Post on 01-Jan-2016
Monitoring of a safety gate with guard
locking in combination with a delay device
Product
Type: Safety gate, guard locking
Name: PNOZsigma, PSENmech
Manufacturer: Pilz GmbH & Co. KG, Safe Automation
Document
Release Number: 03
Release Date: 9 August 2011
Application Note - No. 1002297_EN_03
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728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 2/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
Document Revision History
Release Date Changes Chapter
01 2011-05-30 Creation all
02 2011-05-31 Adjustment data base -
03 2011-08-09 Adjustment entry 3.2.2
Exclusion of liability
We have taken great care in compiling our application note. It contains information about our
company and our products. All statements are made in accordance with the current status of
technology and to the best of our know-ledge and belief.
However, we cannot accept liability for the accuracy and entirety of the information provided,
except in the case of gross negligence. In particular it should be noted that statements do not
have the legal quality of assurances or assured properties.
We are grateful for any feedback on the contents.
August 2011
All rights to this publication are reserved by Pilz GmbH & Co. KG. We reserve the right to
amend specifications without prior notice. Copies may be made for the user’s internal purposes.
The names of products, goods and technologies used in this manual are trademarks of the
respective companies.
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560 pt
574 pt
588 pt
602 pt
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630 pt
644 pt
658 pt
672 pt
686 pt
700 pt
714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 3/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
Support
Technical help round the clock!
Technical support is available from Pilz round the clock.
This service is provided free of charge beyond standard business hours.
Americas
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+31 347 320477
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You can reach our international hotline on:
+49 711 3409-444 or mailto:support@pilz.com
Pilz GmbH & Co. KG
Safe Automation
Felix-Wankel-Straße 2
73760 Ostfildern, Germany
Telephone: +49 711 3409-0
Telefax: +49 711 3409-133
E-Mail: pilz.gmbh@pilz.de
Internet: www.pilz.com
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28 pt
42 pt
56 pt
70 pt
84 pt
98 pt
112 pt
126 pt
140 pt
154 pt
168 pt
182 pt
196 pt
210 pt
224 pt
238 pt
252 pt
266 pt
280 pt
294 pt
308 pt
322 pt
336 pt
350 pt
364 pt
378 pt
392 pt
406 pt
420 pt
434 pt
448 pt
462 pt
476 pt
490 pt
504 pt
518 pt
532 pt
546 pt
560 pt
574 pt
588 pt
602 pt
616 pt
630 pt
644 pt
658 pt
672 pt
686 pt
700 pt
714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 4/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
Contents
1. Useful documentation .................................................................................. 5 1.1. Documentation from Pilz GmbH & Co. KG ............................................................................ 5
1.2. Documentation from other sources of information ................................................................. 5
2. Hardware configuration ................................................................................ 6 2.1. Pilz products ........................................................................................................................... 6
2.2. Hardware configuration .......................................................................................................... 6
3. Application Task ........................................................................................... 7 3.1. Description ............................................................................................................................. 7
3.1.1. Monitoring guard locking and safety gate (safe interlock) ........................................... 8
3.1.2. Safety assessment ...................................................................................................... 9
3.2. Functional safety .................................................................................................................. 10
3.2.1. Classification of the required PL (using the safety gate and guard locking device as
examples) ............................................................................................................................ 10
3.2.1.1. Classification of the required Performance Level (PLr) for the safety gate ........ 10
3.2.1.2. Classification of the required Performance Level (PLr) for the guard locking
device ............................................................................................................................... 11
3.2.2. Classification of the safety levels (PL and SIL) achieved .......................................... 12
3.2.2.1. Safety-related characteristics in accordance with EN ISO 13849-1 ................... 12
3.2.2.2. Safety-related characteristics in accordance with EN 62061 .............................. 13
3.2.2.3. Classification in accordance with EN 954-1 ........................................................ 13
3.3. Circuit diagram of the application ......................................................................................... 14
3.3.1. Circuit diagram 1/2 ..................................................................................................... 14
3.3.2. Circuit diagram 2/2 ..................................................................................................... 15
4. Table of figures ........................................................................................... 16
Abbreviations
SF Safety Function
FBL Feedback Loop (DE: RFK Rückführkreis)
CCF Common Cause Failure
PLr Required Performance Level
PL Performance Level
SIL Safety Integrity Level
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196 pt
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238 pt
252 pt
266 pt
280 pt
294 pt
308 pt
322 pt
336 pt
350 pt
364 pt
378 pt
392 pt
406 pt
420 pt
434 pt
448 pt
462 pt
476 pt
490 pt
504 pt
518 pt
532 pt
546 pt
560 pt
574 pt
588 pt
602 pt
616 pt
630 pt
644 pt
658 pt
672 pt
686 pt
700 pt
714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 5/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
1. Useful documentation
Reading the documentation listed below is necessary for understanding this application note.
