation with the Pilz company and TV Austria
The aim of this event is to make participants more familiar with the legal requirements throughout a machines life cycle, from acquisition up to modification and inter-connection. Particular attention is paid here to modifying and inter-connection machines, and the resulting documentation required by law. From the content Definitions and basic principles: New and old machines, legal requirements, modifying and inter-connecting machines Inventory-taking and retrofitting using a model: required properties, assessment based on a risk analysis or hazard analysis, emergency-off, emergency-stop and stop categories, common faults from practical experience Implementation and design: Requirements for modifying and inter-connecting (Austrian employee protection law, 35), developing new machines in Austria and Germany, basic principles of safe pneumatics and solution variants, electro-technical solutions and variants Documentation: Requirements (Austrian employee protection law, 35), descriptions and operating instructions, technical documents, testing and validation Target group Design engineers from mechanical, electrical and control engineering and control engineers. Duration 1 day For further information, see the Festo Didactic homepage: www.festo.at
WBT Safety engineering web-based training
This training program provides an introduction to the complex issue of safety engineering in industrial machinery and systems. The aim is to make participants more aware of the problems in the design aspects of safety engineering and help them understand safety engineering equipment and hazard analysis methods.
The training program is based on the revised form of machinery directive 2006/42/EC. This will come into force on December 29, 2009. Directive 98/37/EC will apply until this date. There will be no transition period. How will the overall performance level of a technical safety measure be determined? Concepts such as mean time to failure MTTF, degree of diagnostic coverage DC, common cause failure (CCF), redundancy and diversity will be explained in the learning program. The components of safety devices will also be explained in detail. How will the overall performance level of a technical safety measure be determined? Concepts such as mean time to failure MTTF, degree of diagnostic coverage DC, common cause failure (CCF), redundancy and diversity will be explained in the learning program. The components of safety devices will also be explained in detail.
From the content Introduction to machine safety The issue of liability (Who is liable in the event of accidents?) European directives Relationship between directives and standards The new EU machinery directive 2006/42/EC The hierarchy of European standards for machine safety Machine safety in the USA The procedure for risk assessment to EN ISO 14121 and EN ISO 12100 Definitions Risk assessment: determining the required performance level Measures for risk reduction: design measures, technical safety measures, instructive measures Selection of safety function Definition of controller category Further information Available as a CD-ROM version or alternatively WBT version for installation on networks and learning management systems, with as many licenses as you need. Duration approx. 4 hours For further information, see the Festo Didactic homepage: www.festo-didactic.com
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List of abbreviations
Abbreviation a, b, c, d, e AB AC/DC AE ALARP ANSI AOPD/AOPDDR AS-Interface B, 1, 2, 3, 4 B10
B10d
BPCS BPCS BSL BTB/RTO BWP BWS Cat. CC ccd CCF
German name Bezeichnung fr die Performance Level Anzeige-Bediengerte Wechsel-/Gleichstrom Anfahr- und Entlftungsventile So niedrig wie vernnftigerweise mglich US-amerikanische Normungsorganisation Aktive optoelektronische Schutzeinrichtung Aktuator Sensor Interface Bezeichnung fr die Kategorien Anzahl von Zyklen, bis 10 % der Komponenten ausgefallen sind (u.a. fr pneumatische und elektromechanische Komponenten) Anzahl von Zyklen, bis 10 % der Komponenten gefhrlich ausgefallen sind (u.a. fr pneumatische und elektromechanische Komponenten) Betriebs- und berwachungseinrichtungen Betriebs- und berwachungseinrichtungen als ein System Bootstraploader Betriebsbereit Berhrungslos wirkende Positionsschalter Berhrungslos wirkende Schutzeinrichtung Kategorie Stromrichter Kommando-Code, Teil einer SDO-Nachricht Ausfall in Folge gemeinsamer Ursache
English name Denotation of performance levels Display and operating units Alternating current/direct units Start-up and exhaust valves As low as reasonable practicable American National Standards Institute Active optoelectronic protection device responsive to diffuse reflection Aktuator Sensor Interface Denotation of categories Number of cycles until 10 % of the components fail (for pneumatic and electromechanical compnents) Number of cycles until 10 % of the components fail dangerously (for pneumatic and electomechanical components) Basic process control system Basic process control system Bootstraploader Ready-to-operate Electro-sensitive positionswitch Electro-snsitive protective equipment Category Current converter Command-code Common cause failure
