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Safety Chain Solution

Introduction
SAFETY CHAIN SOLUTIONS
Schneider Electric provides you a means to get started on your machine adaptation for the new EN/IEC and EN/ISO functional
safety standards by using our certified Safety Chain Solutions. Safety Chain Solutions is a set of documentation that,
through example, will provide you with most of the information you need to retro-fit existing machine designs, or to integrate
into new machine designs, the new Functional Safety Requirements as specified by EN/IEC 62061, EN/ISO 13849-1 and
other specific standards related to functional safety and its implementation (see list detailed below).
The Safety Chain Solutions documentation contains a safety application example, based on a combination of interoperating
products to realize a safety function, and includes a TV approved principle wiring diagram and the corresponding safety
level calculation.
The application example is made by:
A layout of the solution indicating performance level (PL) and safety integrity level (SIL)
A Bill of Materials and system description file
A functional safety conceptual principle diagram
An example description of the PL and SIL calculation for the safety function and library case included in SISTEMA
tool
Certification of the product combination from an appropriate standards organization
This documentation allows you to save time and money in the effort of obtaining the machine certificate according to the new
European Machinery Directive. The right information can be easily selected, according to your safety level and application
required, by means of our safety selector tool that you can find in our website www.schneider-electric.com.
Please, dont hesitate to contact your Schneider Electric sales office or local distributor for further details or assistance.

IMPORTANT INFORMATION
Safety systems are comprised of many components and no one safety component will ensure the integrity of the system. The
design of the entire safety system should be considered before you begin. It is your responsibility to observe, respect and
implement all pertinent local, regional and national safety regulations when installing, wiring and using the products
described in this documentation. Safety related lifecycle needs to be respected.
Electrical equipment must be installed, operated, serviced and maintained only by qualified personnel. No responsibility is
assumed by Schneider Electric for any consequences arising out of the use or misuse of the information or products
contained in this or any other related documentation.
A qualified person, and specifically a qualified machine designer, is one who has the skills and knowledge related to the design,
construction and operation of electrical equipment, and has received safety training to recognize and avoid the hazards
involved. In addition, a qualified person designing electrical machine equipment is one who is well trained and experienced
in safety system requirements and standards implementation.
The qualified machine designer must detail a Functional Safety Specification to identify the required functionality of the total
system, which includes:
All of the safety chain devices (input, output, and logic).
The interconnections between standard control and the safety control system.
The requirements for integrating devices into the existing system.
The sequence of events due to various demands on the safety system for each mode of machine operation.
The diagnostic requirements.
Any other items related to the system design.

PLEASE NOTE
The Safety Chain Solution documentation and the information contained therein is intended to provide a quick introduction and
means to develop the required level of functional machine safety according to the applicable European standards by way of
a safety application example. It is not intended to replace any specific product documentation, nor any of your own design
documentation. On the contrary, it offers additional information to the product documentation for installing, configuring and
implementing a safety solution system. The safety level calculation and principle diagrams included in this document or any
related document are for illustrative guideline purposes only and are not intended as the definitive method or methods for
implementing a certifiable safety system.
Further, this documentation is not intended as a substitute for determining suitability or reliability of these products for specific
user applications. It is the duty of any such user or integrator to perform the appropriate and complete risk assessment
based on a clear understanding of the machine function and its limits to identify all possible hazards. In addition, it is the
responsibility of the user or integrator to perform the rigorous testing and evaluation of the products with respect to the
relevant specific application or use thereof. Due to the many variables and requirements associated with any particular
machine or installation, neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for the
misuse of the information contained herein, including but not limited to the use of the values and/ or diagrams shown within
this or any other related documentation.

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BEFORE YOU BEGIN


The following wiring diagrams and products specified in this document have been tested under actual service conditions. The
safety products must be used exclusively for safety-related functions in conjunction with the connected safety equipment and
devices that meet applicable standard requirements. Of course, your specific application requirements may be different from those
assumed for this and any related examples described herein. In that case, you will have to adapt the information provided in this
and related documents to your particular needs. To do so, you will need to consult the specific product documentation of the
components that you add or substitute in this architecture. Pay particular attention and conform to any safety information, different
electrical requirements and normative standards the would apply to your adaptation.
There are some major components in this architecture described in this and related documents that cannot be substituted without
significantly compromising or completely invalidating the architecture, descriptions, instructions, wiring diagrams and compatibility
between the various software and hardware components specified herein and in related documentation. You must be aware of the
consequences of component substitutions and additions. A residual risk, as defined by EN/ISO 12100-1, Article 5, will remain if:

it is necessary to modify the recommended circuit and if the added or modified components are not properly
integrated in the control circuit;
the user does not follow the required standards applicable to the operation of the machine, or if the adjustments
to and the maintenance of the machine are not properly made (it is essential to strictly follow the prescribed
machine maintenance schedule);
the devices connected to the safety outputs do not have mechanically-linked contacts.