The availability of the indicated tools and safe handling are also presupposed with the user.
1.1. Documentation from Pilz GmbH & Co. KG
No. Description Item No.
1 Pilz international homepage, download section www.pilz.com
2 Operating instructions PNOZ s3 21 395-6NL-xx
3 Operating instructions PNOZ s9 21 401-6NL-xx
4 Installation and Operating Instructions PSEN me1 0800000624
5 Installation and Operating Instructions PSEN me2 0800000423_en
6
1.2. Documentation from other sources of information
No. Description Item No.
1
2
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392 pt
406 pt
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448 pt
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490 pt
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560 pt
574 pt
588 pt
602 pt
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630 pt
644 pt
658 pt
672 pt
686 pt
700 pt
714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 6/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
2. Hardware configuration
2.1. Pilz products
No. Description Order number Version Number
1 PNOZ s3 750 103 - 1
2 PNOZ s9 750 109 - 1
3 PSEN me1S/1AS 570 000 - 1
4 PSEN me2/2AS 570 200 - 1
2.2. Hardware configuration
Fig. 1: Hardware configuration
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658 pt
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686 pt
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714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 7/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
3. Application Task
3.1. Description
The example shows the safe monitoring of a safety gate with guard locking.
Two PSENmech (S1, S2) are used for monitoring the safety gate (safe interlock) and guard
locking and they are evaluated by a PNOZ s3 (A1) and a PNOZ s9 (A2).
A machine performs a dangerous movement within a protective housing (guard grid and safety
gate).
To ensure that the operator can enter the operating area only when there is no longer any
danger, a delay device will be started at stop of the machine. This provides that standstill of the
movement is achieved before the guard lock of the safety gate can be opened (delay time >
maximum stopping time of the movement).
Fig. 2: Application: Safety gate with guard lock
The process is divided into the following main functions:
� Monitoring Safety Gate
� Monitoring Guard Locking
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294 pt
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560 pt
574 pt
588 pt
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616 pt
630 pt
644 pt
658 pt
672 pt
686 pt
700 pt
714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 8/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
3.1.1. Monitoring guard locking and safety gate (safe interlock)
To start the machine, the safety gate must be closed and the PNOZ s3 must be reset via the
reset button (S3).
The start button (S5) is then used to start the motor.
� The contacts at the contactors KM1 and KM2 are switched off by operating the stop button
(S6). Input circuit S32 on the safety relay PNOZ s9 (A2) is closed as soon as the N/C contact
(21-22) at KM1 and KM2 are re-closed. The safety contact (17-18) on contact expander
module PNOZ s9 (A2) closes once the set delay time has elapsed. Guard locking on safety
switch PSEN me1S/1AS (S2) can then be released via pushbutton S4. A contact on safety
switch S2 is opened as soon as the guard lock is released by the pushbutton S4.
� The contacts on the two safety switches PSEN me2/2AS (S1) and PSEN me1S/1AS (S2) are
opened as soon as the safety gate is opened. As a result the input circuit on the safety relay
PNOZ s3 (A1) is interrupted and the safety contacts from A1 do open. Contactors KM1 and
KM2 de-energise and the motor (M1) is cut off.
Feedback loop monitoring function: Safety gate
The positive-guided N/C contacts on contactors KM1 and KM2 are monitored via safety relay’s
feedback circuit S12-S34 of the safety relay A1.
Start/reset PNOZ s3
The safety relay PNOZ s3 (A1) can be started by pressing reset button S3 if:
� the safety gate is closed and
� the contacts on safety switches S1 and S2 are closed and
� the safety gate is locked and
� contactors KM1 and KM2 are de-energised.
The contact expander module PNOZ s9 (A2) starts automatically if contactors KM1 and KM2
are de-energised.
Settings
� The terminator on the PNOZ s3 must be connected.
� The terminator on the PNOZ s9 must be connected.
� The operating mode selector switch (mode) on the safety relay PNOZ s3 must be set to
"Monitored reset, falling edge with detection of shorts across contacts (In2-)".
� The operating mode selector switch (mode) on the contact expander module PNOZ s9 must
be set to “Delay-on energisation”.
� The delay time on the safety relay PNOZ s9 is set using the time selector switch t[s] and the
factor selector switch n.
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252 pt
266 pt
280 pt
294 pt
308 pt
322 pt
336 pt
350 pt
364 pt
378 pt
392 pt
406 pt
420 pt
434 pt
448 pt
462 pt
476 pt
490 pt
504 pt
518 pt
532 pt
546 pt
560 pt
574 pt
588 pt
602 pt
616 pt
630 pt
644 pt
658 pt
672 pt
686 pt
700 pt
714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 9/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
3.1.2. Safety assessment
� The circuit of PNOZ s3 (A1) is redundant with built-in self-monitoring.