Source DIN EN ISO 13849-1 Festo IEC 61511 Festo IEC 61511 IEC 61511 ISO 12100-1, DIN EN ISO 13849-1 DIN EN ISO 13849-1 DIN EN ISO 13849-1
Abbreviation F, F1, F2 FB FMEA FO FR FTA Gefhrdung Gefhrdungsbereich H & RA H/W HFT HMI HRA I, I1, I2 i, j I/O iab, ibc Inhrente sichere Konstruktion
DIN EN ISO 13849-1
IEC 61511 IEC 61511
EN 61496 DIN EN ISO 13849-1 DIN EN ISO 13849-1 IEC 61508, IEC 62061, prEN ISO 12849-1EN 61511-1:2004, DIN EN ISO 13849-1
CEN CENELEC CMF CRC DC DC DCavg[%] DPV0 DPV1 DR DS DV E E/A E/E/EP E/E/PE E/E/PES EDM EDS
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Europisches Komitee fr Normung Europisches Komitee fr elektrotechnische Normung Ausfall in Folge gemeinsamer Ausfallart Prfsumme in einem Daten-Telegramm, Signatur durch zyklische Redundanzprfung Diagnosedeckungsgrad Gleichstrom Diagnosedeckungsgrad (von Tests) Funktionsversionen von PROFIBUS Druckventile Druckschalter Druckverstrker Externe Einrichtung zur Risikominderung Eingabe/Ausgabe Elektrisch/elektronisch/programmierbar elektronisch Elektrisch/elektronisch/programmierbar elektronisch Elektrisches/elektronisches/programmierbares elektronisches System Schtzkontrolle, Rckfhrkreis Elektronisches Datenblatt
European Commttee for Standardization European Commttee for Electrotechnical Standardization Common mode failure EN 61511-1:2004 Cyclic Redundancy Check Diagnostic Coverage Direct current Diagnostic Coverage, average DIN EN ISO 13849-1, IEC 62061(IEC 61508-2:2000 DIN EN ISO 13849-1
KL Konformittserklrung
KS L, L1, L2 Lambda MTBF MTTF/MTTFd
Pressure control valves Pressure switch Pressure amplifier External risk reduction facilities Input/Output Electrical/Electronical/programmable electronic Electrical/Electronical/programmable electronic Electrical/Electronical/programmable electronic system External Device Monitoring Electronic Data Sheet
Festo Festo Festo EN 61511-1:2004 IEC 61511, IEC 61508 IEC 61511, IEC 61508 IEC 61511
MTTR NMT Nniedrig NOT-AUS NOT-HALT NP
German name English name Hufigkeit und/oder Dauer der GefhrFrequency and/or time of exposure to dungsexposition the hazard Funktionsblock Function block Ausfallarten und Effekt-Analyse Failure modes and effects analysis Funktionsorientierte Antriebe Function-oriented drives Filterregler Filter-regulator unit Fehlerbaumanalyse/Fehlerzustandsbaum- Fault Tree Analysis analyse Potenzielle Quellen von Verletzungen oder Potential source of injury or damage to Gesundheitsschden health Jeder Bereich in einer Maschine und/oder Any zone within and/or around um eine Maschine herum, in dem eine Per- machinery in which a person is subject son einer Gefhrdung ausgesetzt sein kann to a risk to his health or safety Gefhrdungs- und Risikobeurteilung Hazard and risk assessment Hardware Hardware Hardware-Fehlertoleranz Hardware fault tolerance Mensch-Maschine-Schnittstelle Human machine interface Analyse menschlicher Zuverlssigkeit Human reliability analysis Eingabegert, z.B. Sensor Input device, e.g. sensor Index fr Zhlung Index for counting Eingnge/Ausgnge Inputs/Outputs Verbindungsmittel Interconnecting means Schutzmanahme, die entweder GefhrInherently safe design measure dungen beseitigt oder die mit den Gefhrdungen verbundenen Risiken vermindert, indem ohne Anwendung von trennenden oder nicht trennenden Schutzeinrichtungen die Konstruktions-Betriebseigenschaften der Maschine verndert werden Kolbenstangenloser Zylinder Rodless cylinders Verfahren, bei dem der Hersteller oder sein Declaration of conformity in der Gemeinschaft niedergelassener Bevollmchtigter erklrt, dass die in den Verkehr gebrachten Maschine allen einschlgigen grundlegenden Sicherheits- und Gesundheitsanforderungen entspricht Kolbenstangenzylinder Cylinders with position rod Logik Logic Ausfallrate bei ungefhrlichen und Gefahr Rate to failure bringenden Fehlern Mittlere Ausfallzeit eines Gertes Mean time between failure Zeit bis zu einem Ausfall bzw. gefhrlichen Mean time to failure/ Ausfall Mean time to dangeous failure Mittlere Reparaturzeit eines Gertes Mean time to repair Service-Dienste des CAN-Application Layers Network Management Anzahl von SRP/CS mit PLniedrig in einer Number of SRP/CS with PLlow in a Kombination von SRP/CS combination of SRP/CS Ausschalten im Notfall Emergency switching off Stillsetzen im Notfall Nicht programmierbares System Emergency stop Non-programmable system
Source DIN EN ISO 13849-1 DIN EN ISO 13849-1 EN 1050, DIN EN ISO 13849-1 Festo Festo EN 1050 Maschinenrichtlinie 2006/42/EG, EN 1050 (ISO EN ISO 12100-1, DIN EN 1050 IEC 61511 IEC 61511 IEC 61511 IEC 61511 IEC 61511 DIN EN ISO 13849-1 DIN EN ISO 13849-1 DIN EN ISO 13849-1 DIN EN ISO 13849-1 EN ISO 12100-1
Festo Maschinenrichtlinie 2006/42/EG
Festo DIN EN ISO 13849-1 IEC 62061 DIN EN ISO 13849-1 DIN EN ISO 13849-1 DIN EN ISO 13849-1 DIN EN ISO 13849-1 EN 418 (ISO 13850) EN 60204-1 Anhang D ISO 13850 EN 60204-1 Anhang D EN 61511-1:2004
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Abbreviation O, O1, O2, OTE OE OSHA OSI
German name Ausgabegert, z.B. Antriebselement ler
English name Output device, e.g. actuator Lubricator
Source DIN EN ISO 13849-1 Festo
OSSD P, P1, P2 Pdf PE PES PFD PFH PFHd PHA PL/Performance Level
PLr
PLC PLniedrig PR RE Restrisiko Risiko Risikoanalyse
Risikobeurteilung Risikobewertung Risikoeinschtzung S, S1, S2 SA SAT Schaden Schutzmanahme SIF

