Applications & Tools. Speed monitoring with 3TK according to SIL 3 per EN or PL e per EN ISO :2006.

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1 Cover sheet Speed monitoring with 3TK according to SIL 3 per EN or PL e per EN ISO :2006 SIRIUS Safety Application description July 2011 Applications & Tools Answers for industry.

2 Industry Automation und Drives Technologies Service & Support Portal This entry originates from the Internet service portal of Siemens AG, Industry Automation und Drives Technologies. The following link takes you directly to the download page for this document. If you have any questions about this entry, please send an to the following address: 2 1.0, Entry ID: , Doc-ID: CE-FE-I-055-V10-EN

3 s Application description 1 Configuration and wiring 2 Parameterization 3 SIRIUS Safety Speed monitoring with 3TK according to SIL 3 per EN or PL e per EN ISO :2006 Evaluation 4 References 5 History 6 1.0, Entry ID: , Doc-ID: CE-FE-I-055-V10-EN 3

4 Warranty and liability Warranty and liability Note The application examples in this document are not binding and do not claim to be complete regarding the configuration, equipping and any eventuality. These application examples are not specific customer solutions, but are only intended to provide support with typical applications. You are responsible for ensuring that the products described are used correctly. These application examples do not relieve you of your responsibility regarding the safe handling when using, installing, operating and maintaining the equipment. By using these application examples, you agree that Siemens cannot be made liable for possible damage beyond the mentioned liability clause. We reserve the right to make changes and revisions to these application examples at any time without prior notice. For deviations between the recommendations in this application example and other Siemens publications e.g. Catalogs then the contents of the other documentation have priority. Siemens shall not be held liable for the information provided in this document. We accept no liability for any damage or loss caused by the examples, information, programs, configuration or performance data, etc. described in this application example, irrespective of the legal basis for claims arising from such damage or loss, unless liability is mandatory (for example, in accordance with the German Product Liability Act for intent, acts of gross negligence, harm to the life, body or health of human beings, the assumption of a guarantee for a product's characteristics of state, malicious concealment of a defect, or violation of basic contractual obligations). Any claims for damages caused by violation of basic contractual obligations, however, shall be limited to the foreseeable damage or loss which is typically envisaged in contracts unless there has been malfeasance or gross negligence or unless liability is mandatory due to endangerment of life, the body or health. Any change to the burden of proof to your disadvantage is not covered hereby. Any form of duplication of these application examples or excerpts hereof is not permitted without the express consent of Siemens Industry Sector , Entry ID: , Doc-ID: CE-FE-I-055-V10-EN

5 Table of contents Table of contents Warranty and liability Application description Aim of the application Advantages of this solution Configuration and wiring Contents Wiring Hardware and software components used Parameterization Parameterization of the speed monitor Evaluation according to IEC and EN ISO : Safety functions Evaluation safety function 1 and Evaluation according to EN Evaluation according to ISO : Summary safety function 1 and Evaluation safety function 2 and Evaluation according to EN Evaluation according to ISO : Summary safety function 2 and References References Internet links History , Entry ID: , Doc-ID: CE-FE-I-055-V10-EN 5

6 1 Application description 1.1 Aim of the application 1 Application description 1.1 Aim of the application Introduction In machines in which machine movement or moving parts can pose a hazard to people and machinery, the hazardous movement can be monitored with a 3TK speed monitor. Description of the automation task If people (e.g. in manufacturing) work anywhere near machines, technical means must be used to provide appropriate protection. One solution in the area of equipment and machines is to protect hazard areas by means of guard elements or access flaps which ensure mechanical separation. The aim here is to monitor unauthorized access to parts of a plant or equipment and to prevent hazardous machine functions when the guard door / flap is opened. This Safety Functional Example describes monitoring a speed and a protective device providing physical separation in the form of a protective door with spring locking. The speed of rotating parts in machines and plants is to be monitored using a 3TK speed monitor. The mode selector switch permits safe monitoring of two different speeds: Automatic and setup mode. If the predefined speed range is exited, the safety relay opens the downstream contactors Q1 and Q2 via the safe outputs with a positively driven operation in accordance with stop category 0 as indicated in EN After the switch-off monitoring time has elapsed, the device checks whether both contactors have opened. Before switching on again or acknowledging with the start button, a check is made that both contactors are open. The protective door with a SIRIUS position switch with positively driven contact is also monitored by the speed monitor. In automatic mode, the protective door is locked. In setup mode (slow speed), the protective door can be opened by means of a release command. 1.2 Advantages of this solution Certified device with integrated protective door monitoring No additional device is required Shaft break detection Universal speed sensor can be used No software required Solution by wiring only 6 1.0, Entry ID: , Doc-ID: CE-FE-I-055-V10-EN

