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SafelineSENSING AND CONTROL

Application storiesSubaru-Isuzu 3

Safety Interfaces 4

Weeke 6

Somepa 7

Plastic Moulding 8

ProductsFF-SM - Safety Mat 9

CLS - Cable Pull 10

New products preview10

Safety News

What’s the differencebetween Types andCategories? 11

Quality andManufacturing tests onHoneywell safety lightcurtains 12

Honeywell andIndustrial Safety 14

Harmonisation ofEuropean safetystandards numbering15

Issue 2

April 1999

Discover th

e complete range of

our products in Honeywell’s

new “Industrial Safety

Products” catalogue

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2

is published on behalf of Honeywell Europe SA.

All contents remain the copyright ofHoneywell Europe SA, and may not be

reproduced without their expresspermission in writing.

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Local contact

UUSSAAMICRO SWITCH

Sensing and ControlInternational HeadquartersPhone: 1-800-537-6945

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Phone: +(44) 1344 656000Fax: + (44) 1344 656015

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© Honeywell Europe 4/99

Protecting your employees from injury is an important responsibility. But it also makes good businesssense because it enhances employee loyalty, ensures greater productivity, avoids medical costs andreduces downtime.

To help you meet these objectives, Honeywell offers safety products that comply with the strictest safetyand reliability requirements. Our engineers design products to meet the highest recommendedstandards, mainly in Europe and North America. Our specialists are active members of standardisationcommittees, and they contribute, both in Europe and the US, to the definition of standards anddirectives.

As a global company, Honeywell employs 56,500 people in 95 countries, and we make our qualityproducts available to customers around the world. Three Honeywell factories design and manufacturesafety products to protect operators working on dangerous machinery. Our Grenoble factory in France isa Centre of Excellence for photoelectric and electronic safety products. Our factories at Newhouse inScotland and at Freeport, Illinois, in the U.S. manufacture electromechanical safety components.

Honeywell’s products, which meet global standards, are available worldwide, serve to assist you inmaking your workplace a safer place.

EditorialHoneywell is dedicated to making theindustrial workplace a safer place

SafelineSUNSTAR传感与控制 http://www.sensor-ic.com/ TEL:0755-83376549 FAX:0755-83376182 E-MAIL:[email protected]


3

Subaru-IsuzuAutomotive getsrugged, reliableperformance fromHoneywell’s SafetyLight CurtainsSafety light curtains fromHoneywell have beenoperating reliably at theSubaru-Isuzu AutomotiveInc. (SIA) facility in Lafayette,Indiana, for five years. Theirperformance has impressedMark Skidmore, senior groupleader for f irst shiftproduction, body sport utilityvehicles, who said,"Honeywell safety beams area standard safety curtain forour shop. I will not allow anyother light curtain in here."

AdvantagesSIA uses more than 100pairs of Honeywell 'sFF-SB14 Series light curtainsduring the body assembly ofthe Isuzu Rodeo sport utilityvehicle to protect factoryworkers from hazardousmotion in robotic and weldingcells. The light curtains areinstalled across operatoraccess areas to the cells,providing a protective

"curtain" of infrared beams.The machine or process isstopped if any part of thecurtain is broken, typically byan operator's hand.

Rugged performance ofthe FF-SB14 lightcurtain

The light curtains' ruggedperformance in the harshenvironment of an autoassembly plant made theman attractive choice for SIA,especially after they hadexperienced problems withlight curtains from anothersupplier. "In the Body Shop atSIA we routinely use andabuse the light curtains," saidSkidmore. "On a daily basisthese curtains are subjectedto weld spatter and strongmagnetic fields from the spotwelding that is performed onthe body parts. If that isn'tenough abuse, we bang themaround with tools, robots andsteel body parts. TheHoneywell beams stand up toall of this; they are extremelyrugged and reliable.”

Excellent customerservice provided byHoneywell

In addit ion to top-notchproduct performance, SIAhas received top-notchservice from Honeywell,according to Skidmore."Delivery t ime andresponsiveness have beenexcellent,” he said. Anotherway Honeywell has providedservice to SIA is throughtraining. Shortly afterHoneywell light curtains were

specified for use in IsuzuRodeo assembly, Honeywelltrainers paid a visit toLafayette.

SIA operators andmaintenance workerslearned about the designfeatures, operation andtroubleshooting of Honeywell'slight curtains.

Another machine safetyproduct from Honeywell hasattracted the attention of SIA- the FF-SE laser scanner.This new device combinesradar and laser principles toscan computer-defined areasaround dangerous machineryor mobile area scanningapplications. In case ofintrusion into these zones,control-reliable safety outputrelays are immediatelyopened and init iate thestopping of hazardousmovement. While SIA is in theearly stages of evaluating thenew product, Skidmoreeagerly said, "I'd like to put itin use right now.”

Compliance with thehighest standardsThe FF-SB Series safetylight curtains in operation atSIA are specifically designedto meet or exceed machineguarding regulations from theEuropean Machine Directive,American National StandardsInstitute (ANSI), andOccupational Safety andHealth Administration(OSHA). In addit ion, allHoneywell machine safetyproducts are globallyapproved by at least oneindependent third-partyagency such as UnderwritersLaboratories (UL), theCanadian StandardsAssociation (CSA), orEuropean agencies includingBIA and TUV.

Safety on the Automotive Factory Floor

Workers at Subaru-Isuzu Automotive rely on Honeywell's safety lightcurtains on the body assembly line.



4

This text first explains thelegal requirements backgroundfor emergency stops and howthey are respected in theapplication. Path controlthrough transfer line is verytypical on long productionlines where personnel need tocross the production l inewithout any risk of beingharmed.

Emergency stopAn emergency stop should:

• Have priority over allfunctions in any operatingmode.

• Power on the moving partsmust be removed as quicklyas possible without creatinganother danger.

