AS/NZS 4024:1503 - Rexel Industrial Automation
Contents
1. Access DR 2 fa h 2 n Control Panel Station 2 Robotic Assembly Station 3 Load Position Loaded parts index to assembly station ig O MESSAGES Input Devices v GuardShield Logic Devices Click here to add device Output Devices Add vw Click here to add device lt n gt 4 35 PM a HF il do mW ul 4 11 08 2014 VALUED Products Services Solutions Safety Automation Builder mfgurator Powered by RAISE ane Sn CA Product CON igurator Powered by RAISE Export Operations EP Table SISTEMA SISTEMA Subsystem Configuration as Product Configuration Assistant rd x Rotate n Category Conditions and Diagnostic Coverage Category Conditions Check all Tub Washer Subsystem Channel 1 Device s Properties that apply for this device Device F Basic safety principles are being Category NO SELECTION used Conditions Welltric Check all that dn Well tried safety principles Select applied NO SELECTION being used 7 F A single fault tolerance is given SF 1 I evaluate F Accumulation of faults does not Diagnostic lead to a loss of the safety funciton d 8 Coverage 1 Measures against Common Cause Failure from ISO 13849 1 2006 ISO 13849 2 2003 Table F 1 Separation NO SELECTION O2. i i ease SS EIL NI mm E LLLII m A Successful Arc Test AD C o m Arc Resistant Equipment Considerations IEEE C3 20 200 guide for testing metal enclosed switchgear pu Switchgear ated Up to 38 kV for internal Arcing Faults 1 enclosed EEE Guide for Testing Metal Enclo R o expanded to include low voltage switchgear e Defines test criteria and assessment Defines Accessibility Level of equipment and outlines the levels of arc flash protection e Accessibility Level ratings set expectations of equipment arc resistance performance IEEE C37 20 7 2007 is a recognized industry standard that applies to MV and some LV equipment m Passing the Test e Passing an IEEE C37 20 200 test means Doors and covers do not open bowing allowed No parts are ejected No holes in the exterior in the applicable planes for the accessibility level 150 g m Cotton test indicators must not ignited or be perforated approximates typical industrial work clothes he grounding remain effective Safety Features Available for MCC Through the Door Viewing Windows High Visibility Yellow Door for Main Covers and Barriers Through the Door Network Connections Infrared Sightglass for Thermal Inspection Door Mounted Voltage Detection Fiber Optic DeviceNet Programmer SafeZone Laser Arc
3. Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Modern Safety Thinking ts a Culture It s a Process It s a design Philosophy tisa combination of people systems technologies and work habits tis a systematic approach Not a component approach For Machine and Process Safety it is a lifecycle From System Concept through Risk Assessment Verification amp Design Install Commissioning amp Validation Operations and Decommissioning Safety Specifications Drive the Safety Lifecycle Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation 4 TUV Functional Safety Training Copyright 2013 Rockwell Automation Inc All Rights Reserved 26 Rockwell Automation Functional Safety Training RA Safety Services TUV Functional Safety Training Authorised TUV Functional Safety Course Provider 1 Functional Safety Introduction he new standards regarding Functional Safety and relevant law and directives demand that people and organisations performing responsible accountable tasks during all life phases of a machine have to achieve and prove the required competencies In this training an introduction to the defined requirements regarding the design and the proof of Functional Safety of machines in respect to the current Standards
4. Safety Automation Builder Project Views File Operations Edit Operations E i TY go Layout Table Library Zoom New New Open Save m Print Help Paste Copy Cut Delete Rotate Export Operations B Table SISTEMA T ject Properties General Properties Name Tub Washer Description Tub Washer Safety project Notes Notes for Project Name Tu b W ashe r Layout Background Image Color Clear Language For Product Description 7 when available English Safety Questions Safety Risk Assessment and Safety Functions are required before proceeding Safety Automation Builder Project Properties Have you performed a Risk Assessment 7 Yes No Have you written a functional safety specification that outlines the required safety functions usw Have you determined the required performance level for each safety function DM Stub Pa te SAB is tool designed to help develop complete Seas Enter project data and safety requirements Please select page break display properties These will be used to display bd page break lines on the diagrams to assist in device placement Design a graphical layout of the safety soluti Printer settings will need to be manually adjusted for orientation when using Print button 4 13 PM 11 08 2014 adi EN Safety Automation Build
5. How does Lock Out Tag Out meet WHS Companies must have a documented risk position when dealing with the three areas within any business Live Electrical Work Confined Spaces Diving Whose responsibility is it to identify and implement Risk reduction Plans Company Officers for what is reasonably known WHEN PERFORMANCE MATTERS MOST What Is Lockout Tagout Complete Lockout STEP 1 STEP 2 STEP 3 Choose Device Choose Padlock Choose Tag and attach to energy and attach to device 2 and attach to padlock source to secure Lockout for communication DO NOT OPERATE P This lock tag may only be removed by Name Dept Date T y E 7 EE C 1 ex cl telah 1 ANN Ae ty A A P P wer jJ Do b lt re N d ky USA 1 77 LE 40 FAN 7 K NS if j Vv WU y Rm M G 7 7 a x ae Sa BRADY WHEN PERFORMANCE MATTERS MOST Benefits of Lockout Tagout v Provides a safer workplace while doing maintenance cleaning or repairs v Prevents accidents injuries LTIs and fatalities v Increases productivity and reduces equipment downtime and damage v Makes Workplace Safety Easy with the right systems and solutions v Lower premiums for self insured organisations and limits liability WHEN PERFORM
6. A short written report will be provided documenting the findings Why would you want a Safety Circuit Analysis To get a third party opinion that a safety circuit design conforms to the appropriate standards Especially appropriate for customers with less safety design experience Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Machine Stop Time Measurements RA Safety Services Machine Stop Time Measurements RA Safety Consultant will perform a physical measurement to determine the stop time of the machinery How long does it take the machine to reach a safe state Why would you want a Stop Time Measurement he stop time is used to determine what type of safeguarding techniques can be used as well as the appropriate mounting position For example how far away from the hazard does a light curtain need to be mounted in order to give the machine enough time to stop after the light curtain determines that something is approaching the hazard Machine Stop Time is a key component of the safety distance calculation Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Compliance Consulting e Rockwell Automation Safety Services include the following areas of Compliance Consulting Compliance audits ISO ANSI IEC CE OSHA NFPA CSA AS Functional Safety EN ISO 13849 1 and IEC EN
7. Safety Automation Builder Safety Automation n E ol X Project Views File Operations r Edit Operations r Export Operations 4 d F t EHE we Layout Table New Open Save Save As Print Paste Copy Cut Delete Rotate Table SISTEMA Project Layout Tub Washer A CONTROL PANEL GENERAL HAZARDS MECHANICAL HAZARDS M Station 2 Robotic Assembly v R ELECTRICAL HAZARDS Loaded parts index 5 Sta 2 S v THERMAL HAZARDS to assembly station v RADIATION HAZARDS v SUBSTANCE HAZARDS v OTHER HAZARDS Station 3 Load Position GUARDING FIXED MOVABLE GUARDING GUARDING ACCESS POINTS c f 5 Po Point Person T Ji 3 CS M m ca b Le 417 PM gt e UE PS MSN VALUED Products Services Solutions Safety Automation Builder SS Vas Safety Automation Builder Tut Project Views File Operations Edit Operations Export Operations Ped 613 T Ex E Ee p B Layout Table Library Bor New Open Save Save As Print Paste Copy Delete Rotate Table SISTEMA Project Layout Access Point Access Po Safety Fur actio Acces
8. WPR Test Lab 7 8 14 Documentation PL Category MTTFd DCavg CCF Blocks XPR Assembly Line 1 DR Tub Washer Category of subsystem zi SISTEMA Safety on PE E machinery control 4 V5SF SafetyFunction 1 3 Requirements of B and the use of well tried safety principles shall apply Safety related parts When a single fault occurs the safety Mainly characterized by structure LSB Licht Curtain C shall be designed so that 1 a single fault in any of these parts does not lead to a loss of the function is always performed Some but not systems i 9 safety function and 2 whenever reasonably practicable the single fault is detected all faults will be detected Accumulation of 4 SB E Stop Switch undetected faults can lead to the loss of the p wCH Channel 1 safety function b 4 F A b CH Channel 2 her p v Institut f r Arbeit SH Deutschen Geset 4 V5B Subsystem 1 p CH Channel 1 A tool for the evaluation of WCH Channel 2 safety on machinery control systems Requirements for the category An aid to the application of EN ISO 13849 1 Basic safety principles are being used Well tried safety principles are being used A single fault tolerance is given IPHONE MTTFd is Low or Medium or High MI DCavg is Low or Medium Institute for Occupational Safety Z The achieved score of the CCF rating is at least 65 and Health of the German Social Accident Insurance IFA
