Applicable and have been incorporated into North American Standards.

• ANSI B11.0-2010 – Safety of Machinery – General Requirements and Risk Assessment • ANSI B11.TR3-2000 – Risk Assessment and Risk Reduction – A Guide to Estimate, Evaluate and Reduce Risks Associated

with Machine Tools • ANSI/RIA R15.06-1999 (R2009) – For Industrial Robots and Robot Systems – Safety Requirements • NFPA 79-2012 – Electrical Standard for Industrial Machinery • ANSI/ASSE Z244.1-2003 (R2008) – Control of Hazardous Energy – Lockout/Tagout and Alternative Methods • ANSI/PMMI B155.1-2011 – Standard for Packaging Machinery and Packaging-Related Converting Machinery – Safety

Requirements © Omron STI 2012 for Construction, Care, and Use • SEMI S10-0307 – Safety Guideline for Risk Assessment and Risk Evaluation Process • MIL-STD-882D-2000 – Standard Practice for System Safety • CSA Z432-04 – Safeguarding of Machinery – Occupational Health and Safety • CSA Z434-03 – Industrial Robots and Robot Systems – General Safety Requirements • CSA Z460-05 – Control of Hazardous Energy – Lockout and Other Methods • NOM-004-STPS-1999 – Protection Systems and Safety Devices for Machinery and Equipment Used in the Workplace • ISO 12100:2010 – Safety of machinery – General principles for design – Risk assessment and risk reduction • EN 954-1:2000 / ISO 13849-1:1999 – Safety of machinery – Safety-related parts of control systems – Part 1: General

principles of design • ISO 13849-1:2006 – Safety of machinery – Safety-related parts of control systems – Part 1: General principles of design

2006/42/EC – European Machinery Directive

WE WILL ASSIST YOU ON THE WAY FOR OPTIMAL SAFETY

5 STEPS TO SAFETY With the following 5 steps, we will take you through the entire process from risk assessment to safety function.

RISK ASSESSMENT CARRYING OUT THE RISK ASSESSMENT AS PER ISO 12100 IN A SIMPLIFIED VERSION

RISK REDUCTION MEASURES FOR RISK REDUCTION

Levels of Hazard Control (in order) 1. Modify the design to eliminate or reduce the risk

2. Add guarding and safeguarding devices

3. Add awareness devices (lights, bells, whistles)

4. Education, Training and Procedures

5. PPE

THE CONTROL SYSTEM AS A COMPONENT OF RISK REDUCTION

DETERMINING THE MACHINE'S SAFETY FUNCTIONS [PLr]

PLr

S1: Minor injury (commonly a reversible injury)

S2: Death or severe injury (commonly an irreversible injury)

F1: Seldom to occasionally

F2: Frequently to continuously

P1: Possible under certain circumstances

P2: Nearly impossible

ASCERTAINMENT OF THE ACHIEVED PERFORMANCE LEVEL [PL]

For the evaluation of the selected safety chain, the performance level, PL, is determined based on the following values:

• Structure (category)

• MTTFd (Mean Time to Failure dangerous):

Mean time to dangerous failure

• DC (Diagnostic coverage):

Diagnosis coverage level

• CCF (Common cause failure):

Failure mutual cause

ASCERTAINMENT OF THE ACHIEVED PERFORMANCE LEVEL [PL]

• Structure (category)

MTTFd from cat. 1 is higher than from cat. B, therefore the probability of a safety function failure is lower. Nonetheless, errors can lead to a loss of a safety function.

In cat. 2, a fault can lead to the loss of a safety function, if it occurs between two tests.

In category 3, the accumulation of undetected errors can lead to a loss of the safety function. In category 4, the requirement of a safety function cannot be carried out until there is positive testing.