CAUTION
EQUIPMENT INCOMPATIBILITY
Read and thoroughly understand all device and software documentation before attempting any
component substitutions or other changes related to the application examples provided in this
document.
Failure to follow these instructions can result in injury or equipment damage.
Only the user or integrator can be aware of all the conditions and factors present during installation and setup, operation, and
maintenance of the machine, and can therefore determine the automation and associated equipment and the related safeties and
interlocks which can be effectively and properly used. When selecting automation and control equipment, and any other related
equipment or software, for a particular application, the user or integrator must also consider any applicable local, regional or
national standards and/or regulations.

WARNING
REGULATORY INCOMPATIBILITY
Be sure that all equipment applied and systems designed comply with all applicable local,
regional and national regulations and standards.
Failure to follow these instructions can result in death, serious injury or equipment
damage.

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START-UP AND TEST
Before using electrical control and automation equipment after design and installation, the application and associated functional
safety system must be subjected to a start-up test by qualified personnel to verify correct operation of the equipment. It is
important that arrangements for such testing be made and that enough time is allowed to perform complete and satisfactory
testing.

CAUTION
EQUIPMENT OPERATION HAZARD
Verify that all installation and set up procedures have been completed.
Before operational tests are performed, remove all blocks or other temporary holding means
used for shipment from all component devices.
Remove tools, meters and debris from equipment.
Failure to follow these instructions can result in injury or equipment damage.
Follow all start-up tests recommended in the equipment documentation. Store all equipment documentation for future reference.
Verify that the completed system, including the functional safety system, is free from all short circuits and grounds, except those
grounds installed according to local regulations. If high-potential voltage testing is necessary, follow recommendations in
equipment documentation to help prevent injury or equipment damage.
Before energizing equipment:
Remove tools, meters, and debris from equipment.
Close the equipment enclosure door.
Perform all start-up tests recommended by the manufacturer.
OPERATION AND ADJUSTMENTS

Regardless of the care exercised in the design and manufacture of equipment or in the selection and ratings of components, there
are hazards that can be encountered if such equipment is improperly installed and operated.

It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe operation. Always use the
manufacturer instructions as a guide to functional adjustments. Personnel who have access to these adjustments must be familiar
with the equipment manufacturer instructions and the machinery used with the electrical equipment.

Only those operational adjustments actually required by the machine operator should be accessible to the operator. Access to
other controls should be restricted to help prevent unauthorized changes in operating characteristics.

Only the user or integrator can be aware of all the conditions and factors present during installation and setup, operation, and
maintenance of the machine, and can therefore determine the automation and associated equipment and the related safeties and
interlocks which can be effectively and properly used. When selecting automation and control equipment, and any other related
equipment or software for a particular application, the user or integrator must also consider any applicable local, regional or
national standards and/or regulations.

WARNING
REGULATORY INCOMPATIBILITY
Be sure that all equipment applied and systems designed comply with all applicable local,
regional and national regulations and standards.
Failure to follow these instructions can result in death, serious injury or equipment
damage.

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RELATED STANDARDS AND DOCUMENT REFERENCES

EN/IEC 60204-1
EN/IEC 60947-4-1
EN/IEC 60947-5-5

EN/IEC 60947-5-1

EN/IEC 61496-1
EN/IEC 61496-2

EN/IEC 62061
EN/IEC 61508
EN ISO 13850
EN ISO 13855
EN ISO 13849-1
EN ISO 13849-2
PrEN ISO 12100-2
EN 574/ISO 13851
EN ISO 13856

BGIA-Report 2/2008
SISTEMA

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Safety of machinery. Electrical equipment of machines. General


requirements
Low-voltage switchgear and control gear - Part 4-1: Contactors and
motor-starters - Electromechanical contactors and motor-starters
Low-voltage switchgear and control gear - Part 5-5: Control circuit
devices and switching elements - Electrical emergency stop device
with mechanical latching function.
Low-voltage switchgear and control gear - Part 5-1: Control circuit
devices and switching elements - Electromechanical control circuit
devices
Safety of machinery - Electro-sensitive protective equipment - Part
1: General requirements and tests
Safety of machinery - Electro-sensitive protective equipment - Part
2: Particular requirements for equipment using active optoelectronic protective devices (AOPDs)
Safety of machinery - Functional safety of safety-related electrical,
electronic and programmable electronic control systems
Functional safety of electrical/electronic/programmable electronic
safety-related systems
Safety of machinery - Emergency stop - Principles for design
Safety of machinery - Positioning of protective equipment with
respect to the approach speeds of parts of the human body
Safety of machinery - Safety-related parts of control systems - Part
1: General principles for design
Safety of machinery - Safety-related parts of control systems - Part
2: Validation
Safety of machinery - Basic concepts, general principles for design Part 2: Technical principles
Safety of machinery - Two-hand control devices - Functional
aspects and design principles
Safety of machinery -- Pressure-sensitive protective devices -- Part
3: General principles for the design and testing of pressuresensitive bumpers, plates, wires and similar devices
Functional safety of machine controls Application of EN ISO
13849
Assistant tool program (Safety Integrity Software Tool for the
Evaluation of Machine Applications) made by BGIA