Sicherheitspneu en 4

_HB_Safety_030408_en.qxp 03.04.
2008 13:41 Uhr Seite 1
Safety engineering guidelines

_HB_Safety_030408_en.qxp 03.04.2008 13:41 Uhr Seite 2
Your partner in safety
At Festo, quality has many This brochure is intended as a Simple and helpful: In the
aspects – one of these is hand- guide. second part of the brochure, you
ling machines safely. This is the It covers the core questions can find sample circuit diagrams
reason behind our safety-orien- relating to safety-orientated for the most common safety
tated automation technology. It pneumatics: functions related to pneumatic
gives you the certainty that your drives and the associated prod-
workplace is as safe as possible. • Why use safety-orientated uct combinations from Festo.
pneumatics? These can be used to solve many
• How can I identify the risk safety functions.
posed by a system or machine
to the operator or user? If you have further requirements,
• Which standards and our specialists worldwide will be
directives apply? happy to help.
• What safety measures are
derived from these?
• What are the most common
safety measures?
2
Table of contents
Page
Directives and standards 4
Time schedule for EC machinery directive and DIN EN ISO 13849-1
Definition and concept of risk
Risk assessment
Directive-compliant procedure for safe design

(as per EN ISO 12100)
Control architectures (as per DIN EN ISO 13849-1)
4 operation modes – 10 safety functions
Sample circuit diagrams 32
Festo products 46
Services 74
3
Reduce risk – think preventively
Machines have to be designed in The EC machinery directive spe- Safety-orientated pneumatics

a way that protects people, cifies a risk analysis and assess- from Festo provides you with
animals, property and the en- ment for machines. Protection solutions for
vironment from harm. The goal goals are derived and defined • Commissioning
is to prevent physical damage from this directive. The protec- • Automatic/manual operation
of any type. Using safety- tion goals are achieved using • Setting operation
orientated pneumatics from various safety functions. Safety- • Risk situations and emergency
Festo provides you with the orientated pneumatics from functions, such as safe stop-
security of implementing safety Festo, in the form of ping, safe exhausting.
measures in compliance with the • Components • Restarting -> protection against
EC machinery directive. You can • Circuits unexpected starting up
reliably prevent collisions or • Engineering • Servicing/maintenance
uncontrolled restarts after an make it easy to achieve your
emergency stop, for example. safety objectives. Safe operation In addition to this, if errors
At the same time, using safety- of machines should be possible occur, they must not lead to
orientated pneumatics also min- in all modes and stages of their failure of the safety functions,
imises the risk of liability claims. service life. depending on their hazard
potential.
4
Simple – but safe!
In general, the simpler the safety Festo provides solutions on the

engineering used in the appli- basis of risk analyses and
cation, the more efficient it is. assessments for the most com-
The complexity of safety en- mon applications. This ensures
gineering is in the variety of that the electrical safety func-
state combinations and tran- tions for your pneumatic
sitional states. system’s controllers are en-
hanced with the appropriate
As a result, it would seem al- safety concepts.
most impossible to implement
standardised safety engineering
concepts.
Due to their flexible application,

pneumatic drive systems from
Festo need to be included in the
risk analysis and assessment for
each machine, depending on the
application.
5
Basic safety requirements in the manufacturing industry
The development of the single

European market has led to
Free movement of goods in Europe
standardised guidelines for
mechanical engineering for the
manufacturing industry. Article 95 of the EU Treaty Article 137 of the EU Treaty
(free movement of goods) (occupational health and safety)
“Health and safety” outline directive

e.g. machines 89/391/EEC
Low voltage directive Machinery directive “Use of work equipment”

2006/95/EC 98/37/EC single directive 86/655/EEC
2006/42/EC
Harmonised European standards National statutory provisions
Responsibility
Manufacturers Operators
Directives are laws. The EC One option for complying with

machinery directive applies to the EC machinery directive is to
mechanical engineering run on. apply harmonised standards.
The primary aim of the EC Harmonised standards are listed
machinery directive is to specify in the Official Journal of the
basic health and safety require- European Communities.
ments in relation to the design Applying these results in what is
run on and construction of known as the “presumption of
machines. The CE mark identifies conformity”, which reinforces
a machine as compliant with the the legal security of operators
EC machinery directive. and manufacturers.
6
Time schedule for EC machinery directive and DIN EN ISO 13849-1
Machine safety requires safe

control systems. Important 2006 2007 2008 2009 2010 2011
harmonised standards include
29th December 2009
EN 954-1, which is going to be
superseded by EN ISO 13849-1.
Old machinery directive
DIN EN 954-1 will be in force
until the end of 2009. May 2006
EN ratification
Incorporation into national law New machinery directive

Europe
30th November 2009
EN 954-1
8th May 2007
Listing in the Official Journal of the European Communities
EN ISO 13849-1
February 2007
Withdrawn from DIN
DIN EN 954-1
Germany
2nd October February 2007

2006 DIN ratification
EN
ratification DIN EN ISO 13849-1
EN 954-1 has presumption of conformity according machinery directive 98/37/EC
EN ISO 13849-1 has presumption of conformity according machinery directives 2006/42/EC and 98/37/EC
A new machinery directive will Manufacturers have to comply

apply to the trade in and con- with the laws of their country.
struction of machines in
the EU from the end of 2009. Applying standards is an option.
EU member states urgently have Standards reflect the best
to incorporate this directive into available technology.
their national legislation be-
cause, at European level, directi-
ves are laws.
7
Fundamental standards for designing control functions
Applying harmonised
standards provides legal Design and risk assessment of machinery Electrical safety aspects
security in compliance with
EN ISO 12100 EN 60204-1
European law. Safety of machinery Safety of machinery
Basic concepts, general principles for design Electrical equipment of machines,
part 1: General requirements
EN 1050 (EN ISO 14121-1)
Safety of machinery
Risk assessment, part 1: Principles
Functional and safety-related requirements for

safety-related control systems
Designing and implementing safety-related control systems
EN 62061
Safety of machinery
Functional safety of safety-related electrical, electronic and
programmable control systems
Any architectures
Safety integrity level (SIL)
SIL 1, SIL 2, SIL 3
DIN EN ISO 13849-1

Safety of machinery
Safety-related parts of control systems, part 1: General principles for design
Successor standards to EN 954-1:1996, transition period until 2009
Designated architectures (categories)

Performance level (PL)
PL a, PL b, PL c, PL d, PL e
Harmonised standards that

relate to machine safety serve
to reduce safety risks to an
acceptable minimum, as per the
machinery directive.
8
Definition and elements of risk
Risks are the result of hazards

and relate to the gravity of
possible damage and the
probability of the damage
occurring. Low risk High risk
Safety Adequately Danger/hazard

The first step is to reduce risk by reduced
implementing inherent safety. Residual risk Risk before pro-
tective measures
The second step is to reduce risk
by implementing safety meas- Necessary minimum risk reduction
ures. The final measure is to
reduce risk through instruction. Actual risk reduction
Safety = acceptable residual risk
Risk Severity of harm Probability of

in terms of the
considered hazard = that can result from
the considered + occurrance
of that harm
hazard
Exposure of person(s) to
that hazard
The possibility of avoiding

or limiting the harm
The occurrance of a
hazardous event
9
Risk assessment
Directives and standards de-

Start
scribe the process of risk assess-
ment. Every manufacturer is Specification of the machine
limits
obliged to carry out a risk Determination of the limits
• Use limits
of the machinery
assessment. This is followed
Source: EN ISO 12100, 3.14
• Space limits
• Preliminary hazard analysis
Source: • Time limits
by a risk evaluation and, if EN 1050, Section 5 (PHA)
ISO 14121 Source: EN ISO 12100; 5.2 • WHAT-IF method
Risk analysis
necessary, suitable measures • Failure mode and effects

Determining/defining analysis, failure effects
for reducing risk have to be Hazard
states & transitional states analysis (FMEA)
identification
implemented. • Failure simulation for con-
Source: trol systems
EN 1050, Section 6
ISO 14121 • MOSAR procedure
• Fault tree analysis (FTA) –
Focusing on risk reduction
Source: EN ISO 1050/14121
• Human interaction during

DELPHI-Technique
Risk estimation whole life cycle
This guide is primarily concerned • Possible states of the Source: EN 1050, Appendix B
Risk assessment
with the area of risk reduction in machine

Source: • Unintended behaviour of
the form of technical safety EN 1050, Section 7
ISO 14121 the operator or reasonably
foreseeable misuse
measures. We assume that all
Source: EN ISO 12100; 5.3
possible design measures for Risk
evaluation of safety no
Source: EN ISO 12100-1, 5.3
reducing risk have already been design measures – Is the

explored. machine
Risk evaluation
safe?
yes
Risk
evaluation
of technical safety no
measures–
Is the machine
safe?
yes
All possible no
instructive
measures
used
yes
End
Source: Directive 2006/42/EC, Appendix I, 1)
10
When estimating the risk and

identifying the required perfor-
mance level, the degree of risk
Design measures
e.g. inherent safety reduction is established.
Source: EN 12100-2, Section 4 Whether or not the required
risk reduction level has been
achieved for technical safety
measures depends on the follo-
Technical safety measures
and supplementary safety measures
wing parameters:
Identify the safety function to be performed

1) Control architecture
For each safety function specify the required
2) Mean Time To Failure (MTTFd)
characteristics 3) Diagnostic coverage (DC)
Source: EN ISO 12100-1, 5.4
Determining the required PLr 4) Common Cause Failure (CCF)

Risk reduction
For all safety functions
Design and technical implementation of the safety In all cases, the performance
function
level (PL) must be equivalent to
Determining the PL at least the required PLr.
Category MTTFd DC CCF
yes
PL ≤ PLr
no
Source: DIN EN ISO 13849-1, 4.2 Figure 3
User information on the machine and in the user

manual
Source: EN 12100-2, Section 6
11
Evaluating technical safety measures – determination of the performance level
The figure shows the simplified

Determination of the MTTFd = mean time to failure (dangerous)
procedure for determining the
performance level (PL) of a safe-
Determination of the SIL = Safety Integrity Level

1 3
a 10–5 ≤ PFHd < 10–4
ty function. The PL is a function
Determination the PL = Performance Level
of categories B to 4, diagnostic
coverage “none to high”, various b 3 x 10–6 ≤ PFHd < 10–5
MTTFd areas and the common
1
cause failure.
c 10–6 ≤ PFHd < 3 x 10–6
The PL can be assigned to a spe-

cific SIL level. However, it is not d 2 10–7 ≤ PFHd < 10–6
possible to infer the PL from the