ASCERTAINMENT OF THE ACHIEVED PERFORMANCE LEVEL [PL]

Pneumatic Safety Functions

EXPECTATIONS FOR PNEUMATICS Pneumatic systems and electric sensors

Sensors: • Final position switch • Pressure switch • Mechanical plunger query for

valves • Detectable error from the list in

ISO 13849-2: • Change of switching times • Switch failure or incomplete switch • Independent change in the output

switch position (without input signal)

• Valve housing burst

Blue Line: Valve switching output

Red Line: Pressure accumulation at a pressure switch

Δ t: If the pressure does not rise to the pre-defined level after the valve has been actuated, an error has occurred.

EXAMPLE 1 Safe venting (PL e, cat. 4) and protection against unintentional start-up (PL e, cat. 4)

Protected system

Initial situation The opening of the protective grid door must cause the pneumatic system to be vented. In so doing, no unintentional machine start-up may occur within the hazardous area during maintenance procedures.

Safe stop (PL d, cat. 3) and protection against unintentional start-up (PL d, cat. 3)

EXAMPLE 2

For the removal of rejected components from the conveyor belt, the downstream drives should stop safely due to the interruption of the electric eyes. When carrying out work in the hazardous area within the electric eye zone, it must be impossible to unintentionally start-up the machines. The pneumatic valves and the diagnosis by means of a pressure switch should be installed in a valve cluster.

EXAMPLE 3 Two-hand control (PL c, cat. 1) and protection against unintentional start-up (PL c, cat. 1)

Crimping between the cylinder piston and the piston rod is realized by means of a purely pneumatic press with two-hand actuation. When the button is released, the press cylinder will move to the upper final position.

EXAMPLE 4 Protection against unintentional start-up (PL d, cat. 3)

It must not be possible to open the packaging machine's protective casing, until all pneumatic drives are at a standstill.

EXAMPLE 5 Safe venting (PL c, cat. 1) and protection against unintentional start-up (PL c, cat. 1)

If the operator enters into the hazardous area marked in red, the robots should stop and the pneumatic system should vent safely. The hazardous area is monitored using laser scanner. In this example, the robot is not a part of the safety-related evaluation.

Protected system

EXAMPLE 6 Reduce pressure (PL c, cat. 1) and protect against unintentional start-up (PL c, cat. 1)

If the operator enters into the hazardous area marked in yellow, the robot's speed should be reduced and the pneumatic system should reduce the pressure. The hazardous area is monitored by a laser scanner. In this example, the robot is not a part of the safety-related evaluation.

EXAMPLE 7 Monitor pressure (PL d, cat. 3) and protect against unintentional start-up (PL d, cat. 3)

In addition to automatic mode, maintenance mode can also be selected via the operating mode switch. When the handling station is in maintenance mode, the actuators must be moveable under pressure. The pressure should be reduced in the maintenance unit to a defined-level and safely monitored, so that the actuators are not subject to a risk of crushing, while configuration and adjustment options can still be carried out. If the pressure reaches a critical level, the safety PLC receives an analogue signal, and the system is vented.

Standard reference

Suitable components for your application

Suitable components for your application

Residual pressure release valve with position detection sensor

Complies with the ISO13849-1 international safety standard

VP-X536/538/555 VG342-X87 Series

1. Objectives (1) Complies with Safety Standard ISO13849-1

-Mechanical safety is a global requirement. Compliance with the international standard (IEC/ ISO) of machines and equipment become mandatory.

➔EU: ISO13849-1 has been established as the EN standard harmonized with CE Machinery Directive.

Products not compliant with ISO13849-1 cannot be sold in the EU. ➜USA: ANSI, China: GB, Korea: KS. These countries are introducing this standard to the standard of

the countries. - The number of users requesting ISO13849-1 is growing.

1. Objectives (2)

Valves with a position detection function are required to be ISO13849-1 compliant.

- The ISO13849-1 safety standard specifies the requirements for safety related circuits,

and the procedure to verify the circuit and reduce the risk of the circuit. - ISO13849-1 evaluates safety with four parameters: (1)Category of equipment,

(2)B10/MTTD (life data), (3) DCavg (self diagnosis rate), and (4)CCF(Common Cause Failure)

- A residual pressure release valve with position detection sensor is needed to realize the safety related circuit specified by (1)Category of equipment.

