Sicherheitstechnik_135242_en.qxp 02.05.2012 11:57 Uhr Seite 1 Safety engineering guidelines Pneumatic and electric solutions SLS STR STR STO SS1 STO SDI SS2 SOS v v v v v M s s s 0 t 0t0 t 0 t 0 t 0 t Sicherheitstechnik_135242_en.qxp 02.05.2012 11:57 Uhr Seite 2 Overview of technical safety measures Input Logic Output Emergency Limited, safe speed stop Page Reducing pressure and force Two-hand 27–30 .............. control Moving guard: De-energise 31 .................... guard door Safety shut-off mat • Wiring Safe direction • Safe, pneumatic logic of movement • Safety relay • Safety PLC Light curtain Initial position, standstill Set-up and Normal operation Laser scanner service operation Stopping, blocking a movement Emergency operation Enabling switch .............. Page 65–66 Mode selector OFF switch Vision systems Please observe the legal information on page 73. 2 Sicherheitstechnik_135242_en.qxp 20.07.2012 10:09 Uhr Seite 3 Pneumatic Electrical Page .................................................................................................... 44 Reducing speed SLS Safely limited v speed (SLS) ................................ 34 0 t Reducing pressure .............................................................................................. 32–33 and force Exhausting .............................................................................................. 35–41 STO Safe torque off v (STO) ................................ 46 0 t Reversing .............................................................................................. 43–45 a movement SDI Safe direction of v s movement (SDI) 0 t Stopping, .............................................................................................. 50–57 holding, Stopping blocking SS1 STO Safe stop 1 (SS1) without power v s ................................ 42 0 t Stopping, .............................................................................................. 47–49 holding, blocking Stopping with power SS2 SOS Safe stop 2 (SS2) v s 0 t SOS Safe operating v s stop (SOS) 0 t SLP Safe position SPF s (general SLP) t Protection against unexpected start-up .............................................................................................. 58–62 You will see these symbols frequently on the following pages. They clearly and quickly point to the respective safety function. 3 Sicherheitstechnik_135242_en.qxp 02.05.2012 11:57 Uhr Seite 4 Your partner for safety At Festo, quality has many aspects – one of these is handling machines safely. This is the reason for our safety-oriented automation technology. These components ensure that optimum safety is achieved in the workplace. This brochure is intended • Which safety measures are These can be used to implement as a guide. derived from these? many safety functions. It covers the core questions • What are the most common relating to safety-oriented safety measures? If you have more extensive pneumatics and electrical requirements, our specialists engineering: Simple and helpful: The second worldwide will be happy to help. part of the brochure contains • Why use safety-oriented sample circuit diagrams for the pneumatics? most commonly used safety • How can I identify the risk functions in conjunction with posed by a system or machine pneumatic and electric drives to the operator or user? as well as the corresponding • Which standards and Festo product combinations. directives apply? Contents Introduction........................................................................................ 2 Directives and standards.................................................................... 6 Safety functions with products and solutions .................................. 27 Training and consulting .................................................................... 67 4 Sicherheitstechnik_135242_en.qxp 02.05.2012 11:57 Uhr Seite 5 Reduce risk – think preventively 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 safety-oriented pneumatics from Festo provides you with the security of implementing safety measures in compliance with the EC machinery directive. This reliably prevents collisions The protection goals are Safety-oriented solutions from In addition to this, if errors occur, or uncontrolled restarts after achieved using various safety Festo provide you with proposals they must not lead to failure of EMERGENCY-STOP, for example. functions. for the safety functions, depending At the same time, using safety- • Commissioning on their hazard potential. oriented pneumatics also Safety-oriented solutions from • Automatic/manual operation minimises the risk of liability Festo, in the form of • Setting up claims. • Components • Risk situations