SIL. Apart from the average pro- 10–8 ≤ PFHd < 10–7
e 3
bability of a dangerous failure
per hour, other measures are
DC < 60% DC < 60% 60% ≤ DC 90% ≤ DC 60% ≤ DC 90% ≤ DC 99% ≤ DC
needed to achieve a specific PL. 4
none none < 90% < 99% < 90% < 99% high
low medium low medium
2 Cat B Cat 1 Cat 2 Cat 3 Cat 4
5 CCF not relevant CCF ≤ 65%
1 Risk graph: Which performance level is Evaluation MTTFd

required? 3 years ≤ MTTFd < 10 years
Low
PL a to e
Medium 10 years ≤ MTTFd < 30 years
2 Designated architectures: How is the High 30 years ≤ MTTFd ≤ 100 years
control chain or safety function
structured? Cat B to 4 Source: DIN EN ISO 13849-1, Chapter 4.5.2
3 Quality of components in the control

chain. Determining the MTTFd for the
entire process chain – from sensors to
actuators
4 Diagnostic coverage:
Which dangerous failures are identified?
5 Common cause failure (CCF): measures

to reduce CCF DIN EN ISO 13849-1
Chapter 4.5.4
12
Application 13849-1, step 1: Determining the required performance level
The graph for determining the

required performance level is
low risk
based on identifying the risk and P1
F1
a
the resulting necessity for reduc- P2
ing this to an acceptable level. S1
P1 b
Low risk results in PL = a F2
(minimal measures for risk P2
reduction). c
P1
F1
High risk results in PL = e
P2
(comprehensive measures for S2
d
P1
risk reduction). F2
P2
e
high risk Source: DIN EN ISO 13849-1, Appendix 1.2.3
Technically speaking, PLr
(required) is a “nominal value”,
which is the minimum that Statements from other standards
should be achieved by the real DIN EN ISO 13849-1 EN 62061
structure. S Severity of injury Irreversible injury (4 points)
(death, loss of eye or arm)
S1 Slight (normally reversible injury) Irreversible injury (3 points)
Statements from EN 62061 are (broken limb, loss of finger)
S2 Serious (normally irreversible injury, Reversible injury (2 points)
also quoted here for a better or death) (requires further medical attention from a doctor)
assessment of risks. The basic Reversible injury (1 point)
principle of risk is always Frequency (with a duration > 10 min)

F Frequency and/or exposure to hazard < 1 h (5 points)
evaluated in the same way: the > 1 h to < 1 day (5 points*)
severity of the possible damage F1 Seldom to less often and/or exposed time is > 1 day to < 2 weeks (4 points*)
short > 2 weeks to < 1 year (3 points*)
and the probability that the > 1 year (2 points*)
F2 Frequent to continuous and/or exposed
damage will occur. time is long * if exposure lasts less than 10 min, this can be reduced one level
P Possibility of avoiding the hazard Impossible (5 points)
P1 Possible under specific conditions Rare (3 points)
P2 Scarcely possible Probable (1 point)
13
Implementation 13849-1, step 1: Determination of the designated architechture

for category B
Category Summary of requirements System behaviour
B • Safety-related parts of control systems must comply with the • Fault tolerance: zero.
applicable standards The occurrence of a fault can
• Control system must be designed, built, selected, assembled and lead to the loss of the safety
combined to ensure that they withstand the expected influences function
• Mainly characterised by
selection of components
I i m
L i m
O
14
Safety function
Exhausting
Example
Entire control chain = cat. B
Cat. B*
Cat. 1
* Normal PLC control systems (not safety control systems) only achieve category B
15
Control architecture of category 1
1 • The requirements of B shall apply • Fault tolerance: zero, but the

• Well-tried components and well-tried safety principles probability of occurance is
shall be used lower than for category B
Well-tried component: • The occurrence of a fault can
a) Widely used in the past with successful results in similar lead to the loss of the safety
applications, or function
b) Manufactured and verified using principles that • Mainly characterised by
demonstrate its suitability and reliability for safety-related
selection of components
applications
I i m
L i m
O
16
Safety function
Exhausting
Example*
Entire control chain = cat. 1
Hardware structure Wiring
ERGEN
EM
CY
S TOP
*The example shows the schematic representation of a specific category. Depending

on the safety relay, the wiring may be different and the connections may have
different designations. A fault examination has to be carried out for each concrete
application.
17

2 • Requirements of B and the well-tried safety principles shall apply • Fault tolerance: zero, but the
• Safety-related parts of control systems must check safety functions loss of the safety function is
at suitable intervals by the machine control system: when the machi- detected by the check
ne starts up and before a hazardous situation arises, e.g. the start of • The occurrence of a fault can
a new cycle; at the start of other movements and/or periodically lead to the loss of the safety
during operation, if the risk assessment and the operation mode function between the checks
show that this is necessary. • Testing at suitable intervals
(test frequency must fulfil one
hundred times the requirement
rate (safety function))
• Mainly characterised by structure
I i m
L i m
O
TE i m
OTE
18
Safety function
Exhausting
Example*

ERGEN
EM
CY
S TOP

on the safety relay, the wiring may be different and the connections may have
different designations. A fault examination has to be carried out for each concrete
application.
19

3 • Requirements of B and the use of well-tried safety principles • Fault tolerance: one
shall apply When a single fault occurs,
the safety function is always
• Safety-related parts shall be designed so that
performed
a single fault in any one of these parts does not lead to a loss of
the safety function, and • Some but not all faults are
identified
• Whenever reasonably practicable, the single fault is detected
• Accumulation of undetected
faults can lead to the loss of
the safety function
structure
m
I1 i m
L1 O1
i m
m
I2 i m
L2 O2
i m
20
Safety function
Exhausting
Example*

ERGEN
EM
CY
S TOP

on the safety relay, the wiring may different and the connections may have different
designations. A fault examination has to be carried out for each concrete
application.
Note: BGIA certification as a category 3 component as per DIN EN ISO 13849-1 has been
requested for MS6-SV.
21

4 • Requirements of B and the use of well-tried safety principles • Fault tolerance: one
shall apply When single fault occurs, the
safety function is always per-
• Safety-related parts shall be designed so that
formed
a single fault in any of these parts does not lead to a loss of
the safety function, and • Detection of accumulated
• The single fault is detected at or before the next demand upon the faults reduces the probability
safety function, but that if this detection is not possible, an of the loss of the safety func-
tion
accumulation of undetected faults shall not lead to the loss of the
safety function. • The faults will be detected in
time to prevent the loss of the
safety function
structure
m
I1 i m
L1 O1
i m
m
I2 i m
L2 O2
i m
22
Safety function
Exhausting
Example*
ERGEN
EM
CY
S TOP

on the safety relay, the wiring may be different and the connections may have different
designations. A fault examination has to be carried out for each concrete
application.
Note: BGIA certification as a category 3 component as per DIN EN ISO 13849-1 has been
requested for MS6-SV.
23
Implementation 13849-1, step 3: Determination of the Mean Time To Failure (MTTFd)
Input Input signal Logic Control signal Outlet Control signal
Life time data based on the technical data sheet

B10 B10
Application data
MTTFd MTTFd MTTFd MTTFd
Evaluation MTTF d
1 N 1 3 years ≤ MTTFd < 10 years

______ = _______
Low
Medium 10 years ≤ MTTFd <30 years
MTTFd i=1 MTTFd,i 30 years ≤ MTTFd ≤ 100 years
High
Source: DIN EN ISO 13849-1, Chapter 4.5.2
The mean time to failure (MTTFd)

is initially determined for each
redundant channel. Next, a total
MTTFd value is determined for
both channels. This value is
given in years and is a qualita-
tive statement of the safety func-
tion. In line with the applicable
standard, the technical safety
measure is assessed and given
one of three classifications: low,
medium or high.
24
where:
Formula for determining the B10d B10d [cycles] = mean number of cycles until 10% of components fail
MTTFd value for a mechanical MTTFd = dangerously
0.1 • nop
element in a channel B10d = 2 x B10
dop • hop • 3600s/h hop [h/d]: mean operating hours/day

Mean number of annual nop = dop [d/anno]: mean operating days/year
tcycle
actuations nop for the tcycle [s]: mean cycle time
mechanical element
2 1 MTTFdC1 and MTTFdC2:

MTTFd = MTTFdC1 + MTTFdC2 –
Calculating the total MTTFd for 3 1 1 values for two different,
+
two different channels MTTFdC1 MTTFdC2 redundant channels. If the
MTTFd for a channel is more than
100 years, 100 years is used in
subsequent calculations.
25
Implementation 13849-1, step 4: Determination of the diagnostic coverage (DC)
This table shows a summary of
Spontaneous change in the setting

of non-adjustable, circular orifices
Change in the flow rate in the case
Spontaneous change of the initial
moving component(s)/mounting/
Change in flow rate without any
Change in the set value without

Change in the leakage flow rate
sources of fault related to pneu-
switching position (without an
Bursting of the valve hosing/

Fault list
For proportional flow valves:

unintentional change in the
matics, taken from DIN EN ISO
Change of switching times
over a long period of use
change in setting device

13849-2. Under certain condi-
not switching back

tions, it is possible to exclude
housing screws
Non-switching/
faults.
setting value
input signal)
and nozzles
The prerequisites for excluding a Products
Leakage
device
fault are described in detail in
DIN EN ISO 13849-2.
Faults must be examined and Directional control valves
evaluated in the context of each
application to establish whether Shut-off/non-return/quick
the fault has a dangerous effect exhaust/shuttle valves
on the safety function.

Flow control valves
Depending on the construction
principle and the design of com-
ponents, different results may Pressure limiting valves
arise for different applications;
in other words, a specific product Pipework
may be suitable for one appli-
cation but not for another.
Tubing
The design engineer for the
installation is responsible for
checking this. Connecting pieces
Pressure intensifier and pressure

medium converter
Filter
Lubricator
Silencer
Energy storage device

and reservoir
Sensors
Logic elements (AND/OR)
Delay elements
Transformers (pressure switch,

position switch and amplifier)
Cylinder
26
setting value
Change in the set value without
change to the setting device
Unintended unscrewing of the
operating element of the setting
device
Failure at the connector (e. g.
tearing off, leakage)
Clogging (blockage)
_HB_Safety_030408_en.qxp
Bending
Change of the detection or

output characteristics
03.04.2008
Failure of the end position

cushioning
Loosening of the piston/

piston rod connection
13:41 Uhr
Pressure rise
Pressure failure
Seite 27
Electrical power failure
DC1 =
(total
(identified
dangerous fault)
dangerous fault)
Key
DCavg =
DC average
1
DC1
+
+
considered
component
1
DC2
MTTFd1 MTTFd1
MTTFd1 MTTFd1
Fault has to be
Not relevant for this
+ ... +
+ ... +
in certain cases (see
DIN EN ISO 13849-2)
Fault may be excluded
27
1
DCN
MTTFdN
MTTFdN
Implementation 13849-1, step 5: Determining Common Cause Failures (CCF)
Common cause failure

No. Measures against CCF Score S
1 Separation/ Segregation
Physical separation between signal paths, e.g. separation in wiring/piping, sufficient clearances
and creep age distances on printed-circuit boards 15
2 Diversity
Different technologies/design or physical principles are used, for example: first channel program-
mable electronic and second channel hardwired, kind of initiation, pressure and temperature.
Measuring of distance and pressure, digital and analog. Components of different manufactures 20
3 Design/application/experience
3.1 Protection against overvoltage, over pressure, over-current etc. 15
3.2 Components used are well-tried 5
4 Assessment/analysis
Are the results of a failure mode and effect analysis taken into account to avoid common-
causefailures in design. 5
5 Competence/training
Have designers/ maintainers been trained to understand the causes and consequences of
common cause failures? 5
6 Environment
6.1 Electromagnetic compatibility (EMC) 25
The system was checked for EMC immunity
(e.g. as specified in the relevant product norms)
6.2 Other factors 10
Have the requirements for immunity to all relevant environmental influences such as temperature,
shock, vibration, humidity (e.g. as specified in relevant standards) be considered?
Total [max. possible: 100]
Measures for avoiding CCF Total S score
Meets the requirements 65% or better
Process failed; choose additional measures less than 65%
Which common cause failures points may be claimed for each

can arise? The measures against listed measure. If a measure is
these failures should be re- only partially fulfilled, it receives
corded in a grid. Only the zero points.
complete number of points or no
28
Combination or series connection of SRP/CS to achieve an overall performance level
Safety functions can be imple-