1. Objectives (3)

Clarification of SMC’s safety standard response

- 3 types of ISO13849-1 user support from SMC (1) Supply of a residual pressure release valve with a position

detection sensor (2) Providing of reliability information such as B10/MTTF data (3) Providing components to ensure the safety of the control system.

2. Features Highly reliable architecture

- The main valve position detection feature allows the spool valve movement to be detected with a limit switch. This allows for monitoring as required by the standard.

- Long life: B10d = 10 million cycles (Other than S1 type) - Residual pressure is completely released with a spring return

regardless of the pressure.

Spring return

Spool rod Safety limit switch

pressure release valve

safety limit switch for position detection

2. Features X536 For Category 2 [VP542/742-X536]

- The main valve position detection sensor allows for monitoring and allows for compliance with the construction of requirement of Category-2 specified by ISO13849-1.

pressure release valve

safety limit switch for position detection

Category 2

The main valve position detection sensor allows for compliance with the standard.

2. Features X538 X87

For Category-3 and 4 [ＶＰ544/744-X538/Ｘ555、ＶG342-X87] Redundancy is realized by connecting two valves in series. This

realizes conformance with Category 3 and 4.

pressure release valve

safety limit switch for position detection

Category 3,4

By combining two valves, redundancy is achieved and conformance with Category 3 and 4 is realized.

2. Features X555

Valve with soft start-up [VP544/744-X555] - Integrated Soft start-up function available - A fixed orifice and a variable throttle are available.

Outlet pressure - Time

Pneumatic circuit

Flow adjustment valve

Valve Valve2

Soft start-up valve

Soft start up valve

Soft start up valve(open) Secondary pressure

Primary pressure (supply pressure)

3 port valve opens Time: T

2. Features

A Limit switch is available A limit switch is available depending on the market request.

OMRON Rockwell Automation

2. Features

Enclosure & Standard - For the global market sales promotions, the products conform to

enclosure standards and standard compliance requirements.

Series Category Safety limit switch Standard Protection

2

3, 4

3, 4

OMRON

OMRON

OMRON

Rockwell Automation

Rockwell Automation

Rockwell Automation

2. Features

Variations This product has a wide array of variations due to it being based on

the VP and VG valve series.

Series Category

3. Application Examples

# To upgrade the safety level of the source pressure on industrial manufacturing lines where safety is important. This is applicable to general, electric, precision measuring, and transport equipment industries. # With the use of this valve the total safety level of the machinery can be upgraded to category levels 2, 3, or 4.

VG342-X87

Poppet Valve

Valve position detection switch

Spring

Outlet Inlet

Rod

5. Construction

Series VHS Conforming to OSHA Standard Pressure Relief 3 Port Valve with Locking Holes

Series (N)AV Soft Start-up Valve

Combined Soft Start and Dump Valve Compatible with Modular Series FRL Large Cv Factor Low Power Consumption Air Supply and Exhaust can be operated manually

The valve gradually increases supply pressure during start up and rapidly exhausts system air when the supply air is shut off

Series AVL Soft Start-up Valve

Soft start valve with Lock-out function Compatible with Modular Series FRL Large effective area Low power consumption

A valve that gradually increases supply pressure during start up and rapidly exhausts system air when the supply air is shut off

Series (N)AP100 Pressure Relief Valve

The (N)AP Series pressure relief regulator is an adjustable relief valve with a control range of 18 ~100 PSI. If a pressure greater than the set pressure is reached, the unit will open, closing when pressure is less than set pressure.

Series ASP Speed Controller with Pilot-Operated Check Valve

Integrated Pilot Check Valve and Speed Controller Temporary Intermediate Stop and Speed Control of Cylinders is possible 360 Freedom for tube mounting direction

Provides a reliable method of “stopping” the piston rod in the event of air pressure loss or other signaled event (E-Stop)

A mechanical pin or brake-shoe design provides reliable stopping of the piston rod.

