Hydraulic Safety Interlock Manifold Systems

Hydraulic Safety Interlock Manifold Systems
Hydraulic Safety
Interlock Manifold
Systems
1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

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As the need to apply Hydraulic Safety Interlock Systems to machinery in

Australia becomes more prevalent we need to be able to respond
quickly to our customers with concise answers and technical
information.
In order to achieve this it is important to understand the requirements of

the relevant Australian standards and how we can use our products to
allow system integrators to achieve the safety system compliance.

Designers of Safety Systems must comply with local laws and

standards
In Australia, AS4024.1 – Safe Guarding of Machinery is the standard

that needs to be adhered to (also currently under review to be updated)
In Europe, EN954 – is the standard that needs to be adhered to AS

4024.1 is based on this standard.
The question is what information do we need from our customer to

proceed with our design and offer a solution?

The customer must first detail for us the “Determination of Machine Category”.
This will then allow us to offer the appropriate design

The determination of the machine category is critical in determining

what hydraulic circuit option you can offer. The Australian Standard
AS4024.1 is specific. It states “The designer must consider the flow of
power in the system and the action of the stored energy. If the flow of
power can be reliability blocked and the stored energy dissipated or
controlled a machine is considered safe”.
It is not for us to decide the machine category. This is to be done by

either a Risk Management Consultant or a System Integrator.

Once the Category of the “Safety Required” is determined what does it

mean to us?
What do we have to supply to comply with the rules as detailed in

AS4024.1?

Category 1. Single valve without indication of failure
Category 2. Two independent valves each with position monitoring

must be used to block the flow of power.

must be used to block the flow of power. Indication of a failure is
required.

must be used to block the flow of power and the control system must
incorporate cross monitoring of the signals.

AS4024.1 has 2 charts

Interlock Category has 6 levels and the
Safety category has 4 levels
We should be using the 4 Safety Levels
Safety Category 1 would most likely
never apply to hydraulics
• This level 1 needs Interlocks as
shown on the chart to categories 1
&2
Safety Category 2 needs two isolating
valves in series. No indication is required
by Interlock Category 3
Safety Category 3 & 4 needs two
isolating valves in series with indication
is required by Interlock Category 4,5 & 6.
There is no difference between the
hydraulics of Safety Category 3 & 4 only
the electrical control changes.

Typically most applications using hydraulics will fall into the Category 3 or 4.
As we move further through the presentation you will realize that the valves we
offer can be used in either Category 3 or Category 4. The system integrator can
use self monitoring PLC equipment to indicate failure of any of the hydraulic
safety valves thus the system meets Category 4.
We (Bosch Rexroth) are not system integrators we are offering valves &
manifolds for use by system integrators. It is important to note the hydraulic
valving is only part of the safety system. Controls need to be in place to stop the
machine and take the energy source away as well as indicating a fault should a
valve indicate a problem during the cycle
So what questions can we be asked by the customer and how can we best
answer them?

Some customers may ask you questions like
Q1. Does your Hydraulic Safety Interlock Manifold meet AS4024.1?
Q2. Do you have CE Certification?
Q3. Have your valves been assessed independently?
Q4. What valve options are available
Q5. Do you meet the Machinery Directive: 98/37/EC – EN292-1,

EN292-2, EN982, EN954-1 and EN1050 (European Standards)

Q1. Does your Hydraulic Safety Interlock Manifold meet AS4024.1?
Answer – No, our valves have been design and tested and meet
particular EN standards. These individual standards have been meet
and we have the documentation proving this. It means that our safety
interlock valves are suitable to be used by a system integrator in an
application that is required to meet AS4024.1. We have here a
statement/declaration that should be used to give to a customer with
every quote to explain exactly specifically what RR Australia has to
offer.