� The safety function A1 remains effective in the case of one component failure.
� The correct opening and closing of the safety function relays of A1 is tested automatically on
each on-off cycle.
� The PNOZ s3 has an electronic fuse.
� Earth faults and shorts in the reset and input circuit on A1 are detected.
� The PNOZ s9 (A2) monitors its own output contacts.
� The safety function A2 remains effective in the case of one component failure.
� Earth fault in the feedback loop on A2 is detected.
� Earth fault in the input circuit on A2: The output relays de-energise and the safety contacts
open.
� The PNOZ s9 has an electronic fuse.
� The safety relay PNOZ s3 (A1) can only be started if first the input circuit and the feedback
loop of A1 closed and then the reset button S3 are closed and reopened. This avoids an
unwanted reset before the input circuit is closed or as a result of the reset button being
overridden.
� If the position of the operating mode selector switch (mode) on the PNOZ s3 (A1) is changed
during operation, an error message will be triggered and the safety contacts on A1 will open.
This fault condition can only be rectified by switching the supply voltage on the safety relay A1
off and then on again.
� If the position of the operating mode selector switch (mode) o the PNOZ s9 (A2) or the rotary
switch for the time setting is changed during operation, an error message will be triggered; the
safety contacts on A2 open. This fault condition can only be rectified by switching the supply
voltage on the safety relay A2 off and then on again.
� The safety relay PNOZ s3 (A1) and contactors KM1 and KM2 must be installed in a single
mounting area (control cabinet) in order to exclude a short across the output.
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630 pt
644 pt
658 pt
672 pt
686 pt
700 pt
714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 10/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
3.2. Functional safety
3.2.1. Classification of the required PL (using the safety gate and guard locking device as
examples)
The risk assessment for the unit is performed using the iterative process for risk reduction from
EN ISO 12100.
Based on this process, to achieve the necessary safety in our example a guard with a safety
gate as an isolating safety device is built around the machine as a safeguard.
Since the spatial situation means that the necessary safety gap between the safety gate and the
hazardous machine movement cannot be achieved, however, there is still a residual risk
associated with the overrun movement of the drive. This must be assessed by running the
iterative risk reduction process again.
An additional safeguard to reduce the remaining residual risk is added. This is realised by a
guard locking device on the safety gate. The guard locking device prevents anyone going into
the danger zone while the drive has not yet come to a standstill.
The "guard locking device" safety function (SF) thus serves to reduce the residual risk of the
"safety gate" SF and so is linked to this safety function.
Based on the safety gate and guard locking device safety functions, the following example
offers a possible classification of the required Performance Level (PLr) according to EN ISO
13849-1.
CAUTION:
The user must produce a separate classification (for all SFs) specifically for his particular
application. This may produce other values for the respective PLr.
3.2.1.1. Classification of the required Performance Level (PLr) for the safety gate
� Because of the velocity of the machine and the associated force, the severity of injury is
classified as serious (S2).
� The frequency of exposure to the hazard is seldom (F1).
� Because of the high speed, avoidance of the hazard is scarcely possible (P2).
This gives a PLr = d.
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686 pt
700 pt
714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 11/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
Fig. 3: Safety gate risk graph pursuant to EN ISO 13849-1
After the safety gate has been switched off, there is still a residual risk from the machine's
overrun. A separate PLr classification must be performed for the safety function used for this
purpose.
3.2.1.2. Classification of the required Performance Level (PLr) for the guard locking
device
� Because of the velocity of the machine and the associated force, the severity of injury is
classified as serious (S2).
� The frequency of exposure to the hazard is seldom (F1).
� Because of the abrupt reduction in velocity after disconnection by the safety gate switch, the
hazard can be avoided under specific conditions (P1).
This gives a PLr = c.
Fig. 4: Guard locking device risk graph pursuant to EN ISO 13849-1
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378 pt
392 pt
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476 pt
490 pt
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518 pt
532 pt
546 pt
560 pt
574 pt
588 pt
602 pt
616 pt
630 pt
644 pt
658 pt
672 pt
686 pt
700 pt
714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 12/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
3.2.2. Classification of the safety levels (PL and SIL) achieved
3.2.2.1. Safety-related characteristics in accordance with EN ISO 13849-1
No. Safety function Achieved
Performance
Level
Safety-related parts of the control
system
1 It must not be possible to open the guard
locking device while the safe state has not
been reached.
