Download document () of 20

Integrating functional safety in machines

Safety for machines and systems
 
SISTEMA software
 
Safety-related characteristics
 

Switch off and work safely

Functional safety is an essential part of the machine design process, and it is key to protecting the health and safety of machine operators and keeping the production process up and running. In order to ensure functional safety, the latest guidelines must be applied. Design guidelines based on standardised and accepted circuits can significantly reduce the implementation effort.

For more than ten years, DIN EN 60204-1 has ensured the safe design of electrical equipment for machinery and plants. The underlying standard IEC 60204-1 was updated in 2016 – and the European version of the world's most widely used machine safety standard has now been published. This whitepaper provides an overview of the most important changes for machine and plant manufacturers, especially with regards to switchgear technology.

 

eaton-functional-safety-eu-directives-and-standards-graphic-en-us.jpg

The EU's internationally harmonised directives are designed to ensure balanced protection for people and the environment and to reduce competitive disadvantages and business hurdles due to differing safety regulations. 

In the EU, machine safety is primarily governed by two directives. While the Machinery Directive is aimed at machine builders, the Work Equipment Directive is directed at machine operators. A principle known as presumption of conformity applies to the fulfilment of the requirements laid down in the harmonised standards. It presumes that the protective aims of the EU directives are to be regarded as sufficiently met.

Our Safety Manual provides an overview of the EU’s most important directives, standards and regulations for machinery.

Find out how you can control the unexpected in our Safety Manual

Safety manual

The Eaton Safety Manual provides an entry-level introduction to the extensive material on safety technology. The manual contains an overview of the most important elements of the directives, standards and regulations that must be taken into account when using safety equipment with machinery.

SISTEMA software - safety of machine controls - easy to calculate

SISTEMA, the manufacturer-independent calculation tool of the Institute for Occupational Safety and Health of the German Social Accident Insurance (IFA), simplifies risk assessment and helps to evaluate the safety-related control components within the framework of EN ISO 13849-1.

A Windows interface is used to select the design structure of the protective devices and to assign them to an EN ISO 13849-1-compliant architecture. 

On this basis, the software then calculates the reliability ratings and the performance level (PL).
This enables a direct comparison with the required performance level (PLr).

The software records the relevant evaluation parameters, such as MTTFd, B10d, DCavg and CCF. It directly indicates the impact of variable parameters on the overall result.

We provide libraries for integration into the SISTEMA software at: input, logic and output. Please note that the libraries are constantly updated and that new products are regularly added.

Further information and the download link for the SISTEMA software are available directly from the IFA.
eaton-sistema-software-calculation-safety.jpg

Universal database for VDMA 66413 parameters

The EN ISO 13849-1, EN ISO 13849-2 and EN 62061 standards, which have been harmonised in accordance with the Machinery Directive 2006/42/EC, require assessments and calculations of the probability of a dangerous failure and of a machine’s systematic safety functions. We offer a database of Eaton logic modules for all manufacturer-specific calculation tools with a VDMA 66413-compliant import interface in both German and English (for the ESR5 and ES4P product ranges). In addition, the database also includes a description (IL) and a photo of each device. Project managers thus have direct access to the manufacturer's data via the software, meaning they do not have to be entered manually.

Implementing functionally safe circuits with the right products

Emergency-stop push buttons for various applications
Emergency-stop push buttons for various applications
RMQ compact series emergency-stop button with cable and M12 connector
RMQ compact series emergency-stop button with cable and M12 connector
Safety contactors with non-detachable auxiliary switch with yellow cover
Safety contactors with non-detachable auxiliary switch with yellow cover
Safety logic, safety relay, safety logic relay
Safety logic like safety relay and safety logic relay
Safety positioning switches and safe non-contact switches
Safety positioning switches and safe non-contact switches
Eaton rotary cam switches shafts handles accessories
Switch disconnectors

Safety-related characteristics

Functional safety includes the calculation and documentation of the probability of failure of the individual safety functions. Machine builders and system integrators require additional characteristic values for safety-related products, which are made available by the respective manufacturers. These values are used together with statistical calculation tools to determine the safety level, which is referred to as the performance level in EN ISO 13849-1 and as the safety integrity level in IEC 62061 and IEC 61508.

We provide you with the specific characteristic values of all our safety-related components via the following link.

Reliability ratings according to EN ISO 13849-1:

  • B10d: Number of operations after which dangerous failures occur in 10% of tested components
  • MTTFd: Mean time to dangerous failure. The average time it takes until a dangerous failure is to be expected
  • PL: Performance level

Reliability rating according to IEC 62061:

  • B10: Number of operations after which dangerous failures occur in 10% of tested components
  • PFHd: Probability of dangerous failure per hour
  • SIL CL: Safety integrity level claim limit