• Cancelling an emergencystop must not restart themachine.

Every machine should beequipped with Category 0 or 1emergency stop.

There are three categoriesdefined in EN 418:

• Category 0 stop: Stoppingby shutting down powerimmediately on movingequipment.

• Category 1 stop: Stoppingby keeping power on themoving equipment to stop itbefore power is shut down.

• Category 2 stop: Controlledstopping by keeping power onthe moving equipment.

A Category 0 stop used for anemergency stop function mustbe designed only with wirede l e c t r o - m e c h a n i c a lcomponents.

This function must not dependon any electronic logic,network instructions orcommunication link.

A Category 1 stop used foremergency stop functionimplies shutting off the power

on the moving equipment bymeans of wirede l e c t r o m e c h a n i c a lcomponents.

An emergency stop is madeup of one action part (push-button) and one commandpart (logical safety module).The contacts in theemergency stop device mustbe positively driven contacts.After being operated, theemergency stop buttonremains blocked. Anappropriate operation wil lunlock it without restarting themachine.

Path control through transfer lines

FF-SM

Safety mat

FF-SRT

Timermodule

Instant stop

Finalisolation

FF-SRT

Timermodule

FF-SRE3081

Expansionmodule

FF-SRS5935

Emergencystop module2 channels

Reset

Speed

DRIVER

Motor

Cross

demand

E-stoppush-button

Push-button Push-button

Push-button

FF-SRS5935

Emergencystop module2 channels

Standards compliance• EN 954-1• EN 999• EN 1050• EN 418• EN 1760-1• EN 60204• NFPA 79

Honeywell providesapplication sheets whichpresent the installationsystem for typical safetyproducts applications.Thus, it is possible toknow the differentinterconnections of eachHoneywell productaccording to the varioustypes of applications.The example below is atypical i l lustration. Itdeals with path controlthrough a transfer line.

Machines concerned

Transfer lines

• General

• Automotive

• Material handling



5

13

The system is definedaccording to theobjectivesThis system allows theoperation of the controlledstop (Category 2 emergencystop pr EN 418-1 whichfollows a crossing demand)on a transfer path withmaximum safety conditionsand without using theProgrammable LogicController. Furthermore, the systemensures a Category 0emergency stop pr EN 418-1 incase of an excessivecrossing.

Limits of useThis system can only be usedwhen the stop sequence ofthe transfer path iscompatible with the safetydistances agreed upon inorder to avoid risk in case aperson crosses thedangerous zone by mistake.

Safety requirementsSafety light curtains need tobe installed on each side ofthe access zone. A red lightcolumn indicates that accessis forbidden.

If a person crosses the zoneduring this period, it will leadto a Category 0 stop. Amanual restart wil l benecessary.

Further to a crossing demand,a green light column lights up.The crossing of the zone leadsto a Category 2 temporarystop. The time delay of thetime delay module must be10% greater than the normalcrossing time.

Functioning principleThe safety mat and the timedelay module are controlledby the e-stop controlmodule. If they are activated,the movement is immediatelystopped by the speed driver.At the same time, the timedelay module is activated.At the end of the time delaythe energetic isolation of theengine is ensured by thesecond e-stop control module

.

Thus, there is a Category 0stop. Then, a manual reset iscompulsory.

In parallel, two signals havebeen installed at the entranceof the second module.Consequently, if a crossingdemand has been generatedby one of the two push-buttons, the time delay of thetime delay module isactivated and its output isused to inhibit the signalwhich comes from the timedelay module .

In doing so, the Category 0stop is not generated. Thetime delay of the time delaymodule must be greaterthan that of the time delaymodule and barely greaterthan the average crossingtime.

In case of malfunction orunique dangerous breakdown,a Category 0 stop occursand/or the restarting of themotor is prevented.

Variations of theapplicationsIn the above scenario, thesafety mat cannot bereplaced by a single ormultibeam safety light curtain.If this is the case, theCategory 2 stop must besuppressed (a reset iscompulsory at each crossing).

14

12

11

13

Complete range of FF-SR modules

List of Honeywellproducts

FF-SM safety matFF-SRS5935 e-stop

controlmodule

FF-SRT time delaymodule

3

14



6

Looking for the edge

Company Weeke belongs toone of two big groups inGermany, called Homag.Weeke’s 1996 revenue wasappr. $143 M. Weeke wasfounded in 1945 and has 231employees. The Homaggroup represents 10companies with a revenue of$ 218 M.

German woodworkingmachine manufacturers suchas Weeke need to look atnew practices and methodsto stay competit ive andsurvive, especially againstthe competit ion of Ital ianmanufacturers, who are theEuropean leaders in thismarket. The aim is to

increase productivity, reduceproduct cost and showcontinuous quality improve-ments, giving them an edgein the market-place. Onemethod is to automate someof the labor intensiveoperations to enable theemployee to work moreproductively.

However, the introduction ofmachinery and the increasedspeed of operation, bringsome safety-at-work issuesfor the employer andemployee. Higher risks ofpersonal injury can arise andemployers then need to addmore guarding to themachines. Automation doesnot necessarily mean lessoperators, or less risk.

Automation is seen as a long-term signif icant capitalinvestment, which requiresreliable safety equipment tobe fitted.

Light curtains offer easeof installation

In this special case themachine has to be loadedand unloaded with raw woodplates by the workers. Thiscould cause a dangeroussituation because of theunpredictable movement ofthe drilling-head. No personmust be inside the dangerzone in front of the machinewhile the NC-program isrunning.

The primary advantage forWeeke using Honeywell’sFF-SLC safety light curtain(instead of safety mats) isthat they can complete andtest the machine at theirfactory and have noadditional work to installsafety devices at the end-customer’s premises.

