An Pnozs S-Gate Guard Lock 1002297-En-03

Monitoring of a safety gate with guard locking in combination with a delay device
Product Type: Name: Manufacturer: Document Release Number: Release Date:
Safety gate, guard locking PNOZsigma, PSENmech Pilz GmbH & Co. KG, Safe Automation
03 9 August 2011
Application Note - No. 1002297_EN_03
14 pt 28 pt 42 pt 56 pt 70 pt 84 pt 98 pt 112 pt 126 pt 140 pt 154 pt 168 pt 182 pt 196 pt 210 pt 224 pt 238 pt 252 pt 266 pt 280 pt 294 pt 308 pt 322 pt 336 pt 350 pt 364 pt 378 pt 392 pt 406 pt 420 pt 434 pt 448 pt 462 pt 476 pt 490 pt 504 pt 518 pt 532 pt 546 pt 560 pt 574 pt 588 pt 602 pt 616 pt 630 pt 644 pt 658 pt 672 pt 686 pt 700 pt 714 pt 728 pt 742 pt 756 pt 770 pt 784 pt 798 pt 812 pt 826 pt
Pilz GmbH & Co. KG, Felix-Wankel-Strae 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de 2/17 Release 01 02 03 Date 2011-05-30 2011-05-31 2011-08-09 Changes Creation Adjustment data base Adjustment entry Chapter all 3.2.2 Application Note No. 1002297_EN_03 Monitoring of a safety gate with guard locking in combination with a delay device
Document Revision History
Exclusion of liability
We have taken great care in compiling our application note. It contains information about our company and our products. All statements are made in accordance with the current status of technology and to the best of our know-ledge and belief. However, we cannot accept liability for the accuracy and entirety of the information provided, except in the case of gross negligence. In particular it should be noted that statements do not have the legal quality of assurances or assured properties. We are grateful for any feedback on the contents.
August 2011
All rights to this publication are reserved by Pilz GmbH & Co. KG. We reserve the right to amend specifications without prior notice. Copies may be made for the users internal purposes. The names of products, goods and technologies used in this manual are trademarks of the respective companies.
Pilz GmbH & Co. KG, Felix-Wankel-Strae 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de 3/17 Application Note No. 1002297_EN_03 Monitoring of a safety gate with guard locking in combination with a delay device
Support
Technical help round the clock! Technical support is available from Pilz round the clock. This service is provided free of charge beyond standard business hours. Americas Brazil +55 11 8245-8267 Mexico +52 55 5572 1300 USA (toll free) +1 877-PILZUSA (745-9872) Asia China +86 21 62494658-216 Japan +81 45 471-2281 Korea +82 2 2263 9540 Australia Australia +61 3 95446300 Europe Austria +43 1 7986263-0 Belgium, Luxembourg +32 9 3217575 England +44 1536 462203 France +33 3 88104000 Germany +49 711 3409-444 Ireland +353 21 4804983 Italy +39 031 789511 Scandinavia +45 74436332 Spain +34 938497433 Switzerland +41 62 88979-30 The Netherlands +31 347 320477 Turkey +90 216 5775552
You can reach our international hotline on:
+49 711 3409-444 or mailto:support@pilz.com

Pilz GmbH & Co. KG Safe Automation Felix-Wankel-Strae 2 73760 Ostfildern, Germany Telephone: +49 711 3409-0 Telefax: +49 711 3409-133 pilz.gmbh@pilz.de E-Mail: Internet: www.pilz.com
Contents
1. Useful documentation .................................................................................. 5
1.1. Documentation from Pilz GmbH & Co. KG ............................................................................ 5 1.2. Documentation from other sources of information ................................................................. 5
2. Hardware configuration ................................................................................ 6

2.1. Pilz products ........................................................................................................................... 6 2.2. Hardware configuration .......................................................................................................... 6
3. Application Task ........................................................................................... 7