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Referenzmodell zur Datenkommunikation, Open System Interconnection Darstellung als Schichtenmodell mit verteilten Aufgaben fr jede Schicht Ausgangsschaltelement, Output Signal Switching Device Sicherheits-Schaltausgang Mglichkeit zur Vermeidung der Gefhrdung Possibility of avoiding the hazard Wahrscheinlichkeit gefahrbringender Probability of dangerous failure Ausflle Programmierbare Elektronik Programmable electronics Programmierbares elektronisches System Programmale electronic system Ausfallwahrscheinlichkeit bei Auslsen/ Probability of failure on demad Anfrage der Sicherheitsfunktion Ausfallwahrscheinlichkeit pro Stunde Probability of failure per hour Wahrscheinlichkeit gefahrbringender Probability of dangerous failure per hour Ausflle pro Stunde Vorlufige Untersuchung von Gefhrdungen Preliminary hazard analysis Diskreter Level, der die Fhigkeit von Discrete level used to specify the ability sicherheitsbezogenen Teilen einer Steue- of safety-related parts of control systems rung spezifiert, eine Sicherheitsfunktion to perform a safety function under foreunter vorhersehbaren Bedingungen auszu- seeabl condtions fhren Angewandter Performance Level(PL), Performance level (PL) applied in order um die erforderliche Risikominderung fr to achieve the required risk reduction jede Sicherheitsfunktion zu erreichen for each safety function Speicherprogrammierbare Steuerung (SPS) Programmable logic contoller Niedrigster Performance Level einer SRP/CS Lowest performance level of a SPR/CS in einer Kombination von SRP/CS in a combination with SPR/CS Proportionalventile Proportional valves Regler Regulator Risiko, das nach Ausfhrung der SchutzRisk remaining after safety measures manahme verbleibt have been taken Kombination der Wahrscheinlichkeit Combination of the Probability Kombination aus Festlegung der Grenzen Combination of the specification of the einer Maschine, Identifizierung einer limits of the machine, hazard identifiGefhrdung und Risikoeinschtzung cation and risk estimation Gesamtheit des Verfahrens, das eine Overall process comprising a risk Risikoanalyse und Risikobewertung analysis and a risk evaluation umfasst Auf der Risikoanalyse beruhende BeurJudgement, on the basis of risk analysis, teilung, ob die Ziele zur Risikominderung of wheather the risk reduction objectives erreicht wurden have been achieved Bestimmung des wahrscheinlichen AusDefining likely severity of harm and maes eines Schadens und der Wahrprobability of its occurrence scheinlichkeit seines Eintritts Schwere der Verletzung Severity of injury Schwenkantriebe Semi-rotary drives Vor-Ort-Abnahme Site acceptance test Physische Verletzung und/oder Schdigung Physical injuy or damage to health von Gesundheit oder Sachen Manahme zur Beseitigung einer Gefhr- Means that eliminates a hazard or dung oder zur Minderung eines Risikos reduces a risk Sicherheitstechnische Funktion Safety instrumental function
