Dave Collins
Schneider Electric
Industry NOW Express

2011 Schneider Electric. All Rights Reserved.

● You are not alone
● Almost 60% are not aware of
Safety Categories
● 68% not familiar with
Performance Levels
● Most have difficulty in applying safety products
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 2

● Safety is driven by standards
● Standards determine devices to use, how to use them, and sometimes how safety products are constructed
● Some US standards are similar to IEC standards
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 3

A few of the most important US Standards are:
● OSHA 29 CFR1910
● NFPA 79, 2007 Edition, Electrical Standard for Industrial Machinery
● ANSI B11.19, Performance Criteria for Safeguarding
● ANSI/RIA R15.06, Industrial Robots and Robot Systems, Safety
Requirements
Locally
● UL and CSA (in Canada)
●
●
UL is mandatory in most US cities in their codes and requirements.
Customers and users demand these approvals even if local codes do not require it.
Canada
● CSA is mandatory in Canada
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 4

● Safety categories (B, 1, 2, 3, 4) per EN 954-1 are no longer valid since
December 31, 2011
● Performance Levels (a, b, c, d, e) per EN/ISO 13849-1 replaced safety categories on January 1, 2012
● SIL (Safety Integrity Levels) are designed for use primarily for more complex systems or microprocessor and software based systems
● SIL can be determined by either IEC 61508 or IEC 62061
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 5

Risk graph and parameters
F
1
P
1
Uses the same criteria as EN 954-1
S
1
P
2
P
1
F
2
Starting point
for the evaluation of
the risk
F
1
P
P
2
1
S
2
S Severity of injury
S1 Slight (normally reversible injury)
S2 Serious (normally irreversible) injury including death
F Frequency and/or exposure time to the hazard
F1 Seldom to less often and/or the exposure time is short
F2 Frequent to continuous and/or the exposure time is long
F
2
P Possibility of avoiding the hazard or limiting the harm
P1 Possible under specific conditions
P2 Virtually impossible
P
2
P
1
P
2
Required performance level (PL r
)
Low contribution to risk reduction a b c d e
High contribution to risk reduction
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 6

●
EN/ISO 13849-1 adds new parameters to the requirements of the categories of
EN 954-1 in order to determine the Performance Level (PL) :
● MTTF d
= mean time to dangerous failure
Three levels of MTTF d
are defined in this standard in order to classify the requirements of the categories and the performance levels (PL):
Denotation of mean time to dangerous failure low medium high
Range of MTTF d
3 years <= MTTF d
< 10 years
10 years <= MTTF d
< 30 years
30 years <= MTTF d
< 100 years
● DC = diagnostic coverage DC =
λ dd
/
λ d total
Denotation of diagnostic coverage none low medium high
Range of DC
DC < 60%
60% <= DC < 90%
90% <= DC < 99%
99% <= DC ldd / ld total
λ dd
=
Dangerous failures detected
λ d total
=
Dangerous failures total
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 7

a b
* c 1 d 2 e
Cat. B
DC avg =
0
Cat. 1
DC avg =
0
Cat. 2
DC avg = low
MTTF d
of each channel = low
MTTF d
of each channel = medium
MTTF d
of each channel = high
Cat. 2
DC avg = medium
Cat. 3
DC avg = low
Cat. 3
DC avg = medium
Cat. 4
DC avg = high
DC = Diagnostic Coverage
MTTF d
= Mean Time To Failure - Dangerous
PL = Perf ormance Level
3
* In many applications the realization of perf ormance level c by category 1 may not be suf f icient. In this case a higher category e.g. 2 or 3 should be chosen.
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
*
1
8

1
Simplify machine programming & commissioning with SoMachine suite
Safety is at the center of it all
Embedded Intelligence where it is needed
HMI controllers
Drive controllers
Logic controllers
Motion controllers
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
I/Os
9

●
Predetermined equipment lists
●
Tested
● our experts tested each application to ensure that they work in all possible configurations.
●
Validated
●
Full functional compatibility of devices.
●
Documented
● a full user manual contains all the required information for installation and assembly, including CAD and wiring diagrams
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 11

●
●
Reduce cost on the machine safety application through a single automation and complete safety chain provider
Acquire the information Monitor and processing Stop the machine
Safe signal transmission
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 12

●
Fully aligned with our TVDA approach:
●
Answers the machine customer’s needs, complementary with our automation architectures
TVD Architecture
Safe Stop 1 - servo
Safety Chain Solution
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 13

●Optimized implementation for increased levels of protection
●
A cost optimized solution that reaches a very low probability of dangerous failure (PFH d
), which corresponds to PL e and SIL 3
●Typical applications:
●
Assembling, machining centers or similar machines tools
Safe Stop 0, High performance
Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012
14