9. C1 O N O O O D O N C1 O N N O O O ISO 13849 2 2003 his part will remain current and unchanged EN 953 1997 1 2009 his part supersedes the 2006 version of part 1601 ISO 14119 2013 his part supersedes the 2006 version of 1602 pi part will remain current and unchanged his part Supersedes the 2006 version of part 1604 his part Supersedes the 2006 version of part 1701 his part Supersedes the 2006 version of part 1702 is part Supersedes the 2006 version of part 1703 his part supersedes the 2006 version of part 1704 4 O N O O N O 4 A LAB AB O e e N N N N AIR O O e e Co N NIN N N O O O O O ARR O A Oo D D sen o o D Oo o gt 4 O N N O KR NO O A ISO 13857 2008 his part supersedes the 2006 version of part 1801 and 1802 ISO 13854 1996 his part supersedes the 2006 version of part 1803 D gt I OIOI o o N N N N io gt gt ER 00 OO OIOI o o Q N N N NO NO OIOI o aja IBI OD EN 894 1 1997 A1 2008 his part supersedes the 2006 version of part 1901 l EN 894 2 1997 A1 2008 his part supersedes the 2006 version of part 1902 IEC 61310
10. Notes Layout Background Safety Questions Safety Risk Assessment and Safety Functions are required before proceeding Have you performed a Risk Assessment Yes No Have you written a functional safety specification that outlines the required safety functions Yes Have you determined the required performance level for each safety function No PLr e Yes Default System Performance Level A Printer Settings Please select page break display properties These will be used to display page break lines on the diagrams to assist in device placement Printer settings will need to be manually adjusted for orientation when using Print button J Safety Automation Bul Project Name Rockwell Automation lder Patent Pending SAB is a tool designed to help develop complete safety solutions Enter project data and safety requirements Design a graphical layout of the safety solution Select products according to safety requirements Export for evaluation in SISTEMA Open ProposalWorks to import and generate a Bill of Material Begin by filling out the Project tab to the left You must answer the Safety Questions to continue to the design To remove this screen use the options on the Project Tab Select a Layout Background using the Image button or for a blank layout use the Clear button 4 07 PM 11 08 2014 VALUED Products Services Solutions P Pr i
11. 2010 About SISTEMA Documentation reasoning F The SISTEMA software utility provides developers and testers of oo safety related machine controls 4 peer with comprehensive support in the MANIL ES v evaluation of safety in the context of SafetyFunction_1 EN ISO 13849 1 SISTEMA stands e for Safety on machinery control e Source e g standard A aa systems The tool enables you to E Stop Switch 800H FRX 8011 v CH Channel 1 The channels MTTFd has been cut from originally 2077 63 to 100 a For a channel 100 a is the maximum acceptable mean time to a dangerous failure W CHChannel 2 The channels MTTFd has been cut from originally 2077 63 to 100 a For a channel 100 ais the maximum acceptable mean time to a dangerous failure X ta li SISTEMA default library 5 04 PM 11 08 2014 M BF al JALUED Products Services Solutions Safety Automation Builder Summary e Safety Automation Builder makes your project easier Allows you to design your system layout and product selection in the one document Makes product selection less complicated Products Services Solutions 4 INSTRUMENTATION SAFETY SENSING ELECTRICAL SERVICES SOLUTIONS VALUED Products Services Solutions
12. A sae work conditiene when working on potentially ive electrical conductors as per NFPA TOE 120 141 to 8 slower flash rate is not an effective warning for workers Employers must also provide writen LOTO procedures elec and the corresponding training fat property incorporates between 15KV and 43KV Village detectors into Meir saty programs NFPA TOE Point towards window staan eae tee s oS In Stock 134 ENGINEERED PRODUCTS Inic Example Graceports No need to open panel doors for programming increases safety and productivity Can be configured with your choice of connector Port can be powered with Australian 240v outlet Just let us know what configuration you require PRODUCTS Inic Example Graceports IR Windows Save Time and Stay Safe X rm AN 0 10 v ME BEL E Q Note the reduced levels PPE due to the equipment being in a closed and guarded condition Permanent Electrical Safety Devices WWW graceport com sales grace eng com WWW graceport com SAFES D reverse Getting The Right Lens Material Application Consideration Is the window for indoor or outdoor use Subjected to severe environmental conditions such as UV Exposure Sea water Humidity Acids or alkalis Rain Extreme temperatures Snow Vibr
13. SensaGuard RFID coded 9 Rockwell Automation Join our Safety Community Rockwell Automation Safety Portal http discover rockwellautomation com Safet RAGuard Cutter http www twitter com raguard E Safety Automation Forum group Linked in http www linkedin com qroups qgid 1950912 facebook Rockwell Automation Safety Solutions November 19 20 2014 Anaheim CA www safetyautomationforum com Copyright 2013 Rockwell Automation Inc All Rights Reserved TINK SONE Questions fiy Follow ROKAutomation on Facebook amp Twitter Connect with us on Linkedin Rockwell www rockwellautomation com Allen Bradley Rockwell Software Automation Rev 5058 CO900D Copyright 2013 Rockwell Automation Inc All Rights Reserved ie2 BRADY WHEN PERFORMANCE MATTERS MOST Lockout Tagout Essentials Session Overview What is Lockout Tagout Regulatory Responsibilities for Energy Isolation Guidelines for Effective Energy Isolation Practical Solutions for Energy Isolation What Is Lockout Tagout PURPOSE To protect workers involved in the maintenance and servicing of equipment from the dangerous effects of hazardous energy TAGOUT Placement of a tag on an energy isolating device The isolation point visually shows that the energy being controlled and may not be operated until the tagout device is removed 4 re NC
14. With the 440G LZ solid state design it can be connected in series with other devices such as Light Curtains and SensaGuard switches while maintaining a PLe rating Exceeds requirements of ISO TR 24119 referenced in the new EN ISO 14119 2013 standard Short circuit protection E Overload protection Cross fault channel to channel detection Designed to switch DC powered devices Supports switching of up to 200 mA Copyright 2013 Rockwell Automation Inc All Rights Reserved Copyright 2012 Rockwell Automation Inc All rights reserved 126 Rockwell Automation Key Features RFID door target Q Solid state contacts Identical profile to standard TLS GD2 d lt TUV certified to Performance Level to EN ISO 13849 1 A Available in power to release or power to lock format v Easy wiring with M12 8 pin quick disconnect Easy to connect Visual diagnostic Copyright 2012 Rockwell Automation Inc All rights reserved 127 Rockwell Automation RFID Door target Uniquely coded RFID door target and a built in inductive sensor inside the switch signals the door position to the internal microprocessor Mounts close coupled to the fully flexible actuator Based on proven SensaGuard technology Automatic learn process at startup can choose either one time or multi time l
15. some type of monitoring inteface Relay Controller PLC 24V DC Com Copyright 2012 Rockwell Automation Inc All rights reserved Rockwell Automation Selecting a Safety Interface 1 How complex is your safety system 2 What type of input devices 3 What type of outputs are required 4 What category stop is required 5 What is the required Performance Level 6 Do you require communications Copyright 2012 Rockwell Automation Inc All rights reserved 105 Rockwell Automation Copyright 2012 Rockwell Automation Inc All rights reserved 106 Rockwell Automation What is the complexity of system 1 Zone 1 3 Zones 4 Zones GSRX CSRx SmartGuard SmartGuard MSRx GuardLogix Copyright 2012 Rockwell Automation Inc All rights reserved Rockwell Automation What Type of Inputs do you Require 2 NO Contacts 1 NO 1 NC Contact Quadrature te 0 4 We at TIT af 6 SE wae SSS SS Solid State OSSD Mat Short Circuit Mg A 2 Hand Control 500ms C O Edge Circuit Resistance Inductive Prox Hi Freq Copyright 2012 Rockwell Automation Inc All rights reserved 108 Rockwell Automation What types of output devices Contactors Motor Drives Motion Drives Load Type Output Type AC Load
16. 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation 3 Machine Safety Functional Safety Copyright 2013 Rockwell Automation Inc All Rights Reserved 21 Rockwell Automation What Is Functional Safety Functional Safety FS of machinery are those parts of the machine control system that ensures the safety of personnel and machinery An example of Functional Safety is a simple interlock circuit r e gt awe Claw a gt uuu 24 e E The Safety Function could be described as follows The Safety Gate is opened the relay detects the SensaGuard outputs going low and de energises the contactors thus stopping the associated motor K1 re Li L2 L3 1 sce Aux Copyright 2013 Rockwell Automation Inc All Rights Reserved le Er Se 9 m 4 070 1980 A Legacy Initial High Productivity Lower e Low Safety Medium No Assessment Ji Hazard Copyright 2013 Rockwell Automation Inc All Rights Reserved 1 Hazard or Risk Assessment traceable to changes ON CO SSS Ev ERS ER 5 amp Improve j REY WE 5 Maintain N A Ld ae 4 Installation amp Validation 2 Functional Requirements of Safety control accidents 42 traceable to design amp spec stage