Sensors Logic Actuators
mented using multiple SRP/CS
connected in series. The perfor- User design Using certified User design Using certified User design Using certified
components components components
mance of each SRP/CS is either
determined by the user or, ideal-
ly, specified by the manufacturer Architecture Architecture Architecture
selection selection selection
of the component in the techni-
MTTF MTTF MTTF
cal data for the certified com- d d d
B10 value B10 value B10 value

ponents.
To determine the total perform- Application Application Application
data n op data n op data n op
ance level, the number of the

lowest performance level has Diagnostic Diagnostic Diagnostic
coverage coverage coverage
to be identified and the overall 0 ... 99% 0 ... 99% 0 ... 99%
PL is determined using the CCF value CCF value CCF value
standard. common cause common cause common cause
failure failure failure
PL a, b, c, d or e PL a, b, c, d or e PL a, b, c, d or e PL a, b, c, d or e PL a, b, c, d or e PL a, b, c, d or e
Partial result Partial result Partial result

Sensors Logic Actuators
determined by the mechanical engineer PL

specified by the manufacturer
Simplified calculation of PL for Lowest PL Number of lowest PL Entire system

series allignment of Safey- PLlow Nlow PL
related Part of control Systems a >3 not permitted
In a series connection, the >3 a
number of the lowest PL is deter- b >2 a
mined. This result can be used >2 b
to determine the total PL from c >3 b
the table. >3 c
d >3 c
>3 d
e >3 d
>3 e
29
4 operation modes – 10 safety functions
Pressurising Maintaining Reducing pressure Exhausting

pressure and force
Initial position,
standstill
Set-up and
Normal operation
service operation
Two-hand Tamper-proof,
operation prevention of
Emergency operation unexpected
starting up
Reducing speed Free of forces Stopping, holding and Reversing

blocking a movement a movement
30
During the risk assessment, the Specific safety functions can be You can find these safety func-
hazardous situation also has to derived from these operation tions both in the suggested cir-
be determined and, sub- modes: cuits and in the products and
sequently, the risks have to be solutions. The information spe-
evaluated. This applies to a • Pressurising of machines cified always refers to very spe-
machine’s entire service life. • Maintaining pressure cific safety functions.
The following four operating • Reducing pressure and force This will enable you to quickly
modes in particular are used for • Exhausting of machines decide whether the information
operating a machine: • Two-hand operation is relevant to your current task,
• Tamper-proof both in the sample circuits and
• Initial position/standstill • Reducing speed in the products.
• Normal operation • Free of forces
• Set-up and service operation • Stopping, holding and blocking
• Emergency operation a movement
• Reversing a movement
31
Examples of safety-orientated pneumatics
The varying requirements and areas of application for installations mean that the results of risk
analyses are very variable – as are the solutions for them. Here we present some important examples.
Picking & Placing discrete Power-driven interlocking

goods guards
Safety measures Safety measures

1. Prevention of unexpected 1. Prevention of unexpected
start-up, as per EN 1037 start-up, as per EN 1037
2. Two-channel stop, as per 2. Single-channel for safety func-
EN 13849-1 tion exhausting, as per
3. Stop category “1” as per EN 13849-1
EN 60204-1 3. Stop category “1” as per
EN 60204-1
32
Safety for pressing, joining and In progress: safety during

setting procedures setting-up
Safety measures Safety measures

1. Prevention of unexpected 1. Prevention of unexpected
start-up, as per EN 1037 start-up, as per EN 1037
2. Single-channel reversing, 2. Single-channel run at
as per EN 13849-1 reduced speed,
3. Unpowered state using as per EN 13849-1
stop category “1” as per
EN 60204-1
33
Safety function
Two-hand operation
Sample circuit diagram – two-hand control block
Control chain Description

The control block for two-hand
start ZSB 1/8 is a pneumatic
AND gate. If inputs 11 and 12
are pressurised within a
max. of 0.5 s of each other, the
assembly switches through and
there is an output signal at
port 2.
The system is controlled by two

external 3/2-way push-button
valves. If both push-button
valves are activated, outlet
port 2 is pressurised. If one or
both pushbuttons are released,
outlet port 2 is unpressurised.
The system exhausts from 2 to 3.
Note
Part no. Identifier Type Product designation All the information that relates
3527 WV1 ZSB-1/8 Control block for to standards is identified with
two-hand start “max. possible”. Whether the
6817 WV2 SV-3-M5 Front panel valve values are reached does not only
6817 WV3 SV-3-M5 Front panel valve depend on the pneumatics.
9270 DR VD-3-PK-3 Pressure sequence valve It is only possible to assess
whether a specific function is
achieved or not by observing
Function Description (max. possible) the complete system. The design
Control architecture Cat. 2 of the electrical engineering,
Number of channels 1 mechanics, hydraulics and pneu-
Diagnostic coverage Medium matics all play a role.
Performance level d
CCF > 65%
34
Safety function Safety function

Two-hand operation Reversing
Sample circuit diagram – double two-hand control block
Description cap side of the cylinder are

If pressure switch DR1 displays safety-related; in other words,
one-way flow control valve screwed in cylinder the minimum operating pressure they play a decisive role in the
and the two pushbuttons WV5 function and, by extension,
safety relevant
and WV6 are actuated, both safety.
two-hand control blocks (WV3
and WV4) switch through. This If one of these lines is kinked or
safety relevant reverses the WV1 and WV2 clogged, the cylinder does not
safety relevant
power valves and the piston rod receive the pressure it requires
extends. to travel to its retracted position.
This should be noted when
If only one of the two power laying the working lines, for
valves reverses, the piston rod example, in energy chains.
remains retracted. If the piston
rod extends and one power valve If one of the power valves fails,
is reset by the integrated spring, there is an “acoustic” fault
the piston rod retracts again. alarm caused by venting at on
The working lines to the bearing one of the silencers.
Note
1m
hose
All the information that relates
Part no. Identifier Type Product designation to standards is identified with
9270 DR1 VD-3-PK-3 Pressure sequence valve “max. possible”. Whether the
KS1 Any drive values are reached does not
SP1 One-way flow control depend only on the pneumatics.
valve It is only possible to assess
SP2 One-way flow control whether a specific function is
valve achieved or not by observing the
161061 WV1, WV2 VL-5/2-D-01-FR 5/2-way valve complete system. The design of
3527 WV3, WV4 ZSB-1/8 Control block for two- the electrical engineering,
hand start mechanics, hydraulics and pneu-
184135 WV5, WV6 SV/O-3-PK-3x2 Front panel valve matics all play a role.
Function Description (max. possible)

Control architecture Cat. 3
Number of channels 2
Diagnostic coverage Medium
Performance level d
CCF > 65%
35
Safety function
Exhausting
Sample circuit diagram – exhausting via non-return valves
Description These make up the second

Directional control valves WV1 channel for exhausting the drive.
and WV2 are responsible for the
normal operating function. If It is important to note that the
there is no current, they are in two non-return valves also need
their initial position and exhaust a differential pressure in order to
the installation. To make it pos- exhaust. This differential is
sible to retract and extend the application specific.
cylinder, WV3 has to exert pres-
sure on both non-return valves
(SP1 and SP2). Note
In this case, the two non-return to standards is identified with
valves do not affect normal “max. possible”. Whether the
operation. values are reached does not
depend only on the pneumatics.
If both non-return valves (SP1 It is only possible to assess
and SP2) are exhausted, cylinder whether a specific function is
KS1 can also be exhausted via achieved or not by observing the
the non-return valves. complete system. The design of
the electrical engineering,
mechanics, hydraulics and pneu-
Identifier Type Product designation matics all play a role.
KS1 Any drive
DS1 Any pressure switch
SP2, SP1 e.g. HGL, H, HA, HB Non-return valve
WV3, WV2, WV1 e.g. CPE, MHE, MFH Solenoid valve
Function Description (max. possible)

Control architecture Cat. 3
Number of channels 2
Performance level d
CCF > 65%
36
Safety function
Stopping, holding and
blocking a movement
Sample circuit diagram – pneumatic holding using stop valves
Description
The cylinder can be held
pneumatically via two different
channels.
Channel 1 is created by stop
valve WV1. When not actuated
(mid-position), the valve is
closed; in other words, if the
electrical power is switched off,
WV1 switches to its spring
centred mid-position and the
cylinder is held pneumatically.
The second channel is created
by the two stop valves (WV3 and
WV4) and actuating valve WV2.
When not actuated, WV2 is
exhausted and switches the
two stop valves to the closed
position. The two stop valves
create the second channel for
pneumatic holding.
Note
Part no. Identifier Type to standards is identified with
KS1 Any drive “max. possible”. Whether the
DS1 Any pressure switch values are reached does not
DR1, DR2 GR... depend only on the pneumatics.
WV1, WV2 CPE..., MH...,MFH..., VSVA... It is only possible to assess
910445 WV3, WV4 VL-2-1/4-SA3919 whether a specific function is
achieved or not by observing the
complete system. The design of
Function Description (max. possible) the electrical engineering,
Control architecture Cat. 3 mechanics, hydraulics and pneu-
Number of channels 2 matics all play a role.
Performance level d
CCF > 65%
37
Safety function
blocking a movement
Sample circuit diagram – mechanical and pneumatic holding
Description The second channel is controlled

The safety function “stopping a via the mechanical brake by
movement” is implemented both WV2. When exhausted, the
pneumatically and mechanically brake is activated and it holds
(diversified) in this circuit. the piston rod. It is important to
Assuming that both the mecha- note that a brake is used here,
nical brake and the pneumatic and not a retaining device.
holding in the application are
sufficient to fulfil the “stopping a
movement” safety function, this
is a two-channel system.
Channel 1 is implemented via

WV1. In the mid-position (dead),
the valve is closed and the
cylinder stops.
Note
to standards is identified with
Identifier Type Product designation “max. possible”. Whether the
DS1 Any pressure switch values are reached does not
ST1, ST2 GR... Flow control valve depend only on the pneumatics.
KS1 DNCKE.., DNCKE..-S, KEC.., KEC..-S Cylinder It is only possible to assess
WV1, WV2 CPE.., MH.., VSVA.., MFH.. Directional control whether a specific function is
valve achieved or not by observing
the complete system. The design
Function Description (max. possible) of the electrical engineering,
Control architecture Cat. 3 mechanics, hydraulics and
Number of channels 2 pneumatics all play a role.
Performance level d
Max. possible CCF > 65%
38
Safety function
Safety function
Tamper-proof, prevention of
Exhausting unexpected starting up
Sample circuit diagram – servopneumatics
Description
For implementation of the
following safety measures:
• Protection of unexpected
start-up, as per EN 1037
(two-channel design)
-> possible: performance level
“d”, as per EN 13849-1
• Single-channel “exhausting”
safety measure, as per EN
13849-1
“d”, as per EN 13849-1*
• Stop category “0” as per
EN 60204-1
Identifier Suggested products

PR1 MPYE-5-...-010B
KS1 Any drive
WV2 MFH-5/2-...-FR-S...
WV1 MFH-5/2-...-FR-S...
*Requires appropriate diagnostics

(e.g. additional evaluation of the signal
change at the pressure switch)
39
Safety function
Safety function
Tamper-proof, prevention
Exhausting
of unexpected starting up
Description
• Prevention of unexpected
> possible: performance level
“d”, as per EN 13849-1
safety measure, as per
EN 13849-1
“d”, as per EN 13849-1*
EN 60204-1

PR1 MPYE-5-...-010B
KS1 Any cylinder
WV2 VL-5/2-...-FR-...
WV1 VL-5/2-...-FR-...

