Safety-related controls SIRIUS Safety Integrated

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1 Functional Example CD-FE-I-018-V30-EN Safety-related controls SIRIUS Safety Integrated with monitored start up to SIL 1 acc. to IEC and PL c acc. to ISO with a SIRIUS safety relay 3TK28 with contactor relays

2 Preliminary comment Safety Functional Examples are functional and tested automation circuits based on standard I IA/DT products. They can be used to simply, quickly and cost effectively implement applications in safety technology. Each of the Safety Functional Examples covers a sub task of a typical customer application involving safety technology that is frequently encountered. In addition to a list of all of the necessary software and hardware components, and a description of their interconnection, the Functional Examples also contain tested and commented code. This enables the functions described here to be adapted quickly, and thus used as a basis for individual extensions. Important Note The Safety Functional Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The Safety Functional Examples do not represent customer-specific solutions. They are only intended to provide support for typical applications. You are responsible in ensuring that the described products are correctly used. These Safety Functional Examples do not relieve you of the responsibility in safely and professionally using, installing, operating and servicing equipment. When using these Safety Functional Examples, you recognize that Siemens cannot be made liable for any damage/claims beyond the liability clause described above. We reserve the right to make changes to these Safety Functional Examples at any time without prior notice. If there are any deviations between the recommendations provided in these Safety Functional Examples and other Siemens publications - e.g. catalogs - then the contents of the other documents have priority. SIRIUS Safety Integrated Page 2/11 CD-FE-I-018-V30-EN

3 Table of contents 1 Warranty, liability and support Function Description of the functionality Advantages / customer benefits Components required Structure and wiring An overview of the hardware structure Hardware component wiring Evaluation acc to IEC and ISO : Safety function Evaluation according to IEC Evaluation according to ISO : Summary Contact partners History SIRIUS Safety Integrated Page 3/11 CD-FE-I-018-V30-EN

4 1 Warranty, liability and support We do not accept any liability for the information contained in this document. We are not liable for any damage caused by the use of the examples, information, programs, configuration and performance data etc. described in this Safety Functional Example, independent of the legal ground upon which this is based, unless we are imperatively liable according to the product liability law due to, e.g., cases of premeditation, an act of gross negligence, injury to life, body or health, or unless the quality of a product has been guaranteed, or due to fraudulent concealment of a defect or serious breach of contract. Damages due to serious breach of contract are, however, restricted to prevalent and foreseeable contractual damages, in as much as there is no premeditation or gross negligence nor imperative liability due to injury to life, body or health. This does not constitute a change in the burden of proof to your disadvantage. Copyright 2007 Siemens I IA/DT. It is not permissible to transfer or copy these Safety Functional Examples or excerpts of them without first having prior authorization from Siemens I IA/DT in writing. SIRIUS Safety Integrated Page 4/11 CD-FE-I-018-V30-EN

5 2 Function 2.1 Description of the functionality If people (in production technology) are close to machines, then they must be protected using the appropriate equipment. The Emergency Stop control device represents a widely established component that protects man, machine and environment against potential hazard. In this Safety Functional Example, the EMERGENCY-STOP control unit with a positive opening contact is monitored using a SIRIUS 3TK28 safety relay with contactor relays up to SIL 1 according to IEC and PL c according to ISO When the is activated, the safety relay initiates a shutdown via its contactor relays by means of a positively driven operation according to stop category 0 in compliance with EN Before renewed switch-on or acknowledgement of the EMERGENCY-STOP shutdown via the start button, a check is carried out to monitor whether the contact of the EMERGENCY-STOP control unit is closed and the contactors of the safety relay are switched off. Normal switching duty (On/Off) of the contactors is possible. Either an isolated contact between terminals 3 and 4 or a nonisolated output (24 V DC) is connected, e.g. from a standard PLC to terminal 4. Normal switching duty is subordinate to the safety function. If normal switching duty is not required, a wire jumper must be connected between terminals 3 and 4 (see section 3.2). Note Devices, functional aspects and design guidelines for are stored in EN ISO 13850: Standard EN : 2006 must also be observed. 2.2 Advantages / customer benefits Pure hardware engineering without software configuration Minimal and simple wiring Space-saving design thanks to compact safety combination Easily expandable with expansion devices SIRIUS Safety Integrated Page 5/11 CD-FE-I-018-V30-EN

6 3 Components required Hardware components Table 3-1 Component Type Order no / Order information Qty Manufacturer Note Emergency stop Safety relay 3TK28 with contactor relays Start button 1NC 40mm mushroom pushbutton with yellow top, without protective collar 3SB DG3 3TK28 3TK2853-1BB40 1 Empty command point enclosure 1NO contact block for base mounting Black pushbutton with flat button, 22 mm nominal diameter Optional: "Start" label 3SB AA3 3SB3 420-OB 3SB AA11 3SB EL Siemens The functionality was tested with the hardware components listed above. Similar products not found in the above list (e.g. a different 3TK28 safety relay) may also be used. If this is the case, please consider that changes to the wiring of the hardware components (e.g. different terminal assignment) might be required. SIRIUS Safety Integrated Page 6/11 CD-FE-I-018-V30-EN

4 Structure and wiring 4.1 An overview of the hardware structure "Detect" Emergency stop start 3TK28 safety relay with contactor relays "Evaluate" and "Respond" 4.

