Safety_System_Manual.pdf

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Content
1 Regulations and Standards
1.1 General Information
Connecting an actuator to the AS-Interface with
3/22
ASIsafe
Connecting to PROFIBUS with PROFIsafe
1/2
3/24
1.2 Regulations and Standards
1/3
Directly connecting sensors to PROFIBUS with
3/25
in the European Union (EU)
Basic principles of the legal
1/3
PROFIsafe
Connecting a sensor to fail-safe SIMATIC input
3/25
requirements in Europe*
Health and Safety at the workplace in the EU
1/4
modules
Connecting actuators to PROFIBUS with PROFIsafe 3/32
Safety of machinery in Europe
1/5
Process technology in Europe
1/20
4 Fail-safe communications using
standard fieldbuses
4.1 PROFIsafe
Furnace systems in Europe
1/25
1.3 Legal requirements and standards
1/26
regarding safety at work in North America
US - general
4/2
Features/benefits
4/3
1/26
Machine safety
1/27
PROFIsafe applications
4/4
PROFIsafe-capable products
4/4
Process industry in the US
1/30
Safety Regulations and Standards in Canada
1/31
PROFIsafe in the 7-layer communications model
4/4
PROFIsafe functions
4/5
1.4 Safety requirements for machines in Japan
1/34
1.5 Important Addresses
1/35
PROFIsafe interacting with TIA
4/7
4.2 ASIsafe
4/7
2 Specification and design of
safety-relevant controls for machines
2.1 Overview
Overview
4/7
Customer benefits
4/8
2/2
Highlights
4/9
Applications
4/9
2.2 Design and implementation process of
2/3
Principle design and function
4/9
the machine, risk assessment, process
to reduce risks
2.3 Does the protective measure depend on
Integrating into TIA
4/14
2/9
5 Safety industrial controls
5.1 SIRIUS position switches
the control?
2.4 Specification of the safety requirements
2/14
5/2
5.2 SIRIUS Emergency Stop
5/7
2.5 Design and implementation of (safety-related)
2/15
5.3 SIRIUS command and signaling devices
5/8
controls according to IEC 62061
Philosophy/theory
2/17
5.4 SIRIUS safety relays
5/11
Overview
5/11
Process to design a safety-related control system
2/23
Features
5/11
SRECS
2.6 Designing and implementing safety-related
2/34
Applications
5/11
Product family/product groups
5/12
parts of a control according to EN 954-1
(ISO 13849-1 (rev))
2.7 Specification and design of safety-relevant
Design
5/13
2/37
Functions
5/13
Integration
5/15
controls for machines in the United States
Examples
5/16
Technical Data
5/18
3 Connecting sensors/actuators
3.1 Overview
5.5 ASIsafe
5/20
3/2
Product family/product groups
5/20
3.2 Features
3/3
Technical data
5/22
3.3 Standards - an overview
3/4
Example - packaging machine
5/23
3.4 Connecting sensors/actuators
3/6
5.6 ET 200S Safety Motor Starter Solution
5/24
Conventionally connecting sensors whithout
3/12
Overview
5/24
using safety-related communications via
fieldbuses
Connecting sensors/actuators whithout
Applications
5/24
Features
5/25
3/13
ET 200S Motorstarter Solution Local
5/26
safety-related communication
Connecting to AS-Interface with ASIsafe 3/19
Connecting sensors to AS-Interface with ASIsafe 3/20
ET 200S Motorstarter Solution PROFIsafe
5/30
Structure
5/37
Technical Data
5/38
6 Fail-safe optical sensors
6.1 SIGUARD LS4 laser scanners
8.2
Safety Unit
8/32
8.3
Safety Integrated for Motion Control Systems 8/34
6/2
Overview
6/2
9
Fail-safe drives
Application of SIGUARD LS4 laser scanner
6/3
Product families/product groups
6/4
9.1
MASTERDRIVES and SIMODRIVE 611universal 9/2
Design
6/5
9.2
SINAMICS Safety Integrated
9/4
Functions
6/6
9.3
SIMATIC ET 200S FC frequency converters
Overview
Integration into the system
6/7
9/6
Application information
6/8
Benefits
9/7
Calculating the protective field
6/9
Applications
9/7
Technical Data
6/12
Design
9/8
6.2 SIGUARD light curtains and light grids
6/14
Functions
9/8
Overview
6/14
Integration
9/10
Features
6/14
Technical data
9/12
Applications
6/16
Functions
6/21
10 References
10.1 Fail-safe SIMATIC controllers in the body shop 10/2
of Opel Belgium
10.2 Safety technology for Toyota Canada
6.3 SIGUARD light barriers
6/28
6.4 SIGUARD switching strips
6/32
7 Fail-safe controllers SIMATIC Safety Integrated
7.1 Overview
10/4
10.3 Building automobile bodies with distributed
10/6
7/2
safety for Ford Australia
10.4 PLC-based safety concept in the manufacture
7.2 Features
7/3
10/9
7.3 Applications
7/5
of truck wheels for Michelin, Germany
10.5 Exciting trip through Madame Tussauds
7.4 Product group/product family
7/6
10/12
7.5 Engineering
7/10
10.6 Seed production – a pump system for
10/14
7.6 Structure
7/11
