SISTEMA - Sicherheit von Steuerungen an Maschinen

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1 Author: Günter Hog, Parker Hannifin GmbH Dangerous point/machine: File name: L:\PUBLIC\EE\Sicherheitstechnik\Baumusterpruefbescheinigung\Compax 3 Sistema Library\in Vorbereitung\EN\Parker Compax3S STO with fieldbus.ssm Version of software: Version of standard: ISO :2006, ISO :2003 Checksum: Options: Note: 6d391e6fee1b2fdafa7be10bd8303e3d Use DC intermediate levels for calculation of PFH (more precise) Raise the MTTFd-capping for Category 4 from 100 to 2500 years There are no warnings listed for this project (or it's subordinate basic elements). Contained safety functions Name: STO / SS1 Required: PLr d Reached: PL d PFH [1/h]: 1,83E-7 Page 1 / 10

2 Safety function type: Triggering event: Reaction: Safe state: Protection against unexpected start-up Opening of guarding door Controlled stop with following disabling of power stage Drive ist switched in torque off state By opening of a guarding door an external safety control unit triggers via external PLC and fieldbus (STO channel 1) at the Compax3S servo drive an immediate braking ramp on the drive (stop category 1). After the completion of the braking ramp, the external safety control unit triggers with the additional second STO channel input the motor in a torqueless state. Reached PL: d PFH [1/h]: 1,83E-7 PLr (by direct input): d Requirement by customer Source (e.g. standard): File: Subsystems: Name: Switches of door guarding PL: e PFH [1/h]: 2,47E-8 Cat.: 3 DCavg [%]: 99 (High) CCF Points: 80 (fulfilled) MTTFd [a]: 100 (High) Documentation Subsystem Category Subsystem Source (e.g. standard) Category: File: Requirements of the Category: Basic safety principles are being used. [fulfilled] Well-tried safety principles are being used. [fulfilled] Page 2 / 10

3 A single fault tolerance is given. [fulfilled] MTTFd is Low or Medium or High. [fulfilled] DCavg is Low or Medium. [fulfilled] The achieved score of the CCF-rating is at least 65. [fulfilled] Status / Messages Subsystem Channels / Test channels: Name: Channel 1 MTTFd [a]: 285,39 Blocks: Name: Switch contactor 1 MTTFd [a]: 285,39 (High) Documentation Block Status / Messages Block Elements: Name: Switch contactor 1 B10d [cycles]: nop [cycles/a]: T10d [a]: 28,54 MTTFd [a] (from B10d ): 285,39 (High) Documentation Element Technology: electromechanic Diagnostic coverage Element Page 3 / 10

4 Measure: Plausibility check, e.g. use of normally open and normally closed mechanicall linked contacts (Input devices) (99 %) Status / Messages Element Message [Status of Message]: Channels / Test channels: Name: Channel 2 MTTFd [a]: 285,39 Blocks: Name: Switch contactor 2 MTTFd [a]: 285,39 (High) Documentation Block Status / Messages Block Elements: Name: Switch contactor 2 B10d [cycles]: nop [cycles/a]: T10d [a]: 28,54 MTTFd [a] (from B10d ): 285,39 (High) Documentation Element Technology: electromechanic Diagnostic coverage Element Measure: Plausibility check, e.g. use of normally open and normally closed mechanicall linked contacts Page 4 / 10

5 (Input devices) (99 %) Status / Messages Element Message [Status of Message]: Subsystems: Name: Safety control unit PL: e PFH [1/h]: 7,9E-9 Cat.: 4 Documentation Subsystem Manufacturer: Sick Type: UE410 Performance Level Subsystem Category Subsystem Source (e.g. standard) Category: File: Requirements of the Category: Since the category is given by the manufacturer he is responsible to satisfy the requirements. Status / Messages Subsystem Subsystems: Name: Servo drive Compax3S PL: d PFH [1/h]: 1,51E-7 Cat.: 3 DCavg [%]: 71,38 (Low) CCF Points: 85 (fulfilled) MTTFd [a]: 67,27 (High) Documentation Subsystem Page 5 / 10