Subject : Hydraulic Safety Manifold Declaration
Bosch Rexroth have independent certification from

BG-PRUFZERT in Germany. Attached with this
fax is certification from BG-PRUFZERT for the
logic elements/directional valves that we have
offered in your manifolds that have achieved the
Test Certificate Type BM. This certificate indicates
that we have been assessed independently by
BG-PRUFZERT. We have chosen to use BG-
PRUFZERT to assess our valves instead of
applying our own assessment and Declaration of
Conformity. This has been done in order to give
our customers total confidence that the parts we
are offering comply with fundamental health and
safety requirements in accordance with the EN
standards. Should you wish to check this BG-
PRUFZERT’s web site is
http://www.hvbg.de/d/bgp/index.html

The standard AS4024.1 is based on EN954-1. We

understand that in Australia you need to base your
machine design and rework on AS4024.1. Our
system meets the standard for hydraulic systems
up to category 4.

Bosch Rexroth the manufacturer, declares that the

componenets/sub-assmblies delivered have been
manufactured in accordance with the stated
harmonized standards/specifications The
components/sub-assemblies must not be operated
until the machine into which these
componenets/sub-assmblies are to be
incorporated has been declared in conformity with
the provisions of the directive

Applied Harmonized Standards:

EN 292-1 (11.1991) Safety of Machines
EN 292-2 (06.1995) Basic concepts, general

principles for design
EN 982 (09.1996) Safety requirements on

fluid power installations and components
EN 60 204-1 (06.1993) Safety of machinery:

electrical equipment of machines
And thus considered suitable for use with interlock

systems to AS4024.1

In Australia the system must meet the standard

AS4024.1, however should you wish to have our
system assessed independently further locally, this
can be arranged at an additional cost.
Some of our competitors declare that they conform

with EN954-1 and EN1050.
In reference to EN954-1 and EN1050 it should be

noted that these are not the governing standards.
EN1050 is simply a standard for principles of risk

assessment and as we and our German engineers
understand a manifold assembly cannot comply
with principles for risk assessment.
EN954-1 is generally covered in AS4024.1

Q2. Do you have CE Certification?
Answer – Yes, and we also have independent certification from BG-

Prufzert in Germany.
However, the following points can be made.

AS4024.1 does not require that any equipment “must” have the CE
marking.
AS4024.1 does not state that independent certification of any
assemblies including manifold assemblies is required.
AS4024.1 places the responsibility squarely on the system
integrator to ensure that the total system meets the requirements of
the Australian Standard.

CE Marking
RE00 042/11/00 is available and
explains the CE mark and it’s
meaning.
The features of the CE mark:
Does not stand for the
compliance with special quality
and safety requirements
Usually does not signal testing
by a neutral inspectorate
Expresses the assessment of
the manufacturer

Typical Current BG Certificate

Q3. Have your valves been assessed independently?
Answer - Yes, we have up to date independent certification from BG-

Prufzert in Germany for our NG6, NG10, SL Check Valves, LFA…E-7X
and LFA…QR10-6X/CA20 & 40D Logic Elements. These certificates
are available and are in German. They are not available in English.
BG Prufzert (testing and certification system) brings together the 19
test and certification bodies of Germany’s statutory accident insurance
and prevention institutions. A BG Prufzert Information Sheet is
available detailing exactly what this organization does.
4WEH, LFA…EWA, EWB & EH2 are not certified by BG Prufzert
The BG Prufzert mark awarded to certified products holds a higher

accreditation that the self assessed CE Marking.
Q4. What valve options are available,

what do we stock.
We stock valves in NG6 and NG10.

Monitoring is available on NG16 up
NG102 however these are not certified
by BG Prufzert. For the larger flows we
think using the logic elements is a better
option. These are not in MR range.
For the NG6 & NG10 valves we stock

QMA option and QMB option.

QMB senses the spool

when is has completely
returned to the de-
energized position.
QMA senses when the
spool has moved from
the fully energized
position and is moving
back to the rest position.
The oil path is not
blocked when the switch
shows a change of state
and is therefore in some
applications maybe
unsuitable or unsafe
QMA QMB
Q5. Do you meet the Machinery Directive: 98/37/EC – EN292-1,

EN292-2, EN982, EN954-1 and EN1050
Answer – Yes as detailed on the certificate (next page) that can be

supplied for system integrators using our valves and requiring
documentation


Typical Circuits we use that meet the requirements.