They can also use the samesafety l ight curtain fordifferent sizes of themachine. Changing the widthof the machine doesn’t causechanges in the use ofFF-SLC.

The advantage versus single-beam light barriers, whichwere also used, is thecompact housing with sevenbeams inside the same box.

FF-SLC Requirements

The important factors forthe FF-SLC in thisapplication are:• Following the EN

regulations for riskassessment, Type 2protection is theminimum allowed.

• The product is “CE”marked.

• The product has arobust construction.

Honeywell Safety Light Curtainsapplied to woodworking equipment

Features

• Body detection: ø184 mm/7.24 in.

• Scanning range: 24 m/78.72 ft

• Protection height:400 to 1400 mm/15.76 to 55.16 in

• Dimensions:70 x 50 mm/2.75 x 1.97 in

• Small profile withseparate control unit

• Suitable for accesscontrol



The FF-SRM mutingmodule, offers convenientand reliable safetyinterface with “press” or“conveyor” mode.

Systematic protectionchosen by Somepa

Located in Hasparren(France), Somepa is asubcontractor of Le Roy-Somer, an automotive partsmanufacturer. This companyspecialises in steel platework. Its activity includespressing, folding, welding andpunching of steel sheets up to6 mm thick.

With a production of 250 tonsper month, the firmpossesses huge presses, theuse of which presents highrisks. Concerned with its staffsafety and to comply with theSocial Directive (89/655/ECas amended by 95/96/EC),Somepa chose to strengthenits already existing Honeywellsafety equipment. It decidedto equip its biggestmechanical press with twoHoneywell safety l ightcurtains and a muting module.This choice allows Somepa toemploy a systematic protectionagainst risk of crushing of itspress operators.

A reliable principle

Honeywell FF-SRM mutingmodule is an interfacebetween the light curtain andthe control circuitry of thepress. Thanks to the mutingmodule, operators can freelyundertake manual loadingand unloading operationsduring the opening stroke ofthe press: while the punch

comes back to its top dead-centre posit ion, peopleworking on the press canpass through the safety lightcurtains to put metal on thedie as the module mutes theprotective equipment.

During the dangerous cycle ofthe press, when the punchslopes down onto the die, thesafety equipment is notmuted any more. The moduletransmits the same signal asthe l ight curtains: when aperson enters the dangerouszone, a signal is transmittedso that the press isimmediately stopped. Thepush-button simply needs tobe pressed for the machine tobe restarted.

Advantages of thesystem for the operators

• Accustomed to two-handcontrol, operators rapidlyadapted themselves to thenew system• Operators have moreflexible access to the press• Their movement isfacilitated• They can put metal on thedie more easily.

Advantages of the systemfor the plant owner

As the manual loading andunloading operations cantake place as soon as thepunch rises, operators canwork more quickly. Greaterproductivity is assured whilemaintaining safety.

Other possibleapplications

• Palletisers and depalletisers• Automotive transfer lines• Packaging and wrapping

machines• Press-brakes• Welding robots

Somepa, a good illustration of the use of the FF-SRM muting module in “press” mode

opening process

SM1SM2

Inhibition

PMH

SM1SM2

InhibitionProtection

closing process

SM1SM2

ES

PE

PMB

Protection

SM1 SM2

ES

PE

ES

PE

ES

PE

ES

PE

ES

PE

ES

PE

ES

PE

Muting with the

FF-SB14 light curtain

• Two safety limit switches

to control the muting

sequence, SM1, SM2

• Resolution of 35 mm

(suitable for hand

detection)

• Scanning range up to

10 m

• European CE Certification

• Meets applicable parts

of the North American

Regulations and

Standards ANSI/

RIA/OSHA/CSA

7

FF-SRM100P2 muting interface Type 4 according to EN 954-1



8

Using a safety limit switch on sliding guard doors in plastic

moulding applications

BackgroundAutomated and semi-automated plastic mouldmachines typically have asliding guard door for accessto the tool and for clearingany jams which could occurin operation. Typically most ofthese guards will be rarelyused during the process asplastic mould powder will befed automatically to themould tool and parts will beautomatically ejected. Theonly major access to theplastic moulding tool andinjection rams is for majorservicing and toolchangeovers.

The ApplicationThe application uses two GSSSafety Limit Switches. Theyare applied in what is knownas positive / negativeoperation. This scheme makesuse of the fact that a mediumrisk machine should make useof fault-tolerant shutdownsystems. This is why it ispossible to use a simpleprimary sensor such as a limit

switch in conjunction with asafety control module. Thisensures that a single point offailure will not lead to adangerous condition in theapplication. This would beknown as a Category 4pr EN 418-1 application.

The clever part of theapplication is the safety controlmodule. The safety controlmodule is looking for twosignals, one the reverse of theother-thus:Switch1 Switch2 RelayON OFF No FaultOFF ON No FaultON ON FaultOFF OFF Fault

So, regardless of whether ornot the guard door is open orclosed the control module isconstantly cross-checking tosee whether the safetyfunction has been lost. If oneof the switches should remainON or OFF when the otherchanges state, then thesafety control module willinterpret this correctly as afault.

Typical circumstances underwhich this condition couldarise include:1. Loose or faulty wiring.2. Detached or an out-of-

alignment switch.3. Destroyed head on switch.4. Damaged wedge-actuator

on the sliding door, etc.

The point is that the failuremechanism is unlikely tooccur simultaneously on eachswitch and be completely thereverse of the other fault.

Looking at the truth tablebelow, note that in theapplication there will betransition states where bothswitches are ON or bothswitches are OFF due to slightmisalignments in the ON andOFF ramps for the switch. Thisis a fact of life and the safetycontrol modules usually allowstransition states to occur for ashort period of time (3seconds) before a fault isrecognised and shutdown isinitiated.

