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EZ-SCREEN® (TYPE 4) EZ-SCREEN® (TYPE 2) GRIDS & POINTS
Safeguarding Basics
Basics of SafeguardingMachine and personnel safeguarding refers to the combination of requirements, methods and solutions used to protect people who come in contact with dangerous machines in the industrial environment.
RequirementsNational and regional governmental bodies have regulations, mandates, standards and recommendations for implementing a safety method or a solution.
Key regulations regarding general machine guarding include the following:• MachineryDirective-EU• OSHAGeneralDutyClause–USA
(see page 512 for an abridged version list of industry safety standards)
Device RequirementsSafetydevicesmustbeabletoconsistentlyandreliablybringamachinehazardto an orderly stop.
To be considered a safety device, the following methods must be used to ensure reliableoperation:faultexclusion,redundancyandself-checking.
Safety Circuit RequirementsAsafetystopcircuittypicallycomprisesof2normally-opencontactfrommechanically-linkedrelays.Thecircuitismonitoredtodetectcertainfailuresthat could lead to the loss of the safety function.
Machine Control
PLC
Machine
Hazard
Safety Interface
FSD
Personnel Protection
Two-Hand Control
Emergency Stopping
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PhotoelectricsSensors
Fiber OpticSensors
Measurement & Inspection Sensors
Special PurposeSensors
Vision
Lighting &Indicators
Wireless
Safety Light Screens
Safety Laser Scanners
Safety Controllers & Modules
Safety Two-Hand Control Modules
Safety Interlock Switches
Emergency Stop & Stop Control
LIGHT SCREENS
LASER SCANNER
CONTROLLERS &MODULES
TWO-HANDCONTROL MODULES
INTERLOCK SWITCHES
E-STOP &CONTROL DEVICES
TheRiskAssessmentProcessinmachinesafeguardingisaprocessusedtoidentifyhazardsthrougheachphaseofthemachine’slifecycleandtominimizedangerstopersonnelandequipment.
The basic steps in a Risk Assessment Process: 1.Identifyhazardsandwheretheyoccur. 2.Assessriskbyseverityofharmandprobabilityofoccurrence. 3.Reducetheriskthroughtheuseofprotectivemeasures. 4. Validate and document results.
Methods: Risk Assessment
Risk Assessment Standards•OSHA3071,JobHazardAnalysis•MIL-STD-8820,USDODSystemSafetyProgram•ANSIB11.0General(Safety)RequirementsandRiskAssessment•ISO12100,GeneralPrinciplesforDesign,RiskAssessmentandRiskReduction•SEMIS10,RiskAssessment,SemiconductorManufacturingEquipment
Methods: SafetyCircuitsDependingonthelevelofriskassociatedwiththemachineoroperations,anappropriatelevelofcontrol circuitry performance must be incorporated into safety device design.
Basic Single Single with Monitoring Dual with Monitoring
Gen
eric
StopCommand ProtectiveCommandProtectiveCommand MonitoringSignal
Redundant(Safety)StopCommands MonitoringSignal
Simple Device
Machine Stop
Machine Stop
Safe-Guarding
Device
Machine Stop
Safe-Guarding
Device
Machine Stop
Safe-Guarding
Device
•Nonsafety-ratedcomponents•Integratedinaccordancewith
relevant standards•Reliabilitydependsonrobust
components•Redundancynotrequired
•Safety-ratedcomponents•Integratedinaccordancewith
safety principles and design•Redundancynotrequired
•Safety-ratedcomponents•Conductsperiodictestofsystem•Normaloperationallowedifnofaults
are found•Ifunsafefaultisfound,systemwill
default to safe state or indicate that unsafe system exists
•Safety-ratedcomponents•Greatestdegreeoffaulttolerance•Redundancyandself-checking•Singlefailurecannotcauselossof
safety function•Faultsdetectedimmediatelyoratnext
demand on system
Faul
t
PossiblelossofsafetyfunctionGreaterreliability,butpossibleloss
of safety functionFaultdetectedateachtest
Safetyfunctionisensuredwithasinglefault.Anaccumulationoffaultsisnot
possible or detected.