17. 3 Ed 2 0 EN 981 1996 A1 2008 his part supersedes the 2006 version of part 1906 his part supersedes the 2006 version of part 1907 NES Oo D gt O lt j o Oo o ALA Copyright 2013 Rockwell Automation Inc All Rights Reserved 8 Rockwell Automation 2 ASINZS 4024 1503 ISO 13849 2006 Copyright 2013 Rockwell Automation Inc All Rights Reserved 9 GENERIC Electrical IEC EN AS 61508 Control Systems Top level standard IEC AS 61511 Safety Integrity Level MACHINERY Electrical IEC EN AS 62061 2006 Control systems MACHINERY Control Systems AS NZS 4024 1503 ISO 13849 1 2006 Ponomance All technologies Level Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell AS NZS 4024 1 5053 or AS 62061 2006 Automation Both address the functional safety of machinery control systems ASINZS 4024 1503 AS 62061 2006 Can the system be designed simply using the designated architectures Are there complex safety functions e g depending on complex logic decisions Will the system include technologies other than electrical e g Hydraulics Pneumatics Will the system require validation to SIL e g Safety PLC Safety PAC IF the answer to either question is YES IF the answer to either question is YES THEN select AS NZS 4024 1503 THEN select AS 62061 2006 You ca
18. MESSAGES Station 3 Load Position Input Devices v 4401 0960 Modi Delete A 800H FRXTSOOX Modify Copy Delete 30 5mm Type 4 4X 13 2 Pos PB Illum Push Drag Device Pull Twist Mushrm Hd No Contacts to Layout Logic Devices Add Click here to add device 4 gt om F a p fc lo EN X 4 41 PM pe Ch uil LA a 11 08 2014 VALUED Products Services Solutions Safety Automation Builder 8 Product onfigurator Powered by RAISE SISTEMA Subsystem Configuration Product Configuration Assistant Rockwell Automation Accept Validate Cancel Reset Undo fedo IC DUI CVE B E drainage of compressed air e g in compliance with the component manufacturers requirements concerning purity of the pressure medium Electric systems Has the system been checked for electromagnetic immunity e g as specified in relevant standards against CCF For combined fluidic and electric systems both aspects should be considered Total Points Total Points TO Minimum Requirement 65 O MESSAGES Environmental F Prevention of contamination and electromagnetic compatibility EMC against CCF in accordance with appropriate standards Fluidic Systems filtration of the pressure medium prevention of dirt intake drainage of compressed air e g in c
19. and guidelines are described and discussed in detail TUV 2 Functional Safety FS Engineer Certification The 4 5 days are classroom instructions that provides detailed information and examples discussions for understanding and mastering the requirements of IEC 62061 ISO 12100 ISO 13849 1 amp 2 IEC 60204 and other relevant machine functional safety standards There is an optional TUV Functional Safety Certification examination scheduled on the Friday morning following this course This optional exam must be passed to receive the TUV Functional Safety Engineer certification The training can also be attended without taking the exam Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Functional Safety Training RA Safety Services TUV Functional Safety Training TUV 3 Functional Safety FS Technician Certification NEW for 2014 The 3 days are classroom instructions that provides detailed information and examples discussions for the understanding and mastering the requirements of IEC 62061 ISO 12100 ISO 13849 1 amp 2 IEC 60204 and other relevant machine functional safety standards There is an optional TUV Functional Safety Certification examination scheduled on the last day morning following this course This optional exam must be passed to receive the TUV Functional Safety Technician Certificate The training can also be attended without taking the
20. exam Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Agenda 9 safety Services Copyright 2013 Rockwell Automation Inc All Rights Reserved 29 Rockwell Automation Value of RA chine Safety Services Help customers gt with current and emerging standards by providing Consulting Services for safety critical controls Our solutions can help customers Reduce lost time accidents Enhance work place Safety Reduce unplanned downtime Improve employee morale These solutions ultimately deliver enhanced productivity ERES xj SS RES SS RES NT ESS Kw SS Co OR A Ru en i m ey CLR LR ae PRES Sees ey e ss SSS vo Lo f Inc All Rights Reserved Copyright 2013 Rockwell Automation Rockwell Automation Machine Safety Seminar RA Safety Services Machine Safety Seminar One day on site off site training program The starting point for Machine Safety Topics include Risk Assessment process training Machine guarding requirements Safety circuit architectures Presence sensing safety device applications Standards and their application Why would you want a Machine Safety Seminar Looking for a starting point on the implementation of modern machine safety techniques Copyright 201
21. excess of 40 callcm Alternative controls shall be implemented e Purchase appropriate PPE ee UN m Examples of PPE PPE Categories 1 PPE Categories 3 amp 4 m SS 3 ARC FLASH ANALYSIS AND MITIGATION CUSTOMER APPLICATION Arc Flash Analysis report conducted at customer on the Central Coast NSW to provide the onsite inspection analysis and report creation Site inspection for 1 day further information gathering delivered a comprehensive report Report covered Short Circuit Calculations Equipment Evaluation Miss co ordination of Protective Devices and Arc Flash Analysis e Once the risks have been identified then actions that can be taken to mitigate the risks e Mitigation Report This will present a road map for them to undertake actions to reduce the Arc Flash Hazards by revised protective device settings additional of new protective devices implementation of a administrative controls use of remote switching etc e 11 ince Key Take Away Arc resistant equipment offers a higher level of safety to personnel e Ensure that arc resistant equipment has been tested to relevant Standards e Avoid modifications to the standard tested designs e Arc resistant equipment requires some additional engineering steps to successfully implement e Arc resistant equipment requires more diligence for proper installation o can help you with A
22. rooms plumbing etc Valve WHEN PERFORMANCE MATTERS MOST Lockout Tagout Essentials Summary gt The purpose of Lockout I agout is to protect workers from the dangerous effects of hazardous energy Brady makes Workplace Safety Easy by helping customers manage their workplace safety obligations Use the Regulations amp Standards reference to be familiar with the operational benchmark your customer is working towards An isolation procedure should serve as a checklist approach to facilitate an effective program WHEN PERFORMANCE MATTERS MOST Inaco Arc Flash Dynamics Standards Sam Distributor Field Installations and Safety Plan ES Presentation by David Cassidy 1 Arc Flash Dynamics Characteristics 2 Arc Flash Related Standards 3 Field Installations of Arc Flash Contain Equipment 4 Safety Plan amp Mitigation of Arc Flash Hazards m Arc Flash Dynamics m So what is an Arc Flash Simply An arc flash is a short circuit through the air In many instances the arc is initiated by the actions of a person Flash Dynamics a A i c N Intense Heat Sound amp Pressure Waves Expelled Copper Vapors Expansion rate 67 000 times Intense Light INACO m EN automation ost hcl m Figures are Frightening Arc temperatures can rea
23. safety function and whenever reasonably practicable the single fault is detected use of well tried safety principles shall apply Safety related parts shall be designed so that a single fault in any of these parts does not lead to a loss of the safety function and the single fault is detected at or before the next demand upon the safety function but that if this detection is not possible an accumulation of undetected faults shall not lead to the loss of the safety function AS 4024 1501 System behaviour When a single fault occurs the safety function is always performed Some but not all faults will be detected Accumulation of undetected faults can lead to the loss of the safety function When a single fault occurs the safety function is always performed Detection of accumulated faults reduces the probability of the loss of the safety function high DC The faults will be detected in time to prevent the loss of the safety function CKO yy wz vu nu K Well Automation Inc All Rights Reserved ASINZS 4024 1503 Principle used to achieve safety Mainly characterized by structure Requirements Mainly characterized by structure The New Additional Requirements MTTFd Mean Time to Dangerous Failure Low 10 Years 2 _ Medium 10 30 Years MET ALES 1 High 30 100 Years MTTFac2 DC Diagnostic Coverage Ratio of Detected Dangerous Failur
24. 201 ISO 12100 1 EN 292 1 General principles Basic terminology and methodolo 1SO12100 2 EN 292 2 xrinciples Technical 1301 ISO 14121 EN 1050 Risk assessment Principles of risk assessment 1302 Risk assessment reduction of risks to health and safety from hazardous substances emitted by machinery Principles and specifications for machinery manufacturers Ergonomic principles Design principles Terminology and general principle Design of safety related parts of control systems General principles ISO 13849 2 EN 9542 Design of safety related parts of control systems V alidation ISO 14120 EN 953 Design of controls interlocks and guarding Guards General requirements for the design and construction of fixed and movable euards Interlocking devices associated with uards Principles for design and selection Design of controls interlocks and guards Prevention of unexpected start up ISO 13850 EN 418 Design of controls interlocks and guarding Emergency stops Principles for design Rockwell Automation Copyright 2013 Rockwell Automation Inc All Rights Reserved 6 summary of AS4024 2014 Updates Keeping Australia and New Zealand in line with International standards the AS NZS series of machinery safety standards has been revised and released July 2014 The parts are available individually awaiting the release of the application guide part 1100 later this year The par