7 4 Structure and wiring 4.1 An overview of the hardware structure "Detect" Emergency stop start 3TK28 safety relay with contactor relays "Evaluate" and "Respond" 4.2 Hardware component wiring L+(24V DC) Emergency stop start Q1...Qn * A1 A2 1 2 Y11 Y12 Y35 Y21 Y22 Y32 Y33 Y A1 A TK2853-1BB M Q1 Qn * Bridge between terminals 3 and 4 when the operational switching function is not needed * SIRIUS Safety Integrated Page 7/11 CD-FE-I-018-V30-EN

8 5 Evaluation acc to IEC and ISO : Safety function Comments is not a means of risk mitigation. is a "Supplementary Safety Function" Supplementary safety function Further considerations are based on the following supplementary safety function: Supplementary safety function SF 1 The motor must be switched off when is actuated. The safety functions listed abore are evaluated below according to the two standards IEC und ISO :2006. SIRIUS Safety Integrated Page 8/11 CD-FE-I-018-V30-EN

9 5.2 Evaluation according to IEC Parameters for the calculation of PFH D for "Detection" () and "Responding" (contactor) Parameters Value Reason Definition B10 Contactor Proportion of hazardous failures Contactor T1 Service life C Number of operations of Number of operations of contactors DC Degree of diagnostic coverage 1 * * ,200h (20 years) 6 * 10-3 / hrs 6 * 10-3 /h 0 (0%) Manufacturer specifications Manufacturer specifications (20%) (73%) Manufacturer specifications Assumptions: Actuated once per week (7 * 24 hours) ( test). Actuations can take place every day of the year (365 days) The contactors are always activated and are only operated when the is actuated. No fault reaction is initiated. (Worst case). Siemens User Evaluation parameters Parameters Component Value Definition PFH D (3TK) 3TK * Siemens Summary IEC SILCL PFH D Detect 1 Hardware error tolerance HFT = * Architecture: Basic Proportion of safe failures: SFF = 0 (0%) subsystem architectur A Evaluate 3 Use of proven components Manufacturer specifications 1.08 * Manufacturer specifications Respond 1 Hardware error tolerance HFT = 0 Proportion of safe failures:= 0 (0%) Use of proven components 4.34 * Architecture: Basic subsystem architectur A Result 1 SILCL of all tasks of the supplementary safety function is at least 1. PFH D (=1.24* ) of the entire supplementary safety function is less than SIL 1. SIRIUS Safety Integrated Page 9/11 CD-FE-I-018-V30-EN

10 5.3 Evaluation according to ISO :2006 Parameters for the calculation of MTTF d for "Detection" () and "Responding" (contactor) Parameters Value Reason Definition B10 contactor Proportion of hazardous failures contactor d op Mean operating time in days per year h op Mean operating time in hours per day t cycle Mean time between the start of two consecutive cycles of the component Contactor 1 * * Days per year 24 hours per day 168h/cycle 168h/cycle Manufacturer specification Manufacturer specification (20%) (73%) Assumption: Actuation takes place every day of the year. Assumption: There is an interval of one week between actuations of the ( test) and contactors (7 * 24 hours) Siemens Interim results (are identical in this example for and contactor): Interim results Reason MTTF d High MTTF d 30 years DC None DC=0% Measures Not relevant against CCF Category 1 System behavior: A single fault can result in the loss of the safety function. User Evaluation parameters Parameters Component Value Definition PFH D (3TK) 3TK * Siemens Result ISO :2006 PL PFH D Detect c 1.14 * (from Annex K; see note) Evaluate e 1.08 * Respond c 1.14 * (from Annex K; see note) Result c PL of all tasks of the supplementary safety function is at least c Note: The MTTF d for each channel is limited to max. 100 years! SIRIUS Safety Integrated Page 10/11 CD-FE-I-018-V30-EN

11 5.4 Summary IEC ISO :2006 SILCL PFH D PL PFH D Detect * c 1.14 * Evaluate * e 1.08 * Respond * c 1.14 * Result SIL 1 PL c 6 Contact partners Technical Assistance for low-voltage switchgear In person from Mon. Fri. 8 a.m. to 5 p.m. (CET) Phone: +49 (911) technical-assistance@siemens.com Internet: By fax 24 hrs a day Fax: +49 (911) History Table 7-1 History Version Date Change V First issue V Revision of the hardware assembly overview - New chapter: Evaluation according to IEC and ISO V Revision of title and description of functionality - Adjustment of Proportion of hazardous failures for contactors to 73% and resulting PFH D values - Adjustment of PFH D value of 3TK2853 to 1.08 * SIRIUS Safety Integrated Page 11/11 CD-FE-I-018-V30-EN

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.