Ris
k Very LowMinor bump or bruise with
no lost time
LowMinor first aid, infrequent exposure
orhighlikelihoodofavoiding thehazard
Mid RangeInjuries that are slight or normally
reversible, requiring normal healing or only first aid
High or Very HighNormallyreservedforhand-fed
applications where injuries could be severe to irreversible
AN
SI /
B11
— — —
ControlReliableANSIB11.19(Clause6.1andAnnexC)
Category3or4and/orPLdorPLe perISO13849-1
satisfyControlReliabilityrequirements
AN
SI /
RIA
Simple SingleChannel SingleChannelwithMonitoring
ControlReliableANSI/RIAR15.06(1999Clause4.5)
ControlreliabilityforrobotstypicallyexceedsaCat3butisnotnecessarily
intendedtobeaCat4
ISO
/ EN CategoryB
ISO13849-1/EN954-1Category1
ISO13849-1/EN954-1Category2
ISO13849-1/EN954-1Category3&4
ISO13849-1/EN954-1
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EZ-SCREEN® (TYPE 4) EZ-SCREEN® (TYPE 2) GRIDS & POINTS
Solutions: Comparing Guards and Devices*Type Safety Function Advantages Limitations Requirements Standards
Guards: protective physical barrier used to prevent access.
FixedGuard Providesafixedbarriertothehazard
•Lowmaintenance•Longlife•Lowcostforsmallareas•Protectsallindividuals•Cancontainejectedmaterials
•Poorergonomics•Limitedvisibility•Limitedaccess•Costlyforlargeareas•Maintenancemayrequireremoval
of guard
•Protectfromidentifiedhazard•Preventuserfromreaching
over, under, around or through the barrier
•Providesafeopenings
•ANSIB11.19•ISO14120•ISO13857
InterlockedGuard
Interrupts power to machine when guard is opened
•Lowinitialinvestment•Canbeplacedclosetohazard•Protectsallindividuals•Cancontainejectedmaterials
•Costlyforlargeareas•Increasedmaintenance
•Mustbedifficulttodefeat•Guardmayopenonlyaftermachinehasstopped–ormustbe installed at a safe distance
•ANSIB11.19•NFPA79•ISO14119•ISO14120•IEC60204-1•ISO13857•ISO13855
Safeguarding Devices: components, attachments or mechanisms designed to perform a specific safeguarding function.
SafetyLightScreen
Arrestspowertomachinewhen sensing field is interrupted
•Excellentergonomics•Allowsfrequentaccess•Protectsallindividuals•Costeffectiveforlargeareas•Allowsforgoodvisibility
•Limitedtomachinesthatcanbestoppedquickly
•Noprotectionfromejectedparts•Mayrequiretheuseofadditional
guards•Maycreateapass-throughhazard
•Initiateimmediatestopwhensensing field is interrupted
•Appropriateresolutionrequiredtodetectobjectsthesizeofatorso,ankle,handorfinger
•ANSIB11.19•IEC61496•ISO13855
Multiple-BeamSystem:•Grids•Points
Arrestspowertomachinewhen sensing field is interrupted
•Lowinitialinvestment•Allowsfrequentaccess•Allowsforgoodvisibility•Protectsallindividuals
•Limitedtomachinesthatcanbestoppedquickly
•Noprotectionfromejectedparts•Largesafetydistance•Maycreateapass-throughhazard
•Initiateimmediatestopwhensensing field is interrupted
•Appropriateresolutionrequiredtodetectobjectsthesizeofa torso
•ANSIB11.19•IEC61496•ISO13855
Two-HandControl
Operatormustusebothhands to actuate machine motion hereby preventing operator access to hazardousarea
•Operator’shandsareawayfromhazardousarea
•Lowinitialinvestment•Lowmaintenance
•Potentialergonomicimpact•Providesprotectiononlyforoperator•Noprotectionfromejectedparts
•Concurrentactuationwithin 1/2second
•Releaseandreactivationrequired before machine motion may be reinitiated
•ANSIB11.19•NFPA79•ISO13851•IEC60204-1•ISO13855
SafetyMatMonitor
Interrupts power to machine when a minimum pressure is applied
•Excellentergonomics•Protectsallindividuals•Allowsforgoodvisibility
•Costlyforlargeareas•Maintenanceintensive•Largesafetydistance
Minimum object sensitivityof66lbsonand3-1/8"surfaceto detect a foot
•ANSIB11.19•ISO13855•ISO13856
Complementary Safety Devices: used to supplement a primary safeguard.
