Safety in AutomationIn the industrial automation division,safety is a real philosophy in machinedevelopment, not just a generic con-cept to make sure that operators andall the people around the machine aresafe. The milestones about safety arethe European Directives and espe-cially the Machinery Directive (EMD98/37/CE). Including safety devicesin any new project, while developinga new machine, is therefore key toreduce risks.

Providing Solutions for Your SafetyIn our opinion, the implementation of safety compo-nents is not just a way to comply with rules andobtain approval certificates. Carlo Gavazzi’s safety devices are studied to meetuser’s requirements, considering the place wherethey will be used. Carlo Gavazzi’s products ensuefrom ideas, they are not a simple connection ofcomponents. Our solutions are studied to allow the end-user toforget about the safety issue, because we arealways there to assure the highest safety standard. Carlo Gavazzi proposes integrated solutions: ourproducts can be combined to work as the machinesafety backbone, with simple and immediate con-nection procedures.The effectiveness of our devices is assured by our75-years experience in the safety market and by ourability to always introduce the latest technology andsolutions in our products. The long term relationship with our users – based onlistening, communication and reliability – adds valueto Carlo Gavazzi’s safety devices.

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Risk Reduction Safety Devices from Carlo Gavazzi

Safety Light CurtainsWhen the opening and closingof the door appears to be toodifficult, our SB Series safetylight curtains provide a widerange of solutions. Devices withdifferent resolutions and sizessucceed in detecting someoneentering the dangerous area.

Safety Limit SwitchesOur PS Series safety limitswitches manage to provideinformation on the status ofmobile safety gates, that have tobe used to allow access to adangerous area. If the switchesare dirty (i.e.: by food and bever-age) or when the applicationrequires the machine to becleaned up, Carlo Gavazzi’ssafety magnetic switches pro-vide clean and reliable informa-tion on the door status.

Safety MatsSometimes, expecially in ceram-ics or wood applications, thedust does not allow the properworking of light curtains. Thisproblem can be solved by CarloGavazzi’s SM Series safety mats,which cover the floor below thedangerous area, detect the pres-ence and then can stop themachine. All this information isconveyed to the machine,through our safety modules, rul-ing the machine’s functioning.

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Integrated Solutions for Safety in Automation

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DOPPIA PAGINA DEDICATA ALLE APPLICAZIONI PIÙ SIGNIFICATIVE - IMPAGINAZIONE POTRA’ CAMBIARE IN FUNZIONE DI FOTO E TESTI

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Our Safety Devices at Work

Light curtains in packaging machines

The safeguarding of packaging applications oftenrequires that objects such as feed stock, workpieces etc. pass through the sensing field, withoutthe activation of any stop signal. Carlo Gavazzi’sSB4B Series light curtains allow up to three adja-cent beams to be interrupted at any location alongthe sensing field. This system operates withouttriggering any safety output, such as floating orblanking. Quick and safe setting is ensured, thanksto the integrated DIP-switches.

Light curtains on presses

Safety light curtains are widely used in order to pro-tect the working area of presses and punchingmachines. The Master- Slave cascade connectionof the SB4M-SB4N Series provides protection inthe dangerous areas and detects presence of oper-ator. All the electronics for Slave unit monitoring(SB4N) are included into the Master (SB4M).Thanks to Carlo Gavazzi’s solutions, mounting,wiring and set-up become really quicker and safe.

Safety mats on woodworking machines

The use of safety mat layouts may be required whenwoodworking machines, such as CNC work centresand routers, must be protected. In fact, safety matssplit into several sections allow obtaining differentsystem response according to machine head positionand/or operation. SM Series safety mats are designedto comply with stringent reliability and quality princi-ples in order to deliver the safety function anytime,even after millions of operations. Obtaining the need-ed layout is always possible and simple, thanks to thewide range of accessories and to the modular design.

Safety gates

Machines provided with mobile protections to pre-vent access to dangerous areas need safetyswitches, to guarantee immediate shut down incase of gate opening during the working cycle. TheSMS Series encoded safety magnetic sensors canbe used in this application and provide the highestlevel of reliability, thanks to the housing’s high levelof sealing. Contactless technology allows ease ofmounting, no wear and a life span of over a hun-dred million of operations.