6 Category Subsystem Source (e.g. standard) Category: File: Requirements of the Category: Basic safety principles are being used. [fulfilled] Well-tried safety principles are being used. [fulfilled] A single fault tolerance is given. [fulfilled] MTTFd is Low or Medium or High. [fulfilled] DCavg is Low or Medium. [fulfilled] The achieved score of the CCF-rating is at least 65. [fulfilled] Common cause failure Subsystem CCF Measures: Separation / Segregation (15 Points) Physical separation between signal paths: separation in wiring / piping, sufficient clearances and creep age distances on printed-circuit boards. Diversity (20 Points) Different technologies / design or physical principles are used, for example: first channel programmable electronic and second channel hardwired, kind of initiation, pressure and temperature. Measuring of distance and pressure, digital and analog. Components of different manufactures Design / application / experience (15 Points) Protection against over-voltage, over-pressure, over-current, etc. Environmental (25 Points) Prevention of contamination and electromagnetic compatibility (EMC) against CCF in accordance with appropriate standards. Fluidic systems: filtration of the pressure medium, prevention of dirt intake, drainage of compressed air, e.g. in compliance with the component manufacturers requirements concerning purity of the pressure medium. Electric systems: Has the system been checked for electromagnetic immunity, e.g. as specified in relevant standards against CCF? For combined fluidic and electric systems, both aspects should be considered. Environmental (10 Points) Other influences. Have the requirements for immunity to all relevant environmental influneces such as temperature, shock, vibration, humidity (e.g. as specified in relevant standards) been considered? Page 6 / 10

7 Status / Messages Subsystem Channels / Test channels: Name: Channel 1 MTTFd [a]: 10 Blocks: Name: PLC MTTFd [a]: 15 (Medium) DC [%]: 60 (Low) Rate of dangerous failure [FIT]: 7610,35 Documentation Block Diagnostic coverage Block Status / Messages Block Blocks: Name: Compax3S motor control device MTTFd [a]: 30 (High) DC [%]: 90 (Medium) Rate of dangerous failure [FIT]: 3805,17 Documentation Block Diagnostic coverage Block Measure: Monitoring of output of motor control device via external safety device (without dynamic tests) + additional fault detection in the serrvo drive, when power stage isn't running by deactivated STO. (Output device) (0 % - 99 % the frequently signal change of the application) Status / Messages Block Page 7 / 10

8 Channels / Test channels: Name: Channel 2 MTTFd [a]: 200 Blocks: Name: Safety relais MTTFd [a]: 200 (High) Documentation Block Status / Messages Block Elements: Name: Safety relais OA5669 B10d [cycles]: nop [cycles/a]: T10d [a]: 20 MTTFd [a] (from B10d ): 200 (High) Documentation Element Technology: electromechanic Diagnostic coverage Element Measure: Direct monitoring (e.g. electrical position monitoring of control valves, monitoring of electromechanical devices by mechanically linked contact elements) (Output device) (99 %) Status / Messages Element Page 8 / 10

9 Message [Status of Message]: Page 9 / 10

10 EXCLUSION OF LIABILITY Care has been taken in production of the software SISTEMA, which corresponds to the state of the art. It is made available to users free of charge. Use of the software is at the user's own risk. To the extent permissible by law, no liability will be accepted for the software on any legal basis. In particular, no liability will be accepted for material defects or defects in title, whether in the software or in the associated documentation and information, particularly with regard to their correctness, freedom from errors, freedom from property rights and copyright of third parties, up-to-dateness, completeness and/or fitness for purpose, except in cases of malicious or wrongful intent. The IFA undertakes to keep its website free of viruses; nevertheless, no guarantee can be given that the software and information provided are virus-free. The user is therefore advised to take appropriate security precautions and to use a virus scanner prior to downloading software, documentation or information. CONTACT Institute for Occupational Health and Safety of German Social Accident Insurance (IFA) Division 5: Accident Prevention / Product Safety Alte Heerstr. 111, Sankt Augustin (Webcode e20543) Date, signature of the revisor Date, signature of the author Page 10 / 10

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