Fig. 2-1 Evaluation Speed monitor 3TK2810-1 L1 L2 L3 Start Setup/ Automatic mode Frequency converter Q1

7 2 Configuration and wiring 2.1 Contents 2 Configuration and wiring 2.1 Contents Schematic The following figure schematically shows the most important components of the solution: Fig. 2-1 Evaluation Speed monitor 3TK L1 L2 L3 Start Setup/ Automatic mode Frequency converter Q1 Response Q2 Encoder Initiator M1 SIRIUS Position switch with lock Detection SIRIUS Position switch 1.0, Entry ID: , Doc-ID: CE-FE-I-055-V10-EN 7

8 2 Configuration and wiring 2.2 Wiring 2.2 Wiring Installing the hardware The following figure shows the hardware configuration of the application. 24VDC or VAC/DC Fig. 2-2 Magnet Start Setup/ automaticmode Enable open A1 T1 T2 ST P1 P2 MAG EA1 EA2 RF TK RJ 45 = ~ Logic A2 U E1 E2 GND T4 T3 RF Q1 Q2 Q1 Q2 Q1 Q2 M Encoder M G110 Adapter 8 1.0, Entry ID: , Doc-ID: CE-FE-I-055-V10-EN

9 2 Configuration and wiring 2.3 Hardware and software components used 2.3 Hardware and software components used Hardware components Table 2-1 The application was created with the following components. Component Qty. MLFB / order number Note Speed monitor 1 3TK2810-1BA41 Position switch 1 3SE RV40 With separate actuator Position switch 1 3SE5322-0SD21 Spring-locked with lock Actuator for position switch 1 3SE AV05 Radius actuator Contactor Q1, Q2 2 3RT2015-1BB42 Contactor, AC-3, 3 KW / 400 V, 1NC, 24 V DC, 3-pole, size S00, screw terminal Start button and service operation 1 3SB AA3 Empty housing, two command points 2 3SB3 420-OB 1 NO contact for floor attachment 1 3SB AA11 Black pushbutton with flat button, nominal diameter 22 mm 1 3SB3000-4LD01 CES key switch Emergency stop 1 3SB EG3 Mushroom pushbutton, 2NC contactor, 40 mm, with yellow top section, without protective collar Frequency 1 6SL3255-0AA00-4BA1 Basic operator panel G120 converter 1 6SL3244-1BA21-1PA0 CU240S DP-F Control Unit 1 6SL3224-0BE23-0UA0 Frequency converter PM240 Power Module Note The functionality was tested with the hardware components stated. Other similar products not listed above can also be used. Please note that in such a case the example code may have to be modified (e.g. use of another position switch). Example files The list below contains all the files and projects used in this example. You will find these on: Table 2-2 Component SIL3_PLe_Drehzahl_Schutztür_ CD-FE-I-55.zip Note <This packed file contains the project for the Safety Evaluation Tool.> 1.0, Entry ID: , Doc-ID: CE-FE-I-055-V10-EN 9

10 3 Parameterization 3.1 Parameterization of the speed monitor 3 Parameterization Note what configuration steps are required if the hardware is different from the hardware used in the example. what central configuration steps are required for this configuration 3.1 Parameterization of the speed monitor Table 3-1 To enter the parameterization mode of the device, press the following button combinations: No. Result Remark 1. Press the right button and keep it pressed. 2. Press the left button additionally 3. After correct execution of the display test, confirm with the "OK" button (right button) 4. Before the device accepts the modified parameters, you must confirm the parameters again for security. A display test is performed The parameterization can then be modified. You can navigate the menu with the pushbuttons. Any menu option may have additional sub-menus. The menu structure and menu representation are in part directly dependent on the device parameterization and the hardware configuration. No. Result Remark 5. Choose "1. Parameterization" using the arrow buttons and press "OK." A sub-menu opens. 6. Choose "1.1. Monitored Motion." The sub-menu opens. 7. Choose "Rotational" and confirm with "OK." 8. Choose "1.2. Encoder type." The sub-menu opens. 9. Choose "Rot. Encoder" and confirm with "OK." 10. Choose "1.3. Encoder Selection." The sub-menu opens. 11. Choose "RJ45: Encoder + E2" and confirm with "OK." 12. Choose "1.4. Increase/transmit". The sub-menu opens , Entry ID: , Doc-ID: CE-FE-I-055-V10-EN