25. 2013 Rockwell Automation Inc All Rights Reserved 18 Rockwell Automation Two Types of Failure Data Mechanical or Electromechanical Failure is dependent on load and operating frequency B10 Number of operations where 10 of the sample has failed to danger Electronic Failure is dependent on temperature and time MITF or PFH Mean time to failure dangerous e Probability of dangerous failure per year MITF 1 must convert years to hours Need to convert these to one data type to complete the analysis We convert B10 to MI TF Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Common Cause CCF Failure B factor Common Cause Failures CCF result from a single cause and affect more than one channel One part of the failures in both channels reveals as CC failures that means due to one cause a failure in one channel is followed by the same failure in the other channel either at the same time or some time later Common causes are External stress as excessive temperature high e m interferences e g Wireless devices motorized devices Systematic design failures due to the high complexity of the product or missing experience with the new technology No spatial separation between channels use of common cables on one PCB etc Human errors during maintenance and repair Copyright
26. 3 Rockwell Automation Inc All Rights Reserved Rockwell Automation Safety Assessments Rockwell Automation Machine Safety Services include the following Safety Assessments Team based risk assessments Safety audits Hazard assessments 4 4 EE oS gt 4 b jj Copyright 2013 Rockwell Automation Inc All Rights Reserved Modular Assessments Identifies Primary Hazards Provides a scalable solution to help save Identifies guarding hazards for immediate plant actions One Page Report identifying hazards and Risk in rating only Provides customers with a method of categorizing amp prioritizing machines Conformity audits that analyse guarding LOTO e stops and circuit analysis and provides a list of complying amp non complying machines to be assessed Assessment amp Estimate Most common provides report amp estimates to develop safety plans Assessment led by RA Consultant limited customer involvement Report per standard Y Identification of primary hazards tasks List non compliance issues v Risk In Risk Out Rating v Mitigation Guarding and Controls recommendations Prioritized recommendations for safety improvements v Photograph of critical identified hazards based on customer approval Cost estimate per machine Copyright 2013 Rockwell Automation Inc Al
27. ANCE MATTERS MOST Increase Safety amp Lower Risks with Brady Customers are focused on Earning more revenue The value we offer is delivering solutions that protect safety obligations Sa BRADY WHEN PERFORMANCE MATTERS MOST Risk Control Hierarchy HIGHEST Level 1 MOST Eliminate the hazards Level 2 Substitute the hazard with something safer Isolate the hazard from people Reduce the risks through engineering controls Reliability of control measures Level 3 Level of health and safety protection Reduce exposure to the hazard using administrative actions LOWEST LEAST Use personal protective equipment Source Safe Work Australia Code of Practice How to Manage Work Health and Safety Risks December 2011 N WHEN PERFORMANCE MATTERS MOST When is Lockout Tagout Required Whenever a worker performing service or maintenance may be exposed to any form of hazardous energy Rule of thumb is to use Lockout Tagout whenever A machine guard must be bypassed gt A worker must place any part of his body is a danger zone or point of operation WHEN PERFORMANCE MATTERS MOST Lockout Tagout Industry User Groups Manufacturing Food amp amp Processing D AS Beverage Healthcare WHEN PERFORMANCE MATTERS MOST Australian Regulations amp Standards What you need to know and do to be compliant with current regulations www 53
28. AS 62061 e CE Mark Conformance Lockout Tagout compliance North America Conformance audits Safety protocol assessments P p Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Validation Services e Rockwell Automation Safety Services include the following Validation Services Safety system validation and design reviews Safety circuit analysis Machine stop time and safety distance calculations Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Installation and Production Services Rockwell Automation Machine Safety Services include the following Installation and Production Services Project management Material procurement RA products Third party products e g hard guarding Installation assembly services otart up assistance Factory acceptance Field support services A EET Preventative maintenance programs Production floor safety system support Copyright 2013 Rockwell Automation Inc All Rights Reserved Integrated Safety Architecture t Stratix 8000 EtherNet IP CompactLogix nS NS D A RE RER BL fir ig s PanelView Plus on SmartGuard 600 POINT Guard 1 0 Bret GuardShield re er
29. BRADY WHEN PERFORMANCE MATTERS MOST Australian Regulations amp Standards Jurisdiction Application Regulations amp Standards National Electrical AS NZS 4836 2011 Safe working on or near low voltage electrical installations and equipment Specifies a minimum set of procedures safety requirements and recommendations to manage the hazards associated with electricity National Machinery AS 4024 1603 2006 Safety of machinery Design of controls interlocks and guards Prevention of unexpected start up This Standard includes the specific requirement for all isolated energy sources to be locked to ensure that it is not possible for somebody to inadvertently re energise equipment that has been isolated NSW ACT QLD Workplace Safety Work Health and Safety Regulations 2011 SA TAS NT Outlines specific requirements pertaining to General Electrical Safety in Workplaces and Energised Electrical Work A PCBU must ensure electrical work is not carried out while equipment is energised Mining Coal Mining Safety and Health Regulation 2001 Part 4 Electrical activities equipment and installations Part 10 Plant Outlines the requirement for standard operating procedures for safety and controlling risks of unplanned energy release Mining Electrical Engineering Safety Electrical Isolation r Provides guidance material for mine operators in the development of electrical safety standards Australian Regulations amp Stan
30. Detection Arc 193 DNCT Scanner Clamping Systems m Arc Resistant Equipment Considerations o Significant deviations to cabinet design may not be possible if arc resistant integrity is to be maintained oome typical options may not be available More Stringent Installation practices Field modifications must be approved by the manufacturer You don t want to compromise the equipment s ability to control an arc flash event it IS Critical to maintain the arc resistant Capability of arc resistant equipment as purchased m Installation Considerations o Where should the energy from an arc flash be directed o An area inaccessible to personnel and no flammable materials are present e Venting Externally is generally preferred with a barrier used for weather amp vermin protection Ifthe arc gases are released into a control room it must be designed to withstand e Overpressure up to 15 20 psi on a transient basis effects of hot gases and flames as they are released into the room i e non flammable construction materials are required Special ventilation may be required 1 Arc Flash Characteristics Dynamics 2 Arc Flash Related Standards 3 Field Installations of Arc Flash Contain Equipment 4 Safety Plan amp Mitigation of Arc Flash Hazards m The Importance of Arc Flash Safety Plan Prevent personal injuries e Prevent potential loss to
31. Electromechanical Relay DC Load High Current Pneumatic Valves Hydraulic Valves DC Load Low Current Solid State Lasers Thermal Other Copyright 2012 Rockwell Automation Inc All rights reserved Rockwell Automation What category of stop Is required Cat 0 Immediate removal of power coast to stop Cat 1 Brake and then removal of power Cat 2 Stop with power left to actuators Stop Category Output Timing 0 Immediate 1 Immediate and Off Delay 2 Not used for Safety Is other delay timing required Is a jog function required Copyright O 2012 Rockwell Automation Inc All rights reserved Rockwell Automation What is the PLr PLd SIL 2 PLe SIL 3 Input devices can be cascaded Electromechanical devices must be connected directly to relay Two channels in one interlock uu Some self monitoring input Monitoring where practicable devices can still be connected in series for example SensaGuard Redundant outputs must be monitored Copyright 2012 Rockwell Automation Inc All rights reserved Rockwell Automation Are Communications Required Most safety systems use an auxiliary status signal or contact to communicate ON and OFF status to the machine control system Generally communications are only available with electronic programmable controllers GSR Roadmap to in
32. Rockwell Automation Authorised Distributor Allen Bradley Rockwell Software Machine and Plant Safety Seminar m Agenda 1 Machine Safety Standards 9 00 9 30 2 Lockout Tagout 9 30 10 00 3 Arc Flash 10 00 10 30 5 Safety Tools 11 15 11 45 TINK SORTE Functional Safety Wayne Pearse safety Consultant FSExpert TUV Rheinland Machinery FSEngineer TUV Rheinland Machinery Rockwell Allen Bradley Rockwell Software Automation Rev 5058 CO900D Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation 1 AS NZS 4024 2014 Update 2 ASINZS 4024 1503 ISO 13849 2006 3 Machine Safety Functional Safety 4 TUV Functional Safety Training 9 safety Services Copyright 2013 Rockwell Automation Inc All Rights Reserved 4 Rockwell Automation 1 AS NZS 4024 2014 Update Copyright 2013 Rockwell Automation Inc All Rights Reserved 5 AS4024 2006 AS4024 2006 was made up of 26 parts based on International Standard The new AS 4024 1 2006 Safety of machinery standard The new AS 4024 1 2006 is basically made up of these 26 International Standards The list below shows the equivalent International Standards AS 4024 1 2006 Equivalent Title Part No ISO IEC EN Standard Safety of machinery 1070 Terminology General 1