The safety control moduleitself is the critical componentin this whole scheme as it isperforming the crosschecking and monitoringfunction as well as openingthe relay contacts if a Stop orFault condition is detected.

This application demonstrateshow sophisticated controlsystems can be achievedusing relatively low cost andeasy to understand and applycomponents.

The beauty of this applicationis that you can combine keyoperated switches such asGKM (Miniature Safety KeyOperated Switch), GKL(Solenoid Key OperatedSwitch) or GK (Safety KeyOperated Switch) with GSS(Global Safety Switch) or24/924CE’s (DIN SafetySwitch) and still achieve thesame result.

GSS

GSS

Applicable Standards

• EN 60947-5-1, LowVoltage Switchgear

• EN 60947-5-1-3, LowVoltage Switchgearincorporating PositiveBreak

• EN 1088, Safety InterlockSwitches

• EN 954-1, Safety RelatedControl Systems

• EN 1050, RiskAssessment

• EN 292, GeneralPrinciples

• EN 60204-1, ElectricalEquipment

• EN 294, Safety Distances

The full truth table for the configuration wouldlook like this:

Switch1 Switch2 State Rationale

ON OFF Running All Well

OFF ON Stop Door Open

ON ON Stop Fault in either SW1 or SW2

OFF OFF Stop Fault in either SW1 or SW2



BackgroundIn some applications, it isnecessary to control not onlyaccess in a dangerous areabut also to make sure that thisarea is clear before restartingthe dangerous motion. For thispurpose, one can use safetylight curtains mountedhorizontally, safety laserscanners and/or safety mats.Safety mats are used inrelatively small areas wherepresence of an operator is notallowed during certain phasesof the machine cycle. Theprotected area is determinedby the mat’s physical locationand is clearly outlined byyellow and black edges.

How does it work?The sensor inside the matuses an infrared modulatedlight source spread by a fibreoptic cable. The presence of aload greater than the 30 kg /66.14 lbs detection capabilitycauses micro-bendings of thefibre optic cable on the wholeof the sensing surface. Theloss in signal resulting fromthese micro-bendings isdetected by the control unit

which de-energizes its outputrelays to stop the dangerousmovement of the machine.

The control unit is based on apermanent self-checkingprinciple (control reliable). It isequipped with two safetyrelays with guided contactswhich can be used directly inorder to stop the dangerousmovement. Furthermore, thecontrol unit is available in115 Vac, 230 Vac or 24 Vdcsupply voltages.

A reliable safety deviceA failure of the emitting orreceiving circuit leading to the

beam interruption isimmediately detected beforean operator activates thesensor. Moreover, the lightintensity is permanently self-checked by the control unit.

Flexible application

It is possible to connect foursafety mats of standard sizesin series and monitor themwith a single control unit. Indoing so, you can obtain 6 m2 /65 ft2 sensing area.

Innovation in FibreOpticsThe fibre optic technologycommonly perceived as hightechnology for datacommunication has manyadvantages. In fact, it is a veryreliable technique which bringsmany advantages when usedin an industrial environment.

This technology enabledHoneywell to develop amechanical structure able towithstand use in industrialenvironments:• With a 1000 N/cm2 maximumstatic overload, the safety matis resistant to an occasionaloverload of forklift trucks.• It is protected againstdamage caused by the fall ofheavy objects (up to 50 joules).• Its life expectancy is high

(more than 10 millionoperations).• The sensor is sealed toIP 67 and the material usedcan withstand most of theliquids used in the industry.• An excellent chemicalresistance is possible thanksto the coatings we provide.• This fibre optic technology istotally immune to electro-magnetic disturbances. Thus,longer connections betweenthe sensor and its control unitare available compared withelectrical wires.

Applications• Presence sensing device forthe control of dangerous areassuch as robot areas,automotive transfer lines.• Additional protection foroptoelectronic trip devices.

New Industrial Safety Mat (FF-SM)Introduced by Honeywell

The HoneywellFF-SM IndustrialSafety Mat is apressure-sensit iveprotective devicedesigned to detect thepresence of operatorsof power-drivenmachinery inside adangerous area.

Safety requirements

• The design of thisdevice conforms toEN 1760-1.

• The sensor complieswith Category 3 asdefined by theEN 954-1 Europeanstandard.

• The control unitcomplies with Category4 as defined by theEN 954-1.

• Control rel iable isdefined by OSHA &ANSI.

9



10

Versatility and reduced installationcosts result from double-head

versions for cable-pull limit switch line

New Products preview

Honeywell has addedduplex (double-head)versions to its new lineof CLS Series Cable-PullLimit Switches. Duplexversions enable users toextend cable length andreduce installation costs.

The CLS Series of Cable-PullLimit Switches provides ameans to manually forcedisconnection of a normally-closed control circuit bypulling on an attached cable.The CLS is especiallydesigned for use onconveyors, packagingmachinery, assembly lines,process equipment, andtransfer lines. Both single-and double-head versions areavailable with a choice ofmomentary or maintained

(unti l manually reset)actuation. Versions withmaintained actuation featureslackened/broken cabledetection for added safetyand a cable tension indicatoron the operating shaft foreasy adjustment.

Neon and LED indicators areavailable on all styles. Cablelength on single-headversions is up to 200 feet, andcable length on the duplexversions is up to 400 feet(200 feet in either direction).Duplex versions also offer a6-watt incandescent pilot lightto provide powerfully highvisibil i ty for the longerdistances their extendedcable lengths allow.

The CLS Series is UL listed,CSA certified, and designedto meet IEC standards. ULand CSA ratings are 10 amps,NEMA A600/Q300.

Enclosures meet NEMA 1, 3,4, and 13 sealing standards.IEC operating rating isAC15/DC13 (approvalpending). Operatingtemperature range is 30°F to158°F (-1°C to 70°C). Cableand hardware accessoriesand kits can be furnished tosimplify installation.