11 3 Parameterization 3.1 Parameterization of the speed monitor No. Result Remark 13. Choose "Transmission" and press "OK." 14. Set the transmission and confirm with "OK." 15. Choose "1.5. Encoder settings" and press "OK." The sub-menu opens. 16. Set the signal shape and resolution and confirm with "OK." 17. Choose "1.6. Initiator settings." The sub-menu opens. 18. Set the initiator type (pnp) and the resolution for E2 and confirm with "OK." 19. Choose "1.7. Speed limits." The sub-menu opens. 20. Set the max. and min. speed for automatic mode and for setup mode and the speed below which standstill is to be detected. 21. Select "1.8 Times." The sub-menu opens. 22. Set the Start overide, Release delay, Switch-off monit. and confirm with "OK." 23. Choose "1.9 Start type." The sub-menu opens. 24. Choose "Manual Start" and confirm with "OK." 25. Choose "1.9 Prot. door monit.." The sub-menu opens. 26. Choose "Simultaneity on" and confirm with "OK." 27. Back Higher-level menu opens 28. Back The modified parameters are displayed. 29. Modified parameters must be confirmed with OK. Modified parameters have been taken over by the speed monitor NOTICE Carry out functional test of the system To guarantee the safety of the system, a full functional test must be carried out and successfully concluded following parameterization. 1.0, Entry ID: , Doc-ID: CE-FE-I-055-V10-EN 11

12 4 Evaluation according to IEC and EN ISO : Safety functions 4 Evaluation according to IEC and EN ISO : Safety functions Safety functions The following safety functions are used as basis for further consideration: Table 4-1 Normal mode: Safety function SF 1 SF 2 When "protective door" is opened, the motor must be shut down. While the motor is turning, the protective door must be locked. Table 4-2 Service mode: Safety function SF 3 SF 4 If the "protective door" is opened and the motor is not stopped or is in the safe speed range, the motor must be switched off. While the motor is not stopped or is in the safe speed range, the protective door must be locked. The safety functions stated above are evaluated according to the two standards EN and EN ISO :2006 below. Treatment is identical for safety functions 1 and 3 and for safety functions 2 and , Entry ID: , Doc-ID: CE-FE-I-055-V10-EN

13 4 Evaluation according to IEC and EN ISO : Evaluation safety function 1 and Evaluation safety function 1 and Evaluation according to EN Table 4-3 Parameters for calculating PFH D for "Detection" (position switch) and "Response" (contactor) B10 Parameters Value Reason Rule Position switch 1 * 10 6 Specified by manufacturer Contactor 1 * 10 6 Dangerous failure Specified by manufacturer fraction Position switch 0,2 (20 %) Contactor 0,75 (75 %) T1 Service life 175,200 h (20 years) Specified by manufacturer C Assumptions: Number of operations of the position switches Number of operating cycles of the contactors T2 Diagnostics test interval position switch Diagnostic test interval contactor (CCF factor) Susceptibility to commoncause failures DC Diagnostics coverage / h One operating cycle occurs per shift, that is, once every 8 hours / h Operations are performed on all days in the year (365 days). 8 h On opening the protective door, a defective contact is detected in the 3TK It is operated once per shift, that is, every 8 hours (see "C"). 8 h A defective contactor is detected in the 3TK on operation. It is operated once per shift, that is, every 8 hours (see "C"). 0,1 In the case of installation according to EN 62061, a CCF factor of 0.1 (10 %) can be assumed. This value puts the calculation on the safe side ("conservative value"). 0,99 (99 %) Discrepancy evaluation on emergency stop; Evaluation of the read-back signals (positively driven contacts) of both contactors Siemens AG User 1.0, Entry ID: , Doc-ID: CE-FE-I-055-V10-EN 13