●Safety integrated devices for an easier safety chain configuration
●
The drive (ATV32) features an integrated safety torque off function (STO), which meets the requirements of PL e and SIL 3
●Typical applications:
●
Textile, wood-working or simple packaging machines
Safe Stop 1, Drive - high performance
Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012
15

●Improved accuracy through safety integrated devices
●
Stopping the machine with the Safe Stop 2
(SS2) function by using the enhanced safety module (eSM) integrated on the servo-drive; it meets the requirements of PL e and SIL 3
●Typical applications:
●
Packaging, printing, conversion, or similar machines with long freewheel stopping times
(high inertia or low resistive torque)
Safe Stop 2, Servo - enhanced safety
Schneider Electric - Industry Business – Safety –Key to the Machine Solution– 2012
16

Schneider Electric provides a wide variety of scalable and cost effective solutions from simple electromechanical to programmable systems with safety communications, to meet Performance Level “e”, and SIL 3 as well as local and international safety requirements, to help maximize productivity.
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 17

Type
Family
Safety
Relay
XPS
Safety
Controller
XPSMC
Safety PLC
XPSMF
AS-I
ASISAFE
Safety Card
Lexium 32
Function Solution for monitoring one function
Solution for monitoring several functions simultaneously
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
Solution for monitoring many functions simultaneously and communication over Safe Ethernet
Solutions using a safety related communications bus
Solutions using a motion controller
18

• Optional eSM Terminal Adaptor
• for LXM32 M
• Accessories:
- eSM Terminal adapter
(Connection of up to 5 Lxm)
- eSM Cable
AC
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
19

Type Safety Interlock Safety Interlock
Family XCSA XCSB
Safety Interlock
XCSC
Enclosure
Function
Metal
Non-Locking
Metal
Locking by Push Button
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
Metal
Locking by Key
20

Type Safety Interlock Safety Interlock Safety Interlock Safety Interlock
Family XCSE XCSL XCSLE & XCSLF XCSTE
Enclosure
Function
Metal
Solenoid Locking
Metal
Solenoid Locking
Metal - XCSLF
Plastic - XCSLE
Solenoid Locking
Plastic
Solenoid Locking
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
21

Type Safety Interlock Safety Interlock Safety Interlock Safety Interlock
Family XCSPA XCSPL XCSPR XCSMP
Enclosure
Function
Plastic
Non-Locking
Plastic
Non-Locking
Plastic
Non-Locking
Plastic
Non-Locking
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
22

Type
Family
Non-Contact
XCSDMC
Non-Contact
XCSDMP
Non-Contact
XCSDMR
Non-Contact
XCSDM3/4
Operating
Zone
Wiring
Size
Sao: 0.20 in (5 mm)
Sar: 0.59 in (15 mm)
Sao: 0.31 in (8 mm)
Sar: 0.79 in (20 mm)
Cable or connector Cable or connector
2.01 x 0.63 x 0.28 in 3.56 x 0.98 x 0.51 in
Sao: 0.31 in (8 mm)
Sar: 0.79 in (20 mm)
Cable or connector
30 mm dia. 1.51 in
Sao: 0.39 in (10 mm)
Sar: 0.79 in (20 mm)
Cable or connector
3.94 x 1.34 x 1.26 in
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
23

Type
Family
Compact
XUSLB
Compact
XUSLD
Compact
XUSLPZ
Compact
XUSLPB
MOS
Sensing
Distance
SN
14 mm and 30 mm
0.55 in and 1.18 in
1 to 22.9 ft, or
1 to 65.6 ft with PDM
14 mm and 30 mm
0.55 in and 1.18 in
1 to 22.9 ft, or
1 to 65.6 ft with PDM
300, 400,500,600 mm
11.8, 15.7, 19.7, 23.6 in.
2.6 to 65.5 ft or
2.6 to 229.7 ft
500 and 600 mm
19.7 and 23.6 in
2.6 to 26.3 ft
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
24

Type
Family
Cable Pull Switch
XY2
Cable Pull Switch
XY2
Emergency Stop
XB4 – XB5
Feature
Cable Length
Adjustable tripping force
165 ft (50 m)
Viewing windows to aid in adjusting cable tension
50 ft (15 m)
Conforms to ISO 13850
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012
25

In addition to all of the previous products, we offer complete lines of other devices for use in safety related applications:
● E-Stop buttons, EMO
● Indicating banks
● Control Relays and Contactors
● Drives
● Motion
Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 26

Schneider Electric - Industry Business – Safety-Key to the Machine Solution – 2012 27