- IMPAGINAZIONE POTRA’ CAMBIARE IN FUNZIONE DI FOTO E TESTI

Our Safety Devices at Work

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Stopping car-wash systems in presence of danger

In the working area of car-wash machines, there areseveral emergency stop buttons. If a dangerous sit-uation arises, the operator or whoever is nearby thesafety button must be able to stop the machine.The NES02 provides the means for connection ofmultiple E-stop buttons in series. In this way, theneeded safety category for the whole machine isassured.

Managing safety gates on a plastic machine

Generally, safety gates need a safety system guar-anteeing top reliability and durability. In plasticmachines, the main gate must be often opened –i.e. when the moulded part is not correctly releasedor at the end of each use – and safety must not bea problem. NES02 and NES13 simply solve theproblem allowing the opening of the press motormains, when the gates are open.

Starting a press

Presses are really dangerous machines, becauseno gate or light curtain can be used. The only wayto guarantee safety is to make sure the operatorhas both hands busy when the machine works.Safety category III C, complying with EN 574,allows ND12D to be used in the most demandingapplications.

Standstill motor for electrical lock release

If a fast rotating tool is used – for instance to drillwood or glass – the access to the dangerous areamust be allowed only when the tool is immobile. Inthis event, an electrical lock is released and theoperator can access. The MF1C performs thisfunction according to category 3 (EN 954-1). Thegreat advantage of this safety device is that noexternal mechanical sensor or wiring is required.

Safety Light CurtainsSafety light curtains are widely usedto protect dangerous points of oper-ation and to safeguard the access.Whenever at least one of the infraredbeams generated between emitterand receiver is interrupted, the safetyoutputs of our device activate, stop-ping the dangerous motion. Flexibility, ease-of-use and minimumimpact on machine productivity makethis choice much more effective thanmobile material protections.Resolution, operating distance andsafety category are the main parame-ters to be determined when assess-ing the application requirements.

Main AdvantagesCarlo Gavazzi’s commitment in offering a reliable and compre-hensive range of safety solutions continues with the new seriesof safety light curtains. This new set of devices is designed tosatisfy each protection issue, thanks to our knowledge of theapplications and standard requirements. Carlo Gavazzi can pro-vide the right products and every type of accessory, assuring aneasy and effective installation. The safety solutions offeredinclude low risk installations up to complex applications requiringmaximum protection and integrated functionalities.

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Type 2 safety light curtains are available in two differ-ent resolutions: for hand (30 mm) and for presencecontrol protection (90 mm). The main features of thisseries are the built-in control circuits and the inte-grated test function, automatically running every 500ms. The operating distance is 15 m. The SBA2 Series(automatic Start/Reset) or the SBM2 Series (manualStart/Reset) can solve a wide range of industrialapplications. Extremely compact dimensions (31x32mm), protected height between 187 and 1510 mm,easy installation and total reliability, supported by athree year warranty, assure absolute operator safety.

The new series of type 4 safety light curtains, for fin-ger and hand protection, is characterized by integrat-ed advanced functions. Thanks to the EDM function– available on all versions – the light curtain is able toverify the integrity of all external switching devices. AFixed or Floating Blanking – on the SB4B and SB4MSeries – succeeds in deactivating a part of the sens-ing, allowing material passages or mechanical obsta-cle presences, with no machine interruption. TheSB4M Series also has a Cascade feature to combinemultiple light curtains (master and slave), which canbe positioned in different areas. Integrated dip-switches guarantee an instant and safe configuration.

Type 4 safety devices for body protection are well suit-ed for applications that require material passagethrough a dangerous area, such as palettisers ordepalettisers. Installation and alignment really becomeeasy and fast, thanks to pre-assembled, pre-cabled andpre-aligned Muting sensors. Available models include‘T’ shaped versions for bidirectional Muting, ‘L’ versionsfor unidirectional Muting and a linear family version,without integrated Muting sensors. Muting arms areadjustable for the highest flexibility. The integrated DIP-switches guarantee a quick and safe setting of Startmode, Muting mode, muting time and EDM function.

SBA2.../ SBM2...

SB4E.../ SB4B.../ SB4M...

