Applicable and have been incorporated into North American Standards.

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Applicable and have been incorporated into North American Standards. ANSI B11.0-2010 Safety of Machinery General Requirements and Risk Assessment ANSI B11.

2 Applicable and have been incorporated into North American Standards. ANSI B Safety of Machinery General Requirements and Risk Assessment ANSI B11.TR Risk Assessment and Risk Reduction A Guide to Estimate, Evaluate and Reduce Risks Associated with Machine Tools ANSI/RIA R (R2009) For Industrial Robots and Robot Systems Safety Requirements NFPA Electrical Standard for Industrial Machinery ANSI/ASSE Z (R2008) Control of Hazardous Energy Lockout/Tagout and Alternative Methods ANSI/PMMI B Standard for Packaging Machinery and Packaging-Related Converting Machinery Safety Requirements Omron STI 2012 for Construction, Care, and Use SEMI S Safety Guideline for Risk Assessment and Risk Evaluation Process MIL-STD-882D-2000 Standard Practice for System Safety CSA Z Safeguarding of Machinery Occupational Health and Safety CSA Z Industrial Robots and Robot Systems General Safety Requirements CSA Z Control of Hazardous Energy Lockout and Other Methods NOM-004-STPS-1999 Protection Systems and Safety Devices for Machinery and Equipment Used in the Workplace ISO 12100:2010 Safety of machinery General principles for design Risk assessment and risk reduction EN 954-1:2000 / ISO :1999 Safety of machinery Safety-related parts of control systems Part 1: General principles of design ISO :2006 Safety of machinery Safety-related parts of control systems Part 1: General principles of design 2006/42/EC European Machinery Directive

3 WE WILL ASSIST YOU ON THE WAY FOR OPTIMAL SAFETY

4 5 STEPS TO SAFETY With the following 5 steps, we will take you through the entire process from risk assessment to safety function.

5 RISK ASSESSMENT CARRYING OUT THE RISK ASSESSMENT AS PER ISO IN A SIMPLIFIED VERSION

6 RISK REDUCTION MEASURES FOR RISK REDUCTION

7 Levels of Hazard Control (in order) 1. Modify the design to eliminate or reduce the risk 2. Add guarding and safeguarding devices 3. Add awareness devices (lights, bells, whistles) 4. Education, Training and Procedures 5. PPE

8 THE CONTROL SYSTEM AS A COMPONENT OF RISK REDUCTION

under certain circumstances PLr S2: Death or severe injury (commonly

9 DETERMINING THE MACHINE'S SAFETY FUNCTIONS [PLr] S1: Minor injury (commonly a reversible injury) F1: Seldom to occasionally P1: Possible under certain circumstances PLr S2: Death or severe injury (commonly an irreversible injury) F2: Frequently to continuously P2: Nearly impossible

10 ASCERTAINMENT OF THE ACHIEVED PERFORMANCE LEVEL [PL] For the evaluation of the selected safety chain, the performance level, PL, is determined based on the following values: Structure (category) MTTFd (Mean Time to Failure dangerous): Mean time to dangerous failure DC (Diagnostic coverage): Diagnosis coverage level CCF (Common cause failure): Failure mutual cause

2, a fault can lead to the loss of a safety function, if it occurs between two tests.

11 Structure (category) ASCERTAINMENT OF THE ACHIEVED PERFORMANCE LEVEL [PL] MTTFd from cat. 1 is higher than from cat. B, therefore the probability of a safety function failure is lower. Nonetheless, errors can lead to a loss of a safety function. In cat. 2, a fault can lead to the loss of a safety function, if it occurs between two tests. In category 3, the accumulation of undetected errors can lead to a loss of the safety function. In category 4, the requirement of a safety function cannot be carried out until there is positive testing.

13 ASCERTAINMENT OF THE ACHIEVED PERFORMANCE LEVEL [PL]

14 Pneumatic Safety Functions

EXPECTATIONS FOR PNEUMATICS Pneumatic systems and electric sensors Sensors: Red Line: Pressure accumulation at a pressure switch Final position switch Pressure switch Mechanical plunger query for

15 EXPECTATIONS FOR PNEUMATICS Pneumatic systems and electric sensors Sensors: Red Line: Pressure accumulation at a pressure switch Final position switch Pressure switch Mechanical plunger query for valves Detectable error from the list in ISO : Change of switching times Switch failure or incomplete switch Independent change in the output switch position (without input signal) Valve housing burst Blue Line: Valve switching output Δ t: If the pressure does not rise to the pre-defined level after the valve has been actuated, an error has occurred.

