Basics of Safety

Applications
Unrestricted © Siemens 2016 usa.siemens.com/controls
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REGARDING THE USE OF THE APPLICABLE PRODUCTS IN GENERIC APPLICATIONS. THIS INFORMATION IS
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THE PRODUCT FOR THE INTENDED USE, AND ASSUME ALL RISK AND LIABILITY IN CONNECTION WITH THE USE.

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Why Safety Technology?

Protection of…
• People
• Environment

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Why safety technology?

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What aspects do the safety standards cover

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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

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Safety Process Chain

The necessary steps towards a safe machine can be illustrated with a process chain.

Risk Assessment Risk Reduction Proof

Risk Assessment Describe the machine Identify the hazards Evaluate the risks

Define and
Design the architecture Implement a safety concept and
Risk Reduction evaluate
of the safety functions put it into operation
the safety measures

Document the
Proof Carry out a validation Document results
measures

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 Risk Assessment

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 13849-1: “Performance Level” (PL)

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Risk Reduction

Risk Assessment Risk Reduction Proof

• Mechanical Guarding

• Education

• Technology solutions consist of three main components

Detection Evaluation Reaction

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 Detection
Emergency stop and protective area monitoring

Initiates stop
Prevents unauthorized access
Detects dangerous machine functions
Positive opening contacts

Positive opening switches are designed in such a way

that actuation of the switch always results in opening
the contacts. Welded contacts are opened by
actuation (EN 60947-5-5)

Detection Evaluation Reaction

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Detection

Standard position switches

Safety switches with

separate actuator and
interlocking

Safety switch Safety switch

with separate actuator hinge switch

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Detection

Panel Mounted Configurable Enclosures Distributed Safety

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Detection

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Detection

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Reaction

Safety-rated contactors must include positively

driven (mirror) contacts
A component with positive-driven contacts
guarantees that the NC and NO contacts are never
closed simultaneously (EN 60947-5-1)
A mirror contact is an NC contact that is guaranteed
not to be closed at the same time as a main contact
(EN60947-4-1)
Siemens 3RT contactors comply with this
requirement

Detection Evaluation Reaction

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Evaluation
Monitors Inputs / Initiates Reaction

Safety Relays Programmable Safety Relays Distributed Safety Systems

• Limited inputs and outputs • Moderate inputs and outputs • Distributed multiple inputs and
• Simple logic • Simple to semi-complex logic outputs
• Single Zone • Multiple Zone • Complex Logic
• Multiple Zone

Detection Evaluation Reaction

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Siemens Safety Integrated
Machine safety solution selection

3 Safety Functions 8 Safety Functions 25 Safety Functions >25 Safety Functions

Without PC Graphical Programming

Editor Language
e.g., LAD/F-LAD

Cabinet-Free In-Cabinet In-Cabinet Cabinet-Free

(IP 65/67) (IP 20) (IP 20) (IP 65/67)

Modular Safety
Safety Relays ASI-Safe System Fail-Safe Controllers Fail-Safe Controllers

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Functionality of a Safety Circuit
A review

24V or 115VAC
Power Supply

Redundancy
ensures safety Evaluation Reset
functionality even if a Fault detection and Reactivates the
failure disables one evaluation; opens the safety circuit
channel circuit in case of a
failure.
Feedback Loop
Sensors Monitors the correct
operation of the
Initiate machine shut
contactor coils
down
Positive Driven (Mirror)
Positive Opening Guarantees that NC contacts are
Guarantees that all not to be closed at the same time
NC contacts are in as the main contact
the open position
when actuated

0V

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Safety Levels
PL a

Standard Switch and Contactor PL a allows

• NO contacts for
• Enabling
• Two-hand control
• Restart

L1 L2 L3

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Safety Levels
PL b

24 VDC PL b requires

Closed
• Sensors with positive

Open
opening contacts

L1 L2 L3

0 VDC

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Safety Levels
PL c / SIL 1

24 VDC PL c / SIL 1 requires

Closed
• Sensors with positive

Open
ON opening contacts
And
• Safety evaluation unit rated
to SIL 1
• Feedback loop from
L1 L2 L3
contactor’s NC contacts