33. S C Safetv Contactor 12A 24V DC w Drag Device 4 48 PM a Me HF LEE 11 08 2014 VALUED Products Services Solutions Safety Automation Builder ij SISTEMA Safety Integrity Software Tool for the Evaluation of Machine Applica 1 6 eee ae File Edit View Help New Open 8 Save amp Close Project iJ Library P Report Help Wizard What s This fn ne Project Y IFA Help gt WPR Test Lab 7 8 14 e Documentation Safety functions Back Forward Prin XPR Assembly Line 1 p XPR Tub Washer There are messages with red status listed for this project or it s subordinate basic elements These point out either some unaccomplished conditions or inconsistencies SISTEMA Safety on machinery control systems Project name Tub Washer Project file name C Users david cassidy Desktop Tub Washer 11 8 14 ssm Y A Last change 11 08 2014 Institut f r Arbeit _ Checksum Deutschen Geset Author david cassidy A tool for the evaluation of Dangerous point machine INA255510721 safety on machinery control systems Home folder for standards Standards Home folder for documents Documents m An aid to the application of EN ISO 13849 1 Documentation SISTEMA Help v1 1 2 Institute for Occupational Safety and Health of the German Social Accident Insurance IFA 2010 About SISTEMA The SISTEMA soft
34. Safety Light LE Curtain E E Ensign3 z Hinge E 1005 it 1 ES E E Stop o Servo Motors 5 Contactor 440 or lie Enabl ifeli MEA pns CompactBlock Guard 1 0 Pull Switch vesci La Mute Right Sight Lamp i E Photo Eyes Proximity Sensors Elf Safety E with 8790 V Cable Interlock Switch LS 700 Safety Control Relays eem On Machine ArmorBlock Guard 1 0 DeviceNet i 8 CompactBlock n m i TE Pte 1 0 ArmorPoint 1 0 E Stop s mc ArmorStart with PowerFlex 70 eee E 2 2 4 T Safety Monitor With DriveGuard RO TET a 440 isis FORT Enable Motor Switch Horn m z Safety Safety Limit Interlock Proximity Sensors Elf Safety Switch Switch with 8790 V Cable Interlock Switch MatGuard pressure sensitive safety mat system AE Kinetix 6000 amp 6200 with GuardMotion non contact interlock switch Rockwell Automation Stratix 8000 CIP Safety on EtherNet IP POINT Guard 1 0 B u 1783 ETAP Kinetix 6500 with advanced safe speed control Servo Motors PowerFlex 750 series AC Drive with advanced safe speed control PanelView Plus SafeZone MultiZone Safety Laser Scanner a CompactBlock Guard I 0 KI Safedge Pressure sensitive edge strip
35. Ww00 44 552 62 34 522 12 MSR Q uei ut va v2 34 9 0110 4 32X 9 Programmable with Drive Explorer 1 Pet Multi axis applications 13 45 9 57P ee _ 8 Diagnostics LED LI otop Category 0 1 2 2 x Encoder Input TTL or Sin Cos Copyright 2013 Rockwell Automation Inc All Rights Reserved 115 Rockwell Automation Highlight GuardMaster Safety Relay Platform for future Safety Relay development 2012 Control Engineering Engineers Choice Award 22 5mm housing for 2 x dual channel inputs Configuration amp zoning via selector switch 7 x modules consolidate 85 of MSR applications Sl Single Input DI Dual Input Relay Out DIS Dual Input OSSD Out Cl Terminal Layout as MSR EM Expansion Module Expansion Module Delayed Outputs GLP Prox Monitor for Safe Stop Copyright 2013 Rockwell Automation Inc All Rights Reserved 116 Rockwell Automation Highlight GuardMaster Safety Relay Universal Inputs Supports numerous sensor types such as E otops interlock switches light curtains and mats Global e stop Zone 1 Zone 2 Zone 3 Automatic enabling of cross loop monitoring M M Logic Simple AND OR logic between stand alone units via single wire cascading AND AND logic combination of input devices on dua
36. ation SS ud Permanent Electrica afety Devices WWW graceport com sales grace eng com www graceport com vf S N WITHOUT IT Hey Burnie it says here that frying is bad for your health GRACE ENGINEERED PRODUCTS Inic d 1 Automati four yasin Authorised Allen Bradley Rockwell Software Committed to exceeding our customers expectations Products Services Solutions Products Services Solutions Rockwell Automation Safety Automation Builder David Cassidy Safety Automation Builder ae Rockwell Automation Safety Automation Builder is a free tool that will allow you to Enter a project and safety requirements Design a layout for the solution Select Products according to safety requirements Export the document to Sistema Open Proposal Works and generate a BOM Products Services Solutions Safety Automation Builder Lets get started IT Safety Automation Project Views File Operations Edit Operations Export Operations gt B E a out Table Library Zoom Save Sav A Help Paste Copy rs Delete Rotate Table SISTEMA te Layout Properties General Properties Name Project Name Description Description for Project Name Notes for Project Name image color ear eee Engish when available
37. cautionary measure Does not utilise Incident Energies to select HRC amp PPE ee AS NZS 4836 2011 TABLE 9 2 GUIDE TO THE SELECTION OF PERSONAL PROTECTIVE EQUIPMENT CURRENT EXCEEDING 100 TASK Switching isolating removing fuses or CURRENTS UP TO AND INCLUDING 100 A Footwear Protective clothing Eye protection Gloves if required Hearing protection if required Safety helmet if required A AND UP TO AND INCLUDING 400 A Footwear Protective clothing Eye protection Gloves Hearing protection if required Safety helmet if required Respiratory CURRENTS EXCEEDING 400 A Footwear Protective clothing Eye protection Gloves Hearing protection if required Safety helmet if required Respiratory links Respiratory protection if required protection if required protection if required Footwear Protective clothing Eye Se Isolation Footwear Protective clothing Eye protection Gloves Arc flash suit and Footwear esu clothing Eye ificati protection Gloves Hearing hood if required Hearing protection Gloves Face shield Arc verification protection if required Safety protection if required Safety iuh dors bear testing or fault helmet if required Respiratory helmet if required Respiratory SUE lif re T finding protection if required protection if required Face shield y ae if required Respiratory protection if required E orar dici pras ey Footw
38. ch software Intuitive software simplifies configuration Restart mr c5 c f vw Ww vA ASE 83 gt 4 v T Bb D 9o 6 5 3 SE 6 Y PUBLIC INFORMATION Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Guardmaster 440C CR30 Safety Relay 2080 Plug in Support 2080 IQ4OBA4 plug in for expansion 1 0 otandard Input Expansion Use standard inputs for standard Q signals such as circuit resets Reset Feedback Muting feedback monitoring or muting sensors Monitoring Sensors otandard Diagnostics and auxiliary contacts of series wired safety devices and share with PanelView Component terminals Use standard outputs to drive indicator LEDs or send gate unlock commands y Expansion I O with no impact to panel footprint PUBLIC INFORMATION Copyright 2013 Rockwell Automation Inc All Rights Reserved Guardmaster 440C CR30 Safety Relay Single Wire Safety Support Rockwell Automation Supports Single Wire Safety for easy integration of GSR relays Add Safety Relay Outputs Add multiple dry contact outputs by utilizing GSR EM Expansion module while only consuming a single safety output configured for Single Wire Safety Connect Upstream GSR Relays a e Expand inputs and functionality using GSR relays by connection through Single Wire Safety PUBLIC INFORMATION C
39. ch up to 20 000 C 4 times the temperature on sun s surface Pressure Waves can snap the heads off 10mm bolts and burst ear drums Sound pressure levels greater than 140dB louder then a jet Metal shrapnel flying 1 100 km per hour 10 000 Amp arc blast at 480 volts is equivalent to approx 8 sticks of dynamite Clothing can be ignited several meters away LL m Bolted Fault vs Arc Fault Bolted faults Low impedance and high current Energy is contained by the conductor bus or cable Cleared quickly by circuit breakers or fuses Inst Arcing is confined within the circuit breaker or fuse Relatively low safety risk to personnel Arcing faults High impedance air results in lower current Energy released into surrounding air Persist longer Inv Time Propagate along bus High release of heat and blast energy Are very destructive and dangerous to personnel LL Typical Arc Pressure amp Temperature Profile Total clearing time Opening time of a 5 cycle breaker with coordinated 83 ms NOT including relaying overcurrent latency protection up to 225 ms typical Temperature 212 700 gt 23 000 F 2 105 Pa Sree d Pt KA s n 729 PSI Pressure Pa calories Copper fire 1100 C Cable fire Bul 200 ms t Extensive damage to equipment and critical injury to personnel gt 250 ms ed TL 1 Arc Fla