Abbreviation SIL SIS SP SPE SRASW SRECS SRESW SRP SRP/CS SRS ST SW1A, SW1B, SW2 SYNC
EN 61496-1 DIN EN ISO 13849-1 IEC 61508, IEC 62061 EN 61511-1:2004 EN 61511-1:2004, DIN EN IEC 61508, IEC 62061 IEC 62061 IEC 62061 EN 1050 01/97 Anhang B.2 DIN EN ISO 13849-1
German name Sicherheits-Integrittslevel Sicherheitstechnisches System Sperrventile Sensitive Schutzeinrichtung mechanisch behaftetes Betriebsmittel Sicherheitsbezogene Anwendungssoftware Sicherheitsbezogenes elektrisches Steuerungssystem Sicherheitsbezogene Embedded-Software Sicherheitsbezogenes Teil Sicherheitsbezogenes Teil von Steuerungen Spezifikation der Sicherheitsanforderungen Stromventile Positionsschalter
English name Safety integrity level Safety instrumented system Shut-off valves Sensitive Protection Equipment
Source IEC 61511, DIN EN ISO 13849-1 EN 61511-1:2004 Festo ISO 12100-1
Safety-Related Application Software DIN EN ISO 13849-1 Safety-Related Electrical Control System IEC 62061 Safety-Related Embedded Software Safety-Related Part Safety-Related Part of Control Systems Safety Requirements Specification Flow control valves Position switces Synchronisation objects Test equipment DIN EN ISO 13849-1 Protective measure using safeguards to EN 1050, EN ISO 12100-1 protect persons from the hazard which cannot reasonably be eliminated or from the risks which cannot be sufficiently reduced by inherently safe design measures DIN EN ISO 13849-1 DIN EN ISO 13849-1 DIN EN ISO 13849-1 IEC 61511 Festo DIN EN ISO 13849-1
DIN EN ISO 13849-1
IEC 61511, DIN EN ISO 13849-1 DIN EN ISO 13849-1 Festo Festo EN 1050 EN ISO 12100-1 EN ISO 12100-1, DIN EN 1050
Objekt zur Synchronisierung von Teilnehmern im Netzwerk TE Testeinrichtung Techn. Schutz- Schutzmanahmen, bei denen Schutzeinmanahmen richtungen zur Anwendung kommen, um Personen vor Gefhrdungen zu schtzen, die durch inhrent sichere Konstruktion nicht in angemessener Weise beseitigt werden knnen, oder vor Risiken zu schtzen, die dadurch nicht ausreichend vermindert werden knnen TM Gebrauchsdauer TR Trockner WE Wartungseinheiten WV Wegeventile ZS Zylinderschalter
Mission time Air dryers Service units Directional control valves Proximity sensors
DIN EN ISO 13849-1 Festo Festo Festo Festo
EN ISO 12100-1, DIN EN 1050
EN ISO 12100-1, DIN EN 1050
EN ISO 12100-1, DIN EN 1050
Legal notice The examples specified here are intended purely as suggestions that must be checked for suitability in the context of each separate application, paying attention to the applicable standards. This might involve applying standards DIN EN ISO 13849-1 and 2, for example. Depending on the application, the examples specified may only partially satisfy the actual requirements (for all safety functions), and must therefore be adjusted using suitable measures and modifications. To do this, it is necessary to examine the entire system (entire control loop system), which might consist of multiple technologies (e.g. pneumatics, hydraulics, electrical engineering, mechanics ...) and therefore multiple applicable standards. The sample circuits given here are not suitable as a complete validation report in the legal sense due to the lack of any reference to an actual system (real application).