3.1. Description ............................................................................................................................. 7 3.1.1. Monitoring guard locking and safety gate (safe interlock) ........................................... 8 3.1.2. Safety assessment ...................................................................................................... 9 3.2. Functional safety .................................................................................................................. 10 3.2.1. Classification of the required PL (using the safety gate and guard locking device as examples) ............................................................................................................................ 10 3.2.1.1. Classification of the required Performance Level (PLr) for the safety gate ........ 10 3.2.1.2. Classification of the required Performance Level (PLr) for the guard locking device ............................................................................................................................... 11 3.2.2. Classification of the safety levels (PL and SIL) achieved .......................................... 12 3.2.2.1. Safety-related characteristics in accordance with EN ISO 13849-1 ................... 12 3.2.2.2. Safety-related characteristics in accordance with EN 62061 .............................. 13 3.2.2.3. Classification in accordance with EN 954-1 ........................................................ 13 3.3. Circuit diagram of the application ......................................................................................... 14 3.3.1. Circuit diagram 1/2 ..................................................................................................... 14 3.3.2. Circuit diagram 2/2 ..................................................................................................... 15
4. Table of figures ........................................................................................... 16
Abbreviations
SF FBL CCF PLr PL SIL Safety Function Feedback Loop Common Cause Failure Required Performance Level Performance Level Safety Integrity Level (DE: RFK Rckfhrkreis)
1. Useful documentation
Reading the documentation listed below is necessary for understanding this application note. The availability of the indicated tools and safe handling are also presupposed with the user. 1.1. Documentation from Pilz GmbH & Co. KG
No. 1 2 3 4 5 6 Description Pilz international homepage, download section Operating instructions PNOZ s3 Operating instructions PNOZ s9 Installation and Operating Instructions PSEN me1 Installation and Operating Instructions PSEN me2 Item No. www.pilz.com 21 395-6NL-xx 21 401-6NL-xx 0800000624 0800000423_en
1.2. Documentation from other sources of information