40

Tamper-proof, prevention Stopping, holding and
of unexpected starting up blocking a movement
Description
“d”, as per EN 13849-1
EN 13849-1-> possible:
performance level “d”, as per
EN 13849-1*
EN 60204-1

WV3 Appropriate valve
WV2 MFH-5/2-...-FR-S...
WV1 MFH-5/2-...-FR-S...
PR1 MPYE-5-...-010B
ST1 GRLA-..
KS1 Any drive

41

Tamper-proof, prevention Stopping, holding and
of unexpected starting up blocking a movement
Description
“d”, as per EN 13849-1
• Two-channel “stop” safety
measure, as per EN 13849-1*
“d”, as per EN 13849-1

WV2 VL-5/2-...-FR-...
WV1 VL-5/2-...-FR-...
PR1 MPYE-5-...-010B
ST1 GRLA-..
KS1 Any drive

42

Safety function
Tamper-proof, prevention Reversing
Reducing the speed
Description • Single-channel “reduced

For implementation of the speed” safety measure, as per
following safety measures: EN 13849-1
• Prevention of unexpected -> possible: performance
start-up, as per EN 1037 level "d", as per EN 13849-1*
“d”, as per EN 13849-1
• Single-channel “reversing”
EN 13849-1
“d”, as per EN 13849-1*

PR1 MPYE-5-...-010B
KS1 Any drive
WV2 MFH-5/2-...-FR-S...
WV1 MFH-5/2-...-FR-S...

43

Safety function
Tamper-proof, prevention Reversing
Reducing speed
Description • Single-channel “reduced

For implementation of the speed” safety measure, as per
following safety measures: EN 13849-1
• Prevention of unexpected -> possible: performance level
start-up, as per EN 1037 “d”, as per EN 13849-1
(two-channel design) • Stop category “1”, as per
-> possible: performance level EN 60204-1 (however, no sens-
“d”, as per EN 13849-1* ing of speed “0”, instead the
• Single-channel “reversing” reduced speed starts after a
safety measure, as per set time)
EN 13849-1
“d”, as per EN 13849-1*

WV2 VL-5/2-...-FR-...
WV1 VL-5/2-...-FR-...
PR1 MPYE-5-...-010B
ST1 GRLA-..
KS1 Any drive

44
Safety function
Safety function
Reducing speed
Description
(single-channel design)
“c”, as per EN 13849-1
• Single-channel “run at reduced
speed” safety measure, as per
EN 13849-1
“d”, as per EN 13849-1*
EN 60204-1

PR1 MPYE-5-...-010B
KS1 Any drive
WV2 MFH-5/2-...-FR-S...
WV1 MFH-5/2-...-FR-S...

45
Products for safety engineering
Complete safety – products

Everything from a single source:
our aim – in the field of safety
technology as elsewhere – is to
provide and implement solutions
for every safety task in the form
of components or systems.
On the following pages you will

find our range of products, to-
gether with brief descriptions of
their function and application
ranges. For additional infor-
mation, consult the electronic
catalogue on CD-ROM or online
at www.festo.com/catalogue
If you have any further ques-

tions, please consult your Festo
sales engineer, who will be
happy to help.
46
Safety function
blocking a movement
Braking units DNCKE-S, KEC-S
Description Use
• Holding force of the clamp • As a holding device (static
is larger than the cylinder’s application)
max. permissible feed force – Holding and clamping in the
• For use in category 1 control event of power failure
systems, as per DIN EN 954-1 – Protection against pressure
(“reliable component”) If used failure and pressure drop
Technical data in higher categories, further – Holding the piston rod during
technical control measures intermediate stops, for
NDiameter NDiameter need to be taken operative procedures in a
40, 63, 100 mm of the round material to be • Certified by the Institute process
clamped for Occupational. Safety and • As braking device
TStroke length 16 ... 25 mm Health (BGIA) for use in safety- (dynamic application)
10 ... 2000 mm oriented control systems – Braking or stopping move-
OHolding force • CE mark as per EU machinery ments
OHolding force 1300 ... 8000 N directive – Suspension of a movement
1300 ... 8000 N if a danger area is entered
Function
Order code
Part no. Type Certification
526482 DNCKE-40--PPV-A
526483 DNCKE-63--PPV-A
526484 DNCKE-100--PPV-A
538239 DNCKE-40--PPV-A-S BGIA certified
527492 KEC-16
527493 KEC-20
527494 KEC-25
538242 KEC-16-S BGIA certified
47
Safety function
blocking a movement
Clamping unit KP, KPE
Selection Description
• For customer-built clamping
Clamping cartridge KP Clamping unit KPE DNC-...-KP units
• Ready-to-install combination
of clamping cartridge KP and
housing
• Various mounting options
• Holding or clamping the piston
rod in any position
• Holding the piston rod for long
Technical data periods of time, even under
changing loads, fluctuations or
N Diameter of the round NDiameter of the round NDiameter of the round leakage
material to be clamped material to be clamped material to be clamped
4 ... 32 mm 4 ... 32 mm 4 ... 32 mm
O Static holding force O Static holding force O Static holding force

80 ... 7500 N 80 ... 7500 N 80 ... 7500 N
Function
Order code
Part no. Type Part no. Type Part no. DNC-KP Stroke
178455 KP-10-350 178465 KPE-10 [mm]
178456 KP-12-600 178466 KPE-12 163302 Ø32 10-2000
178457 KP-16-1000 178467 KPE-16 163334 Ø40 10-2000
178458 KP-20-1400 178468 KPE-20 163366 Ø50 10-2000
178459 KP-20-2000 178469 KPE-25 163398 Ø63 10-2000
178460 KP-25-5000 178470 KPE-32 163430 Ø80 10-2000
178461 KP-32-7500 178462 KPE-4 163462 Ø100 10-2000
178452 KP-4-80 178463 KPE-6 163494 Ø125 10-2000
178453 KP-6-180 178464 KPE-8
178454 KP-8-350
48
Safety function
blocking a movement
Clamping unit for short-stroke cylinders
Description
• Holding or clamping the piston
rod in any position
• Holding the piston rod for long
periods of time, even under
changing loads, pressure
fluctuations or leakages
Technical data Function
N Diameter
20 ... 100 mm
T Stroke length
10 ... 500 mm
O Static holding force

350 ... 5000 N
Order code
Part no. Type KP type

548206 ADN-20-...-KP KP-10-350
548207 ADN-25-...-KP KP-10-350
548208 ADN-32-...-KP KP-12-1000
548209 ADN-40-...-KP KP-16-1400
548210 ADN-50-...-KP KP-20-1400
548211 ADN-63-...-KP KP-20-2000
548212 ADN-80-...-KP KP-25-5000
548213 ADN-100-...-KP KP-25-5000
49
Safety function
blocking a movement
Mini slide DGSL unit with clamping unit or end position locking
Description • Use as end position locking

• Use as clamping unit – Mechanical locking when
– Mechanical clamping the end position is reached
– For fixing the slide in any – For fixing the slide in the
position unpressurised, retracted
– Frictional locking state
• Clamps with frictional locking – Positive locking
at any position • Locks with positive locking in
• Clamping via spring force, the retracted end position only
released via compressed air • Locking via spring, unlocked
via compressed air
NDiameter C clamping unit E3 end position locking

6 ... 25 mm
O Static holding force

80 ... 600 N
L Pressure
3 ... 8 bar
Order code
Part no. Type
543903 DGSL-6
543904 DGSL-8
543905 DGSL-10
543906 DGSL-12
543907 DGSL-16
543908 DGSL-20
543909 DGSL-25
50
Safety function
blocking a movement
End position locking …-EL
DNC-...-A-...-EL ADN-...-EL Description

• Mechanical locking when the
end position is reached
• Locking is automatically
released only when pressure is
applied to the cylinder
• End position locking at one or
both ends
Technical data Order code

Part no. Type Stroke [mm]
N Diameter N Diameter 163302 DNC-32-EL 10-2000
32 ... 100 mm 20 ... 100 mm 163334 DNC-40-EL 10-2000
163366 DNC-50-EL 10-2000
T Stroke length TStroke length 163398 DNC-63-EL 10-2000
10 ... 2000 mm 10 ... 500 mm 163430 DNC-80-EL 10-2000
163462 DNC-100-EL 10-2000
Function
Part no. Type
548214 ADN-20-EL
548215 ADN-25-EL
548216 ADN-32-EL
548217 ADN-40-EL
548218 ADN-50-EL
548219 ADN-63-EL
548220 ADN-80-EL
548221 ADN-100-EL
51
Safety function
Two-hand operation
Two-hand control block ZSB
Description This ensures that both of the

• Category 3 as per DIN EN ISO operator’s hands are outside
13849-1 can be reached with a the machine’s danger area. The
suitable control architecture. product is a safety component
• Max. possible performance in line with the EC machinery
level = d directive. The ZSB 1/8 control
As intended, the control block block for two-hand start corres-
for two-hand start enables ponds to type IIIA, according to
triggering of a control signal with DIN EN 574, and category 1,
both hands simultaneously according to DIN EN
(synchronous) over two separate ISO 13849-1.
push-button valves.
Technical data Function Sample circuit

2
Control chain
MFlow rate 3
up to 50 l/min
LPressure 1 1
3 ... 8 bar
QTemperature range
-10 ... 60 °C
Order code
Part no. Type Certification
3527 ZSB-1/8 CE certified
52
Safety function
Two-hand operation
SV/O front panel valve
Description Mushroom pushbutton with

• Use: detent PRS
– two-channel directional After pressing the pushbutton, it
control valve for use in front can only be unlocked using a
panels key. The key can be removed in
– Suitable for higher category both switching positions.
control systems
– Can be combined with Key actuator Q with key
various actuator attachments The key actuator can only be
operated with the key.
Mushroom actuator PS The key can be removed in both
The actuator is unlocked by switching positions.
turning the detent ring on the
mushroom head.
MFlow rate Function