40. clude an DLR Ethernet diagnostics module complete with Logix AOP ean t ON La alas all Nota mn natin linn All enn tn panna Copyright 2012 Rockwell Automation Inc All rights reserved MSR100 Single Function Relays GSR Modular Relay System MSR200 Modular Safety Relay System MSR300 Configurable Safety Relay System Copyright 2012 Rockwell Automation Inc All rights reserved 113 Rockwell Automation Highlight MSR100 Safety Relay Broad range of safety monitoring relays Applications up to Cat 4 PLe EN amp SIL 3 Wide range of input voltages 24AC DC 110AC 240AC 22 5mm amp 45mm housing OSSD or dry contact inputs amp outputs Wide range of contact layouts Auto manual reset amp EDM functionality Delayed outputs modules control stop to EN60204 1 2 Hand Control Muting Stop Motion Back EMF Mats Edges amp Expansion Packs Copyright 2013 Rockwell Automation Inc All Rights Reserved 114 Highlight MSR57P Rockwell Automation Safe Stop Zero Speed Monitoring Safe Limited Speed Safe Direction y 4 Safe Acceleration and Deceleration Dead man switch control 532 S42 11 82 6 OSSD Outputs gt que 72 82 S34 Y2 Y 4 Solid State Auxiliary Outputs SIL3 PLe Cat 4 Non K6K and 755 customers will require MSR57P to solve their safety applications 0
41. ction ear canal inserts Heavy duty leather gloves See Note 1 Leather work shoes Arc rated Clothing Selected so that the System Arc Rating Meets the Required Minimum Arc rating of 25 cal cm See Note 3 Arc rated long sleeve shirt AR Arc rated pants AR Arc rated coverall AR Arc rated arc flash suit jacket AR Arc rated arc flash suit pants AR Arc rated arc flash suit hood AR Arc rated gloves See Note 1 Arc rated jacket parka rainwear or hard hat liner AN Protective Equipment Hard hat Safety glasses or safety goggles SR Hearing protection ear canal inserts Leather work shoes oe 1 DB nc Arc rated Clothing selected so that the System Arc Rating Meets the Required Minimum Arc Rating of 40 cal cm Arc rated long sleeve shirt AR Arc rated pants AR Arc rated coverall AR Arc rated arc flash suit jacket AR Arc rated arc flash suit pants AR Arc rated arc flash suit hood AR Arc rated gloves See Note 1 Arc rated jacket parka rainwear or hard hat liner AN Protective Equipment Hard hat Safety glasses or safety goggles SR Hearing protection ear canal inserts Leather work shoes m ASINZS 4836 2011 Safe working on or near LV installations Revised in May 2011 to include Arc Flash Safety Emphasises Risk Assessment amp Risk Management Lists suitable Safety Equipment and Tools PPE is not first line of defence but to be used as a pre
42. dards Application Regulations amp Standards Victoria Workplace Safety WorkSafe Victoria Isolating Plant Guidance Note Includes recommended procedures for isolating plant South Australia Workplace Safety SafeWork SA Plant Isolation Procedures Lockout Danger and Out of Service Tags Provides guidance to employers and employees on the appropriate isolation procedures for plant undergoing maintenance cleaning repair or construction Mining Department of Industry and Resources WA Isolation and Tag out Procedures Guideline he purpose of the guidelines is to describe well established principles from which employers can develop effective isolation policy appropriate to particular minesite conditions Sa BRADY WHEN PERFORMANCE MATTERS MOST Guidelines for Effective Isolation Other Considerations Communication is important Tell affected workers about the isolation details Isolation procedures should serve as a checklist that allows workers to move through the steps without confusion Only authorised workers who have completed the appropriate training should undertake the Isolation procedures Lockout Tagout Practical Solutions Padlocks Lockout Training Kits Tools WHEN PERFORMANCE MATTERS MOST Two Types of Lockout Applications 1 Electrical to control all types of electrical control points switches plugs etc 2 Valve to lockout all types of valves Steam pipe boiler
43. dary An approach distance for a given Incident Energy where if entered could result in second degree burns i e above 1 2 cal cm2 Arc Flash Hazard Category number from 0 to 4 that aligns with an Incident Energy rating and identifies a corresponding level of PPE LL Hazard Risk Category Protective Clothing and PPE 0 Protective clothing non melting or untreated natural fiber e g untreated cotton wool rayon or silk or a blend of these materials with a fabric weight of at least 4 5 oz yd Shirt long sleeve Pants long Protective Equipment Safety glasses or safety goggles SR Hearing protection ear canal inserts Heavy duty leather gloves AN See Note 1 Arc rated Clothing Minimum Arc rating of 4 cal cm See Note 3 Arc rated long sleeve shirt and pants or arc rated coverall Arc rated face shield See Note 2 or arc flash suit hood Arc rated jacket parka rainwear or hard hat liner AN Protective Equipment Hard hat Safety glasses or safety goggles SR Hearing protection ear canal inserts Heavy duty leather gloves See Note 1 Arc rated Clothing Minimum Arc Rating of 8 cal cm See Note 3 Arc rated long sleeve shirt and pants or arc rated coverall Arc rated flash suit hood or arc rated face shield See Note 2 and arc rated balaclava Arc rated jacket parka rainwear or hard hat liner AN Protective Equipment Hard hat Safety glasses or safety goggles SR Hearing prote
44. e circuit needs two phases O Written procedure must validate device ENGINEERED PRODUCTS INC Voltage Indicator Advantages over a Voltmeter Voltage only device Hardwired to the voltage source Permanent less opportunity for damage Checks L1 L2 L3 GRD 24 7 365 Detects both AC amp DC Stored energy Self powered no batteries e Visual blade indication NEW Medium Voltage Indicator ledium Voltage Indicator Catalog Number Product Data Sheet R 1VH003 R 1VLOO3 part rrumber contains 3 units Power Warning Alert safety demands the answer to one question k there voltage The R TVH f R TVL Medium Voltage Indicator mounts to a medium voltage bus and flashes when voltage is present on the bus This product is designed to provide sufficient Buminaion to be easily seen through IR or viewing windows on a medium voltage starter transformers switchgear and other power distribution equipment The R 1VH R 1VL is built for long life and re amp abaity with solid state LED s and flame rated material Because the R 1VL capacitively couples to ground it provides high surge immunity and has electrical installation integrity ns volts E 7 ON 4 y Bolts to each LOAD SIDE phase Red flashing LED s can be viewed use through enclosure window a i vM te am Becincally to flash at least once every 3 seconde 20 per minute
45. ear Protective clothing Eye ut satani vis uired protection Safety helmet Insulating Footwear Protective clothing Eye Live electrical TN Rte oe sired gloves Arc flash suit and hood if protection Insulating gloves Flame Face shield if r 5 uired required Flame resistant gloves if resistant gloves Arc flash suit and work q y required Face shield if required hood Hearing protection helmet if required Hearing protection if required Respiratory rotection if required Hearing protection if required Respiratory protection if required Respiratory protection if required inaco m Electrical Safety Standards NFPA 70E USA NFPA 70E the Standard for Electrical Safety in the Workplace 2012 Electrical Safety including Arc Flash Hazards are a focus of all users Intended to help protect employees from electrical hazards Users are looking for more safety related features to be integrated into equipment o NFPA OE is not a direct design standard for the installation modification or construction of electrical systems m IEEE 1584 2002 Provides most accepted method for calculating Incident Energy and Flash Protection Boundary Equations are based on extensive practical experiments Applies up to 15kV 106KA Background physics now being challenged LL 1 Arc Flash Characteristics Dynamics 2 Arc Flash Related Standards 3 Field Installatio
46. earn 8x Available as a spare part Will detect if the key breaks or if the actuator separates from its door mounted position Copyright O 2012 Rockwell Automation Inc All rights reserved Rockwell Automation Authorised uw Distributor Allen Bradley Rockwell Software integrated Safety Solutions Voltage Indicators Communication Portals and IR Windows Definition PESDs Permanent Electrical Safety Devices are permanently mounted to electrical systems and reduce arc flash and shock hazard risks provide voltage verification without exposure to voltage are directly connected to voltage s source s within an electrical enclosure provide multiple voltage state determinations audible visual indications and or a physical action by the worker all voltage sources wired to PESDS NFPA 70E RACE 120 1 1 Voltage Indicator A Voltage Only device that illuminates when voltage is present between any 2 phases tS Hardwired Checks L1 L2 L3 GRD Simultaneously 24 7 365 AC DC Operation 40 750VAC 30 1000VDC Class 1 Division 2 Rated Powered by Line Voltage No Batteries Cat ITI amp IV Rated Long Life LED S GRACE ENGINEERED PRODUCTS Inic Voltage Indicator Reliability High Resistance Passive Input Impedance entre Voltage if Illuminated Internal Flashing Circuitry Dual LED s per Phase Complet
47. ent as well fault can lead to the as their components shall be loss of the safety designed constructed function Mainly selected assembled and combined accordance with relevant standards so that they can withstand the e expected influence Basic safety principles shall be used characterized by selection of The occurrence of a fault can lead to the Mainly characterized by selection of components Requirements of B shall loss of the safet apply Well tried components OSS lt I and well tried safety principles or ability of shall be used sens a occurence 5 lower than for category B Requirements of B and the The occurrence of a use of well tried safety fault can lead to the principles shall apply loss of the safety Mainly Safety function shallbe ees characterized checked at Suitable intervals by structure by the machine control The loss of safety System function is detected by the check Functional Safety standards bring additional requirements Copyright 2013 Rockwell Automation Inc All Rights Reserved system Requirements Old vs New Rockwell Automation Category Summary of requirements see 6 27 Requirements of B and the use of well tried safety principles shall apply Safety related parts shall be designed so that Requirements of B and the a single fault in any of these parts does not lead to the loss of the