Features

• Tension indicator foreasy adjustment

• Broken/slackened cabledetection

• Four conduit threadsizes

• -1°C to 70°C / 30°F to 158°F operatingtemperature

• IP 67 - NEMA 1, 3, 4,13 sealing

• Indicator lights available• 60 m / 200 ft maximum

cable run• Explosion-proof version

available

New ElectromechanicalSafety Switches fromHoneywell

Honeywell is extending itsrange of ElectromechanicalSafety Switches to meet evenmore Safety needs in machineguarding applications.

The GKM (Miniature Key-Operated Safety Switch) rangehas been extended to includea 2 Normally Closed versionthat offers added electricalredundancy of the Safety NCcircuits. In some safetyschemes this is necessary toachieve Category 4compliance through safetycontrol modules.

Four new switching Optionshave been introduced on theGlobal Safety Switch (GSS) toextend the range inanticipation of emergingstandards of switchcombinations in Safetyapplications. These areavailable with normal and lowenergy gold contacts. As befits

a market leader, Honeywell iscontributing to the developmentof new standards.

The GK Dual Entry KeyOperated Safety InterlockSwitch has been upgradedwith new switching, head andkey options, as has theGKL/GKR Dual Entry SolenoidKey Operated Safety InterlockSwitch. The new head offersmore mounting flexibility andless opportunity for tampering.Finally, the 24CE MiniatureSafety Switch is now officiallyBG approved, to add to the listof other approvals it alreadyhas.

E + M III



11

What’s the difference between Types and Categories?People are very oftenconfused by the vocabularyused to describe the safetylevel of machine safetyproducts: the words “Type”and “Category” are very oftenmixed and misused. Let us tryto clarify this.

The words which are requiredto be used are the wordswhich are used in theEuropean safety standards,and they are often repeatedon the product documentationand certificates.

The word “Category” is usedin the standard EN 954-1(Safety related parts of controlsystems). EN 954-1 describesdifferent Categories (B, 1, 2, 3,

4), corresponding to differentrequirements for a safetysystem or interface.All that can be said about thesafety performance for agiven technology is:- Categories 1, 2, 3, and 4 are allbetter than Category B;- In Categories B, 1 and 2 asingle fault can lead to the lossof the safety function;- Categories 3 and 4 will not faildue to a single fault (commonmode faults are considered asa single fault);- Category 4 has the bestperformance as regards tofault tolerance because anaccumulation of faults isconsidered.

The word “Type” is used by

some standards (the type B2standards) to group productsaccording to the stringency ofrequirements. For example,EN 574 (two-hand controldevices) defines differentTypes of two-hand controldevices: Type 1, Type 2 andType 3.

EN 61496-1 (Electro-sensitiveprotective equipments /General requirements) alsodefines Types (1, 2, 3 and 4).

Generally speaking, there is acorrespondence betweenTypes and Categories. Forexample, for EN 61496-1, theTypes of ESPE (Electro-sensitive protective equipment)are based on the categories of

performance of safety-relatedparts of control systems: AType 2 ESPE corresponds to aCategory 2 control system.

The requirements set in theType B2 standards, though, gofurther than a simplecorrespondence withCategories. For example,EN 61496 defines opticalrequirements for a Type 4ESPE (±2.5° aperture angle).

The same thing applies toEN 574: Type 1 correspondsto Category 3 per EN 954-1,Type 2 corresponds toCategory 3 per EN 954-1,etc... (for more details, pleaserefer to this standard).

New Safety LaserScanner from Honeywell

Honeywell 's new FF-SE laserscanner combines radarprinciples with a laser beam tocreate safe zones arounddangerous machinery andAGVs.

The FF-SE consists of a laserbeam mounted in a rotatinghead. If any object or personbreaks the beam as it sweepsaround, dangerous machinerycan be immediately shutdown. FF-SE is Honeywell'sfirst safety product to useconfigurable protection zones,allowing it to adapt to - andcreate safe zones around -any shaped area up to a

radius of 6 m / 19.68 ft. It isalso being successfullyapplied to a variety of otherapplications includingAutomatic Guided Vehicles(AGVs).

Because the FF-SE iscapable of making 300°sweeps, the non-active zoneis very limited. Turning at afrequency of 8 Hz, the rotatinghead will immediately detectany object within a radius of6 m / 19.68 ft. Users can configure twolevels of security usingFF-SE: an “alarm zone” up to10 m / 32.8 ft around themachinery and a “safety zone”up to 6 m / 19.68 ft. If anintrusion is detected in the“alarm zone,” an audible orvisual alarm could beactivated to warn the personto back-off. Any activationwithin the “safety zone,”however, would open 2 safetyrelay contacts and shut theequipment down immediately.

New Safety Light Curtainfrom Honeywell

The FF-SYA Series isHoneywell's new generationof safety l ight curtains.Approved for use in Europeand in North Americaaccording to the highestsafety requirements (CEapproval as a Type 4electrosensitive protectiveequipment by INRS) and CSAapproval, it is a UNIVERSALlight curtain which suits anyapplication with possibleresolutions of 14 mm, 30 mmand 60 mm/0.6 in, 1.2 in, 2.4 in.With a 42 x 55 mm2 / 1.65 x2.16 in2 cross section, theFF-SYA is one of the mostCOMPACT light curtains

available on the market aswell as its optional controlmodule, with its 45 mm /1.77 in width.The FF-SYA Series offersSMART features intended toease installation, use andmaintenance of the product.Built- in alignment aid andcross-talk reduction systemincluding an alarm indicatorconsiderably ease the lightcurtain installation. Equippedwith redundant fail-safe solidstate outputs, this light curtainis maintenance free. Allsett ings are done on thecontrol module which isinstalled in the machinecabinet to ease maintenance.