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DIN EN ISO 13849-1 Festo IEC 61511 EN 1050, EN 61511-1:2004 EN 1050, EN ISO 12100-1, EN 61511-1:2004 EN 61511-1:2004
Festo worldwide
Argentina Festo S.A. Edison 2392 (B1640 HRV) Martinez Prov. Buenos Aires Tel. ++54 (0)11/47 17 82 00, Fax 47 17 82 82 E-mail: info@ar.festo.com Australia Festo Pty. Ltd. Head Office (Melbourne) 179-187 Browns Road, P.O. Box 261 Noble Park Vic. 3174 Call Toll Free 1300 88 96 96 Fax Toll Free 1300 88 95 95 Tel. ++ 61(0)3/97 95 95 55, Fax 97 95 97 87 E-mail: info_au@festo.com.au Austria Festo Gesellschaft m.b.H. Linzer Strae 227 1140 Wien Tel. ++43 (0)1/9 10 75-0, Fax 9 10 75-250 E-mail: automation@festo.at Belarus IP Festo Minsk, 220035 Mascherov Prospekt, 78 Belarus Tel. ++375 (0)17/204 85 58, Fax 204 85 59 E-mail: info_by@festo.com Belgium Festo Belgium sa/nv Rue Colonel Bourg 101 1030 Bruxelles/Brussel Tel. ++32 (0)2/702 32 11, Fax 702 32 09 E-mail: info_be@festo.com Brazil Festo Automao Ltda. Rua Guiseppe Crespi, 76 KM 12,5 - Via Anchieta 04183-080 So Paulo SP-Brazl Tel. ++55 (0)11/50 13 16 00, Fax 50 13 18 68 E-mail: info_br@festo.com Bulgaria Festo EOOD 1592 Sofia 9, Christophor Kolumb Blvd. Tel. ++359 (0)2/960 07 12, Fax 960 07 13 E-mail: info_bg@festo.com Canada Festo Inc. 5300 Explorer Drive Mississauga, Ontario L4W 5G4 Tel. ++1 (0)905/624 90 00, Fax 624 90 01 E-mail: info_ca@festo.com Chile Festo S.A. Mapocho 1901 6500151 Santiago de Chile Tel. ++56 (0)2/690 28 00, Fax 695 75 90 E-mail: info.chile@cl.festo.com China Festo (China) Ltd. 1156 Yunqiao Road Jinqiao Export Processing Zone, Pudong, 201206 Shanghai, PRC Tel. ++86 (0)21/58 54 90 01, Fax 58 54 03 00 E-mail: info_cn@festo.com Colombia Festo Ltda. Avenida El Dorado No. 98-43 Bogot Tel. ++57 (0)1/404 80 88, Fax 404 81 01 E-mail: festo@festo.com.co Croatia Festo d.o.o. Nova Cesta 181 10000 Zagreb Tel. ++385 (0)1/619 19 69, Fax 619 18 18 E-mail: info_hr@festo.com Czech Republic Festo, s.r.o. Modransk 543/76 147 00 Praha 4 Tel. ++420 261 09 96 11, Fax 241 77 33 84 E-mail: info_cz@festo.com Denmark Festo A/S Islevdalvej 180 2610 Rdovre Tel. ++45 70 21 10 90, Fax ++45 44 88 81 10 E-mail: info_dk@festo.com Estonia Festo OY AB Eesti Filiaal Laki 11B 12915 Tallinn Tel. ++372 666 15 60, Fax ++372 666 15 61 E-mail: info_ee@festo.com
