Automotive plant required a lightweight guarding system that was flexible - allowing maintenance and future modifications - while robust enough to offer a high degree of personnel safety.

The building which houses the T5 model platform for Land Rover's Discovery 3 and the Range Rover Sport contains 260 ABB robots and is 75% automated. The Manufacturing Engineering team at Land Rover required a guarding system that was lightweight and flexible (to facilitate maintenance and any future modifications) while still being robust enough to offer a high degree of safety for personnel. Bosch Rexroth's EcoSafe system meets the most stringent guarding legislation (EN292, 294 and 811) and for the Manufacturing Engineering teams' requirements, it meant that their system conformed to the Machinery Directive.

* Aluminium replaces steel - one of the major advantages of the EcoSafe protective barrier system is that it is made from aluminium and its anodised surfaces offer the clean finish preferred in modern manufacturing environments.

When compared with heavy, cumbersome and corrosion-prone 'traditional' steel guarding, the system has numerous benefits.

EcoSafe's modular, durable, bolt-together design eliminates the need for welding, painting, special tooling and skilled labour.

The bolted design allows for rapid assembly, disassembly and re-use.

In any business cost is a consideration and with the price of steel continuing to rise and the price of aluminium continuing to fall the differential between the two types of systems is narrowing considerably.

In terms of lifetime cost though there is no comparison, the lightweight, modular EcoSafe system is quick and easy to install and is also simple to reconfigure.

Having designed an EcoSafe installation (CAD planning software is available) assembly couldn't be simpler.

After marking the perimeter on the floor the support posts are anchored, 'hook and hang' brackets are installed and screwed into place.

* Looks are everything - in the 'hard-nosed' world of automotive manufacturing it is perhaps surprising that the looks of the EcoSafe system are so highly valued.

At Land Rover the fact that the system gave the facility a 'corporate feel' was incredibly important.

The EcoSafe system offers the option of wire mesh screens or protective panels.

At Land Rover the wire mesh has been left in the original colour of grey with the inner sections galvanised to resist the water thrown off during the spot welding process.

On this project the EcoSafe system was up against three other guarding systems.

However, the combination of cost-competitive pricing, a known end product and the support of Bosch Rexroth more than met expectations.

* Integration - hugely important to Land Rover was the ease with which the EcoSafe system could be integrated with other equipment.

Access is obviously a major issue in machine guarding: if a system is too complicated or unwieldy then productivity can be affected and employees may look for an opportunity to 'bypass' the safety fencing.

If access can be gained too readily then there is the possibility of an employee venturing too close to a robot which has not finished its cycle.

There is a delicate balance to be struck.

This balance exists at Land Rover in the form of an electronic interlocked trapped key gate system incorporating technology from Fortress Interlocks.

Other products which the fence line must integrate with are light guards, light scanners and signal towers.

Land Rover's Manufacturing Engineering team were quick to point out that retrofitting these devices was simplicity itself due to the design of the EcoSafe product.

Installing a signal tower for example simply requires brackets being fitted into the grooves on the profiles, a process which with a traditional steel guarding system would have required a great deal of time, effort and equipment.

With the specification of the EcoSafe product, Land Rover was looking for a lightweight, flexible, affordable guarding system provided by a supplier that had the infrastructure to support the project through all of its various phases.

Perhaps the clearest indication of Land Rover's satisfaction is that the next major project at Land Rover's Halewood plant will incorporate the EcoSafe system.

Sounders are designed for maximum efficiency in relation to their size and provide up to 100dBA sound output with 26 user selectable tones, which can be selected using a five-way DIL switch.

RTK Instrument's DB5 Sounders are designed for maximum efficiency in relation to their size. The DB5 provides up to 100dBA sound output with 26 user selectable tones which can be selected using a five-way DIL switch. Two different tones can be switched remotely by switching the supply negative.

Low frequencies are also available to confirm to British Safety standards, making them ideal for fire alarm systems and other annunciator applications.

The Sounders are ATEX certified to EX II 1G, EEx ia IIC T4 and are suitable for zones 0, 1 and 2 and for all gas groups.

An IP65 enclosure enables the DB5 Sounder to cope with the harsh environmental conditions found offshore and well as those on the onshore oil, gas and chemical industries.

When used in hazardous areas, the DB5 Sounders must be powered through suitable intrinsically safe Isolators or Barriers.

RTK Instruments manufacture a full range of suitable interfaces such as the S951 or S931.

The DB5 intrinsically safe multitone Sounder is ideally suited for use in areas of high ambient noise.

Additionally, for extreme noise levels, they can be linked with the DA135 Intrinsically Safe Beacons to combine audible and visual warnings.

RTK Instruments, as major suppliers of industrial alarm systems and components for safe and hazardous area, can also supply complete alarm systems and help with all industrial alarm applications.

A range of LED Clusters provides visual on/off indication - in six super-bright colours - of process conditions in safe and hazardous areas and provide a minimum of 100,000h of service life.


The DA170 range of LED Clusters provides visual on/off indication of process conditions in safe and hazardous areas. The LED Clusters are available in six super-bright colours and feature an integral current regulator to limit the current to 20mA. This ensures that all colours are matched to obtain consistent brightness across the range including white and blue.