4) Initial situation The opening of the protective grid door must cause the

16 EXAMPLE 1 Safe venting (PL e, cat. 4) and protection against unintentional start-up (PL e, cat. 4) Initial situation The opening of the protective grid door must cause the pneumatic system to be vented. In so doing, no unintentional machine startup may occur within the hazardous area during maintenance procedures. Protected system

17 EXAMPLE 2 Safe stop (PL d, cat. 3) and protection against unintentional start-up (PL d, cat. 3) For the removal of rejected components from the conveyor belt, the downstream drives should stop safely due to the interruption of the electric eyes. When carrying out work in the hazardous area within the electric eye zone, it must be impossible to unintentionally start-up the machines. The pneumatic valves and the diagnosis by means of a pressure switch should be installed in a valve cluster.

1) Crimping between the cylinder piston and the piston rod is realized by means

18 EXAMPLE 3 Two-hand control (PL c, cat. 1) and protection against unintentional start-up (PL c, cat. 1) Crimping between the cylinder piston and the piston rod is realized by means of a purely pneumatic press with two-hand actuation. When the button is released, the press cylinder will move to the upper final position.

19 EXAMPLE 4 Protection against unintentional start-up (PL d, cat. 3) It must not be possible to open the packaging machine's protective casing, until all pneumatic drives are at a standstill.

1) If the operator enters into the hazardous area marked in red, the robots should stop and

20 EXAMPLE 5 Safe venting (PL c, cat. 1) and protection against unintentional start-up (PL c, cat. 1) If the operator enters into the hazardous area marked in red, the robots should stop and the pneumatic system should vent safely. The hazardous area is monitored using laser scanner. In this example, the robot is not a part of the safety-related evaluation. Protected system

be reduced and the pneumatic system should reduce the pressure.

21 EXAMPLE 6 Reduce pressure (PL c, cat. 1) and protect against unintentional start-up (PL c, cat. 1) If the operator enters into the hazardous area marked in yellow, the robot's speed should be reduced and the pneumatic system should reduce the pressure. The hazardous area is monitored by a laser scanner. In this example, the robot is not a part of the safety-related evaluation.

22 EXAMPLE 7 Monitor pressure (PL d, cat. 3) and protect against unintentional start-up (PL d, cat. 3) In addition to automatic mode, maintenance mode can also be selected via the operating mode switch. When the handling station is in maintenance mode, the actuators must be moveable under pressure. The pressure should be reduced in the maintenance unit to a defined-level and safely monitored, so that the actuators are not subject to a risk of crushing, while configuration and adjustment options can still be carried out. If the pressure reaches a critical level, the safety PLC receives an analogue signal, and the system is vented.

23 Standard reference

24 Suitable components for your application

25 Suitable components for your application

26 Residual pressure release valve with position detection sensor Complies with the ISO international safety standard VP-X536/538/555 VG342-X87 Series

Complies with Safety Standard ISO13849-1 1.

Compliance with the international standard (IEC/ ISO) of machines and equipment become

EU: ISO13849-1 has been established as the EN standard harmonized with CE Machinery

27 Complies with Safety Standard ISO Objectives (1) -Mechanical safety is a global requirement. Compliance with the international standard (IEC/ ISO) of machines and equipment become mandatory. EU: ISO has been established as the EN standard harmonized with CE Machinery Directive. Products not compliant with ISO cannot be sold in the EU. USA: ANSI, China: GB, Korea: KS. These countries are introducing this standard to the standard of the countries. - The number of users requesting ISO is growing.

1. Objectives (2) Valves with a position detection function are required to be ISO13849-1 compliant.

28 1. Objectives (2) Valves with a position detection function are required to be ISO compliant. - The ISO safety standard specifies the requirements for safety related circuits, and the procedure to verify the circuit and reduce the risk of the circuit. - ISO evaluates safety with four parameters: (1)Category of equipment, (2)B10/MTTD (life data), (3) DCavg (self diagnosis rate), and (4)CCF(Common Cause Failure) - A residual pressure release valve with position detection sensor is needed to realize the safety related circuit specified by (1)Category of equipment.

1. Objectives (3) Clarification of SMC s safety

Providing of reliability information such as B10/MTTF

29 1. Objectives (3) Clarification of SMC s safety standard response - 3 types of ISO user support from SMC (1) Supply of a residual pressure release valve with a position detection sensor (2) Providing of reliability information such as B10/MTTF data (3) Providing components to ensure the safety of the control system.

movement to be detected with a limit switch.