Finland Festo OY Mkituvantie 9, P.O. Box 86 01511 Vantaa Tel. ++358 (09)/87 06 51, Fax 87 06 52 00 E-mail: info_fi@festo.com France Festo Eurl Numro Indigo Tel. 0820/204640, Fax 204641 ZA des Maisons Rouges 8 rue du Clos Sainte Catherine 94367 Bry-sur-Marne cedex Tel. ++33 (0)1/48 82 64 00, Fax 48 82 64 01 E-mail: info_fr@festo.com Germany Festo AG & Co. KG Postfach 73726 Esslingen Ruiter Strae 82 73734 Esslingen Tel. ++49 (0)711/34 70, Fax 347 21 44 E-mail: info_de@festo.com Greece Festo Ltd. 40 Hamosternas Ave. 11853 Athens Tel. ++30 210/341 29 00, Fax 341 29 05 E-mail: info_gr@festo.com Hong Kong Festo Ltd. 6/F New Timely Factory Building, 497 Castle Peak Road, Kowloon, Hong Kong Tel. ++ 852/27 43 83 79, Fax 27 86 21 73 E-mail: info_hk@festo.com Hungary Festo Kft. Csillaghegyi t 32-34. 1037 Budapest Tel. ++36 1/436 51 11, Fax 436 51 01 E-mail: info_hu@festo.com India Festo Controls Private Ltd. 237B, Bommasandra Industrial Area, Bangalore Hosur Highway, Bangalore 560 099 Tel. ++91 (0)80/22 89 41 00, Fax 783 20 58 E-mail: info_in@festo.com Indonesia PT. Festo JL. Sultan Iskandar Muda No.68 Arteri Pondok Indah Jakarta 12240 Tel. ++62 (0)21/27 50 79 00, Fax 27 50 79 98 E-mail: info_id@festo.com Iran Festo Pneumatic S.K. # 2, 6th street, 16th avenue, Tehran 1581975411 Km 8, Special Karaj Road, P.O.Box 15815-1485 Tehran 1389793761 Tel. ++98 (0)21 44 52 24 09, Fax ++98 (0)21 44 52 24 08 E-mail: Mailroom@festo.ir Ireland Festo Limited Unit 5 Sandyford Park Sandyford Industrial Estate Dublin 18 Tel. ++ 353(0)1/295 49 55, Fax 295 56 80 E-mail: info_ie@festo.com Israel Festo Pneumatic Israel Ltd. P.O. Box 1076, Ha'atzma'ut Road 48 Yehud 56100 Tel. ++972 (0)3/632 22 66, Fax 632 22 77 E-mail: info_il@festo.com Italy Festo S.p.A Via Enrico Fermi 36/38 20090 Assago (MI) Tel. ++39 02/45 78 81, Fax 488 06 20 E-mail: info_it@festo.com Japan Festo K.K. 1-26-10 Hayabuchi, Tsuzuki-ku Yokohama 224-0025 Tel. ++81 (0)45/593 56 10, Fax 593 56 78 E-mail: info_jp@festo.com Korea South Festo Korea Co., Ltd. 470-1 Gasan-dong, Geumcheon-gu Seoul #153-803 Tel. ++82 (0)2/850 71 14, Fax 864 70 40 E-mail: info_kr@festo.com
Latvia Festo SIA Deglava 60 1035 Riga Tel. ++371 67/57 78 64, Fax 57 79 46 E-mail: info_lv@festo.com Lithuania Festo UAB Karaliaus Mindago pr. 22 3000 Kaunas Tel. ++370 (8)7/32 13 14, Fax 32 13 15 E-mail: info_lt@festo.com Malaysia Festo Sdn.Berhad 10 Persiaran Industri Bandar Sri Damansara, Wilayah Persekutuan 52200 Kuala Lumpur Tel. ++60 (0)3/62 86 80 00, Fax 62 75 64 11 E-mail: info_my@festo.com Mexico Festo Pneumatic, S.A. Av. Ceyln 3 Col. Tequesquinahuac 54020 Tlalnepantla, Edo. de Mxico Tel. ++52 (01)55/53 21 66 00, Fax 53 21 66 55 E-mail: festo.mexico@mx.festo.com Netherlands Festo B.V. Schieweg 62 2627 AN Delft Tel. ++31 (0)15/251 88 99, Fax 261 10 20 E-mail: info@festo.nl New Zealand Festo Limited MT. Wellington Auckland NZ Tel. ++64 (0)9/574 10 94, Fax 574 10 99 E-mail: info_nz@festo.com Nigeria Festo Automation Ltd. Motorways Centre, First Floor, Block C Alausa, Ikeja, Lagos, NIGERIA Tel. ++234 (0)1/794 78 20, Fax 555 78 94 E-mail: info@ng-festo.com Norway Festo AS Ole Deviks vei 2 0666 Oslo, Norway Tel. ++47 22 72 89 50, Fax ++47 22 72 89 51 E-mail: info_no@festo.com Peru Festo S.R.L. Calle Amador Merino Reyna #480, San Isidro Lima, Per Tel. ++51 (0)1/222 15 84, Fax 222 15 