Up to two LED Clusters can be driven from a single IIC power source.

The lamps are designed to provide a minimum of 100,000h of service life.

The DA170 LED Clusters are ATEX certified to Ex II 1G, EEx ia IIC T4 and are suitable for zones 0, 1 and 2 and for all gas groups.

When used in hazardous areas, the LED Clusters must be powered through suitable intrinsically safe Isolators or Barriers.

RTK Instruments manufacture a complete range of suitable interfaces such as the S951 and S953.

The LED Clusters are simple to install on any panel door.

The lens simply drops through an industry standard 22.5cm diameter hole and the body is screwed securely from the rear, providing a seal to the panel of IP65.

The DA170 range of LED Clusters can be linked into either the LN1000 Intrinsically Safe Alarm Annunciator or one of a number of safe area annunciators.

Also, a range of matching pushbuttons and selector switches can be supplied.

With the LED's lower power consumption, low heat dissipation and long life expectancy, the DA170 is an ideal indicator for safe and hazardous areas alike.

RTK Instruments, as major suppliers of industrial alarm systems and components for safe and hazardous area, can also supply complete alarm systems and help with all industrial alarm applications.

Latest free edition of 'On Your Guard' gives the basics, as well as information about the full range of regulations and standards that are applicable and indicates the current versions of standards.


Procter Machinery Guarding, the UK's leading supplier of modular and bespoke machine guards, is publishing a third edition of its ever-popular free guide to machinery guarding standards. Available as a PDF document for printing by the recipient, the third edition of 'On Your Guard' has been updated to reflect recent changes in standards. It also has an entirely new section for 'Useful Resources'.

Now running to eight pages, the latest edition of 'On Your Guard' gives machine designers, health and safety managers, health and safety representatives and guarding specifiers the basics, as well as information about how they can find out more on specific topics.

Machinery guarding is essential if a machine is to operate safely, but many people are unaware of the full range of regulations and standards that are applicable.

This guide not only helps in that respect, but it also indicates what the current versions of the standards are so that users do not inadvertently continue working with out-of-date standards.

As a leading supplier of machinery guarding, Procter Machinery Guarding is fully aware of the applicable standards in the UK, Europe and beyond, so is ideally positioned to share some of this knowledge.

'On Your Guard' explains the importance of guarding and the ways in which well-designed guards can enhance productivity while ensuring operator safety.

It then goes on to describe the requirements of machinery guarding in relation to the machinery directive and CE Marking (often an area of confusion and misunderstanding), before listing the main standards that apply to machinery guarding and conveyor guarding.

In addition to providing information about standards, the guide also offers advice on how to approach the design of guarding and the specification of the access control system (interlock switches, for example).

This will aid the creation of cost-effective guard designs that will deliver an appropriate level of safety and help to avoid the dangerous practice of operators and maintenance personnel attempting to bypass the safety measures.

A new feature in the third edition of 'On Your Guard' is a section for Useful Resources.

This tells readers how they can request further free items such as a Risk Assessment Calculator, a Safety Distance Calculator and, for forward-thinking managers planning for every eventuality, a Machine Accident Investigation Kit.

At the rear of the guide there are contact details for a variety of sources of further information, including the HSE, BSI and DTI.

Many of these have been updated to reflect changes that have occurred since the last edition of 'On Your Guard' was published.

Phoenix Contact has added two additional modules to its range for safety-relevant applications - the Namur interface modules and isolating amplifiers comply with SIL 2 for functional safety.

Namur isolating amplifiers comply with SIL2 Phoenix Contact has added two additional modules to its range for safety-relevant applications - the Namur interface modules and isolating amplifiers comply with SIL 2 for functional safety. Phoenix Contact has added two additional modules to its range for safety-relevant applications. The NAMUR interface modules PI-EX-NAM/RNO-NE and PI-EX-NAMTO-P Ex isolating amplifiers now comply with the requirements of SIL 2 for functional safety.

Both modules are part of the easy to use pluggable Process Interface electronic modules for use in potentially dangerous areas and provide EX i explosion protection.

Their particular advantage is that they save both space and time.

Combination with base terminals allows direct installation at the switching level of the control cabinet as well as pre-wiring of the modules which are only 12.4mm wide.

The application-dependent electronics can then be plugged in afterwards.

* About Phoenix Contact - Phoenix Contact is one of the world leaders in developing and manufacturing connectivity solutions and automation components.

Its principal product ranges include: printed circuit board connectors; modular terminal blocks; fieldbus components; surge voltage protection systems; industrial plug and socket connectors and interface units.

Low-cost single-beam light barriers are provided with either an infrared beam or, for applications where extremely rapid response or a long sensing range is required, a laser beam.

Pilz Automation Technology is launching new low-cost single-beam light barriers with either an infrared beam or, for applications where extremely rapid response or a long sensing range is required, a laser beam. Considerably more cost-effective than safety light curtains for body detection, the PSEN op2S/4S light barriers are suitable for use in machinery safety applications conforming to the requirements of BS EN 954-1 Category 2, 3 or 4. The sensors are quick and simple to install thanks to their compact M22 threaded bodies that are sealed to IP67, and wiring is completed via M12 connectors on the transmitter and receiver.