E-Stop•Button•RopePull
Operatoractivatesbuttonin emergency situation to shut off power to machine
•Immediateresponse•Safeshutdownofmachine
process
•Notconsideredasafeguard•Requiresconsciousactofoperator•Limitsinjuryormachinedamage
but typically does not prevent it
•Overridesallotherfunctionsand operations
•ResetofE-stopdoesn’tinitiatemachine motion
•Buttonmustberedwithyellowbackground
•Shouldbelocatedateachoperation station
•Finalremovalofpowerdonebyelectromechanical components
•ANSIB11.19•NFPA79•ISO12100•IEC60204-1•ISO13850
*Thisrepresentsapartiallistofavailablesafeguards&devices.
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PhotoelectricsSensors
Fiber OpticSensors
Measurement & Inspection Sensors
Special PurposeSensors
Vision
Lighting &Indicators
Wireless
Safety Light Screens
Safety Laser Scanners
Safety Controllers & Modules
Safety Two-Hand Control Modules
Safety Interlock Switches
Emergency Stop & Stop Control
LIGHT SCREENS
LASER SCANNER
CONTROLLERS &MODULES
TWO-HANDCONTROL MODULES
INTERLOCK SWITCHES
E-STOP &CONTROL DEVICES
Locating a Safety Product
Solutions: Choosing and Locating a SafeguardWhen choosing a safeguard, ask yourself the following questions: 1)isitsafe,2)isitlegaland3)doesitmakesensefortheapplication.
Choosing a Safety Product
□ Who will use it?
□Howwilltheyuseit?
□Whathazardsareassociatedwithwhichtask?
□ What are the types of hazards?
□ Where will the safeguard be located?
E=Excellent A=Acceptable P=Poor X=NotAcceptable
Guarding Solutions M
aint
enan
ce $
Freq
uent
Acc
ess
Infre
quen
t Acc
ess
Loca
te C
lose
to H
azar
d
Long
Mac
hine
Sto
p Ti
me
Ergo
nom
ic
Visi
bilit
y
Mul
tiple
Ope
rato
rs
Gua
rds
Agai
nst E
ject
ed
Mat
eria
l
Comments
FixedHardGuard P P E E E P P E E•Limitedaccess•Limitedvisibilitytothemachine•Costlyforlargeareas •Costlytomaintainandfix
LockingGuard P P E E E P P E E
InterlockGuard P P A E A P P E E
Two-HandControl A A A A A A A P P •Onlyprotectsoperator(s)
High-ResolutionSLS E E P E P E E E X •Locateclosertohazard
Low-ResolutionSLS E E P E P E E E X •CostslessthanhighresolutionSLS
3-or4-BeamPerimeter E A A P A E E E X •Takeslessspacethan2-beam
2-BeamPerimeter E A A P A E E E X •Costslessthan3-or4-beam
SafetyMats P A A P A E E E X •Maintenance-intensive
Safety DistanceDs = K (Ts + Tr) + Dpf
Ds =SafetyDistance(inches) K =OSHAHand-SpeedConstant Ts =MachineResponse(sec) Dpf =DepthPenetrationFactor(inches)
Low-resolution two-beam safety grid(48"Dpf)
Low-resolution three- or four-beam safety grid(36"Dpf)
Standard-resolution safety light screen(3"to8"Dpf)
Horizontal sensing fields, including safety mats, horizontalsafetylightscreensandareascanningdevices(48"Dpf)
Hard guard or solenoid-locking guard
Standard or magnetic interlock hard guard interlockedguard opens away or laterally
fromthehazard(+/-Dpf)
Two-hand control (0"Dpf)
High-resolution safety light screen (1"to2"Dpf)
+ DpfDs
K * Ttotal
NOTE:Illustrationexamplesarebaseduponthedescribedsafeguardsbeingusedastheprimarysafeguardingdevice,allexampleshavingidenticalstoppingtime, andfollowinggenerallyacceptedindustrialengineeringpracticesthatarefoundwithinANSIB11.19safetystandard.