The FF-SYA Series is aFULL-FEATURED packageproviding all necessaryfeatures and accessories toreliably install and interfacethe l ight curtain to themachine.

(More information about thisproduct will appear in the nextissue of Safeline)

BerufsgenossenschaftlichesInstitut fürArbeitssicherheit

BIA



Honeywell l ight curtainsundergo many checks toensure they functioncorrectly. They are testedduring manufacture andbefore they leave the factory.

Some characteristics of thelight curtains are controlledon a 100% basis: scanningrange, conformity betweenthe optic and mechanicalaxis, voltage, detectionsensitivity, sealing, emissionfrequency of the crit icalelectronic componentsvalues, signall ing (statusindicators), test on thedielectric rigidity, test on theearth continuity, resistance toelectric interferences,functionalities accessible tooperators and burn-in.

Tests on subsystemsand electronic boards(Figure 1)

Electronic boards are testedin situ (in the factory) on theboard tester. The followingpoints are tested:• Short circuit/current

conduction.• Presence or value of

resistors, capacitors andinductive resistors.

• Tests on the junctions oftransistors.

• Relay coils.• Transformers winding.• Relay contacts.• Tests on fuses and Zener

diodes.• Tests on coil-driven

transistors.

In addition, tests on the sub-systems functionality areperformed on selectedboards.

The aim of these tests is toensure the correct functioningof the electronic boards.Those boards that do notfunction properly go back to

the repair loop. The functionaltests of the boards aresystematically saved into acomputing file which is part ofthe tester.

Functional testsperformed during theassembly(Figure 2)

Tests are run in order tocheck if the electronic boardsare assembled correctly. Thetest checks the function of theproduct in its f inalconfiguration and at shortscanning range.

Test after assembly(Figure 3)

After the assembly of theoptical part with the electronicpart, a test is performed inorder to check if the l ightcurtain functions correctly.

Test before burn-in(Figure 4)

The following test is an opticaltest. These tests are made onthe optical testing stand afterassembling (before burn-in).Before the burn-in, thefunctioning of each product iscontrolled on the opticaltesting stand. It is analignment test, which isundertaken in order to checkif the angles values of thelight curtains are consistentwith the standards (± 2.5°).

The safety light curtainsalso undergo a burn-intest (Figure 5)

After they have beenassembled and controlled onthe optical testing stand, aburn-in is undertaken on allthe products. For 72 hours,the functioning andresistance of the light curtainsare checked. These tests arerun in order to check theeffects of the thermic cycleson the light curtains. It checksthe function of the products athigh temperature (32 °C / 0 °F).• The main voltage is

controlled.• There is a visual checking

of the function every day.• Test function controlled

every four hours.• Power is switched off and

restored every four hours.

Failing products are repairedand then undergo a newcomplete burn-in cycle.

EMC test(Figure 6)

Honeywell also undertakes anEMC (Electromagneticcompatibil i ty) test whichcontrols the electromagneticcompatibility of the safetyl ight curtains. The powersupply voltage range iscontrolled on each product(emitter /receiver couple).

Furthermore, a test on theearth/module l inking isundertaken on the emitterand the receiver under directcurrent and according to theIEC standard.

Also tested is the dielectricrigidity of the safety l ightcurtains.

All the tests are made beforethe products are wrapped.

Test in the climatictesting oven (Figure 7)

One safety light curtain perweek is tested in the climaticchamber for 26 hours and ata 0 to 55°C / 32 to 131 °Ftemperature.

Finally, all the data resultingfrom these tests is collected.The quality of Honeywellproducts is followed throughand analyzed, correctiveactions are taken and qualitylevels are checked eachmonth.

QUALITY AND MANUFACTURING TESTS ON HONEYWELL SAFETY LIGHT CURTAINS

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Figure 3Test after assembly

Figure 2Functional tests onproducts during the

assembly

Figure 5Burn-in test

Figure 4Test before

burn-in

Figure 6Electromagnetic Compatibility test

Figure 7Test in the

climatic oven

Figure 1Test on subsystems

and electronic boards



Honeywell at a glanceHoneywell is a global controls companyfocused on creating value throughtechnology that enhances comfort,improves productivity, saves energy,protects the environment and increasessafety. The company serves customersworldwide in the homes and buildings,industrial, and aviation and spacemarkets. Honeywell employs 56,500people in 95 countries and had 1997sales of $8 billion.

Our industrial safety productrange

Honeywell offers one of the broadestportfolios of machine safety products in theindustry. We are a leading supplier ofindustrial control systems and componentsthat ensure plant safety, and we are aworldwide leader in advanced switchingand sensing technology. Our productrange includes electronic safety sensors(single beam sensors, laser scanners, lightcurtains, pressure-sensitive mats andproximity sensors), electromechanicalsafety switches (limits, cable pulls and keyinterlocks) and safety control modules.

Safety: a definitionOur goal is to provide safety productsand systems which “will make theindustrial workplace a safer place.” Butwhat is industrial safety all about: itconcerns all the means which are

implemented to ensure safety tooperators who work with dangerousmachinery. Thus risk of injuries in theindustrial workplace can be decreased. Infact, safety concerns the ability of asystem to identify, define and prevent theprobability and severity of industrialinjury. Risks of a mechanical nature(perforation, severing cuts, crushing,shock), risks of electrical nature(electrocution) or risks of a physical-chemical nature (projection of dangeroussubstances, burns) can be suppressedthanks to our products and systems.

Honeywell’s competence

Our safety specialists’ know-how is at thedisposal of our customers to provide themwith maximum support. Moreover,Honeywell can offer solutions made froman extensive line of integrated safetyproducts properly connected together.