No. 1 2 Description Item No.
Pilz GmbH & Co. KG, Felix-Wankel-Strae 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de 6/17 No. 1 2 3 4 Description PNOZ s3 PNOZ s9 PSEN me1S/1AS PSEN me2/2AS Order number 750 103 750 109 570 000 570 200 Version Number 1 1 1 1 Application Note No. 1002297_EN_03 Monitoring of a safety gate with guard locking in combination with a delay device
2. Hardware configuration
2.1. Pilz products
2.2. Hardware configuration
Fig. 1: Hardware configuration
3. Application Task
3.1. Description The example shows the safe monitoring of a safety gate with guard locking. Two PSENmech (S1, S2) are used for monitoring the safety gate (safe interlock) and guard locking and they are evaluated by a PNOZ s3 (A1) and a PNOZ s9 (A2). A machine performs a dangerous movement within a protective housing (guard grid and safety gate). To ensure that the operator can enter the operating area only when there is no longer any danger, a delay device will be started at stop of the machine. This provides that standstill of the movement is achieved before the guard lock of the safety gate can be opened (delay time > maximum stopping time of the movement).
Fig. 2: Application: Safety gate with guard lock
The process is divided into the following main functions: Monitoring Safety Gate Monitoring Guard Locking
3.1.1. Monitoring guard locking and safety gate (safe interlock) To start the machine, the safety gate must be closed and the PNOZ s3 must be reset via the reset button (S3). The start button (S5) is then used to start the motor. The contacts at the contactors KM1 and KM2 are switched off by operating the stop button (S6). Input circuit S32 on the safety relay PNOZ s9 (A2) is closed as soon as the N/C contact (21-22) at KM1 and KM2 are re-closed. The safety contact (17-18) on contact expander module PNOZ s9 (A2) closes once the set delay time has elapsed. Guard locking on safety switch PSEN me1S/1AS (S2) can then be released via pushbutton S4. A contact on safety switch S2 is opened as soon as the guard lock is released by the pushbutton S4. The contacts on the two safety switches PSEN me2/2AS (S1) and PSEN me1S/1AS (S2) are opened as soon as the safety gate is opened. As a result the input circuit on the safety relay PNOZ s3 (A1) is interrupted and the safety contacts from A1 do open. Contactors KM1 and KM2 de-energise and the motor (M1) is cut off.
Feedback loop monitoring function: Safety gate The positive-guided N/C contacts on contactors KM1 and KM2 are monitored via safety relays feedback circuit S12-S34 of the safety relay A1.
Start/reset PNOZ s3 The safety relay PNOZ s3 (A1) can be started by pressing reset button S3 if: the safety gate is closed and the contacts on safety switches S1 and S2 are closed and the safety gate is locked and contactors KM1 and KM2 are de-energised. The contact expander module PNOZ s9 (A2) starts automatically if contactors KM1 and KM2 are de-energised.
Settings The terminator on the PNOZ s3 must be connected. The terminator on the PNOZ s9 must be connected. The operating mode selector switch (mode) on the safety relay PNOZ s3 must be set to "Monitored reset, falling edge with detection of shorts across contacts (In2-)". The operating mode selector switch (mode) on the contact expander module PNOZ s9 must be set to Delay-on energisation. The delay time on the safety relay PNOZ s9 is set using the time selector switch t[s] and the factor selector switch n.
3.1.2. Safety assessment The circuit of PNOZ s3 (A1) is redundant with built-in self-monitoring. The safety function A1 remains effective in the case of one component failure. The correct opening and closing of the safety function relays of A1 is tested automatically on each on-off cycle. The PNOZ s3 has an electronic fuse. Earth faults and shorts in the reset and input circuit on A1 are detected. The PNOZ s9 (A2) monitors its own output contacts. The safety function A2 remains effective in the case of one component failure. Earth fault in the feedback loop on A2 is detected. Earth fault in the input circuit on A2: The output relays de-energise and the safety contacts open. The PNOZ s9 has an electronic fuse. The safety relay PNOZ s3 (A1) can only be started if first the input circuit and the feedback loop of A1 closed and then the reset button S3 are closed and reopened. This avoids an unwanted reset before the input circuit is closed or as a result of the reset button being overridden. If the position of the operating mode selector switch (mode) on the PNOZ s3 (A1) is changed during operation, an error message will be triggered and the safety contacts on A1 will open. This fault condition can only be rectified by switching the supply voltage on the safety relay A1 off and then on again. If the position of the operating mode selector switch (mode) o the PNOZ s9 (A2) or the rotary switch for the time setting is changed during operation, an error message will be triggered; the safety contacts on A2 open. This fault condition can only be rectified by switching the supply voltage on the safety relay A2 off and then on again. The safety relay PNOZ s3 (A1) and contactors KM1 and KM2 must be installed in a single mounting area (control cabinet) in order to exclude a short across the output.
3.2. Functional safety 3.2.1. Classification of the required PL (using the safety gate and guard locking device as examples) The risk assessment for the unit is performed using the iterative process for risk reduction from EN ISO 12100. Based on this process, to achieve the necessary safety in our example a guard with a safety gate as an isolating safety device is built around the machine as a safeguard. Since the spatial situation means that the necessary safety gap between the safety gate and the hazardous machine movement cannot be achieved, however, there is still a residual risk associated with the overrun movement of the drive. This must be assessed by running the iterative risk reduction process again. An additional safeguard to reduce the remaining residual risk is added. This is realised by a guard locking device on the safety gate. The guard locking device prevents anyone going into the danger zone while the drive has not yet come to a standstill. The "guard locking device" safety function (SF) thus serves to reduce the residual risk of the "safety gate" SF and so is linked to this safety function. Based on the safety gate and guard locking device safety functions, the following example offers a possible classification of the required Performance Level (PLr) according to EN ISO 13849-1.
CAUTION: The user must produce a separate classification (for all SFs) specifically for his particular application. This may produce other values for the respective PLr.
3.2.1.1. Classification of the required Performance Level (PLr) for the safety gate Because of the velocity of the machine and the associated force, the severity of injury is classified as serious (S2). The frequency of exposure to the hazard is seldom (F1). Because of the high speed, avoidance of the hazard is scarcely possible (P2). This gives a PLr = d.
Fig. 3: Safety gate risk graph pursuant to EN ISO 13849-1
After the safety gate has been switched off, there is still a residual risk from the machine's overrun. A separate PLr classification must be performed for the safety function used for this purpose. 3.2.1.2. Classification of the required Performance Level (PLr) for the guard locking device Because of the velocity of the machine and the associated force, the severity of injury is classified as serious (S2). The frequency of exposure to the hazard is seldom (F1). Because of the abrupt reduction in velocity after disconnection by the safety gate switch, the hazard can be avoided under specific conditions (P1). This gives a PLr = c.
Fig. 4: Guard locking device risk graph pursuant to EN ISO 13849-1
Pilz GmbH & Co. KG, Felix-Wankel-Strae 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de 12/17 4 Characteristic data of contactors KM1/KM2: 2 3 Mission time: Operating interval (electromechanical components): Sensor S1/S2 Actuator KM1/2 Actuator me1 B10d 3 2 1 It must not be possible to open the guard locking device while the safe state has not been reached. (GUARD LOCKING DEVICE - standstill) A start must be prevented if the guard locking device is not closed. (GUARD LOCKING DEVICE - start-up) Dangerous movements must be stopped when the safety gate is opened; it must not be possible to restart if the safety gate is open. (SAFETY GATE) PL e PL c Sensor (PSEN me1 S1) Logic (PNOZ s3 A1) Actuator (contactors KM1, KM2) Sensor (PSEN me1/me2 S1, S2) Logic (PNOZ s3 A1) Actuator (contactors KM1, KM2) Application Note No. 1002297_EN_03 Monitoring of a safety gate with guard locking in combination with a delay device
3.2.2. Classification of the safety levels (PL and SIL) achieved 3.2.2.1. Safety-related characteristics in accordance with EN ISO 13849-1
No. Safety function Achieved Performance Level PL c Sensor (contactors KM1, KM2) Logic (PNOZ s9 A2) Actuator (me1/magnet S2) Safety-related parts of the control system
Prerequisites:
No. 1 Description Common cause failure (CCF): Identification Requirements are considered to be met (must be tested on implementation) 20 years one operation per hour one operation per hour one operation per hour 2,000,000
Please note the further requirements of EN ISO 13849-1, e.g. requirements for avoiding systematic faults.
Pilz GmbH & Co. KG, Felix-Wankel-Strae 2, 73760 Ostfildern, Germany Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de 13/17 4 Characteristic data of contactors KM1/KM2: 2 3 Proof test interval: Operating interval (electromechanical components): Sensor S1/S2 Actuator KM1/2 Actuator me1 B10d Dangerous failure rate 3 2 1 It must not be possible to open the guard locking device while the safe state has not been reached. (GUARD LOCKING DEVICE - standstill) A start must be prevented if the guard locking device is not closed. (GUARD LOCKING DEVICE - start-up) Dangerous movements must be stopped when the safety gate is opened; it must not be possible to restart if the safety gate is open. (SAFETY GATE) SIL 3 SIL 1 Sensor (PSEN me1 S1) Logic (PNOZ s3 A1) Actuator (contactors KM1, KM2) Sensor (PSEN me1/me2 S1, S2) Logic (PNOZ s3 A1) Actuator (contactors KM1, KM2) Application Note No. 1002297_EN_03 Monitoring of a safety gate with guard locking in combination with a delay device
3.2.2.2. Safety-related characteristics in accordance with EN 62061