- Long life: B10d = 10 million cycles (Other than S1 type) - Residual pressure

30 Highly reliable architecture 2. Features - The main valve position detection feature allows the spool valve movement to be detected with a limit switch. This allows for monitoring as required by the standard. - Long life: B10d = 10 million cycles (Other than S1 type) - Residual pressure is completely released with a spring return regardless of the pressure. pressure release valve Spring return safety limit switch for position detection Spool rod Safety limit switch

31 For Category 2 [VP542/742-X536] 2. Features X536 - The main valve position detection sensor allows for monitoring and allows for compliance with the construction of requirement of Category- 2 specified by ISO Category 2 The main valve position detection sensor allows for compliance with the standard. pressure release valve safety limit switch for position detection

32 2. Features X538 X87 For Category-3 and 4 [VP544/744-X538/X555 VG342-X87] Redundancy is realized by connecting two valves in series. This realizes conformance with Category 3 and 4. Category 3,4 By combining two valves, redundancy is achieved and conformance with Category 3 and 4 is realized. pressure release valve safety limit switch for position detection

33 2. Features X555 Valve with soft start-up [VP544/744-X555] - Integrated Soft start-up function available - A fixed orifice and a variable throttle are available. Primary pressure (supply pressure) Soft start up valve(open) Secondary pressure Soft start up valve Flow adjustment valve Valve Valve2 3 port valve opens Time: T Outlet pressure - Time Soft start-up valve Pneumatic circuit

34 A Limit switch is available A limit switch is available depending on the market request. 2. Features OMRON Rockwell Automation

35 Enclosure & Standard 2. Features - For the global market sales promotions, the products conform to enclosure standards and standard compliance requirements. Series Category Safety limit switch Standard Protection 2 OMRON Rockwell Automation 3, 4 OMRON Rockwell Automation OMRON 3, 4 Rockwell Automation

36 Variations 2. Features This product has a wide array of variations due to it being based on the VP and VG valve series. Series Category

3. Application Examples # To upgrade the safety level of

measuring, and transport equipment industries.

37 3. Application Examples # To upgrade the safety level of the source pressure on industrial manufacturing lines where safety is important. This is applicable to general, electric, precision measuring, and transport equipment industries. # With the use of this valve the total safety level of the machinery can be upgraded to category levels 2, 3, or 4.

38 5. Construction VG342-X87 Valve position detection switch Spring Rod Poppet Valve Outlet Inlet

39 Series VHS Conforming to OSHA Standard Pressure Relief 3 Port Valve with Locking Holes

Series (N)AV Soft Start-up Valve Combined Soft Start and Dump Valve Compatible with Modular Series FRL Large Cv Factor Low Power Consumption Air Supply and

40 Series (N)AV Soft Start-up Valve Combined Soft Start and Dump Valve Compatible with Modular Series FRL Large Cv Factor Low Power Consumption Air Supply and Exhaust can be operated manually The valve gradually increases supply pressure during start up and rapidly exhausts system air when the supply air is shut off

Series AVL Soft Start-up Valve Soft start

increases supply pressure during start up and

41 Series AVL Soft Start-up Valve Soft start valve with Lock-out function Compatible with Modular Series FRL Large effective area Low power consumption A valve that gradually increases supply pressure during start up and rapidly exhausts system air when the supply air is shut off

42 Series (N)AP100 Pressure Relief Valve The (N)AP Series pressure relief regulator is an adjustable relief valve with a control range of 18 ~100 PSI. If a pressure greater than the set pressure is reached, the unit will open, closing when pressure is less than set pressure.

Controller Temporary Intermediate Stop and Speed

43 Series ASP Speed Controller with Pilot-Operated Check Valve Integrated Pilot Check Valve and Speed Controller Temporary Intermediate Stop and Speed Control of Cylinders is possible 360 Freedom for tube mounting direction

45 Provides a reliable method of stopping the piston rod in the event of air pressure loss or other signaled event (E-Stop) A mechanical pin or brake-shoe design provides reliable stopping of the piston rod. Ideal for vertical applications in which either tool damage or the possibility of human injury could occur.