Ideal for vertical applications in which either tool damage or the possibility of human injury could occur.

Cylinder with End Lock Drop prevention at stroke end Locks when air is exhausted at the stroke end Separate air piping is not required for locking Simple spring loaded shot pin design Pin is retracted as cylinder port is pressurized Allows for reliable holding of retracted or extended

piston rod for indefinite periods of time

Cylinder with Lock Can be locked at any stroke position Emergency stop and intermediate stop are possible Locking position can be changed to accommodate an exterior

stopper position or the thickness of clamped work pieces

Series ASS Slow Start Control Valve Meter-out Type

Prevents accidents caused by the cylinder rod sudden extensions If pressure is applied only to one side of the cylinder, the rod could get out of control, leading to accidents that could involve injury to humans or damage to the product or jigs. The meter-out type SSC valve prevents the sudden extensions by effecting meter-in control when there is no pressure, and resumes the ordinary meter-out control after the cylinder has been pressurized. With the meter-in type, there is no risk of sudden extensions because the cylinder speed is constantly under meter-in control.

Series AS Tamper Proof Speed Controller

Flow Control with both meter-in and meter-out options Flow Control cannot be adjusted without the use of a

special tool

Electronically Controlled Flow Control

Valves

Leaves speed control in the hands of the programmer Direct operated poppet valve construction Seal material: FKM Body material: C37, stainless steel Port size: 1/8” Available in body ported or base mounted styles

Series ASE Speed Control with Residual Pressure Relief Valve

A standard acting flow control with the additional feature of the red button, which when depressed – releases all residual pressure in that line to atmosphere.

An inline fitting that has a push button on top of it. When the button is depressed, all residual air pressure in that line is vented to atmosphere.

KE Residual Pressure Relief Valve

Series PSE200 Multi-Channel Controller

Series PSE530 Pressure Sensor

A multi-channel controller which can independently sense pressure from 4 sensors.

Ideal for confirmation of residual pressure in critical system lines.

Series VR3100/3110 provides visual confirmation of pressure.

Series VR51 Two Hand Anti-Tie-Down Valve Output air signal is not present unless both buttons are pressed

within 0.5 sec The output air signal will stop if one hand is removed during

operation In order to restart, remove both hands from the mechanical

pushbutton valves and re-apply NOT FOR USE UNDER 0.24 MPa

Series VQC-X10 Pilot Valve On/Off with Pressure Monitoring 5/2 monostable valve; Air pressure-assisted spring return with reinforced spring; Controls pilot signal to manifold

o Switching off this valve sends remaining valves back to safety position Integrated pressure switch provides confirmation of pilot pressure Manual override is actuated A-side ISO13849-2 validated 2 sizes, 8 standard valve functions and other special valve functions available

Series SY-X31 Pilot Valve On/Off with Position Monitoring External pilot pressure control Auto-switch spool detection Return spring for spool Red end-cap ISO13849-2 validation pending Other special valve functions available

Series SY52-X25 Bi-Stable 5/2 Valve with Detent Valve with physical detent

o Instead of relying on internal friction For safety circuits when maintaining valve

position is required

Silencer Series (N)AN

Silencer Series ANA1/ANB1 High Noise Reduction Type Silencer

M3, M5, 1/8” Sintered Bronze 13-21 dB noise reduction

¼” ~ 2”

Over 30 dB noise reduction

Standardized thread and one-touch connection Choice of two orifice sizes Compact, robust construction Minimum flow restrictions for low back pressure Wide range of options High noise attenuation (40 dB)(A) for ANA1

Series (N)AMC Exhaust Cleaner

Ensures clean plant air and noise reduction of distributing noise contamination

Over 35 dB noise reduction Over 99.9% oil mist removal

Conclusion

Safety and efficient production can go hand and hand

A safe workplace makes a better employee

Skeptical???

oConsider cost avoidance

Questions?