SB4T.../ SB4L.../ SB4S...

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Safety MatsThe safety mats are safeguardingdevices designed for the protectionand surveillance of potentially haz-ardous areas, such as the surround-ings of industrial machineries. SM simple structure, matched with aspecial soldering process - whichensures total sealing of the layers -make SM safety mats also suitable forheavy-duty applications in damp anddusty environments, where almost noother safety devices could be used.In conjunction with safety control unitNT12D, SM safety mats constitute areliable and effective solution for areamonitoring, in compliance with SafetyCategory 3 requirements.

Main AdvantagesCarlo Gavazzi’s safety mats guarantee the controlof a whole restricted area and not just of a perime-ter. This feature is very important, especially whendangerous areas (not visible from the machine con-trol points) must be protected. Safety mats offercustomers the opportunity to have integrated solu-tions, delivering unbeatable reliability and durabili-ty, with no maintenance. Therefore, complexshapes and layouts can be put together with thevariety of available accessories.

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SM safety mats are electrical pressure-sensitivedevices, activated by pressure (usually the opera-tor’s body weight) and utilized for presence control.The external structure of the mat consists of twogenerously sized PVC layers, containing two innerconductive surfaces separated by an appropriateinsulating material. The special soldering processguarantees the total sealing of the outer shells. Thenew external fixing trim ensures a firm anchoring tothe floor and protects cable routine. The cable con-nection monitoring is provided by the NT12D safe-ty control module.The simple and robust construction deliversextreme dependability and a life span of more thanone million cycles.

The concept of modularity was the inspiration forCarlo Gavazzi’s new safety mat accessories,designed for easy and safe installation.The range includes internal and external angularjoints, with sections dedicated to cable routine, andlinear joints with cable outlet for a quick mountingand a full protection of wirings. The ‘H’ section join-ing trim is designed to combine more safety matsegments together. The resulting achievement isthe desired layout, ensuring sensitivity along thejoint side, too. Dedicated coloured adhesive tapesare also available for visible mat section delimita-tions.

Features

Accessories

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Safety ModulesSafety modules play their role in therisk reduction phase of the machinedevelopment process. If, for instance,the installation of a fixed gate appearsto be impossible, but a moving gatehas to be opened to load and unloadthe appliance, the machine has to besafely stopped when the gate is open.This is what Carlo Gavazzi’s safetygate modules are designed for.The same can be said when we haveto manage emergency stop buttons,light curtains, two hand controls, orsafety mats. Carlo Gavazzi provideseasy installation, simple workingmode and immediate fault detection,in conjunction, with the usual CarloGavazzi reliability, of course.

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NES02D... / NSC13D...

If the safety input device is amechanical safety switch (like ourPS21S safety limit switch for safetygates or the emergency stop but-ton EMPB) the NES02 and NES13are the ideal solution to operate upto safety category 4, in compliancewith EN954. If the input device is asafety magnetic switch like ourSMS Series, NSO02 and NSO13are the ideal counterpart. If one ofthe contacts is normally closed, theNSC02 and NSC13 are the mosteffective solution.

MF1C

Measuring the regenerated voltageon a motor's coils, is the best wayto figure out if the tool on a motor’sshaft is moving. Of course thisoperation must be performed safe-ly in order to comply with safetycategory 3. The MF1C providesthis function, allowing for the open-ing of the lock of a safety gate, onlywhen the motion of a motor hascomes to a complete stop.

NLG02D... / NLG13D ...

The NLG02 and NLG13 allowstopping dangerous activitieswhen the operator enters a riskyarea. These Carlo Gavazzidevices assure absolute safety,accepting the transistor outputof our SB Series light curtainsand providing a safety relay out-put.

ND12D

Two-hand systems are indispen-sable when there is no way tokeep the operator away from thedangerous area. The ND12D twohand module of category IIIC incompliance with to EN 574, isconnected to a 2-hand safetybuttons system. This specialdevice allows the machine tofunction only if both buttons arepressed simultaneously.

NT12D

Being the natural completion ofour SM Series safety mats, theNT12D provides a category 3certified safety system, comply-ing with EN954. This device pro-tects the dangerous area fromoperator’s accesses, whileworking.