0 ... 70 l/min
LPressure
0 ... 8 bar
QTemperature range
-10 ... +60 °C
Order code
Part no. Type
184135 SV/O-3-PK-3x2
53
Safety function
Tamper-proof flow control valve GRLA-…-SA
Description
• Setting a defined flow rate
• A spring pin protects against
unauthorised resetting of the
volumetric flow rate
• Impossible to change the flow Surface for additional safety
control valve’s setting with label from the system’s
standard tools – thanks to the manufacturer or fitting company
spring pin protection
• Six different sizes from M5
to 3/4"
MFlow rate 2
0 ... 2500 l/min
L Pressure
0.2 ... 10 bar
1
QTemperature range
-10 ... +60 °C
Order code
Part no. Type
539717 GRLA-M5-B-SA218543
539661 GRLA-1/8-B-SA218543
539662 GRLA-1/4-B-SA218536
539715 GRLA-3/8-B-SA18541
539716 GRLA-1/2-B-SA218540
539714 GRLA-3/4-B-SA218542
54
Safety function
blocking a movement
Stop valve VL-2-1/4-SA
Description
• Stop valve for blocking the
flow in a cylinder (supply/
exhaust air) in both directions.
A control signal opens the
closed ports
• Design: poppet valve control-
led via a swivel connection
• Tube fitting (thread G1/4)
• Port G1/4
• Nominal diameter Ø 4 mm
L Pressure
0 ... 10 bar
Q Temperature range
-20 ... 80 °C
Order code
Part no. Type
910445 VL-2-1/4-SA3919
55
Safety function
Shut-off valves: European version
Description Use
• Shut-off valve for shutting off Shutting off the compressed air
and exhausting pneumatic supply whilst simultaneously
systems. Can be shut off a exhausting systems powered
max. of 6 times in the closed by compressed air. Pressing
(exhausted) state the actuating button closes the
• Padlocks prevent unauthorised passage from 1 to 2 and opens
starts the passage from 2 to 3.
• For systems that require pneu- The maximum exhaust flow is
matic shut-off, e.g. during achieved by holding the actuat-
maintenance or repair work. ing button in its end position
The valve is integrated into the until the downstream system is
air supply lines completely exhausted.
• Any mounting position
Greater safety: lockable
When closed, the valve can be
locked using a padlock. This
Technical data Function makes it impossible to supply an
inoperative system (e.g. during
M Flow rate maintenance work) with air
3100 ... 6000 l/min without authorisation.
L Pressure
0 ... 16 bar
Note
Q Temperature range The shut-off valve cannot be
-10 ... +60 °C used as an emergency-stop
valve.
O Max. actuating force
90 N
Order code
• PWIS-free Part no. Type
187026 HE-3/8-D-MIDI-NOT-SA
186688 HE-3/4-D-MAXI-SA
186689 HE-1-D-MAXI-SA
56
Safety function
Shut-off valve HE-LO: US standard
Description Hazardous Energy” from the US

• Valve for shutting off the com- Department of Labor. Pressing
pressed air supply whilst the actuating button closes the
simultaneously exhausting passage from 1 to 2 and opens
systems powered by compres- the passage from 2 to 3.
sed air The maximum exhaust flow is
• Pneumatic shut-off during achieved by holding the actuat-
maintenance or repair work ing button in its end position
• Fulfils the US Department of until the downstream system is
Labor’s requirements completely exhausted.
The valve is installed in the air
supply lines and fulfils the requi- Greater safety: lockable
rements set out in When closed, the valve can be
OSHA 29 CFR 147 “Control of locked using a padlock. This
makes it impossible to supply an
inoperative system (e.g. during
maintenance work) with air
Technical data Function without authorisation.
MFlow rate
5200 ... 12000 l/min
L Operating pressure
1 ... 10 bar
Note
Q Temperature range The shut-off valve cannot be
-10 ... +60 °C used as an emergency-stop
valve.
OMax. actuating force
90 N
Order code
Part no. Type
197136 HE-G1-LO
197135 HE-G3/4-LO
197134 HE-G1/2-LO
197133 HE-G3/8-LO
197132 HE-N1-LO
197131 HE-N3/4-LO
197130 HE-N1/2-LO
197129 HE-N3/8-LO
57
Safety function
Exhausting
On-off valve with piston position sensing
Description Sensors from Festo

• Electric on-off valve for pres- Standard sensors with reed con-
surising and exhausting pneu- tacts for T-slots can be used: type
matic systems SME-8M, SMT-8M, SME-8, SMT-8
• With solenoid coil, without
plug socket • Switching output non-contac-
• 3 voltage ranges can be ting or with reed contact
selected • Various mounting and connec-
• Direct position sensing for the tion options
piston spool • Heat resistant and corrosion
• Can be used in circuits with a resistant designs
higher diagnostic coverage • Versions free of copper or PTFE
• Senses position, not pressure
• Single-channel Please note: sensors are ordered
separately.
Voltage
P24 V DC
2
Pressure 12
L 2.5 ... 16 bar 1 3
Temperature range
Q-10 ... +60 °C
Order code
Part no. Type

533537 HEE-D-MIDI-...-SA207255
548535 HEE-D-MAXI-...-SA217173
58
Safety function
Safety function
Pressurising
Exhausting
Pressure build-up and exhaust valve, type MS 6-SV
Description • Continuous sensing of the

• Exhaust reliably quickly in function for fast exhausting at
safety-critical areas of the any time
system, e.g. during • Switch-on and pressure build-
an emergency stop up functions integrated into
• Provides greatest possible the exhaust valve
machine availability thanks to • Prevention of unexpected
reliable processes start-up (two-channel
• Institute for Occupational control)
Safety and Health (BGIA) • Compact design
certification as per • Internal evaluation of the
DIN EN 13849-1, Category 4 piston position sensing
(requested)
• Quick exhaust for fast pressure
reduction
• Exhaust rate is one and a half
times the pressurising rate
PVoltage M
24 V DC Flow (exhaust) 2
up to 9000 l/min 12
L Pressure Q 1 3
4 ... 10 bar Temperature range
-10 ... +50 °C
MFlow (pressurise)
up to 6000 l/min
Order code
Part no. Type
548713 MS6-SV-D
548714 MS6N-SV-D
548715 MS6-SV-D-1/2-10V24-AG
548717 MS6-SV-D-1/2-10V24-SO-AG
submitted
59
Safety function
Exhausting
Safety silencer, type UOS-1
Description Contamination in the system

• The UOS silencer combines can block standard cylinders.
the advantages of a standard The consequence: increased
silencer and those of an open back pressure, which leads to
silencer: large flow with low increased exhaust times in the
noise level and a compact system. This is prevented with
design this silencer, due to its special
• For “reliable exhausting” as design.
per DIN EN ISO 13849-1
• Suitable for use with the Dangerous cylinder movements
MS6-SV valve can lead to injury to people and
• Design: open machines.
• Port: 1”
L Pressure
0 ... 10 bar
Q Temperature range
-10 ... +50 °C
• Design: open
• Port: 1”
• PWIS-free
• “Reliable exhausting” as per
DIN EN ISO 13849-1
• Suitable for use with the
MS6-SV valve
Order code
Part no. Type
552252 UOS-1
60
Safety function
Exhausting
Valve block for “reliable exhausting” of sub-systems
Description • Ports ISO 1: QS8

• Pre-installed, operationally • Ports ISO 3: QS12
integrated tested solution • Optional extension of the per-
• Number of channels: 2 missible time window for elec-
• Diagnostic coverage tric actuation (approx. 10 ms)
DC = medium (integrated fault by connecting additional
diagnostics) volumes (for each 0.5 l
• PLmax = e -> approx. 0.5 sec.)
• Air quality: 40 μm unlubricated • Safe exhausting (two-channel)
• Protected against uninten- of pneumatic port A when one
tional start-up (two-channel). of the two coils is turned off
If the two solenoid coils are • Switching position sensing of
activated simultaneously, the the directional control valves
compressed air is switched on in their initial position using
auxiliary pilot air for the other
directional control valve pro-
Technical data Function tects against an uncontrolled
restart and prevents a dange-
PVoltage 2 rous state
24 V DC 12
LPressure 1 3
3 ... 8 bar
QTemperature range
0 ... +40 °C
MFlow rate ISO 1:

500 Nl/min
MFlow rate for ISO 3:

1500 Nl/min
Order code
Part no. Type Flow rate
549146 ISO 1 valves 500 Nl/min
550521 ISO 3 valves 1500 Nl/min
submitted
61
ISO valves in accordance with 5599-1 with position sensing of the piston spool
Description Sensors from Festo

• The position of the piston Standard sensors with reed
spool is sensed directly contacts for T-slots can be used:
• Senses position, not pressure type SME-8M, SMT-8M, SME-8,
• Suitable for circuits with a SMT-8
higher diagnostic coverage
• Suitable for higher category • Switching output contactless
circuits as per or via reed contacts
DIN EN ISO 13849-1 • Various mounting and connec-
tion options
• Heat resistant and corrosion
resistant designs
• Versions free of copper or PTFE
Please note: sensors are ordered

separately.
MFlow rate 4 2
1200 ... 4500 l/min 14
LPressure 5 1 3
3 ... 10 bar
QTemperature range
-10 ... +50 °C
PVoltage
24 V DC
Order code
Part no. Type
185994 MDH-5/2-D1-FR-S-C-A-SA27102
188005 MDH-5/2-D2-FR-S-C-A-SA23711
188006 MDH-5/2-D3-FR-S-C-A-SA23712
62
ISO valves in accordance with 15407-2 with switching position sensing
Description • The piston spool’s initial

• Solenoid valve as per position is monitored by a
ISO 15407-1, plug form C, for proximity sensor
individual electrical connection • For higher category control
• Solenoid valve as per architectures
ISO 15407-2, for use with • Proximity sensor with M8 port
valve terminal VTSA
• Valve function: 5/2-way valve
• ISO size 01, other sizes on
request
• Width 26 mm
Technical data Order code

Part no. Type Version
PVoltage 560723 VSVA-B-M52-MZD-A1-1T1L-APC Size 01, 5/2RF, plug-in valve,
24 V DC with PNP sensor and cable
560724 VSVA-B-M52-MZD-A1-1T1L-APP Size 01, 5/2RF, plug-in valve,
L Pressure with PNP sensor and M8 plug
3 ... 10 bar 560725 VSVA-B-M52-MZH-A1-1C1-APC Size 01, 5/2RF, CNOMO valve,
with PNP sensor and cable
QTemperature range 560726 VSVA-B-M52-MZH-A1-1C1-APP Size 01, 5/2RF, CNOMO valve,
-5 ... +50 °C with PNP sensor and M8 plug
560742 VSVA-B-M52-MZD-A1-1T1L-ANC Size 01, 5/2RF, plug-in valve,
MFlow rate with NPN sensor and cable
1100 l/min 560743 VSVA-B-M52-MZD-A1-1T1L-ANP Size 01, 5/2RF, plug-in valve,
with NPN sensor and M8 plug
560744 VSVA-B-M52-MZH-A1-1C1-ANC Size 01, 5/2RF, CNOMO valve,
Function with NPN sensor and cable
560745 VSVA-B-M52-MZH-A1-1C1-ANP Size 01, 5/2RF, CNOMO valve,
with NPN sensor and M8 plug
4 2
14 Expected to be available from mid 2008
5 1 3
63
Safety function
Safety function
Reversing
ISO terminal for controlling presses
Description Valve manifold with individual

Valve terminal with multiple electrical connection as per
connector plate/fieldbus con- ISO 15407-1
nection as per ISO 15407-2 • Double connecting plate plus
• Vertical stacking plus two two sensor valves with C shape
sensor valves plug pattern
• Pressurising/exhausting via Valve block comprising a double
linked standard VTSA valves sub-base and two VSVA valves,
Valve terminal, consisting of width 26 mm, with piston posi-
24 V DC multi-pin plug connector tion sensing via inductive PNP
with cable, a series manifold, proximity sensor, size M8, and
right-hand end block, double plain cable end.
vertical stacking and 2 VSVA 24 V DC pilot valve with elec-
plug-in valves, width 26 mm, trical interface, C shape, and
with piston position sensing by covered manual override. The
inductive PNP proximity sensor, valves are pneumatically inter-
size M8, and plain cable end and linked via two channels in the
covered manual override. The connecting plate (port 2 is con-
valves are pneumatically inter- nected in parallel, port 4 inline).
linked via the vertical stacking
plate using two channels (port 2
is connected in parallel, port 4
inline).