14 4 Evaluation according to IEC and EN ISO : Evaluation safety function 1 and 3 Table 4-4 Parameters for evaluation Parameters Component Value Rule PFH D (3TK) 3TK speed monitor 3,38 * 10-9 Siemens AG Table 4-5 Result EN SIL CL PFH D Detection 3 Hardware failure tolerance: HFT = 1 Safe failure fraction: SFF 0.99 (99 %) 2,5 * Architecture: Basic subsystem architecture D Evaluation 3 Specified by manufacturer 3,38 * Specified by manufacturer Response 3 Hardware failure tolerance: HFT = 1 Safe failure fraction: SFF 0.99 (99 %) 9,4 * Architecture: Basic subsystem architecture D Result 3 The SIL CL of all tasks of the safety function is at least 3. PFH D (= 4,56 * ) of the total supplementary safety function complies with SIL , Entry ID: , Doc-ID: CE-FE-I-055-V10-EN

15 4 Evaluation according to IEC and EN ISO : Evaluation safety function 1 and Evaluation according to ISO :2006 Table 4-6 Parameters for calculating MTTF d for "Detection 2" (position switch) and "Response" (contactor) Parameters Value Reason Rule B10 Specified by manufacturer Position switch 1 * 10 6 Contactor 1 * 10 6 Dangerous failure fraction Specified by manufacturer Position switch 0,2 (20 %) Contactor 0,75 (75 %) d op Average operating time in days per year h op Average operating time in hours per day t cycle Mean time between the beginning of two consecutive cycles of the component Position switch Contactor 365 days per year 24 hours per day 8 h / cycle 8 h / cycle Assumption: Operations are performed on all days in the year. Assumption: The protective door is opened and the contactors are operated at intervals of 8 hours (one shift). Table 4-7 Interim results (In this example, the interim results for emergency stop and contactor are identical) Interim result Reason Siemens AG MTTF d high MTTF d 30 years DC high DC = 99 % Discrepancy evaluation for the position switches; evaluation of the read-back signals (positively driven contacts) of both contactors Measures condition met It is assumed that the user has taken the necessary measures. against CCF Category 4 System behavior: One failure does not result in the loss of the safety function. The individual failure is detected. MTTF d : high, DC: high, measures against CCF: condition met User Table 4-8 Parameters for evaluation Parameters Component Value Rule PFH D (3TK) 3TK speed monitor 3,38 * 10-9 Siemens AG 1.0, Entry ID: , Doc-ID: CE-FE-I-055-V10-EN 15

16 4 Evaluation according to IEC and EN ISO : Evaluation safety function 1 and 3 Table 4-9 Result ISO :2006 PL Average probability of a dangerous failure per hour Detection e 2,47 * (from Appendix K; see Note) Evaluation e 3,38 * Response e 2,47 * (from Appendix K; see Note) Result e The PL of all tasks of the safety function is at least e. Number of tasks is less than or equal to 3. Note: The MTTF d for each channel is limited to a maximum of 100 years! Summary safety function 1 and 3 Table 4-10 EN ISO :2006 SIL CL PFH D PL Average probability of a dangerous failure per hour Detection 3 2,5 * e 2,47 * Evaluation 3 3,38 * e 3,38 * Response 3 9,4 * e 2,47 * Result SIL 3 PL e , Entry ID: , Doc-ID: CE-FE-I-055-V10-EN

17 4 Evaluation according to IEC and EN ISO : Evaluation safety function 2 and Evaluation safety function 2 and Evaluation according to EN Table 4-11 Parameters for calculating PFH D for "Response 2" (lock, spring-locked) Parameters Value Reason Rule B10 Lock 1 * 10 6 Specified by manufacturer Dangerous failure Specified by manufacturer fraction Lock 0,2 (20 %) T1 Service life C Number of operations Lock DC Diagnostics coverage 175,200 h (20 years) / h 0,90 (90 %) Table 4-12 Parameters for evaluation Specified by manufacturer Assumptions: One operating cycle occurs per shift, that is, once every 8 hours. Operations are performed on all days in the year (365 days). The feedback signal is permanently monitored by the feedback circuit input of the 3TK Siemens AG User Parameters Component Value Rule PFH D (3TK) 3TK speed monitor 3,38 * 10-9 Siemens AG Table 4-13 Result EN SIL CL PFH D Evaluation 3 Specified by manufacturer 3,38 * Specified by manufacturer Response 2 Hardware failure tolerance: HFT = 0 Safe failure fraction: SFF = 0.90 (90 %) (SIL CL is limited to SIL 2; because of fault short-circuit, breakage of the separate actuator) 2,5 * Architecture: Basic subsystem architecture C Result 2 The SIL CL of all tasks of the safety function is at least 2. PFH D (= 3,63 * ) of the total safety function complies with SIL , Entry ID: , Doc-ID: CE-FE-I-055-V10-EN 17