NE14D

In some cases, several safetypieces of information arerequired to deliver the machine'soperation. The NE14D providesfour safety outputs keeping, ofcourse, the safety category ofthe system.

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Safety BusKeep up production and make your plant saferThe trend is clear: big advantages can be achievedusing bus communication in safety related sys-tems. Compared to the traditional serial wiring ofnormally closed safety switches, the diagnosticsare vastly improved. The immediate indication ofcauses for production interruptions makes it possi-ble to significantly reduce downtime, especially onlarge machines and plants. Furthermore, a bussolution is safer, because the risk of undetectedbridges over normally closed safety contacts isconsiderably reduced.

Bus-powered input modulesBus-powered input modules provide the interfaceto the safety switches, which may be emergencystop palm buttons, pull-cord switches or otherdevices with NC contact. The small-dimensionIP67-rated housing makes it possible to install theinput modules inside or nearby the safety switches,even in rough environmental conditions.

A unique set of featuresDuplineSafe is based on the Dupline® fieldbus, asystem used in more than 120.000 installationsworldwide in the harshest industrial environments.Dupline® is particularly known for its reliability, sim-plicity and ability to transmit signals over long dis-tances. All the features of this Gavazzi’s system areespecially demanded in safety related systems.

Configurable Safety RelayThanks to the handheld DuplineSafe configurationunit, the user can define the addresses of the inputmodules, in order to monitor them with the safetyrelay. In operation mode, the safety relay will trip ifone or more of these input contact does not send avalid “contact closed” signal or if any fault on the busis detected. Several relay output modules can beconnected to the same bus, and each of them canbe configured to monitor any input module. Therebyit is possible to stop several machines in differentlocations, activating a single emergency stop switch.

Approved by TÜV complying to EN61508-SIL3 and EN954-1 Cat. 4The development of the DuplineSafe products hasbeen carried out in close cooperation with TÜVRheinland Group.

Diagnostics via PLC, PC or Text DisplayDuplineSafe Gateways for Profibus-DP andModbus RTU make it possible to read out theDuplineSafe diagnostics information via a PLC, PCor Text Display.

Up to 63 safety signals on a single two-wire cableBus-powered Input ModulesImmediate and precise safety diagnostics

Up to 5 km transmission distance without Repeater

High noise immunity and reliabilityEasy to design, install and commission a system

Several safety relays can read the same input modulesFree topology and no requirement for special cable

Safety signals and standard digital/analogue I/O'sallowed on the same bus

Features

Reduced wiring cost compared to parallel wired systemNo need for local power suppliesMachine stops can be fixed faster, leading to higherproduction efficiencyNo need for special modules or special handlingwhen long distances are involvedHigh system availability - false trips avoidedReduced risk for human error, steep learning curve,no dependence on specialists, and time savingsEasy to use where one safety input can be used tostop several machines at different locationsEasy and flexible wiring with possibility to useexisting cablesOne bus can handle all signals, and safety func-tions can be added to existing Dupline systems

Benefits

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PLC

GS389025230Profibus Gateway

GS3830043230Safety Relay

Motor

Text Display

GS75102101Safety Transmitter

GS75102101Safety Transmitter

GS75102101Safety Transmitter

Pull-cord switch

Emergency Stop

Pull-cord switch

Safety Magnetic SensorsThe SMS Series encoded safety mag-netic sensors are designed to monitorthe position of hinged, sliding orremovable guards of industrial appli-cations. Carlo Gavazzi’s safety sensors – con-nected to a monitoring safety module– provide a method to stop or discon-nect the dangerous motions, if themobile protections are opened or dis-placed. The multiple flux coding ensures thecorrect activation of the sensor withdedicated magnetic units only. Thissystem – in conjunction with redun-dancy frames used in the design –makes the SMS Series suitable forsafety gates applications up to safetycategory 4, complying with EN 954-1.

Main AdvantagesCarlo Gavazzi’s safety magnetic sensors are theright answer, in the presence of harsh industrialenvironments with damp and dusty conditions, orin case of applications where high hygiene stan-dards are needed.The SMS Series is the solution wherever stringenthygienic standards need to be maintained, thanksto the dirt and water resistant sealed boy, and to itsshape, which has no dust collecting cavities. Theseeasy to clean units provide high security perform-ances. Contactless technology means tremendousdurability and allows concealed assembling onnon-magnetic materials: this feature avoids manyproper problems which affect mechanical switches. Multiple flux coding and redundancy ensure safeand protected installations, preventing incidentalaccess.

