Siemens Safety Integrated Take a safe step into the future

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Engineered with TIA Portal Machine Safety Life-Cycle Siemens Safety Integrated Take a safe step into

2 Machine Safety Safety Process Chain The necessary steps towards a safe machine can be illustrated with a process chain. Risk assessment Risk reduction Proof Cutting disc > Cutting off Chips > Cutting, penetrating Transport rollers > Crushing and shearing Clamping plates > Crushing Page 2

Machine Safety Are Risk Assessments Required?

3 Machine Safety Are Risk Assessments Required? Risk assessment Risk reduction Proof European Union : USA: DIRECTIVE 2006/42/EC (Machinery Directive) NFPA 79 ANSI B11.19 ANSI / RIA ANSI ASSE Z244.1 Page 3 YES! All new & revised machine safety standards state that a Risk assessment MUST be performed

Machine Safety Risk Assessment Process The following standards should be applied for the techniques to evaluate and assess these risks: For USA: ANSI B11.

4 Machine Safety Risk Assessment Process The following standards should be applied for the techniques to evaluate and assess these risks: For USA: ANSI B , Safety of Machinery; General Requirements And Risk Assessment. For Europe: EN ISO "Safety of machinery basic terminology, general principles for design risk assessment & risk reduction Page 4

5 Machine Safety How to find Risk Levels? Risk assessment Risk reduction Proof The measure for achieved functional safety is the probability of dangerous failures, the fault tolerance and the quality that is to be guaranteed as a result of freedom from systematic faults. It is expressed in the standards using different terms In IEC 62061: Safety Integrity Level (SIL) In ISO : Performance Level (PL) Page 5

Machine Safety Typical Safety Circuit example

Redundancy ensures safety functionality even

Controller Evaluation Fault detection and

Initiate machine shut down OR Feedback Loop

contactor coils Positive Opening Guarantees

6 Machine Safety Typical Safety Circuit example SIL 3 / PL e wiring 24V or 115VAC Power Supply Redundancy ensures safety functionality even if a failure disables one channel Safety Controller Evaluation Fault detection and evaluation; opens the circuit in case of a failure. Reset Reactivates the safety circuit Sensors Initiate machine shut down OR Feedback Loop Monitors the correct operation of the contactor coils Positive Opening Guarantees that all NC contacts are in the open position when actuated Positive Driven (Mirror) Guarantees that NC contacts are not to be closed at the same time as the main contact 0V Page 6 The Complete Safety Solution

7 Machine Safety Understanding Safety Levels - PL a Standard Switch and Contactor PL a allows NO contacts for Enabling Two-hand control Restart L1 L2 L3 Page 7 The Complete Safety Solution

8 Machine Safety Understanding Safety Levels - PL b Open Closed 24 VDC PL b requires Sensors with positive opening contacts L1 L2 L3 0 VDC Page 8 The Complete Safety Solution

9 Machine Safety Understanding Safety Levels - PL c / SIL 1 Open Closed 24 VDC ON PL c / SIL 1 requires Sensors with positive opening contacts And Safety evaluation unit rated to SIL 1 L1 L2 L3 Feedback loop from contactor s NC contacts Q1 0 VDC Page 9 The Complete Safety Solution

Machine Safety Understanding Safety Levels - PL d / SIL 2 Open Closed 24 VDC ON PL d / SIL 2 requires Sensors with positive opening contacts Q1 L1 L2 L3 Safety

10 Machine Safety Understanding Safety Levels - PL d / SIL 2 Open Closed 24 VDC ON PL d / SIL 2 requires Sensors with positive opening contacts Q1 L1 L2 L3 Safety evaluation unit rated to SIL 2 Feedback loop from contactor s NC contacts And Redundancy in sensor contacts Redundancy in contactors 0 VDC Q2 Page 10 The Complete Safety Solution

Machine Safety Understanding Safety Levels - PL e / SIL 3 Open Closed 24 VDC ON PL e / SIL 3 requires Sensors with positive opening contacts Safety evaluation unit rated to SIL 3 L1 L2 L3