chemicals in controlled using ASIsafe
10.7 AS-Interface simplifies safety at work
7.7 Functions
7/12
10/16
7.8 Examples
7/14
for UPS
10.8 CROWN Vourles – safety in the packaging
7.9 Technical Data
7/18
10/19
industry with Safety Motor Starter Solution
PROFIsafe
10.9 More safety in the automobile industry
8 Fail-safe motion control systems
8.1 SINUMERIK Safety Integrated -
8/2
10/22
10.10 New standard for machine tools
10/23
the safety package for machine tools
Brief description 8/3
Equipment components 8/5
System prerequisites 8/8
Safe stopping process 8/9
Monitoring speed and position 8/13
Logically combining safety-related process signals 8/14
Vertical axes are protected from dropping
10.11 Safety when testing products used for
10/25
safety at work
10.12 A synthesis of speed & safety
10/30
10.13 Safe standstill in the printing industry
10/32
8/15
11 Appendix
11.1 Terminology and abbreviations
11/2
Integrated and partially-automated acceptance
8/19
11.2 References
11/6
report
Forced checking procedure for SINUMERIK
11.3 Contact – Internet Hotlines
11/6
8/21
11.4 Seminars available for safety technology,
11/7
Safety Integrated
Connecting sensors/actuators - basics
Standards and Directives
11.5 List of contents
8/22
11/15
Connecting sensors/actuators via separate
8/24
hardware I/O from the PLC and NC
Connecting sensors/actuators via ET 200S
8/30
PROFIsafe fail-safe modules
Application examples
8/31
Certification
8/31
Foreword
Regulations and Standards
1
Specification and design of
safety-relevant controls for machines
2
Connecting sensors/actuators
3
Fail-safe communications
using standard fieldbuses
4
Safety industrial controls
5
Fail-safe optical sensors
6
Fail-safe controllers SIMATIC Safety Integrated
7
Fail-safe motion control systems
8
Fail-safe drives
9
References
10
Appendix
11
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Dear Readers,
From the sensor through the evalua-
tion equipment up to the safety-related
implementation, “Safety Integrated”
with the SIRIUS, SIGUARD, SIMATIC,
and SINUMERIK/SIMODRIVE product
groups provides maximum protection
against functional faults.
Open and integrated
An automation system mainly com-
prises standard components such as
standard PLC, drives etc.
Depending on the application, the
component of safety technology of
a complete system can vary widely.
Independent of the application area,
the safety level always comprises a
chain of sensors, evaluation devices
and actuators for a safety-related
condition of the plant or machines.
Today, the two levels of a plant or
system - standard and safety related
technology - are strictly separated.
Generally, different engineering tech-
niques and tools are used for these
two levels. This not only results in
higher costs associated with personnel
training, but also in many cases, these
two levels can only be linked with con-
siderable expenditure.
These product groups have already
proven themselves for many years
in standard automation solutions
and that worldwide. Since the safety-
related communications via PROFIBUS
and via the actuator-sensor-interface -
ASIsafe have been certified, these
components can now also be com-
bined in the system.
Helmut Gierse
A&D Group Board
In addition to the conventional wiring
between the individual components,
by using standard fieldbus systems,
also for safety technology, additional
value is added thanks to the overall
system integration. This allows more
cost-effective engineering, as the same
components are used and the plant and
system availability is simultaneously
increased thanks to improved diagnos-
tics.
Applications in the area of machine
safety or process technology – state-of-
the-art technologies in the automation
process - demand the highest degree
of safety for man, machine and the
environment.
The requirements regarding cost-saving
potential can be especially fulfilled by
selecting the appropriate installation
system. In standard technology, the
move to distributed concepts and the
use of modern fieldbuses have already
resulted in significant cost savings.
Further cost savings in the future will
be achieved by transferring additional
safety-related signals along existing
standard fieldbuses.
This “Safety Integrated” System Manual,
that has already been updated a mul-
tiple number of times, indicates that
hazards and dangers, caused by func-
tional faults, can either be reduced or
removed.
2 Safety Integrated System Manual
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