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Thanks to our long experience on designing mag-netic-based sensors, Carlo Gavazzi is able to offeran extensive range of safety magnetic sensors,covering a large variety of safety gate applicationsin different industrial contexts. The wide range of products includes versions withrectangular or cylindrical housings, made in ther-moplastic material. The whole series is charac-terised by multiple flux coding, activation with the

dedicated magnetic unit only (CLS series), long life(contactless), sealed to IP67, excellent tolerancesto misalignment, insensitiveness to dirt and suit-ability for concealed assembling. A very importantfeature is the unbeatable durability and reliability ofall Carlo Gavazzi’s devices.

The Range

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Rectangular seriesSeveral models are available, ranging from single todouble channel, 1NO, 2NO or 1NO + 1NC con-tacts.Gavazzi offers versions with signalling auxiliary out-puts, LED indication and pig-tail output connectionwith M12 connector. The safety rating is includedbetween 2 and 4, in compliance with EN954-1. Thedevices can be operated with CLS magnetic unitseries.

Cylindrical seriesThe M18 or M30 versions range from single to dou-ble channel, 1NO, 2NO or 1NO + 1NC contacts.Versions with LED indication, pig-tail output con-nection with M12 connector are available. Safety isincluded between 1 to 4 in compliance withEN954-1. The devices can be operated with CLSAmagnetic unit series.

Safety Limit Switches with PullButton ResetThese devices are studied in order to be used forthe detection and monitoring of faults in hoistingmachines, electric lifts, freight elevators,escalators, conveyor belts, etc. The Limit Switchesprotect the operators working on dangerousmachines, by opening the control circuit. Thenormally closed safety contacts remain in the openposition, after having completed a control deviceand having overshooted the latching point. Thereturn to the initial operating state can take placeonly by voluntary action on the pull button reset.

Main AdvantagesThe limit switches are available in different sizesand materials. They are developed in reinforcedUL-V0 thermoplastic fiber-glass, zinc alloy(Zamack) or aluminium body. IP65 (thermoplastic)and IP66 (metal) assures a high degree ofprotection, that allows use of the limit switches indifferent kinds of environments. The contact block,Zb type, is consistent with the safety requirementsof the IEC 947-5-1 with NC contact with PositiveOpening Operation.Others main advantages are:• Minimum Actuation Force/Torque• Minimum Force to achieve Positive Opening Operation• Precise operating points (consistency)• Immune to electromagnetic disturbances

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Safety Limit SwitchesSafety Limit Switches supervise security ofindustrial machines, that often cannot rely uponsecure working areas because an inadequatedown-time does not occlude access. Carlo Gavazzi’s Safety Limit Switches assure thecontrol of the hazardous areas access points,intervening on the control circuit. In particular, theoperators’ safety is granted by the fact that themachine immediately comes to a complete stop incase of the mobile protector (covers, cases, doors,grids, etc.) is opened or a rope is just pulled.

Emergency Stop Push Button The emergency stop switches are devices thatusers employ to initiate the complete shutdown ofa machine, system, or process. Pushbuttons arerelatively large devices that open or close a switch,when pressed. Usually a double-pole, single-throw (DPST)contact block is used to turn off the power.The twist-to-reset switches require users to twist abutton, in order to reset the switch and resumeoperation.

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Main FeaturesThe emergency stop push button must be pressed,in order to be locked. Then, the device has to betwisted clockwise, in order to be released.The high degree of protection (IP65) makes thisdevice effective in different kinds of environment.Five different ways of cable entry (PG13.5 / M20)offer different solutions of installation.Others main advantages are:• 4 captive screws • Double insulation• Contact block with forced opening NC contact

It is designed to protect operators working ondangerous machines, by opening the controlcircuit. In compliance with the EN418 (safety ofmachinery – emergency stop), it allows switchingoff the electric power by pushing the REDEmergency Stop Push Button.

Applications

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