95 Philippines Festo Inc. KM 18, West Service Road South Superhighway 1700 Paranaque City, Metro Manila Tel. ++63 (0)2/776 68 88, Fax 823 42 19 E-mail: info_ph@festo.com Poland Festo Sp. z o.o. Janki k/Warszawy, ul. Mszczonowska 7 05090 Raszyn Tel. ++48 (0)22/711 41 00, Fax 711 41 02 E-mail: info_pl@festo.com Romania Festo S.R.L. St. Constantin 17 010217 Bucuresti Tel. ++40 (0)21/310 29 83, Fax 310 24 09 E-mail: info_ro@festo.com Russia Festo-RF OOO Michurinskiy prosp., 49 119607 Moskow Tel. ++7 495/737 34 00, Fax 737 34 01 E-mail: info_ru@festo.com Singapore Festo Pte. Ltd. 6 Kian Teck Way Singapore 628754 Tel. ++65/62 64 01 52, Fax 62 61 10 26 E-mail: info_sg@festo.com Slovakia Festo spol. s r.o. Gavlovicov ul. 1 83103 Bratislava 3 Tel. ++421 (0)2/49 10 49 10, Fax 49 10 49 11 E-mail: info_sk@festo.com
Slovenia Festo d.o.o. Ljubljana IC Trzin, Blatnica 8 1236 Trzin Tel. ++386 (0)1/530 21 00, Fax 530 21 25 E-mail: info_si@festo.com South Africa Festo (Pty) Ltd. 22-26 Electron Avenue, P.O. Box 255 Isando 1600 Tel. ++27 (0)11/971 55 00, Fax 974 21 57 E-mail: info_za@festo.com Spain Festo Pneumatic, S.A. Tel. 901243660 Fax 902243660 Avenida Granvia, 159 Distrito econmico Granvia L'H ES-08908 Hospitalet de Llobregat, Barcelona Tel. ++ 3493/261 64 00, Fax 261 64 20 E-mail: info_es@festo.com Sweden Festo AB Stillmansgatan 1, P.O. Box 21038 20021 Malm Tel. ++46 (0)40/38 38 40, Fax 38 38 10 E-mail: info_se@festo.com Switzerland Festo AG Moosmattstrasse 24 8953 Dietikon ZH Tel. ++41 (0)44/744 55 44, Fax 744 55 00 E-mail: info_ch@festo.com Taiwan Festo Co., Ltd. Head Office 24450, No. 9, Kung 8th Road Linkou 2nd Industrial Zone Linkou Hsiang, Taipei Hsien, Taiwan, R.O.C. Tel. ++886 (0)2 26 01 92 81, Fax ++886 (0)2 26 01 92 86-7 E-mail: festotw@festo.com Thailand Festo Ltd. 67/1 Moo 6 Phaholyothin Road Klong 1, Klong Luang, Pathumthani 12120 Tel. ++66 29 01 88 00, Fax ++66 29 01 88 33 E-mail: info_th@festo.com Turkey Festo San. ve Tic. A.S. Tuzla Mermerciler Organize Sanayi Blgesi, 6/18 TR 34956 Tuzla - Istanbul/TR Tel. ++90 (0)216/585 00 85, Fax 585 00 50 E-mail: info_tr@festo.com Ukraine Festo Ukraina Borisoglebskaja 11 Kiev 04070 Tel. ++380 (0)44/239 24 33, Fax 463 70 96 E-mail: info_ua@festo.com United Kingdom Festo Limited Applied Automation Centre, Caswell Road Brackmills Trading Estate Northampton NN4 7PY Tel. ++44 (0)1604/66 70 00, Fax 66 70 01 E-mail: info_gb@festo.com United States Festo Corporation (New York) Call Toll-free 800/993 3786 Fax Toll-free 800/963 3786 395 Moreland Road, P.O.Box 18023 Hauppauge, N.Y. 11788 Tel. ++ 1(0)314/770 01 12, Fax 770 16 84 E-mail: info_us@festo.com Venezuela Festo C.A. Av. 23, Esquina calle 71, No. 22-62 Maracaibo, Edo. Zulia Tel. ++58 (0)261/759 09 44, Fax 759 04 55 E-mail: festo@festo.com.ve Viet Nam Festo Co., Ltd (Cong Ty Tnhh Festo) No. 206 Tran Nao Street Ward Binh An , District 2 Ho Chi Minh City, Vietnam Tel. ++84 (0)8/740 69 09, Fax 740 69 10 53087 en 06/2009