No. Safety-related control function (SRCF): Achieved Safety Integrity Level SIL 2 Sensor (contactors KM1, KM2) Logic (PNOZ s9 A2) Actuator (me1/magnet S2) Subsystems
Prerequisites:
No. 1 Description Common cause failure (CCF): Identification = 2 % (must be tested on implementation) 20 years one operation per hour one operation per hour one operation per hour 2.000.000 65 %
Please note the further requirements of EN 62061, e.g. requirements for systematic safety integrity. 3.2.2.3. Classification in accordance with EN 954-1 Depending on the area of application and the regulations applicable there, under EN 954-1 this connection example applies up to category 1 for the guard locking device standstill monitoring SF up to category 1 for the guard locking device start-up SF up to category 4 for the safety gate SF
4. Table of figures
Fig. 1: Hardware configuration ...................................................................................................... 6 Fig. 2: Application: Safety gate with guard lock ............................................................................ 7 Fig. 3: Safety gate risk graph pursuant to EN ISO 13849-1 ....................................................... 11 Fig. 4: Guard locking device risk graph pursuant to EN ISO 13849-1 ........................................ 11
Recommended printer settings

Adobe Acrobat Reader ( www.adobe.com )
PDF-XChange Viewer ( www.tracker-software.com )

An Pnozs S-Gate Guard Lock 1002297-En-03

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

An Pnozs S-Gate Guard Lock 1002297-En-03

Uploaded by

Copyright:

Available Formats

Monitoring of a safety gate with guard locking in combination with a delay device

Product Type: Name: Manufacturer: Document Release Number: Release Date:

Application Note - No. 1002297_EN_03

Document Revision History

You can reach our international hotline on:

+49 711 3409-444 or mailto:support@pilz.com

2. Hardware configuration ................................................................................ 6

3. Application Task ........................................................................................... 7

4. Table of figures ........................................................................................... 16

1.2. Documentation from other sources of information

2.2. Hardware configuration

Fig. 1: Hardware configuration

Fig. 2: Application: Safety gate with guard lock

Fig. 3: Safety gate risk graph pursuant to EN ISO 13849-1

Fig. 4: Guard locking device risk graph pursuant to EN ISO 13849-1

3.2.2.2. Safety-related characteristics in accordance with EN 62061

Recommended printer settings

PDF-XChange Viewer ( www.tracker-software.com )

You might also like