Fault-tolerant productsIt is important to note that safetycomponents must be correctly connectedbecause the fact that the machine isoperating does not mean that it isfunctioning safely. Besides the originaltask of connecting wires, there is amultitude of electrical and electronicfunctions integrated into the interface levelto execute safe wiring. A safety productmust be fault-tolerant. Honeywell machinesafety products intended for use in high

risk applications are designed using failuremode effect analysis (FMEA) and featurefault-tolerant design so a single fault doesnot cause loss of the safety function. Theyalso include redundancy and permanentself-checking electronic circuitry.

Global products covering a greatrange of applications

Industrial machines are numerous andour range of safety components coversa variety. Our products can be used fordifferent types of applications such asperimeter protection, presence detectionin robot areas, door control and accesscontrol. Examples of typicalapplications: assembly machines,packaging / food processing equipment,moulding / thermoforming machines,metal presses, material handling or pickand place machines. Our support isglobal: there are customer responsecentres in every major country; we offera wide network of repair centres withtrained staff and an extensive Web site(visit our Virtual Trade Show at:www.honeywell.com/sensing/virtual).

Compliance with higheststandardsFurthermore, because we want toensure the safe operation of ourindustrial equipment, we respect thestrictest standards and regulations ofsafety and reliabil i ty: in fact, ourproducts meet European andinternational machine safety standards.Our products also comply with Americanstandards and regulations (which arepublished by OSHA and ANSI). Ourproducts are always consistent with thestrictest standards and in compliancewith the newest ones.

Quality of our productsand servicesFinally, Honeywell has established aquality policy in order to help youcompete by delivering products andservices of the highest quality andreliability. Our safety interfaces aretested and approved by best knownapproval organisations.

Honeywell and Industrial Safety

Honeywell Industrial Safety Product Range

Electronic SensorsElectromechanical

Switches Control Modules

Limits, Cable pulls,Key Interlocks

Wide Variety of Control Functions

Single Beam Laser Scanner

Light curtains

Safety Mats Proximity Sensors

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Approval of European SafetyStandardsThe approval of European safetystandards follows a clearly definedprocess. A working group is organised todiscuss the possible changes and draft astandard. Then, the safety standards areissued with a “pr” prefix. This prefixstands for “project” as the safetystandard already exists but has not yetreplaced the national standard to which itcorresponds.

Vote between the differentEuropean countries

A vote occurs between Europeancountries in order to agree on the text ofthe standard. Each European countryhas a fixed number of votes: for instanceFrance, Germany and Italy have 10 voteseach and Belgium has 5 votes. The textof a standard is confirmed when themajority of the countries accept the textand when the proportion of favorablevotes is more than or equal to 71%.When the countries have voted and if thenumbering is approved, a definitive codenumber is assigned to the standard.Usually, this number is the same as theold one, but without the “pr” prefix.Finally, the code number becomes officialwhen each of the countries hastransmitted it to its Official Journal.

The harmonisation of certain Europeansafety standards has recently occurred.The new recently approved standardsreplace the “pr” ones.

“Safety Related Parts of ControlSystems”This is the case for the standard entitled“Safety of Machinery - Safety RelatedParts of Control Systems.” This Type Bstandard describes the categories ofsafety equipment necessary consideringthe type of risk you will encounter. Itshows to what risk they correspond andtheir significance in terms of obligations.

The “pr EN 954” standard has become“EN 954.” The text of the second part ofthis standard was submitted to a parallelvote of the IEC/Cenelec organisations (ENstandards are European standardswhereas IEC are international ones). Theresult of the IEC vote was positive: theinternational IEC 61496-2 standard hasbeen ratified. However, the text has beenrejected by the Cenelec organisation andconsequently the EN standard does notexist. Thus, the pr EN 61496-2 standardremains without the standard beingharmonised. The consequence for safetylight curtain manufacturers is that beforecommercialising their products in Europe,they have to submit them to a CE typeexamination which has to be carried out bya notified body. There will probably be noharmonised EN 61496-2 standard beforethe year 2003.

“Safety of Machinery - GeneralRequirements for ElectroSensitive Protective Equipment”

Moreover, the “pr EN 50100-1” standardcalled “Safety of Machinery - Generalrequirements for Electro-Sensit iveProtective Equipment” has also beenharmonised. It is now “EN 61496-1” or“IEC 61496-1.” This standard permits thedesign of adequate circuits ofelectrosensitive protective equipment.

“Safety of Machinery - Principlesfor Risk Assessment”

As for the “pr EN 1050” standard which istitled “Safety of Machinery - Principles forRisk Assessment,” i t has become“EN 1050.” This standard offers asuccession of logical steps to helpevaluate risks.

“Safety of Machinery - PressureSensitive Protective Devices”

Finally, the “pr EN 1760-1” standardnamed “Safety of Machinery - PressureSensitive Protective Devices” (Part 1concerns the general principles for thedesign and testing of pressure sensitivemats and pressure sensitive floors) isnow numbered “EN 1760-1.” Thisstandard is the first part of a four-partType B standard and concerns devicesthat detect the presence of a personthrough the application of a pressure orforce by a part of the person’s body.

Harmonisation of European Standards Numbering



Honeywell Global Sales and ServiceHoneywell serves its customers through a worldwide network of sales offices and distributors. For application assistance, currentspecifications, pricing or name of nearest Authorized Distributor, contact one of the offices listed below.