48. er see T Safety Automation Project Views File Operations Zueo u unBHBe2f Layout Table Library Zoom New Open Save Save As Print Help Paste Project Project Properties J General Properties Name Tub Washer Description Tub Washer Safety project Notes for Project Name Color Clear Language For Product Description when available English v Safety Questions Safety Risk Assessment and Safety Functions are required before proceeding Notes Layout Background Have you performed a Risk Assessment Yes No Have you written a functional safety specification that Yes No outlines the required safety functions Have you determined the required performance level Yes No for each safety function v Default System Performance Level J Printer Settings Please select page break display properties These will be used to display page break lines on the diagrams to assist in device placement Printer settings will need to be manually adjusted for orientation when using Print button r Edit Operations Export Operations Cut Delete Rotate Table SISTEMA L Jo Station 2 Robotic Assembly Station 1 Load Position Station 3 Load Position Loaded parts index to assembly station 4 15 PM M B9 wl od 11 08 2014 VAILIETg LA Products Services Solutions
49. es All Dangerous Failures lt 60 LOW 60 lt DC lt 90 DC DC DCy Medium 90 DC 99 Cu ee T High DC gt 99 _ H ____ MITFy MTTFS MTT Fay CCF Common Cause Failure gt Two or more separate faults having a common cause shall be considered as a single fault Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Relationship between PL and SIL Performance Average probability of a Safety level PL dangerous failure per hour Integrity Level 1 h SIL gt 10 to lt 10 No special safety EN EM gt 3 x108 8 x108to lt 105 te gt 10 to lt 3x10 ___4___ gt 107 to lt 10 gt 10 to lt 107 Copyright 2013 Rockwell Automation Inc All Rights Reserved Calculations for Electro Mechanical Components Rockwell Automation Biog Number of cycles until a component fails dangerously d xh x3600s h dap Number of days per year when the n Top Hop 51 machine is operational leycie Nop Number of hours per day the machine is operational Mean time in seconds between To the beginning of two consecutive cycles ny of the component To be determined Number of switching cycles per year Operation time of the component until it MTTF fails dangerously 0 1 Mean time to dangerous failure MTTF Copyright
50. l Rights ReservedCopyri Detailed Risk Assessment In depth analysis required for critical or special machines Team based assessment led by RA Consultant for all machine life phases Report per standards Identification of primary hazards tasks Y List non compliance issues Y Risk In Risk Out Rating Y Mitigation Guarding and Controls recommendations Prioritized recommendations for safety improvements v Photograph of critical identified hazards based on customer approval Cost estimate per machine Mitigation Drawing Includes ergonomics review slip trip and fall hazards Rockwell Automation Conformity Audit Sample Audit Report Conformity Audit Results Alisting of machines with compliance status that can be used to prioritise next steps Example Conformity Audit Report Emergency Stops identify duplicate machines and any urgent issues Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Safety Circuit Analysis RA Safety Services Safety Circuit Analysis RA Safety Consultant will review the machine safety circuit supplied by the customer for compliance to the safety circuit performance level specified by the customer fthe circuit is not found to be in compliance the corresponding areas of the drawing will be red lined with notations that reference back to the standard showing the deficiency of the design
51. l input modules Configuration Automatic manual and manual monitored Reset Logic for inputs and SWC Timing functions and ranges on Timer modules single Wire Cascading SWC Cascading of safety functions in multi zone applications Logic combination of stand alone units Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Highlight GuardMaster Safety Relay New addition GSR GLP Safe Speed and Zero Speed Monitor Uses 2 x Prox 3KHz Frequency SIL2 PLd Works with SafeSpeed Drives Works with TLSZ GD2 Coming Soon GSR COMMS Remote Diagnostics DeviceNet EthernetlP DLR Copyright 2013 Rockwell Automation Inc All Rights Reserved 118 kuvell p 26 Y Que y gt i i Wy B b VA eh i LA LA We 7 E 7 4 D 7 mee du Wu y 3 2 aed duse L A 1 0 1e c E oingle Function Configurable Modular opecialty Copyright 2013 Rockwell Automation Inc All Rights Reserved NEW Guardmaster 440C CR30 software Configurable Safety Relay Rockwell Automation CR30 Software Configurable Safety for machine safety applications PLeand SIL 3 22 Safety I O Supports expanded standard I O via plug in Configured using free Connected Components Workben
52. n choose the most suitable standard for your use Two Methods to Achieve the Same Goal of Risk Reduction AS NZS AS4024 is the usual choice Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Risk Graph AS NZS 4024 1503 Performance Contribution to Level PLr Risk Reduction F1 S1 F2 F1 S2 F2 S Severity F Frequency or Duration of Exposure P Avoidance Probability Must be determined for each safety function Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation What are Performance Level PL Hardware Fault Tolerance Categories structure Reliability of the HW Mean Time To Failure dangerous MTTF Quality of the diagnostic measures DC CAT 2 and higher Sufficient measures against Common Cause Failures CCF Performance Level PL acc To AS NZS 4024 1503 C e D 3 j C D gt O gt CO O D C D a b C d Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation system Requirements Old vs New AS4024 1501 AS NZS 4024 1503 Principle used Category Summary of requirements System behaviour to achieve safety SRP CS and or their The occurrence of a Req U re M e ts protective equipm
53. ns of Arc Flash Contain Equipment 4 Safety Plan amp Mitigation of Arc Flash Hazards v u taer Ff E 4 m Arc Resistant Equipment Arc Resistant is a term used to describe how a piece of equipment resists the effects of an internal arc fault relates to arc flash exposure The level of arc flash protection is defined by the level to which an arc flash blast is Extinguished or Controlled Channeled away from personnel Prevented from propagating Testing must be performed to validate a level of resistance protection Defined as the Arc Resistant Accessibility Rating The equipment manufacturer is responsible to test to a given standard or guide to validate a given accessibility rating The Accessibility Rating defines one of the performance characteristics for arc resistant esed m Arc Resistant Equipment Considerations Letter of Attestation Tested to a relevant testing standard Letter of Attestation should be available am o v e Global arc resistant testing guides and standards include AS 3439 1 2002 e IEEE C37 20 7 2007 e IEC 62271 200 Annex a G14 1 enroll IEC 61641 2008 ER pP ata mtm m i r ot de T had bes ow ee Typical Test Setup 4 HI E T JM AN DEB Amp s 2 E amp t M
54. ompliance with the component manufacturers requirements concerning purity of the pressure medium Electric systems Has the system been checked for electromagnetic immunity e g as specified in relevant standards against CCF For combined fluidic bn 1 Load Position Input Devices v 440L P4KLO960YD 800H FRXTSOOX 30 5mm Type 4 4X 13 2 Pos PB Illum Push Pull Twist Mushrm Hd No Contacts Drag Device Logic Devices w Click here to add device to Layout Export Operations ore Table SISTEMA Tub Washer Control Panel Station 2 Robotic Assembly S Sta 2 5 S ight Curt e Station 3 Load Position Loaded parts index lo assembly station P adi EF EE E gt 4 43 PM 11 08 2014 VALUED Products Services Solutions Safety Automation Builder Safety Automation uilder Tub Project Views r File Operations Edit Operations Export Operations Q p gt AE E af EH A E 4 i HE Layout Table Library Zoom New Open Save Save As Print Help Paste Copy Cut Delete Rotate Table SISTEMA A ZONES CONTROL PANEL Control Panel Control Panel HAZARDS v GENERAL HAZARDS MECHANICAL HAZARDS Station 2 Robotic Assembly v ELECTRICAL HAZARDS Loaded parts index S Sta 2 5 S v RADIATION HAZARDS
55. opyright 2013 Rockwell Automation Inc All Rights Reserved NEW Guardmaster 440G LZ Safety certified to PLe and Cat 4 EN ISO 13849 1 EN ISO 14119 2013 Solid state design and monitored outputs Scalable protection with Unique or Standard coded RFID actuators High holding force of 1300N Fzh Energy Efficient Green Device only uses 2 5W IP69K and hygienic design Power to Release and Power to Lock versions Compact design optimized for ease of mounting Diagnostic info provided with 2 bright 270 LEDs Rockwell Automation Bar code with URL link to user manual LEDs both sides 4 LEDs both sides G obal approvals 1 ean design sealed bo Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Standards compliance The 440G LZ provides the highest safety rating with PLe and Category 4 EN ISO 13849 1 EN ISO 14119 2013 A required symbol from the EN ISO 14119 2013 standard is marked the device to show that the switch has this safety rated lock monitoring function ar The safety function and safety outputs include both the monitoring of the guard position and lock status Only product on the market that is TUV certified for PLe for BOTH the door position and lock monitoring Copyright 2013 Rockwell Automation Inc All Rights Reserved Rockwell Automation Solid state safety outputs and design