11 Machine Safety Understanding Safety Levels - PL e / SIL 3 Open Closed 24 VDC ON PL e / SIL 3 requires Sensors with positive opening contacts Safety evaluation unit rated to SIL 3 L1 L2 L3 Feedback loop from contactor s NC contacts 0 VDC Q1 Q2 Redundancy in sensor contacts Redundancy in contactors And Separate channels of evaluation for sensors Page 11 The Complete Safety Solution

13 SIMATIC Safety Integrated Proven Track Record /2014 S5-110F S5-115F S5-95F NFPA79 allows Safety PLC s S7-400FH F-Systems S7-300F/400F Distributed Safety WinAC RTX F STEP 7 Safety Advanced V11 S7-1200F Next Generation of SIMATIC Safety Integrated Safety Advanced in TIA Portal Page 13 ET 200SP STEP 7 Safety Advanced V12 STEP 7 Safety S7-1500F Advanced V13

SIMATIC Safety Integrated From standard to fail-safe

Response Sensors Periphery CPU & Program Periphery

I/O Hard-& Firmware upgrade Fail-safe I/O-modules Step2

PROFINET PROFIsafe Step3 User program F-Program Standard

Detect Evaluate Respond Safety PLC Sensors Periphery F- CPU

14 SIMATIC Safety Integrated From standard to fail-safe automation in 3 easy steps Standard PLC Detect Evaluate Response Sensors Periphery CPU & Program Periphery Actuators Step1 Hard-/Firmware F-CPU Standard CPU Standard I/O Hard-& Firmware upgrade Fail-safe I/O-modules Step2 Communication Standard communication via PROFIBUS or PROFINET PROFIsafe Step3 User program F-Program Standard program STEP7 Safety program STEP7 and Safety Advanced Detect Evaluate Respond Safety PLC Sensors Periphery F- CPU & Program Periphery & F-Sensors & F-Peripherie & F-Program & F-Peripherie Actuators Page 14

SIMATIC Safety Integrated Safety Software -

Controllers PC-based Controllers ET 200F

15 SIMATIC Safety Integrated Safety Software - One engineering for all fail-safe controllers One engineering system STEP 7 Safety One fail-safe program Modular Controllers PC-based Controllers ET 200F S7-300F S7-400F Fail-safe S7-CPU S7-1200F/S7-1500F WinAC RTX F Page 15

16 STEP 7 Safety V13 SP1 Coded Processing in the F-CPU Classic F-controller principle: structural redundancy (HFT) Two (or more) identical controllers All of them execute the same program The results are compared Safety Advanced F-controller principle: Coded Processing Generation of a coded user F-program through F-compiler (diversity) Sequential program execution of uncoded and coded (time redundancy) The results are compared è Implementation of a fail-safe system with only one CPU (a single processor with self-tests) Page 16

17 STEP 7 Safety V13 SP1 Safety concept Detection Evaluation Reaction F-DI F-CPU F-DO F-S F-A Page 17 short circuit, cross circuit, wire break data loss, data corruption, transmission delay processor fault, memory error short circuit, ground leak, wire break Completely detection of errors through üf-i/o: two-channel processor system and signal tests üf-plc: Coded Processing and internal tests ücommunication error: PROFIsafe

18 STEP 7 Safety V13 SP1 Coded Processing in the F-CPU (Standard Code) z = x + y x = 127 y = 1 Operators Operation z = 128 Output Page 18

19 STEP 7 Safety V13 SP1 Coded Processing in the F-CPU (Code Diversity) Diversity z = x + y x = 127 y = 1 Operators Operation z = 128 Output x c = f(x) y c = f(y) x c = y c = Coded Operators z c = x c + y c + 1 Coded Operation z c = Coded Output Page 19

20 STEP 7 Safety V13 SP1 Coded Processing in the F-CPU (Time Redundancy) Time redundancy and diversity z = x + y x = 127 y = 1 Operators Operation z = 128 Output x c = f(x) y c = f(y) x c = y c = Coded Operators z c = x c + y c + 1 Coded Operation z c = Coded Output Time redundancy Time Page 20

21 STEP 7 Safety V13 SP1 Coded Processing in the F-CPU (Time Redundancy) Time redundancy and diversity z = x + y x = 127 y = 1 Operators Operation z = 128 Output x c = f(x) y c = f(y) Comparison x c = y c = Coded Operators z c = x c + y c + 1 Coded Operation z c = Coded Output Time redundancy Time Page 21