NG6 Cat 3 or 4 Block Only


NG10 Cat 3 or 4 Block Only


NG10 Cat 3 or 4 Block and Bleed


Logic Element 3 or 4 Block and Bleed


Logic Element with active piston 3 or 4 Block and Bleed

1. What is Dual Flow Path and why do we use it?

2. What is a Logic Element with Active Piston and why do
we use it?

What is Dual Flow Path and why do we use it?

Dual flow path means that we connect
the P & A ports together in the manifold
and the B & T ports together in the
manifold. How this helps us is to allow
high flow rates through the DCV without
causing unbalanced Bernoulli forces on
the spool within the DCV. The data
sheet states that single flow path
through any DCV will result in
significantly less flow capacity than
specified on the tables. The data sheet
only allows for “Dual Flow paths through
the valve”

What is Dual Flow Path and why do we use it?

In the de-energized position the valve
provides a safe blocked condition.
When energized the flow is allowed to
pass from P to B and from A to T. The
maximum pressures need to be
checked to ensure that the tank port
pressure as specified by the data sheet
is not exceeded. Otherwise this circuit
works perfectly well. Using this circuit
we can easily pass 60lpm (NG6) and
120lpm (NG10) at no more than 5 bar
pressure drop through the valve.

What is a Logic Element with Active Piston and why do we

use it?
Our logic element with active piston has
advantages that can be used to
overcome particular circuit problems.
The piston assembly mounted to the top
of the logic element has an area much
greater than any area on the actual
poppet element of the assembly. This
offers to distinct advantages

What is a Logic Element with Active Piston and why do we

use it?
1. Using the pressure from the inlet
side (P port) of the manifold to
drive the poppet shut in the de-
energized safe position you can
always be assured that the poppet
will be driven home as the force
generated always exceeds ant
downstream pressures.
2. If the system requires the poppet
to be driven open for response of
flow rate reasons it can easily be
done by connecting the Z1 port to
the pilot DCV instead of to tank

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Hydraulic Safety Interlock Manifold Systems

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

As the need to apply Hydraulic Safety Interlock Systems to machinery in

In order to achieve this it is important to understand the requirements of

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

Designers of Safety Systems must comply with local laws and

In Australia, AS4024.1 – Safe Guarding of Machinery is the standard

In Europe, EN954 – is the standard that needs to be adhered to AS

The question is what information do we need from our customer to

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

The determination of the machine category is critical in determining

It is not for us to decide the machine category. This is to be done by

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

Once the Category of the “Safety Required” is determined what does it

What do we have to supply to comply with the rules as detailed in

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

Category 1. Single valve without indication of failure

Category 2. Two independent valves each with position monitoring

Category 3. Two independent valves each with position monitoring

Category 4. Two independent valves each with position monitoring

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

AS4024.1 has 2 charts

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

Some customers may ask you questions like

Q1. Does your Hydraulic Safety Interlock Manifold meet AS4024.1?

Q2. Do you have CE Certification?

Q3. Have your valves been assessed independently?

Q4. What valve options are available

Q5. Do you meet the Machinery Directive: 98/37/EC – EN292-1,

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

Q1. Does your Hydraulic Safety Interlock Manifold meet AS4024.1?

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

Subject : Hydraulic Safety Manifold Declaration

Bosch Rexroth have independent certification from

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

The standard AS4024.1 is based on EN954-1. We

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

Bosch Rexroth the manufacturer, declares that the

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

Applied Harmonized Standards:

EN 292-2 (06.1995) Basic concepts, general

EN 982 (09.1996) Safety requirements on

EN 60 204-1 (06.1993) Safety of machinery:

And thus considered suitable for use with interlock

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

In Australia the system must meet the standard

Some of our competitors declare that they conform

In reference to EN954-1 and EN1050 it should be

EN1050 is simply a standard for principles of risk

EN954-1 is generally covered in AS4024.1

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

Q2. Do you have CE Certification?

Answer – Yes, and we also have independent certification from BG-

However, the following points can be made.

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

1/2005 - Bosch Rexroth Melbourne, Australia - 2005 Sales Conference Presentation

Typical Current BG Certificate