56. organisations through Loss of skilled manpower e Litigation fees e Higher insurance costs Loss of company morale e Production losses WH amp S refers to keeping workers safe around electrical equipment without referencing any specific standard s E Safety Plan amp Arc Flash Risk Mitigation Arc Flash Analysis shall be part of the overall company safety plan understand what you may not know Adequate training and use of PPE shall be mandatory as per the safety procedures and plan dentify and label the hazards as per risk assessment Use Arcfault resistance switchgears in the plant to minimise risk eee D Is m Arc Flash Safety Plan Actions List Use Arc Fault contain equipment e g Centreline 2500 MCC e Install phase indicators e g voltage vision from Grace port e implement remote controls Replace older protection devices Add additional protection devices Replace old amp dangerous switchboards s ee m Arc Flash Safety Plan Actions List e raining Establish Skills and PPE Rating Table Competencies Arc Flash Incident energy Hazard Risk PPE Category rating in cal cm Cateqor e Change Control Procedures i o j for Plant Maintenance Standard designs amp equipment specification for new equipment Regular updates to Arc Flash PPE controls are not suitable for incident energies Studies in
57. rc Flash Analysis and Mitigation Reports Arc resistant equipment can be a vital part of a comprehensive program for improving personnel safety 1 Automati four yasin Authorised Allen Bradley Rockwell Software Committed to exceeding our customers expectations Products Services Solutions Products Services Solutions Integrated Safety Solutions Safety Controllers amp Interfaces Authorised LE Te 5 amp uw Distributor windows Presentation by David Cassidy TINK SORTE Safety Interfaces Rockwell Allen Bradley Rockwell Software Automation Rev 5058 CO900B Copyright 2012 Rockwell Automation Inc All rights reserved Rockwell Automation What is a Safety Interface Provides monitoring and logical functions to a safety related control system Monitors the operation of safety device i e safety Switch and contactor Provides logical functions resets timers etc 24V DC L Machine control system can replace this circuit Transmitter Receiver i arrangement n Application specific devices muting speed Restart not used monitoring EDM not used All safety systems Cat 2 SIL1 up require MSR127TP 440R N23135 440L P4K0960YD 889D F4AC 2 889D F8AC 2
58. s Point v Access Point Access Point 1 Tub Washer Safety Functions Add SF 1 SafetyFunction 1 Required fields are marked by Control Panel Performance Level Category Type Prevention of unexpected start up Triggering Event Light curtain interrupted Reaction Robot power is isolated Station 1 Load Position Station 2 Robotic Assembly Station 3 Load Position Safe State Robot isoltaed Loaded parts index P Lge cut Zp to assembly station 16 Operations Hours Days Operations Per Per Hour Per Day Per Year Year 1 24 365 8760 Input Devices Add v Click here to add device Copy Logic Devices Add v Click here to add device Copy Output Devices Add Click here to add device Copy E 1 SLE 11 08 2014 VALUED Products Services Solutions Safety Automation Builder Safety Automation Export Operations BR i Table SISTEMA Edit Operations Paste Copy Cut Delete Rotate File UB Views Es Q Q oy LT Table Library Eod Rew u E As Print Help Project Layout Access Point v Access Point Access Point 1 7 Tub Washer Safety Functions J SF 1 SafetyFunction_1 Required fields are marked by Performance Level PLlr e v Category Type Prevention of unexpected start up Control Panel Triggering E
59. sh Characteristics Dynamics 2 Arc Flash Related Standards 3 Field Installations of Arc Flash Contain Equipment 4 Safety Plan amp Mitigation of Arc Flash Hazards Australian Standards for ARC Flash 3 SAI GLOBAL Audit and Certify Compliance and Risk Standards Legislation Codes and Business Information Encompass Property Newsfeeds Database Product Business Excellence and Improvement Risk Assessments Who We Are What We Do Our Mission Values and Vision Corporate Governance Leadership Investor Relations Corporate News Careers Search Results Search Results Buy Standards amp Technical Information about ARC flash jmd d m Arc Flash Standards No Australian Standard currently exists for Calculation Method AS NZS 4836 2011 Safe working on or near low voltage electrical installations and equipment e ENANENS 09 Selection and use of PPE for Arc flash hazard e AS 3439 Series Internal Arc fault containment EEE 1584 1 2013 Series Guide for Performing Arc Flash Hazard Calculations e NFPA 70E 2012 Edition Standard for Electrical Safety in the Workplace ee m But First Terminology Arc Flash Incident Energy The amount of energy a surface or person is exposed to at a set distance from an arc typically the working distance Units used are cal cm2 Arc Flash Approach Boun
60. ts are direct text adoptions of the international standard this means all references in the parts refer to international Standards numbers Nineteen 19 parts have been superseded 1201 1302 1401 1601 1602 1604 1701 1702 1703 1704 1801 1803 1901 1902 1903 1904 1905 1906 and 1907 two new chapters have been added 1303 1503 and four chapters superseded and withdrawn 1101 1202 1301 1802 with the application guide 1100 to follow Rockwell Automation Copyright 2013 Rockwell Automation Inc All Rights Reserved 7 AS NZS 4024 2014 Safety of Machinery ss Rockwell AS NZS 4024 2014 International Equivalent IOC IEC EN Part No Standard 4024 1100 2014 NA Application Guide for the AS 4024 1 series Still at drafting stage 4024 1101 2006 NA Available but will not be part of the reused AS 4024 1 series SO 12100 2010 his part supersedes the 2006 versions of parts 1201 1202 and 1301 uperseded by AS 4024 1201 2014 EN 626 1 1994 A1 2008 EN 614 1 2006 A1 2009 his part Supersedes the 2006 version of part 1401 ISO 13849 1 1999 his part will remain current and unchanged Title Safety of Machinery 4 O N NO O N O A ATA c ie D D fe D D D c ie his part supersedes the 2006 version of part 1302 4 O N rm O NO O rm D O NO
61. v SUBSTANCE HAZARDS v OTHER HAZARDS J GUARDING FIXED MOVABLE GUARDING GUARDING Tub Washer Station 3 Load Position ACCESS POINTS Person 4 45 PM zd EE 11 08 2014 VALUED Products Services Solutions Safety Automation Builder File Operations a NE L s u m Help Project Views auo Layout Table Library Zoom Edit Operations Export Operations Paste Copy Delete 0 Table SISTEMA fety Function Access Point Access Point Access Point_1 Safety Functions Library SF 1 SafetyFunction 1 Tub Washer Required fields are marked by Performance Level v Category Type Prevention of unexpected start up Triggering Event Light curtain interrupted BR The selected output device requires a redundant device to meet the SISTEMA Performance Level and Category A duplicate Reaction Robot power is isolated device will be add d PRE Robot Click on the duplicate device name to change to a different device Operations Hours Days Operations Per Hour Per Year Per Year 1 365 8760 Input Devices Add v 440L PAKLO960YD Modify Copy Delete v 800H FRXTSO0X Modify Copy Delete Logic Devices v 440R D22R2 Modify Copy Output Devices Add 100S C12EJ14BC Modify Copy MCS 100
62. vent Light curtain interrupted Reaction Robot power is isolated Station 1 Load Position Station 2 Robotic Assembly Station 3 Load Position Safe State Robot isoltaed Loaded parts index S Sta 2 E to assembly station ht Cu pi Operations Hours Days Operations Per Hour Per Day Per Year Year 4 1 Click to configure and add a Input Device 8760 Help Me Select gt Safety Switches gt Presence Sensing Safety Devices gt Operator Interface Custom Logic Devices w Click here to add device Output Devices Add v Click here to add device 4 34 PM 11 08 2014 M o VALUED Products Services Solutions Safety Automation Builder El X Export Operations exo EEE GEE Table SISTEMA GuardShield Safety Light Curtains Product Configuration Assistant Enter the catalog number for the desired GuardShield Safety Light Curtains 4401 4 make the selections for the product that you need using the interactive R tative Phot SAFETY LIGHT CURTAIN DATA Select an attribute to the left to Tub Washer Type of Unit Pair Transmitter Tx and Receiver Rx start making selections Protected Height NO SELECTION Integrated Laser NO SELECTION Alignment Resolution NO SELECTION Beams NO SELECTION System NO SELECTION Connector CORDSETS Cordsets 2 NO SELECTION Required one for transmitter and one for
63. ware utility provides developers and testers of safety related machine controls with comprehensive support in the m evaluation of safety in the context of EB EN ISO 13849 1 SISTEMA stands for Safety on machinery control systems The tool enables you to 1 h model the structure of the safety related control components based d upon the designated architectures thereby permitting automated Document mm calculation of the reliability values E Stop Switch The current configuration does not allow to calculate the PFH value using the standard p se FOOTER B00HC FRX Twist m to release E Stop Switch Not all the conditions of the chosen category are met Please check the list of requirements in the tab category of the subsystem X SB 800H FRX B800HC FRX Twist to release li af TJ ObLannal 1 The nb om an an nln KITTEN ben hama mit deen avin mille 977 2242 10024 Cara TAN A in the wm eii aa ame umm dium te mn man ta J SISTEMA default library 4 53 PM 11 08 2014 8 8 ad do 1 VALUED Products Services Solutions Safety Automation Builder alj SISTEMA Safety Integrity Software Tool fi File Edit View Help New Open Save amp Close Project ij Library A Report Help Wizard What s This 22 Subsystem IFA aera E
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