ASIA PACIFIC

AustraliaHoneywell LimitedPhone: +(61) 2-9353-7400FAX: +(61) 2-9353-7406Toll Free 1300-36-39-36Toll Free Fax 1300-36-04-30

China - PRC - BeijingHoneywell China Ltd.Phone: +(86-10) 6561-0208FAX: +(86-10) 6561-0209

China - Hong KongHoneywell Ltd.Phone: +(852) 2331 9133FAX: +(852) 2953-6767

IndiaHoneywell Europe Inc.Phone: +(91) 22-641-0897FAX: +(91)-22-640-9513

IndonesiaHoneywell Indonesia Pte Ltd.Phone: +(6221) 521-3330FAX: +(6221) 521-3735

JapanYamatake Corporation Phone: +(81) 466-20-2187FAX: +(81) 466-20-2309

South KoreaLG - Honeywell Co. Ltd.Phone: +(822) 799-6011FAX: +(822) 792-9013

MalaysiaHoneywell Engineering Sdn BdhPhone: +(603) 758-4988FAX: +(603) 758-8922

New ZealandHoneywell LimitedPhone: +(64-9) 623-5050FAX: +(64-9) 623-5060Toll Free (0800) 202-088

PhilippinesHoneywell Systems (Philippines) Inc.Phone: (632) 636-1649FAX: (632) 636-1650

Singapore/SE Asia Regional OfficeHoneywell Southeast Asia Pte. Ltd.Phone: +(65) 355-2828FAX: +(65) 445-3033

Taiwan R.O.C.Honeywell Taiwan Ltd.Phone: +(886-2) 2245-1000FAX: +(886-2) 2245-3241

ThailandHoneywell Systems Ltd.Phone: +(662) 693 3099FAX: +(662) 693 3085

Honeywell Asia Pacific Inc.Phone: (65) 351-0882FAX: (65) 354-6775

NORTH AMERICA

CanadaHoneywell Ltd.Phone: 1-800-737-3360FAX: 1-800-565-4130

USAMICRO SWITCH Sensing and Control, International HeadquartersPhone: 1-800-537-6945

1-815-235-6847FAX: 1-815-235-6545E-mail: [email protected]

EUROPE

AustriaHoneywell Austria GmbHPhone: +(43) 1 727 80 366/246FAX: +(43) 1 727 80 337

BelgiumHoneywell SA/NVPhone: +(32) 2 728 2522FAX: +(32) 2 728 2502

BulgariaHoneywell EOODPhone: +(359) 2 79 40 27FAX: +(359) 2 79 40 90

Czech RepublicHoneywell spol. s.r.o.Phone: +(420) 2 6112 3469/3424Fax: +(420) 2 6112 3461

DenmarkHoneywell A/SPhone: +(45) 39 55 55 55FAX: +(45) 39 55 55 58

FinlandHoneywell OYPhone: +(358) 9 3480101FAX: +(358) 9 34801375

FranceHoneywell SAPhone: +(33) 1 60 19 82 68FAX: +(33) 1 60 19 81 73

GermanyHoneywell AGPhone: +(49) 69 8064 444FAX: +(49) 69 8064 442E-mail: SENSORLINE-GE01 @GERMANY.honeywell.comHungaryHoneywell Kft.Phone: +(36 1) 451 4300FAX: +(36 1) 451 4343

ItalyHoneywell S.p.A.Phone: +(39) 02 92146 450/456FAX: +(39) 02 92146 490

The NetherlandsHoneywell B.V.Phone: +(31) 20 565 69 11FAX: +(31) 20 565 66 00

NorwayHoneywell A/SPhone: +(47) 66 76 20 00FAX: +(47) 66 76 20 90

PolandHoneywell Sp. zo.oPhone: +(48) 22 606 0900FAX: +(48) 22 606 0901

PortugalHoneywell Portugal LdaPhone: +(351 1) 424 50 00FAX: +(351 1) 424 50 99

RomaniaHoneywell BucharestPhone: +(40) 1 2110076FAX: +(40) 1 2103375

Commonwealth of Independent States (CIS)HoneywellPhone: +(7-095) 796-9800Fax: +(7-095) 796-9893

Slovakia Honeywell, spol s.r.o. Phone: +(421-7) 58247 403/400Fax: +(421-7) 58247 415

South Africa (Republic of) Honeywell SouthernHoneywell S.A. Pty. Ltd.Phone: +(27) 11 805 1211Fax: +(27) 11 805 1354

SpainHoneywell S.A.Phone: +(34) 91 313 6100FAX: +(34) 91 313 6129

SwedenHoneywell ABPhone: +(46) 8 775 55 00FAX: +(46) 8 775 56 00

SwitzerlandHoneywell AGPhone: +(41) 1 839 25 25FAX: +(41) 1 831 03 14

TurkeyHoneywell Turkey A.S.Phone: +(90) 216 4644764FAX: +(90) 216 4644794

United Kingdom Honeywell Control Systems LtdPhone: +(44) 1344 656000FAX: +(44) 1344 656015

Mediterranean & AfricaDistributorsHoneywell SpAPhone: +(39) 2 921 46 232FAX: +(39) 2 921 46 233

Middle East HeadquartersHoneywell Middle East Ltd.Phone: +(9712) 272533FAX: +(9712) 269539

LATIN AMERICA

ArgentinaHoneywell S.A.I.C.Phone: (54-1) 383-9282FAX: (54-1) 325-6470

BrazilHoneywell do Brasil & CiaPhone: (55-11) 865-2055FAX: (55-11) 865-3894

ChileHoneywell Chile, S.A.Phone: (56-2) 233-0688FAX: (56-2) 231-6679

ColumbiaHoneywell Columbia, S.A.Phone: (57-1) 623-3239/3051FAX: (57-1) 623-3395

EcuadorHoneywell S.A.Phone: (593-2) 981-560/1FAX: (593-2) 981-562

MexicoHoneywell S.A. de C.V.Phone: (52-5) 259-1966FAX: (52-5) 570-2985

Puerto RicoHoneywell Inc.Phone: (809)792-7075FAX: (809) 792-0053

VenezuelaHoneywell CAPhone: (58-2) 238-0211FAX: (58-2) 238-3391

www.honeywell.com

107050-10-EN FR26 GLO 0499 Printed on environmentally friendly paper in FranceOrder: BR107050-EN



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