and emergency • Circuits functions, such as safe stop, The EC Machinery Directive • Engineering safe exhausting. specifies a risk analysis and make it easy to achieve your • Restart -> Protection against assessment for machines. These safety objectives. Safe operation unexpected start-up have helped to develop and of machines should be possible • Service/maintenance define protection goals. in all modes and stages of their service life. Simple but safe As a general rule, the simpler the As a result, it would seem To ensure that the electrical safety technology used in the virtually impossible to safety functionality of your application, the more efficient it implement standardised safety control system is a suitable is. The complexity of safety engineering concepts. continuation of in your safety engineering is in the variety of concept for pneumatic state combinations and Due to their flexible applications, components, Festo offers transitional states. Festo drive systems can be solutions based on risk analyses incorporated in the risk analysis and risk assessments for the and assessment for each most commonly used machine, depending on the applications. application. 5 Sicherheitstechnik_135242_en.qxp 02.05.2012 11:57 Uhr Seite 6 Technical safety conditions There are global framework conditions to ensure that machinery can be built and operated safely. Almost all laws require a risk assessment which reveals risks and results in risk minimising measures. Objective: safe machines Laws e.g. EC Machinery Directive Risk assessment Objective: standardised process + “check list” Risk analysis Risk assessment Risk reduction Design measures Technical measures User information Safety function Objective: risk reduction Input Logic Output EN ISO 13849-1 IEC 61508/61511/62061 Objective: evaluation and assessment of technical safety measures Solutions from Festo Solutions from Evaluation Objective: evaluation whether risk reduction is sufficient PL ≥ PL SIL ≥ SIL Festo Didactic: training and consulting Didactic: training Festo r r 6 Sicherheitstechnik_135242_en.qxp 02.05.2012 11:57 Uhr Seite 7 Basic safety requirements in the manufacturing industry As part of the development of the single European market, the directives for machine construction in the manufacturing industry were harmonised. Free movement of goods in Europe Article 95, EC treaty (free movement of goods) Article 137, EC treaty (safety at work) “Health and Safety” Framework Directive e.g. machines 89/391/EEC Machinery Directive Low Voltage Directive “Use of work equipment” 98/37/EC 2006/95/EC single directive 86/655/EEC 2006/42/EC Harmonised European standards National legal provisions Responsibility Manufacturers Operators Directives are comparable with the design and construction in the Official Journal of the laws. Among others, the EC of machines. The CE mark European Communities. machinery directive is applicable indicates compliance with the Applying these results in what is for machine construction. machinery directive. known as the “presumption of The primary aim of the EC Harmonised standards provide conformity”, which reinforces machinery directive is to specify assistance in complying with the legal security of operators basic health and safety the EC machinery directive. and manufacturers. requirements in relation to Harmonised standards are listed 7 Sicherheitstechnik_135242_en.qxp 02.05.2012 11:57 Uhr Seite 8 Basic standards for designing control functions Harmonised standards that relate to machine safety serve to reduce safety risks to an acceptable minimum, as per the EC Machinery Directive. Design and risk assessment of machinery Electrical safety aspects EN ISO 12100 EN 60204-1 Safety of machinery Safety of machinery General principles for design Electrical equipment of machines, Part 1: General requirements Functional and safety-oriented requirements for safety-related control systems Designing and implementing safety-related control systems EN 62061 Safety of machinery Functional safety of electrical/electronic/ programmable safety-related electronic control systems Any architectures Safety integrity level (SIL) SIL 1, SIL 2, SIL 3 DIN EN ISO 13849-1 Safety of machinery Safety-related parts of control systems, Part 1 – General principles for design Designated architectures (categories) Performance Level (PL) PL a, PL b, PL c, PL d, PL e 8 Sicherheitstechnik_135242_en.qxp 02.05.2012 11:57 Uhr Seite 9 Definition and concept of risk Risks are the result of hazards and relate to the gravity of possible damage and the probability of the damage occurring. Low risk High risk Safety Adequately reduced Danger Residual risk Risk without safety measures Necessary minimum risk reduction Actual risk