• Valve function: 5/2-way valve
PVoltage QTemperature range • ISO size 01
24 V DC -5 ... +50 °C • Position sensor with M8 port
• Valve width 26 mm
L Pressure MFlow rate
3 ... 10 bar 1100 l/min
Order code
Part no. Type Version
560729 VABF-D1-26-C1V2-C-T1 Vertical sub-base for two plug-in valves,
size 01, for installation in VTSA
560730 VABF-D1-26-C1V2-C Vertical sub-base for two CNOMO valves,
size 01, for installation in VTSA
560731 VABS-D1-26S-G14 Sub-base for 2 CNOMO valves, size 01
submitted
Expected to be available from mid 2008
64
Safety function
Stopping, holding and blocking
a movement (mechanically)
ISO valve for lifting and semi-rotary cylinders
Description
• For lifting and semi-rotary
cylinders in the automotive
industry
Use
• Self-holding and subsequent
pressure supply in both end
positions
• During the stroke, the cylinder
needs to be held under pres-
sure in the event of an emer-
gency (e.g. if someone steps
on a safety shut-off mat)
Order code Function

Part no. Type
560727 VSVA-B-P53AD-H-A1-1T1L Size 01, 5/3 mid-position 3
1 port pressurised and 1 port exhausted,
switching position 14 detenting
Function Normal operation After an emergency stop Control

(electrical power switched off )
Retract clamping The clamping device is retracted via The clamping device remains pres- 5/3 WV 12 switched
device the 5/2 WV surised in both chambers (no automatic locking)
5/3 WV 14 initial position 5/2 WV 12 switched
5/2 WV 12 switched
Extend clamping The clamping device is extended via The clamping device remains 5/3 WV 12 switched
device the 5/2 WV pressurised in both chambers (no automatic locking)
5/3 WV 14 initial position 5/2 WV 14 switched
5/2 WV 14 switched
Clamping device in The end positions remain The pressure is sustained in the end 5/3 WV switched to 12 (automatic
end position pressurised positions locking)
5/3 WV 12 automatic locking 5/2 WV switched to 14 or 12
5/2 WV 14 or 12 switched
65
Safety function (3 stages)

Free of forces
ISO valve for pneumatic manual clamping device
Description Function
Pneumatic manual clamping
device for facilities in car body
construction work (insert loca-
tions)
Technical data
PVoltage
24 V DC
L Pressure
3 ... 10 bar
QTemperature range
-5 ... +50 °C
MFlow rate
Order code 1000 l/min
Part no. Type
560745 VSVA-B-P53ED-H-A1-1T1L Size 01, 5/3 mid-position ex-
hausted, switching position 14
detenting
Function Normal operation After an emergency stop Control

(electrical power switched off )
Clamping device is closed Unpressurised Unpressurised Valve is in the mid-position
geschlossen
Clamping device is in the end Force supported by air pressure Force supported by air pressure Coil 12 is switched
position (panel is clamped) (self-locking)
Valve remains in position 12
Clamping device opens Pneumatically operated Valve returns to the mid-position Coil 14 is switched
automatically
66
Safety function
Pressurising
HEL soft-start valve
Description
• Gradual pressure build-up
• The drives travel slowly into
their initial positions
• Sudden and unpredictable
movements are avoided
• Main seat opens at approx.
50% of the supply pressure
• Adjustable time delay for
pressure response
• To be used with HE and HEE
on-off valves

2
MFlow rate
1000 ... 6500 l/min
L Pressure
3 ... 16 bar
1
QTemperature range
-10 ... +60 °C
Order code
Part no. Type
170690 HEL-D-MINI
170691 HEL-D-MIDI
170692 HEL-D-MAXI
165076 HEL-1/8-D-MINI
165077 HEL-1/4-D-MINI
165078 HEL-3/8-D-MINI
186521 HEL-1/4-D-MIDI
165079 HEL-3/8-D-MIDI
165080 HEL-1/2-D-MIDI
165081 HEL-3/4-D-MIDI
186522 HEL-1/2-D-MAXI
165082 HEL-3/4-D-MAXI
165083 HEL-1-D-MAXI
67
Safety function
Reducing pressure and force
Dual-pressure regulator
Description
Diaphragm pressure regulating
valve with secondary venting for
setting two different initial pres-
sures in one device. The lower
value of p2 (p21) can be set
mechanically (SW12 on the ad-
justing screw). The higher value
of p2 (p22) can be set with the
rotary knob. Switching from the
lower to the higher value occurs
electronically.
MFlow rate
up to 1300 l/min
1 2
QTemperature range
-10 ... +60 °C
Technical data
p2 regulator pressure regulation
range 0.5 <= 7 bar
p1 supply pressure 1 1.5 bar <= 12 bar
Hymax max. pressure hysteresis 0.5 bar
p1max p1max: 12bar
P2max p2max: 7bar
PWIS-free
Corrosion resistance class CRC2
Ports G1/4
Order code
Part no. Type
550588 LR-D-MINI-ZR-V24-SA234223
68
Safety function
Pressurising
Soft-start/quick exhaust valve for ISO valve terminal type VTSA
Description Once the initial pressure reaches

Solenoid actuated on-off and the adjustable switch-over pres-
exhaust valve for gradual pressure, the valve switches to full
sure build-up in pneumatic flow.
systems. This protects start-up
of pneumatic systems. Use
A small quantity of air flows into • Adjustable switch-over pres-
the system through an adjust- sure (2, 3, 4, 5 bar)
able flow control valve. The • Adjustable filling time
initial pressure is built up • 24 V DC or 110 V AC solenoid
gradually. Downstream cylinders • G1/2 or NPT 1/2 ports
and devices gradually reach • Built-in piston position sensing
their initial position. • Flow rate (QNn):
pressurising 3000 l/min
exhausting 3400 l/min
Pressure
Key Function
Switch-over pressure 2
Working
pressure
Filling time
1 3
Examples
Fast filling time, switch-over
pressure at 6 bar
Slow filling time, switch-

over pressure at 4 bar
Order code
Part no. Type
557337 VABF-S6-1-P5A4-G12-4S-1R3P
submitted
69
Pressure zones for valve terminal type 44 VTSA
Creating pressure zones and Further examples of pressure

separating exhaust air supply and pilot air supply via
• With the VTSA, pressure zones an end plate
can be introduced in many • Internal pilot air supply, ducted
ways for different working exhaust air/silencer
pressures • External pilot air supply,
• Pressure zones can be created silencer/ducted exhaust air
by separating the internal
supply ducts between the Reliable exhausting of valves or
series sub-bases with a corres- pressure zones
ponding channel separator If used together with the
• Pressure supply and MS6-SV valve, specific areas can
exhausting via supply plate be exhausted safely whilst the
Zone 1 Zone 2 Zone 3
• Free positioning of the supply pressure is retained for specific
plates and separating seals in valves or pressure zones. This
VTSA is a common requirement for
• Channel separator integrated protective circuits.
ex works as per the order,
differences can be indicated
via the coding system for
assembling valve terminals
P1 P2 P3
VTSA with CPX terminal
connection
• Up to 16 pressure zones pos-
The illustration shows an sible with VTSA (if only size 1,
example of how three pressure ISO 5599-2, is used, up to 32
zones are built up and con- pressure zones are possible)
nected with channel separation –
with internal pilot air supply.
70
Pressure zones for valve terminal type 32 MPA
Creating pressure zones and Further examples of pressure

separating exhaust air supply and pilot air supply
• With the MPA pressure zones • External pilot air supply, flat
can be introduced in many plate silencer
ways for different working • Internal pilot air supply, ducted
pressures exhaust air
• A pressure zone can be created • External pilot air supply,
by separating the internal ducted exhaust air
supply ducts between the sub-
bases, with a corresponding Reliable exhausting of valves or
separating seal or via a separa- pressure zones
tor integrated into the sub- If used together with the
base (code I) MS6-SV valve, specific areas can
Zone 1 Zone 2 Zone 3
• Pressure supply and be exhausted safely whilst the
exhausting via supply plate pressure is retained for specific
• Free positioning of the supply valves or pressure zones. This
plates and separating seals in is a common requirement for
MPA with CPX and MPM protective circuits.
(multiple connector plate)
• Separating seals integrated
ex works as per the order,
differences can be indicated
P1 P2 P3
via the coding system for
assembling valve terminals
MPA with CPX terminal

connection
The illustration shows an Example of pressure zones
example of how three pressure • Up to 8 pressure zones pos-
zones are built up and connec- sible with MPA and CPX
ted with separating seals – with
external pilot air supply.
71
CPX terminal – power supply concept
Description Together with all the supply

The use of decentralised devices lines, interlinking blocks make
on the fieldbus – particularly up the backbone of the CPX ter-
those with a high protection minal. They provide the power
class for direct machine assem- supply for the modules mounted
bly – requires a flexible power on them, as well as their bus
supply concept. connection.
A valve terminal with CPX can Many applications require the

generally be supplied via a CPX terminal to be separated
socket for all voltages. into voltage zones.
Here, we distinguish between This is particularly true for
supplying the switching off the solenoid coils
• Electronics plus sensors and the ports separately. The
• Valves plus actuators. The interlinking blocks can either be
following connecting threads designed as a centralised power
are possible supply for the entire CPX ter-
- M18 minal (which saves on instal-
- 7/8” lation work), or they can be
designed as galvanically
separated, all-pin disconnec-
table potential groups/voltage
segments.
72
73
Knowledge provides greater safety
Safety is always more than just

the hardware and the corres-
ponding circuit diagrams. Safety
starts at the concept stage, for
example by identifying necessary
performance levels.
For comprehensive qualification

on the subject of safety, Festo
Didactic provides numerous
seminars on various topics.
More than 40 years of expe-

rience in training and consulting
and 30,000 participants at more
than 2,900 events each year
speak for themselves: our
instructors provide you with their
own experience and give you
the best possible preparation for
your own specific safety tasks.
When it comes to self-structured

and flexible modular learning,
our web-based training course
“Safety engineering” is ideal.
74
“Energy-efficient design of systems, practical use of

pneumatics – part 2 (KONST2)”
The EC machinery directive Contents Target group
requires safety in machines and • Representing control Design engineers and planners
systems. One of the bases for procedures (GRAFCET)
this is designing the pneumatics • Practical flow control for pneu- Requirements
correctly. In this part, we will matic drives, depending on the Basic knowledge of pneumatics,
look at KONST2 and also at the load case in question for example from our P111
standards to be observed in • Influence of the mass moment seminar “Fundamentals of pneu-
circuit technology for safety- of inertia in semi-rotary drives matics and electropneumatics”.
orientated pneumatic and elec- • Intermediate positions with
tro-pneumatic circuits. To this pneumatic drives Duration
end, we will examine the charac- • Introduction to proportional 2 days
teristics of pneumatic drives and technology, its use, function
controlling them in the event of and soft stop Note
pressure failure, pressure reco- • Safety in the event of power Parts 1 and 2 of the “Energy-
very, emergency stop and other failure: holding, 5/3-way efficient design of systems,
situations. The GRAFCET plan- valves, piloted non-return practical use of pneumatics”
ning method and representing valves seminar can be booked inde-
circuits complete the training. • Characteristics of pneumatic pendently of one another.
drives in the event of power
recovery For more information, see the
• Safety-orientated pneumatics Festo Didactic homepage:
• Using symbols to represent
the devices, as per www.festo-tac.de
DIN/ISO 1219-1
• Designation of the devices in www.festo-didactic.com
a circuit diagram, as per
DIN/ISO 1219-2
• Graphic representation of
pneumatic plans in
FluidDRAW®
• Simulation of pneumatic cir-
cuits in FluidSIM®
75
“Reliable electrical and pneumatic control technology