(GUARD LOCKING DEVICE - standstill)
PL c Sensor (contactors KM1, KM2)
Logic (PNOZ s9 A2)
Actuator (me1/magnet S2)
2 A start must be prevented if the guard locking
device is not closed.
(GUARD LOCKING DEVICE - start-up)
PL c Sensor (PSEN me1 S1)
Logic (PNOZ s3 A1)
Actuator (contactors KM1, KM2)
3 Dangerous movements must be stopped
when the safety gate is opened; it must not
be possible to restart if the safety gate is
open.
(SAFETY GATE)
PL e Sensor (PSEN me1/me2 S1, S2)
Logic (PNOZ s3 A1)
Actuator (contactors KM1, KM2)
Prerequisites:
No. Description Identification
1 Common cause failure (CCF): Requirements are considered to be met
(must be tested on implementation)
2 Mission time: 20 years
3 Operating interval (electromechanical
components):
Sensor S1/S2 one operation per hour
Actuator KM1/2 one operation per hour
Actuator me1 one operation per hour
4 Characteristic data of contactors KM1/KM2: B10d 2,000,000
Please note the further requirements of EN ISO 13849-1, e.g. requirements for avoiding
systematic faults.
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560 pt
574 pt
588 pt
602 pt
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630 pt
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658 pt
672 pt
686 pt
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714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 13/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
3.2.2.2. Safety-related characteristics in accordance with EN 62061
No. Safety-related control function (SRCF): Achieved Safety
Integrity Level
Subsystems
1 It must not be possible to open the guard
locking device while the safe state has not
been reached.
(GUARD LOCKING DEVICE - standstill)
SIL 2 Sensor (contactors KM1, KM2)
Logic (PNOZ s9 A2)
Actuator (me1/magnet S2)
2 A start must be prevented if the guard locking
device is not closed.
(GUARD LOCKING DEVICE - start-up)
SIL 1 Sensor (PSEN me1 S1)
Logic (PNOZ s3 A1)
Actuator (contactors KM1, KM2)
3 Dangerous movements must be stopped
when the safety gate is opened; it must not
be possible to restart if the safety gate is
open.
(SAFETY GATE)
SIL 3 Sensor (PSEN me1/me2 S1, S2)
Logic (PNOZ s3 A1)
Actuator (contactors KM1, KM2)
Prerequisites:
No. Description Identification
1 Common cause failure (CCF): ß = 2 % (must be tested on
implementation)
2 Proof test interval: 20 years
3 Operating interval (electromechanical
components):
Sensor S1/S2 one operation per hour
Actuator KM1/2 one operation per hour
Actuator me1 one operation per hour
4 Characteristic data of contactors KM1/KM2: B10d 2.000.000
Dangerous failure
rate
65 %
Please note the further requirements of EN 62061, e.g. requirements for systematic safety
integrity.
3.2.2.3. Classification in accordance with EN 954-1
Depending on the area of application and the regulations applicable there, under EN 954-1 this
connection example applies
� up to category 1 for the guard locking device standstill monitoring SF
� up to category 1 for the guard locking device start-up SF
� up to category 4 for the safety gate SF
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392 pt
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476 pt
490 pt
504 pt
518 pt
532 pt
546 pt
560 pt
574 pt
588 pt
602 pt
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756 pt
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826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 16/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de
4. Table of figures
Fig. 1: Hardware configuration ...................................................................................................... 6
Fig. 2: Application: Safety gate with guard lock ............................................................................ 7
Fig. 3: Safety gate risk graph pursuant to EN ISO 13849-1 ....................................................... 11
Fig. 4: Guard locking device risk graph pursuant to EN ISO 13849-1 ........................................ 11
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14 pt
28 pt
42 pt
56 pt
70 pt
84 pt
98 pt
112 pt
126 pt
140 pt
154 pt
168 pt
182 pt
196 pt
210 pt
224 pt
238 pt
252 pt
266 pt
280 pt
294 pt
308 pt
322 pt
336 pt
350 pt
364 pt
378 pt
392 pt
406 pt
420 pt
434 pt
448 pt
462 pt
476 pt
490 pt
504 pt
518 pt
532 pt
546 pt
560 pt
574 pt
588 pt
602 pt
616 pt
630 pt
644 pt
658 pt
672 pt
686 pt
700 pt
714 pt
728 pt
742 pt
756 pt
770 pt
784 pt
798 pt
812 pt
826 pt
Application Note – No. 1002297_EN_03
Monitoring of a safety gate with guard locking in combination with a delay device
Pilz GmbH & Co. KG, Felix-Wankel-Straße 2, 73760 Ostfildern, Germany 17/17 Telephone: +49 711 3409-0, Telefax: +49 711 3409-133, E-Mail: pilz.gmbh@pilz.de