STEP 7 Safety V13 SP1 Coded Processing in the F-CPU (Time Redundancy) Time redundancy and diversity z = x + y x = 127 y = 1 Operators Operation z = 128 Output x

22 STEP 7 Safety V13 SP1 Coded Processing in the F-CPU (Time Redundancy) Time redundancy and diversity z = x + y x = 127 y = 1 Operators Operation z = 128 Output x c = f(x) y c = f(y) Comparison x c = y c = Coded Operators z c = x c + y c + 1 Coded Operation z c = Coded Output Time redundancy Time Page 22

23 STEP 7 Safety V13 SP1 F-Runtime group (F-CALL) Read F-PII (F_CTRL_1) Execute F-user program Execute coded F-user program F-Runtime group Compare results Write F-PIO (F_CTRL_2) t Page 23

24 STEP 7 Safety V13 SP1 Coded F-user program Coded F-user program F-user program Page 24

25 Machine Safety Risk Reduction Risk assessment Risk reduction Proof Solutions consist of three main components Detection Evaluation Reaction Very Important as this is how the safety function is defined when doing the calculations for SIL/PL levels Page 25

26 Detection Input Devices May Include Several or Just One of the Following: (Depending Upon Safety Category Desired) Mechanical Input Devices Emergency Stop (with or without enable or resets) Position Switch Interlock Switch AS-I Safe Page 26

27 Detection Input Devices May Include Several or Just One of the Following: (Depending Upon Safety Category Desired) Electronic Input Devices Solenoid Interlock Gate Switches Magnet or RFID Position Switches Light Grids / Area Laser Scanners Encoder Position Switches Safety Mats Page 27

28 Detection Page 28

29 Evaluation Safety Relay & Programmable Controllers May Include One, Several, or a Combination of the Following: (Depending Upon Safety Category Desired and Complexity) Safety Relays Programmable Safety Relays MSS (Modular Safety System) Page 29

30 Evaluation Programmable Controllers May Include One, Several, or a Combination of the Following: (Depending Upon Safety Category Desired and Complexity) S7-1200F ET200SP F S7-1500F Page 30

31 Evaluation SIMATIC Controller Overview V10.5 V11 V12 V SIMATIC S7-400 TIA Portal Basic Advanced SIMATIC S7-400 SIMATIC S7-300 SIMATIC S SIMATIC S SIMATIC S7-300 S Micro SIMATIC S7-200 SIMATIC S SIMATIC S S Programmable Relay Page 31 LOGO!

Evaluation SIMATIC Safety Integrated Fail-safe Controllers - Overview System Performance

automation architectures requiring many HMI s, drives, other field devices Customized

production process Perfect for space constraints S7-1200FC for Basic Control Optimized

Material handling and Available packaging as an open controller Vertical form, fill and

32 Evaluation SIMATIC Safety Integrated Fail-safe Controllers - Overview System Performance S7-1500F for Advanced Control Balance of control for machines or plants Complex automation architectures requiring many HMI s, drives, other field devices Customized mass production control Perfect for machine-to-machine controls required for an entire production process Perfect for space constraints S7-1200FC for Basic Control Optimized for on-machine distributed Perfect for stand-alone architectures simple machine control Material handling and Available packaging as an open controller Vertical form, fill and seal ET 200SP F CPUs for Distributed Control Perfect for modular machines Application complexity Page 32

Evaluation SIMATIC S7-1200 with Safety Integrated unique, innovative and efficient safety solution Minimization of types and parts Standard and fail-safe automation with just one controller PROFINET

33 Evaluation SIMATIC S with Safety Integrated unique, innovative and efficient safety solution Minimization of types and parts Standard and fail-safe automation with just one controller PROFINET integrated Investment protection Simply addition of fail-safe modules to the PLC Simple porting of existing application programs between S <> S Certified according to EN nd Edition and EN ISO PL e Field-proven Coded Processing + instead of multi-processor system + Integrated Diagnostics + Easy and rapid localization of faults through granular fault messages in plain text also worldwide access via WEB-Server Maximum protection against manipulation Additional password for access to F configuration and F program + Page 33