Cylinder with End Lock Drop prevention at stroke end

air piping is not required for locking Simple spring

port is pressurized Allows for reliable holding of

46 Cylinder with End Lock Drop prevention at stroke end Locks when air is exhausted at the stroke end Separate air piping is not required for locking Simple spring loaded shot pin design Pin is retracted as cylinder port is pressurized Allows for reliable holding of retracted or extended piston rod for indefinite periods of time

Locking position can be changed to accommodate an

47 Cylinder with Lock Can be locked at any stroke position Emergency stop and intermediate stop are possible Locking position can be changed to accommodate an exterior stopper position or the thickness of clamped work pieces

Series ASS Slow Start Control Valve Meter-out Type Prevents accidents caused by the cylinder rod sudden extensions If pressure is applied only to one side

The meter-out type SSC valve prevents the sudden extensions by effecting meter-in control when there is no pressure, and resumes the ordinary meter-out

48 Series ASS Slow Start Control Valve Meter-out Type Prevents accidents caused by the cylinder rod sudden extensions If pressure is applied only to one side of the cylinder, the rod could get out of control, leading to accidents that could involve injury to humans or damage to the product or jigs. The meter-out type SSC valve prevents the sudden extensions by effecting meter-in control when there is no pressure, and resumes the ordinary meter-out control after the cylinder has been pressurized. With the meter-in type, there is no risk of sudden extensions because the cylinder speed is constantly under meter-in control.

49 Series AS Tamper Proof Speed Controller Flow Control with both meter-in and meter-out options Flow Control cannot be adjusted without the use of a special tool

valve construction Seal material: FKM Body material: C37,

50 Electronically Controlled Flow Control Valves Leaves speed control in the hands of the programmer Direct operated poppet valve construction Seal material: FKM Body material: C37, stainless steel Port size: 1/8 Available in body ported or base mounted styles

Series AS E Speed Control with Residual Pressure

the additional feature of the red button, which

fitting that has a push button on top of it.

51 Series AS E Speed Control with Residual Pressure Relief Valve A standard acting flow control with the additional feature of the red button, which when depressed releases all residual pressure in that line to atmosphere. KE Residual Pressure Relief Valve An inline fitting that has a push button on top of it. When the button is depressed, all residual air pressure in that line is vented to atmosphere.

Series PSE200 Multi-Channel Controller Series

Ideal for confirmation of residual pressure in

52 Series PSE200 Multi-Channel Controller Series PSE530 Pressure Sensor A multi-channel controller which can independently sense pressure from 4 sensors. Ideal for confirmation of residual pressure in critical system lines. Series VR3100/3110 provides visual confirmation of pressure.

Series VR51 Two Hand Anti-Tie-Down Valve Output air

is removed during operation In order to restart,

53 Series VR51 Two Hand Anti-Tie-Down Valve Output air signal is not present unless both buttons are pressed within 0.5 sec The output air signal will stop if one hand is removed during operation In order to restart, remove both hands from the mechanical pushbutton valves and re-apply NOT FOR USE UNDER 0.24 MPa

Series VQC-X10 Pilot Valve On/Off with Pressure Monitoring 5/2 monostable valve; Air pressure-assisted spring return with reinforced spring; Controls pilot signal to manifold o Switching off this

54 Series VQC-X10 Pilot Valve On/Off with Pressure Monitoring 5/2 monostable valve; Air pressure-assisted spring return with reinforced spring; Controls pilot signal to manifold o Switching off this valve sends remaining valves back to safety position Integrated pressure switch provides confirmation of pilot pressure Manual override is actuated A-side ISO validated 2 sizes, 8 standard valve functions and other special valve functions available

functions available Series SY52 -X25 Bi-Stable 5/2 Valve with Detent Valve with physical detent o

55 Series SY-X31 Pilot Valve On/Off with Position Monitoring External pilot pressure control Auto-switch spool detection Return spring for spool Red end-cap ISO validation pending Other special valve functions available Series SY52 -X25 Bi-Stable 5/2 Valve with Detent Valve with physical detent o Instead of relying on internal friction For safety circuits when maintaining valve position is required

Silencer Series (N)AN M3, M5, 1/8 Sintered Bronze 13-21 db

Series ANA1/ANB1 High Noise Reduction Type Silencer

orifice sizes Compact, robust construction Minimum flow

56 Silencer Series (N)AN M3, M5, 1/8 Sintered Bronze db noise reduction ¼ ~ 2 Over 30 db noise reduction Silencer Series ANA1/ANB1 High Noise Reduction Type Silencer Standardized thread and one-touch connection Choice of two orifice sizes Compact, robust construction Minimum flow restrictions for low back pressure Wide range of options High noise attenuation (40 db)(a) for ANA1

57 Series (N)AMC Exhaust Cleaner Ensures clean plant air and noise reduction of distributing noise contamination Over 35 db noise reduction Over 99.9% oil mist removal

58 Conclusion Safety and efficient production can go hand and hand A safe workplace makes a better employee Skeptical??? o Consider cost avoidance

59 Questions?

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866-522-2300 / www.asesafety.com Integrating Safety and Automation Presented by: Dennis Aulbrook Safeguarding of Automated Machinery A safeguard is a solution or a combination of solutions that eliminate