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EZ-SCREEN® (TYPE 4) EZ-SCREEN® (TYPE 2) GRIDS & POINTS
Requirements: Standards
Safety Standards Acronyms
ANSI: AmericanNationalStandardsInstitute
CE: MarkofEuropeanConformity
CEN: EuropeanCommitteeforStandardization
CENELEC:EuropeanCommitteeforElectrotechnical
Standardization
CSA: CanadianStandardsAssociation
EN: EuropeanNorm
IEC: InternationalElectrotechnicalCommission
ISO: InternationalOrganizationforStandardization
OSHA: OccupationSafetyandHealthAdministration
SEMI: SemiconductorEquipmentandMaterialsInternational
UL: UnderwritersLaboratory
SafetyandSafeguardingstandardsareminimumrequirements for product and machine design, manufacture, use and evaluation that guide the methods used to improve safety. Note: The following is not all inclusive and is provided for informationonly.Supersededdesignationsarecontained in parentheses.
General Requirements (A & B standards)
U.S.OSHA29CFR1910.212GeneralRequirementsforAllMachinesOSHA3071JobHazardAnalysisANSIB11.0(ANSIB11.TR3)GeneralRequirementsandRiskAssessmentOSHA29CFR1910.147TheControlofHazardousEnergy(lockout/tagout)ANSIZ244.1Lockout/TagoutofEnergySourcesANSI/NFPA79ElectricalStandardforIndustrialMachinery
International/EuropeanISO12100(ISO12100-1/-2andISO14121)GeneralPrinciplesforDesign-RiskAssessmentand
RiskReductionISO14118(EN1037)PreventionofUnexpectedStartUpIEC60204-1ElectricalEquipment ofMachines:GeneralRequirements
Safety and Safeguarding Design
U.S.ANSIB11.19PerformanceCriteriaforSafeguardingANSIB11.20IntegratedManufacturingSystemsANSIB11.24Transfer MachinesANSIB11.TR1ErgonomicGuidelinesANSIB11.TR5SoundLevelMeasurementGuidelinesANSIB11.TR6SafetyControlSystemsANSIZ535seriesSafetySigns,Tags/Labels,Symbols,ColorCodesandManuals/Instructions
International/EuropeanISO11161IntegratedManufacturingSystemsISO14119(EN1088)InterlockingDevicesAssociatedwithGuardsISO14120(EN953)Guards
ISO13849-1(EN954-1)SafetyRelatedPartsofControlSystemsISO13850(EN418)EmergencyStopDevicesISO13851(EN574)Two-HandControlDevicesISO13854(EN349)Minimum gaps to avoid crushing of parts of the human bodyISO13855(EN999)ThePositioningofProtectiveEquipmentISO13857(ISO13852/EN294,ISO13853/EN811)SafetyDistances[openings]-UpperandLowerLimbsIEC61508FunctionalSafetyofelectrical/electronic/programmableelectronicsafety-relatedsystemsISO62061FunctionalSafetyofSafety-RelatedElectrical, ElectronicandProgrammableControlSystems
Machine Specific Applications, Grouped by Type (C Standards) Mechanical Power Transmission ApparatusOSHA29CFR1910.219Note:ANSI/ASMEB15.1MechanicalPowerTrans-missionApparatushasbeenincorporatedintoANSIB11.0&ANSIB11.19.
Machine Tools- Mechanical Power Presses(Note:RefertotheANSIB11.xxseriesforadditionalMachine Tool standards)OSHA29CFR1910.217ANSIB11.1EN692
ConveyorsANSI/ASMEB20.1ISO9851
Industrial RobotsANSI/RIAR15.06ISO10218(EN775)
Injection Molding / Extruding (Rubber & Plastics)ANSIB151.xxseriesEN201EN1114-1EN289EN422EN1612
Mills and CalendersOSHA29CFR1910.261OSHA29CFR1910.216ANSIB28.1EN1417
PackagingANSI/PMMIB155.1EN415series
SemiconductorSEMISxxseriesSEMIS2SEMIS10
LasersANSIZ136.1ANSIB11.21
Turning Machines / Machining CentersANSIB11.22ANSIB11.23
These and other standards are available from:OSHADocuments:http://www.osha.gov AmericanNationalStandardsInstitute(ANSI): http://www.ansi.org NSSNNationalResourceforGlobalStandards:http://www.nssn.org/