for design engineers (SEP-SICK)”
The European directives and Contents Target group
standards describe the safety • Introduction, machinery Design engineers from mecha-
requirements for machines and directives and standards: laws, nical, electrical and control
systems. These frequently inclu- machine directives and their engineering and control
de the use of both electrical and implementation, safe control engineers
pneumatic drives and/or control technology in accordance with
systems. In this seminar, you will DIN EN 954-1, perspective on Duration
learn about both aspects and the new DIN EN ISO 13849-1 2 days
will therefore be in a position to • Safety-orientated electrical
design them for optimal interac- engineering, safe circuit en- For more information, see the
tion. gineering: functional safety, Festo Didactic
examining faults, and safety homepage:
Take advantage of the combined technologies www.festo-tac.de
expert knowledge of specialists Applications: locking units,
from Sick AG and Festo Didactic non-contacting devices, control
GmbH & Co. KG in one seminar. technology safety devices and
emergency-stop devices
After the seminar, you will know • Safety-oriented pneumatics,
what requirements and options selected safety measures in
are available for safe and re- safety-orientated pneumatics,
liable electrical engineering and characteristics of pneumatic
pneumatics. You will be familiar drives and controlling them,
with and able to use DIN power failure, power recovery
EN 954-1/DIN EN ISO 13849-1 and restarting, two-hand
“Safety-related parts of control circuits, sample circuits
systems – General principles for
design” and associated norms.
76
“Reliable design of machinery and systems (SEP-PILZ)”
The European directives and Contents Target group

standards describe the safety • Introduction, machine Design engineers from mecha-
requirements for machines and directives and standards: laws, nical, electrical and control en-
systems. These frequently inclu- machinery directives and their gineering and control engineers
de the use of both electrical and implementation, safe control
pneumatic drives and/or control technology in accordance with Duration
systems. In this seminar, you will DIN EN 954-1, perspective on 2 days
learn about both aspects and the new DIN EN ISO 13849-1
will be in a position to design • Safety-orientated electrical en- For more information, see the
them for optimal interaction in gineering, safety engineering Festo Didactic homepage:
the future. design of control systems, www.festo-tac.de
reliable locking; attaching light
Take advantage of the combined grids; scanners and safety
expert knowledge of specialists shut-off mats and their test
from Pilz GmbH & Co. KG and cycles; emergency-stop classi-
Festo Didactic GmbH & Co. KG fications; stop categories and
in one seminar. Demonstrations operating modes; safe
take place using an actual drives; frequency converters;
machine model. speed monitoring; axis area
monitoring; discussion on
After the seminar, you will know sample applications and cir-
what requirements and options cuits
are available for safe and re- • Safety-orientated pneumatics,
liable electrical engineering and selected safety measures in
pneumatics. You will be familiar safety-oriented pneumatics,
with and able to use DIN characteristics of pneumatic
EN 954-1/DIN EN ISO 13849-1 drives and controlling them,
“Safety-related parts of control power failure, power recovery
systems – General principles for and restarting, two-hand cir-
design” and associated norms. cuits, sample circuits
77
“Safe machines in operation (SMB)” in cooperation with

the Pilz company and TÜV Austria
The aim of this event is to make From the content Target group
participants more familiar with • Definitions and basic prin- Design engineers from
the legal requirements through- ciples: mechanical, electrical and con-
out a machine’s life cycle, from New and old machines, trol engineering and control
acquisition up to modification legal requirements, modifying engineers.
and inter-connection. Particular and inter-connecting machines
attention is paid here to modi- • Inventory-taking and retrofit- Duration
fying and inter-connection ting using a model: required 1 day
machines, and the resulting properties, assessment based
documentation required by law. on a risk analysis or hazard For further information, see the
analysis, emergency-off, Festo Didactic homepage:
emergency-stop and stop www.festo.at
categories, common faults
from practical experience
• Implementation and design:
Requirements for modifying
and inter-connecting (Austrian
employee protection law,
§ 35), developing new
machines in Austria and
Germany, basic principles of
safe pneumatics and solution
variants, electro-technical
solutions and variants
• Documentation:
Requirements (Austrian
employee protection law,
§ 35), descriptions and opera-
ting instructions, technical
documents, testing and valida-
tion
78
WBT – Safety engineering web-based training
From the content We can meet your needs

• Project 1: With a CD-ROM version, a web-
MPS® Distribution station based training version for instal-
(hazard types, danger from lation on networks and learning
crushing, safety measures management systems for any
for housings and door number of licences.
switches, protective circuits)
• Project 2: Duration
MPS® Robot station (danger approx. 4 hours
from impact, control
categories, operating modes, For more information, see the
stop categories, component Festo Didactic homepage:
selection) www.festo-didactic.com
• Hazard analysis
• Planning and implementing
The “Safety engineering” train- safety measures
ing program provides an intro- • Specialist safety engineering
duction to the complex subject terminology: hazards, hazard
of safety engineering in indus- areas, intended use, fore-
trial machines and systems. seeable misuse, limits of the
The aim is to make participants machine, redundancy, diversity
more aware of the problems in • Standards and their applica-
the design aspects of safety tion: structure of A B C stan-
engineering and help them dards, risk assessment as per
understand safety engineering EN 1050
equipment and hazard analysis • Risk reduction as per EN 292,
methods. control categories as per
EN 954-1 and their basic
circuits
• Safety engineering compo-
nents
79
List of abbreviations
Abbreviation German name English name Source

a, b, c, d, e Bezeichnung für die Performance Level Denotation of performance levels DIN EN ISO 13849-1
AB Anzeige-Bediengeräte Display and operating units Festo
AC/DC Wechsel-/Gleichstrom Alternating current/direct units IEC 61511
AE Anfahr- und Entlüftungsventile Start-up and exhaust valves Festo
ALARP So niedrig wie vernünftigerweise möglich As low as reasonably practicable IEC 61511
ANSI US-amerikanische Normungsorganisation American National Standards Institute IEC 61511
AOPD/AOPDDR Aktive optoelektronische Schutzein- Active optoelectronic protection ISO 12100-1,
richtung device DIN EN ISO 13849-1
AS-Interface Aktuator Sensor Interface Aktuator Sensor Interface
B, 1, 2, 3, 4 Bezeichnung für die Kategorien Denotation of categories DIN EN ISO 13849-1
B10d Anzahl von Zyklen, bis 10 % der Kompo- Number of cycles until 10% of the com- DIN EN ISO 13849-1
nenten gefährlich ausgefallen sind ponents fail dangerously (for pneumatic
(u.a. für pneumatische und elektro- and electomechanical components)
mechanische Komponenten)
BPCS Betriebs- und Überwachungseinrichtungen Basic process control system IEC 61511
BPCS Betriebs- und Überwachungseinrichtungen Basic process control system IEC 61511
als ein System
BSL Bootstraploader Bootstraploader
BTB/RTO Betriebsbereit Ready-to-operate
BWP Berührungslos wirkende Positionsschalter Electro-sensitive positionswitch
BWS Berührungslos wirkende Schutzeinrichtung Electro-sensitive protective equipment EN 61496
Cat. Kategorie Category DIN EN ISO 13849-1
CC Stromrichter Current converter DIN EN ISO 13849-1
ccd Kommando-Code, Teil einer SDO-Nachricht Command-code
CCF Ausfall in Folge gemeinsamer Ursache Common cause failure IEC 61508, IEC 62061,
prEN ISO 12849-1EN 61511-1:2004,
DIN EN ISO 13849-1
CEN Europäisches Komitee für Normung European Commttee for Standardization
CENELEC Europäisches Komitee für elektro- European Commttee for Electrotechnical
technische Normung Standardization
CMF Ausfall in Folge gemeinsamer Ausfallart Common mode failure EN 61511-1:2004
CRC Prüfsumme in einem Daten-Telegramm, Sample calculation in a data telegram,
Signatur durch zyklische Redundanzprüfung Cyclic Redundancy Check
DC Diagnosedeckungsgrad Diagnostic Coverage DIN EN ISO 13849-1,
IEC 62061,(IEC 61508-2:2000
DC Gleichstrom Direct current
DCavg[%] Diagnosedeckungsgrad (von Tests) Average diagnostic coverage DIN EN ISO 13849-1
DPV0
DPV1 Funktionsversionen von PROFIBUS
DR Druckventile Pressure control valves Festo
DS Druckschalter Pressure switch Festo
DV Druckverstärker Pressure amplifier Festo
E Externe Einrichtung zur Risikominderung External risk reduction facilities EN 61511-1:2004
E/A Eingabe/Ausgabe Input/Output
E/E/EP Elektrisch/elektronisch/programmierbar Electrical/Electronical/programmable IEC 61511, IEC 61508
elektronisch electronic
E/E/PE Elektrisch/elektronisch/programmierbar Electrical/Electronical/programmable IEC 61511, IEC 61508
elektronisch electronic
E/E/PES Elektrisches/elektronisches/programmier- Electrical/Electronical/programmable IEC 61511
bares elektronisches System electronic system
EDM Schützkontrolle, Rückführkreis Protection control, feedback loop
EDS Elektronisches Datenblatt Electronic Data Sheet
80