Q1

0 VDC

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Safety Levels
PL d / SIL 2

24 VDC PL d / SIL 2 requires

Closed
• Sensors with positive

Open
ON opening contacts

• Safety evaluation unit rated

to SIL 2
• Feedback loop from
L1 L2 L3
contactor’s NC contacts
And
• Redundancy in sensor
Q1
contacts
• Redundancy in contactors

Q2
0 VDC

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Safety Levels
PL e / SIL 3

24 VDC PL e / SIL 3 requires

Closed
• Sensors with positive

Open
ON opening contacts

• Safety evaluation unit rated

to SIL 3
• Feedback loop from
L1 L2 L3
contactor’s NC contacts

• Redundancy in sensor
Q1
contacts
• Redundancy in contactors
And
• Separate channels of
Q2
0 VDC
evaluation for sensors

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Siemens Safety Evaluation Portfolio

F-CPU: S7-1200 /
S7-1500 / ET 200SP

MSS 3RK3
MSS ASIsafe
3SK2
3SK1

Safety device Failsafe

Safety Relays Modular Safety System
SIMATIC
SIRIUS 3SK SIRIUS 3RK3
PLCs and distributed I/O
Engineering Hardware-
Software-parameterized Software-programed
parameterized
Number of
Up to 3* Up to 6 Up to 20 From 10
safety functions
Communication AS-i, PROFIBUS,
none AS-i and PROFIBUS PROFINET, PROFIsafe,
I-WLAN

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Online Configurator

www.siemens.com/industrymall

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Evaluation - Safety Relay

3SK1 Standard 4 RO 3 RO
5 Amp 10 Amp

Output Expansion

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Evaluation - Safety Relay

Power Supply
3SK1 Advanced Device Connector

Output Expansion
Input Expansion

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Traditional Safety Relay

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New 3SK1 Safety Relay

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Safety Relay Application Example

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Evaluation – Programmable Safety Relay

Power Supply
3SK2 Device Connector

Output Expansion

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Evaluation – Programmable Safety Relay

Area Estop

Zone Estop Zone Estop

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SIRIUS Innovations
Motor starter 3RM1 Failsafe

• Contactor and Overload

Direct / reversing start
Same Size Enclosure

With Safety functionality

• Suitable for safety applications up to PL e / SIL 3

With overload protection

• ATEX certified up to SIL 2

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Evaluation
SIL 3 application with a safety relay

6 Wires / starter
• 4 wires for 2 coils
Emergency
Stop
• 2 wires for feedback

Start

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SIRIUS 3SK1 and 3RM1 Failsafe
Application

3RM1 Failsafe
Motor Starters

Emergency
Stop
3SK1
Safety
Start Relay

Motor Starter

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Distributed Safety

SIMATIC AS-i F-Link with TIA Portal

Standard data
PROFINET / PROFIsafe

SIMATIC PN / AS-i F-Link

AS-i double master and
F-DI module

AS-i / ASIsafe

Safety cell Safety cell

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Distributed Safety

Motor Management System

SIMOCODE pro

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Safety Application Manual

https://support.industry.siemens.com/

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Safety Application Manual

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Safety Application Manual

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Safety Application Manual

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 Siemens Safety Integrated
Machine Safety Life-Cycle Support — USA

► Siemensprovides competent support

Safety Education
throughout the entire machine safety lifecycle
• Machine Safety Standards
► Support
• Safety Webinars
►Safety Consultants • Newsletter
►Safety Core Team • Safety White Papers
• Siemens Safety Website
►Safety Validation
Compliance
► Implementation • OSHA Website
►Siemens Solution Partners • Consensus Standards
– Safety • Risk Assessment Standard
• Safety Evaluation Tool - SET
►Safety Functional Examples
Products and Solutions
►Safety Training
• Safety Products
►Risk Assessment Training • Safety Software
• Wireless Safety
• PC-Based Safety
• BMS
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Questions

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Basics of Safety Applications

John Burns
Lead Application Consultant
SII DF CP
5300 Triangle Parkway
Norcross, GA 30092
Tel.: +1 (770) 625-5726
Fax: +1 (678) 297-7250
Cell: +1 (678) 575-3086
E-mail:
john.burns@siemens.com

siemens.com

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Basics of Safety
Applications
Unrestricted © Siemens 2016 usa.siemens.com/controls