Festo Safety Engineering

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Festo Safety Engineering

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Safety engineering guidelines

Your partner in safety

Sample circuit diagrams

Reduce risk think preventively

Simple but safe!

Basic safety requirements in the manufacturing industry

Time schedule for EC machinery directive and DIN EN ISO 13849-1

Free movement of goods in Europe

Article 95 of the EU Treaty (free movement of goods)

Article 137 of the EU Treaty (occupational health and safety)

Old machinery directive

Health and safety outline directive 89/391/EEC

Incorporation into national law

New machinery directive

Low voltage directive 2006/95/EC

Machinery directive 98/37/EC 2006/42/EC

Use of work equipment single directive 86/655/EEC

Harmonised European standards

National statutory provisions

Operators Germany DIN EN 954-1

February 2007 Withdrawn from DIN

February 2007 DIN ratification

DIN EN ISO 13849-1

Fundamental standards for designing control functions

Definition and elements of risk

Design and risk assessment of machinery EN ISO 12100

Electrical safety aspects EN 60204-1

Low risk Safety Residual risk

EN 1050 (EN ISO 14121-1)

Danger/hazard Risk before protective measures

Functional and safety-related requirements for safety-related control systems

Designing and implementing safety-related control systems EN 62061

Actual risk reduction

Safety = acceptable residual risk

Risk in terms of the considered hazard

Severity of harm that can result from the considered hazard

Probability of occurrance of that harm

DIN EN ISO 13849-1

Exposure of person(s) to that hazard

Designated architectures (categories)

The possibility of avoiding or limiting the harm

The occurrance of a hazardous event

Risk analysis Source: EN ISO 12100, 3.14

Determination of the limits of the machinery

Determining/defining states & transitional states

Determining the required PLr

Risk evaluation Source: EN ISO 12100-1, 5.3

Source: EN ISO 12100; 5.3

For all safety functions

Design and technical implementation of the safety function Determining the PL

All possible instructive measures used yes

User information on the machine and in the user manual

Risk reduction Source: EN ISO 12100-1, 5.4

For each safety function specify the required characteristics

Evaluating technical safety measures determination of the performance level

Application 13849-1, step 1: Determining the required performance level

Determination the PL = Performance Level

Determination of the SIL = Safety Integrity Level

Determination of the MTTFd = mean time to failure (dangerous)

3 x 106 PFHd < 105

106 PFHd < 3 x 106

107 PFHd < 106

108 PFHd < 107