F, F1, F2 Häufigkeit und/oder Dauer der Gefähr- Frequency and/or time of exposure to DIN EN ISO 13849-1
dungsexposition the hazard
FB Funktionsblock Function block DIN EN ISO 13849-1
FMEA Ausfallarten und Effekt-Analyse Failure modes and effects analysis EN 1050, DIN EN ISO 13849-1
FO Funktionsorientierte Antriebe Function-oriented drives Festo
FR Filterregler Filter-regulator Festo
FTA Fehlerbaumanalyse/Fehlerzustandsbaum- Fault Tree Analysis EN 1050
analyse
Hazard Potenzielle Quellen von Verletzungen oder Potential source of injury or damage to Machinery directive
Gesundheitsschäden health 2006/42/EG, EN 1050 (ISO
Hazard area Jeder Bereich in einer Maschine und/oder Any zone within and/or around EN ISO 12100-1,
um eine Maschine herum, in dem eine Per- machinery in which a person is subject DIN EN 1050
son einer Gefährdung ausgesetzt sein kann to a risk to his health or safety
H & RA Gefährdungs- und Risikobeurteilung Hazard and risk assessment IEC 61511
H/W Hardware Hardware IEC 61511
HFT Hardware-Fehlertoleranz Hardware fault tolerance IEC 61511
HMI Mensch-Maschine-Schnittstelle Human machine interface IEC 61511
HRA Analyse menschlicher Zuverlässigkeit Human reliability analysis IEC 61511
I, I1, I2 Eingabegerät, z.B. Sensor Input device, e.g. sensor DIN EN ISO 13849-1
i, j Index für Zählung Index for counting DIN EN ISO 13849-1
I/O Eingänge/Ausgänge Inputs/Outputs DIN EN ISO 13849-1
iab, ibc Verbindungsmittel Interconnecting means DIN EN ISO 13849-1
Inherently Schutzmaßnahme, die entweder Gefähr- Inherently safe design measures EN ISO 12100-1
safe design dungen beseitigt oder die mit den Gefähr-
dungen verbundenen Risiken vermindert,
indem ohne Anwendung von trennenden
oder nicht trennenden Schutzeinrichtungen
die Konstruktions-Betriebseigenschaften
der Maschine verändert werden
KL Kolbenstangenloser Zylinder Rodless cylinders Festo
Declaration Verfahren, bei dem der Hersteller oder sein Declaration of conformity Machinery directive
of conformity in der Gemeinschaft niedergelassener 2006/42/EG
Bevollmächtigter erklärt, dass die in den
Verkehr gebrachten Maschine allen ein-
schlägigen grundlegenden Sicherheits- und
Gesundheitsanforderungen entspricht
KS Kolbenstangenzylinder Cylinders with position rod Festo
L, L1, L2 Logik Logic DIN EN ISO 13849-1
Lambda Ausfallrate bei ungefährlichen und Gefahr Rate to failure IEC 62061
bringenden Fehlern
MTBF Mittlere Ausfallzeit eines Gerätes Mean time to failure DIN EN ISO 13849-1
MTTF/MTTFd Zeit bis zu einem Ausfall bzw. gefährlichen Mean time to failure/ DIN EN ISO 13849-1
Ausfall Mean time to dangeous failure
MTTR Mittlere Reparaturzeit eines Gerätes Mean time to repair DIN EN ISO 13849-1
NMT Service-Dienste des CAN-Application Layers Network Management
Nniedrig Anzahl von SRP/CS mit PLniedrig in einer Number of SRP/CS with PLlow in a DIN EN ISO 13849-1
Kombination von SRP/CS combination of SRP/CS
NOT-AUS Ausschalten im Notfall Emergency switching off EN 418 (ISO 13850) EN 60204-1
Appendix D
NOT-HALT Stillsetzen im Notfall Emergency stop ISO 13850 EN 60204-1
Appendix D
NP Nicht programmierbares System Non-programmable system EN 61511-1:2004
81

O, O1, O2, OTE Ausgabegerät, z.B. Antriebselement Output device, e.g. actuator DIN EN ISO 13849-1
OE Öler Lubricator Festo
OSHA
OSI Referenzmodell zur Datenkommunikation, Open System Interconnection
Darstellung als Schichtenmodell mit ver-
teilten Aufgaben für jede Schicht
OSSD Ausgangsschaltelement, Output signal switching device EN 61496-1
Sicherheits-Schaltausgang
P, P1, P2 Möglichkeit zur Vermeidung der Gefährdung Possibility of avoiding the hazard DIN EN ISO 13849-1
Pdf Wahrscheinlichkeit gefahrbringender Probability of dangerous failure IEC 61508, IEC 62061
Ausfälle
PE Programmierbare Elektronik Programmable electronics EN 61511-1:2004
PES Programmierbares elektronisches System Programmale electronic system EN 61511-1:2004, DIN EN
PFD Ausfallwahrscheinlichkeit bei Auslösen/ Probability of failure on demad IEC 61508, IEC 62061
Anfrage der Sicherheitsfunktion
PFH Ausfallwahrscheinlichkeit pro Stunde Probability of failure per hour IEC 62061
PFHd Wahrscheinlichkeit gefahrbringender Probability of dangerous failure per hour IEC 62061
Ausfälle pro Stunde
PHA Vorläufige Untersuchung von Gefährdungen Preliminary hazard analysis EN 1050 01/97 Appendix B.2
PL/ Diskreter Level, der die Fähigkeit von Discrete level used to specify the ability DIN EN ISO 13849-1
Performance sicherheitsbezogenen Teilen einer Steue- of safety-related parts of control systems
Level rung spezifiert, eine Sicherheitsfunktion to perform a safety function under fore-
unter vorhersehbaren Bedingungen auszu- seeable conditions
führen
PLC Speicherprogrammierbare Steuerung (SPS) Programmable logic contoller IEC 61511, DIN EN ISO 13849-1
PLniedrig Niedrigster Performance Level einer SRP/CS Lowest performance level of a SPR/CS DIN EN ISO 13849-1
in einer Kombination von SRP/CS in a combination with SPR/CS
PR Proportionalventile Proportional valves Festo
RE Regler Regulator Festo
Residual risk Risiko, das nach Ausführung der Schutz- Risk remaining after safety measures EN 1050
maßnahme verbleibt have been taken
Risk Kombination der Wahrscheinlichkeit Combination of the Probability EN ISO 12100-1
Risk analysis Kombination aus Festlegung der Grenzen Combination of the specification of the EN ISO 12100-1, DIN EN 1050
einer Maschine, Identifizierung einer limits of the machine, hazard identifi-
Gefährdung und Risikoeinschätzung cation and risk estimation
Risk Gesamtheit des Verfahrens, das eine Overall process comprising a risk EN ISO 12100-1, DIN EN 1050
assessment Risikoanalyse und Risikobewertung analysis and a risk evaluation
umfasst
Risk Auf der Risikoanalyse beruhende Beur- Judgement, on the basis of risk analysis, EN ISO 12100-1, DIN EN 1050
evaluation teilung, ob die Ziele zur Risikominderung of wheather the risk reduction objectives
erreicht wurden have been achieved
Risk appraisal Bestimmung des wahrscheinlichen Aus- Defining likely severity of harm and EN ISO 12100-1, DIN EN 1050
appraisal maßes eines Schadens und der Wahr- probability of its occurrence
scheinlichkeit seines Eintritts
S, S1, S2 Schwere der Verletzung Severity of injury DIN EN ISO 13849-1
SA Schwenkantriebe Semi-rotary drives Festo
SAT Vor-Ort-Abnahme Site acceptance test IEC 61511
Damages Physische Verletzung und/oder Schädigung Physical injuy or damage to health EN 1050, EN 61511-1:2004
von Gesundheit oder Sachen
Safety Maßnahme zur Beseitigung einer Gefähr- Means that eliminates a hazard or EN 1050, EN ISO 12100-1,
measures dung oder zur Minderung eines Risikos reduces a risk EN 61511-1:2004
SIF Sicherheitstechnische Funktion Safety instrumental function EN 61511-1:2004
82

SIL Sicherheits-Integritätslevel Safety integrity level IEC 61511, DIN EN ISO 13849-1
SIS Sicherheitstechnisches System Safety instrumented system EN 61511-1:2004
SP Sperrventile Shut-off valves Festo
SPE Sensitive Schutzeinrichtung mechanisch Sensitive protection equipment ISO 12100-1
behaftetes Betriebsmittel
SRASW Sicherheitsbezogene Anwendungssoftware Safety-related application software DIN EN ISO 13849-1
SRECS Sicherheitsbezogenes elektrisches Safety-related electrical control system IEC 62061
Steuerungssystem
SRESW Sicherheitsbezogene Embedded-Software Safety-related embedded software DIN EN ISO 13849-1
SRP Sicherheitsbezogenes Teil Safety-related part DIN EN ISO 13849-1
SRP/CS Sicherheitsbezogenes Teil von Steuerungen Safety-related part of control systems DIN EN ISO 13849-1
SRS Spezifikation der Sicherheitsanforderungen Safety requirements specification IEC 61511
ST Stromventile Flow control valves Festo
SW1A, SW1B, Positionsschalter Position switces DIN EN ISO 13849-1
SW2
SYNC Objekt zur Synchronisierung von Synchronisation objects
Teilnehmern im Netzwerk
TE Testeinrichtung Test equipment DIN EN ISO 13849-1
Technical Schutzmaßnahmen, bei denen Schutzein- Protective measure using safeguards to EN 1050, EN ISO 12100-1
safety richtungen zur Anwendung kommen, um protect persons from the hazard which
measures Personen vor Gefährdungen zu schützen, cannot reasonably be eliminated or from
die durch inhärent sichere Konstruktion the risks which cannot be sufficiently
nicht in angemessener Weise beseitigt reduced by inherently safe design
werden können, oder vor Risiken zu measures
schützen, die dadurch nicht ausreichend
vermindert werden können
TM Gebrauchsdauer Mission time DIN EN ISO 13849-1
TR Trockner Air dryers Festo
WE Wartungseinheiten Service units Festo
WV Wegeventile Directional control valves Festo
ZS Zylinderschalter Cylinder sensors Festo
Legal notice
The examples specified here are intended purely as suggestions that must be checked for suitability in
the context of each separate application, paying attention to the applicable standards. This might involve
applying standards DIN EN ISO 13849-1 and 2, for example.
Depending on the application, the examples specified may only partially satisfy the actual requirements
(for all safety functions), and must therefore be adjusted using suitable measures and modifications.
To do this, it is necessary to examine the entire system (entire control loop system), which might consist
of multiple technologies (e.g. pneumatics, hydraulics, electrical engineering, mechanics ...) and therefore
multiple applicable standards.
The sample circuits given here are not suitable as a complete validation report in the legal sense due to
the lack of any reference to an actual system (real application).
83
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_HB_Safety_030408_en.qxp 03.04.

2008 13:41 Uhr Seite 1

Safety engineering guidelines

Your partner in safety

Directives and standards 4

Time schedule for EC machinery directive and DIN EN ISO 13849-1

Definition and concept of risk

Directive-compliant procedure for safe design

Control architectures (as per DIN EN ISO 13849-1)

4 operation modes – 10 safety functions

Sample circuit diagrams 32

Reduce risk – think preventively

Machines have to be designed in The EC machinery directive spe- Safety-orientated pneumatics

Simple – but safe!

In general, the simpler the safety Festo provides solutions on the

Due to their flexible application,

Basic safety requirements in the manufacturing industry

The development of the single

“Health and safety” outline directive

Low voltage directive Machinery directive “Use of work equipment”

Harmonised European standards National statutory provisions

Directives are laws. The EC One option for complying with

Time schedule for EC machinery directive and DIN EN ISO 13849-1

Machine safety requires safe

Incorporation into national law New machinery directive

30th November 2009

2nd October February 2007

EN 954-1 has presumption of conformity according machinery directive 98/37/EC

A new machinery directive will Manufacturers have to comply

Fundamental standards for designing control functions

Functional and safety-related requirements for

Designing and implementing safety-related control systems

DIN EN ISO 13849-1

Designated architectures (categories)

Harmonised standards that

Definition and elements of risk

Risks are the result of hazards

Safety Adequately Danger/hazard

Safety = acceptable residual risk

Risk Severity of harm Probability of

The possibility of avoiding

Directives and standards de-

necessary, suitable measures • Failure mode and effects

• Human interaction during

with the area of risk reduction in machine

reducing risk have already been design measures – Is the

Source: Directive 2006/42/EC, Appendix I, 1)

When estimating the risk and

Identify the safety function to be performed

Determining the required PLr 4) Common Cause Failure (CCF)

Category MTTFd DC CCF

Source: DIN EN ISO 13849-1, 4.2 Figure 3

User information on the machine and in the user

Source: EN 12100-2, Section 6

Evaluating technical safety measures – determination of the performance level

The figure shows the simplified

Determination of the SIL = Safety Integrity Level

The PL can be assigned to a spe-

possible to infer the PL from the

2 Cat B Cat 1 Cat 2 Cat 3 Cat 4

5 CCF not relevant CCF ≤ 65%

1 Risk graph: Which performance level is Evaluation MTTFd