18 4 Evaluation according to IEC and EN ISO : Evaluation safety function 2 and Evaluation according to ISO :2006 Table 4-14 Parameters for calculating MTTF d for "Response" (lock, spring-locked) Parameters Value Reason Rule B10 Specified by manufacturer Lock 1 * 10 6 Dangerous failure fraction Lock 0,2 d op Average operating time in days per year h op Average operating time in hours per day t cycle Mean time between the beginning of two consecutive cycles of the component Lock 365 days per year 24 hours per day 8 h / cycle Specified by manufacturer (20 %) Assumption: Operations are performed on all days in the year. Assumption: The protective door is opened at intervals of 8 hours (one shift). Siemens AG User Table 4-15 Interim results Interim result Reason MTTF d high MTTF d 30 years DC Average DC = 90 % The feedback signal is permanently monitored by the feedback circuit input of the safety monitor. Measures condition It is assumed that the user has taken the necessary measures. against CCF met Category 2 System behavior: A single failure can result in the loss of the safety function. The loss of the safety function will be detected by the test. MTTF d : high, DC: medium, measures against CCF: condition met. Table 4-16 Parameters for evaluation Parameters Component Value Rule PFH D (3TK) 3TK speed monitor 5,7 * 10-9 Siemens AG Table 4-17 Result PL EN ISO :2006 Average probability of a dangerous failure per hour Evaluation e 5,7 * Response d 2,29 * (from Appendix K; see Note) Result d The PL of all tasks of the safety function is at least d. Number of tasks is less than or equal to 3. Note: The MTTF d for each channel is limited to a maximum of 100 years! , Entry ID: , Doc-ID: CE-FE-I-055-V10-EN

19 4 Evaluation according to IEC and EN ISO : Evaluation safety function 2 and Summary safety function 2 and 4 Table 4-18 EN EN ISO :2006 SIL CL PFH D PL Average probability of a dangerous failure per hour Evaluation 3 5,7 * e 5,7 * Response 2 2,5 * d 2,29 * Result SIL 2 PL d 1.0, Entry ID: , Doc-ID: CE-FE-I-055-V10-EN 19

20 5 References 5.1 References 5 References 5.1 References This list does not claim completeness and merely reflects a selection of suitable literature. Table 5-1 Source of topic Title \1\ Brochure Functional Safety of Machines and Systems Easy Implementation of the European Machinery Directive (Order No.: E20001-A230-M103-V1-7600) \2\ Technical book Patrick Gehlen Funktionale Sicherheit von Maschinen und Anlagen Umsetzung der Europäischen Maschinenrichtlinie in der Praxis (in German) (Publicis Corporate Publishing, ISBN: ) 5.2 Internet links This list does not purport to be complete and merely reflects a selection of suitable information. Table 5-2 Topic Title \1\ Reference to the entry \2\ Siemens I IA/DT Customer Support \3\ Safety Evaluation Tool \4\ Safety Integrated , Entry ID: , Doc-ID: CE-FE-I-055-V10-EN

21 6 History 6 History Table 6-1 Version Date Revision V First edition 1.0, Entry ID: , Doc-ID: CE-FE-I-055-V10-EN 21

SIRIUS Safety Integrated. Modular safety system 3RK3

SIRIUS Safety Integrated. Modular safety system 3RK3 Functional Example CD-FE-I-048-V10-EN SIRIUS Safety Integrated Modular safety system 3RK3 Emergency Stop with monitored Start and Protective Door with automatic start according to category 4 in EN 954-1.