Evaluation SIMATIC S7-1200 with Safety Integrated Portfolio Failsafe S7-1200-CPU s (DC/DC/DC; DC/DC/Rly) S7-1214FC S7-1215FC Failsafe S7-1200 IO-Module SM 1226

34 Evaluation SIMATIC S with Safety Integrated Portfolio Failsafe S CPU s (DC/DC/DC; DC/DC/Rly) S7-1214FC S7-1215FC Failsafe S IO-Module SM 1226 F-DI 16 x 24VDC SM 1226 F-DQ 4 x 24VDC SM 1226 F-DQ 2 x Relay STEP 7 Safety Advanced V13 SP1 S7-300F/400F/1500F/1200F STEP 7 Safety Basic V13 SP1 S71200F Page 34

35 Evaluation SIMATIC S with Safety Integrated Portfolio CPU Features CPU 1211C CPU 1212C CPU 1214FC CPU 1215FC CPU 1217C Standard CPU DC/DC/DC, AC/DC/RLY, DC/DC/RLY DC/DC/DC Failsafe CPU - - DC/DC/DC, DC/DC/RLY - Work Memory, Integrated 30 KB 50 KB 75 / 100 KB 100 / 125 KB 125 KB Load Memory, Integrated 1 MB 1 MB 4 MB 4 MB 4 MB Retentive Memory, Integ. 10 KB 10 KB 10 KB 10 KB 10 KB Bit Memory (M) 4 KB 4 KB 8 KB 8 KB 8 KB Integ. Standard Digital I/O 6 Inputs / 4 Outputs 8 Inputs / 6 Outputs 14 Inputs / 10 Outputs 14 Inputs / 10 Outputs 14 Inputs / 10 Outputs*) Integ. Standard Analog I/O 2 Inputs 2 Inputs / 2 Outputs Process Image Size Signal Board Expansion 1024 Bytes for Inputs / 1024 Bytes for Outputs 1 max. Signal Module Expansion none 2 max. 8 max. Max. Local I/O Digital Max. Local I/O Analog Page 35

36 Reaction Output Devices May Include Several or Just One of the Following: (Depending Upon Safety Category Required & Operation Desired) Safety Contactors (Positively Driven Mirror Contacts) Safety Relays (Positively Driven Mirror Contacts) Safety Motor Starters (3RM1 / ET200s) Safety VFDs (G120 / S120) Page 36

Siemens Safety Integrated Safety Design Compliance - Safety Evaluation Tool The Safety Evaluation tool A free Internet-based tool for calculating safety functions ISO 13849-1 (successor standard of

37 Siemens Safety Integrated Safety Design Compliance - Safety Evaluation Tool The Safety Evaluation tool A free Internet-based tool for calculating safety functions ISO (successor standard of EN 954-1) IEC For documenting the results by a report Offers easy, identical handling for both standards Optimum support when using the Siemens products Safety Evaluation Tool Online Access SET Getting Started Document SET Tutorial (YouTube) Risk assessment Risk reduction Proof Page 37

38 Siemens Safety Integrated Machine Safety Services Risk Assessments Partners GP Strategies White Horse Safety Safety Validation Partner TÜV Rheinland of North America Page 38 The Complete Safety Solution

39 Demo Unit Layout LED Indicators Global ESTOP KTP400 Comfort Panel RFID Safety Door Switch Acknowledgement Button Door Indicator Light Local ESTOP Zone 2 LED Safety Relay Output Module #1 Zone 1 LED Safety Relay Output Module #2 S F Safety PLC Safety Input Module Page 39

40 Thank you for your attention! SIMATIC Safety Integrated Now your power, to go full force ahead Page 40

Safe shutdown of SIRIUS 3RA6 compact starters with IO-Link interface. SIRIUS Industrial Controls, Safety Integrated, IO-Link FAQ 05.

FAQ 05.2016 Safe shutdown of SIRIUS 3RA6 compact starters with IO-Link interface SIRIUS Industrial Controls, Safety Integrated, IO-Link http://support.automation.siemens.com/ww/view/en/66005100 Siemens