LEDs are incorporated within each unit to assist with commissioning and troubleshooting, and diagnostics are further improved by linking the sensors to either a Pilz PNOZmulti modular safety controller or a Pilz PSS (programmable safety system).

Indeed, it costs less to purchase three of the single-beam sensors and a PNOZmulti safety controller than to buy a standard three-beam safety light curtain for body detection.

The infrared units have a maximum operating range of 8m and a response time of 2ms, while the laser version has an extended range of 40m and a response time of just 333 microsec.

Pilz has teamed up with a number of its key distributors to offer jointly branded safety services, so users can find out about these directly from their normal points of contact at the distributors.

Pilz Automation Technology has built an enviable reputation for its safety-related services since the company first launched them a few years ago. In a drive to make them more widely available, Pilz is now offering its services through a number of its key distributors. Many machine builders, OEMs and end users purchase components through distributors and rarely, if ever, have direct contact with Pilz.

Consequently they may not be fully aware of the range of services available, or they may be reluctant to contact Pilz having built up a close relationship with a distributor.

At the same time, while distributors are usually knowledgeable about the products they sell, and many also have a good understanding of machinery safety, they do not necessarily have the competencies required to offer safety-related services such as risk assessments, plant assessments and training.

Pilz is therefore teaming up with a number of its key distributors to offer jointly branded safety services.

Customers can find out about these directly from their normal points of contact at the distributors, yet the services themselves will be provided by experts from the Safety Services Division of Pilz.

The consultants providing these services act independently so, if any products need to be purchased, the distributors are free to work with the customers to specify the optimum components for each particular application.

Among the services available, the most popular are likely to be risk assessments, SIL determination, plant assessments, advice on compliance with machinery safety standards, and training courses.

A broad range of courses is offered, covering electrical design, machinery safety regulations and standards, plant machinery maintenance requirements, general machinery safety, and the management of safety.

As one of the UK's leading providers of independent safety-related services, the Safety Services Division of Pilz operates to exceptionally high standards.

And for companies that already have a good relationship with a distributor, it is reassuring and convenient to be able to access such services through a known and trusted channel.

The latest version of the personal noise dosemeter equipment has been uprated to comply with more regulations, guidelines and working-practice standards, including ATEX and EEx.


The latest version of the personal noise dosemeter equipment available from Cirrus Research Plc has been uprated to comply with more regulations, guidelines and working-practice standards. The new features and functions incorporated ensure a wider range of applications, wherever personnel are subject to levels of noise pollution (above first and second action levels). An intrinsically safe ATEX and EEx certified version is also available for hazardous area operation.

The equipment is ideal for the assessment of occupational noise, particularly where employee mobility or other factors mean that noise exposure cannot otherwise be determined using standard noise-level measurements.

The equipment comprises a CR:110A doseBadge and RC:110A Reader Unit, designed to simplify the process of noise monitoring within a working environment.

The lightweight and compact doseBadge is user programmable and comprises a non-removable microphone capsule and rechargeable battery, securely encased within a robust metal enclosure which provides protection against corrosion from inadvertent chemical contact, or impact damage particularly if the unit is dropped.

The doseBadge is also devoid of buttons, controls or displays, which eliminates unauthorised tampering, and maintains the validity of measurement results.

This degree of safety and security is not necessarily common to other manufacturers' equipment, where accessible microphones can be easily damaged and flimsy plastic housings provide only limited protection.

In addition the provision of localised controls and displays increases the potential for falsified or inaccurate readings, nullifying the validity of monitoring surveys.

The Cirrus doseBadge also incorporates a rechargeable NiMH battery with a 'shake-to-wake' function which extends battery life and operating time.

The unit is totally self contained, without controls or trailing cables, ideal for use in confined or constricted spaces.

An infra-red two-way link with a separate hand-held Reader Unit is used to calibrate, supply commands and record information on noise levels and exposure times.

The Reader Unit can be used with a number of doseBadge units, leading to higher efficiency and economy.

Noise level and duration recordings can be viewed on the Reader Unit, as well as being downloaded to dBlink3 and doseBadge Database software programs for PC analysis.

This includes the following.

* Overall noise level and Time History data logging with Peak(C) and battery level.

* Independent configuration of Exchange Rate, Criteria level and Time, * Threshold and Time Weighting.

* Compliance with the new 2005 Control of Noise at Work Regulations as well as OSHA.

The doseBadge is attached to the wearer using an epaulette type mounting which incorporates clip attachments.

A helmet mount option is also available, together with a windshield for outdoor operation and a user on/off keyfob, which can be used as an alternative Reader Unit control.

The intrinsically safe CR:110AIS is the smallest ATEX and EEx noise dosemeter currently available and features a gold plated doseBadge unit for both Group 1 (mining) and Group II (non-mining) applications.

It is also suitable for use in petrochemical plants and oil refineries, etc, or wherever explosive or otherwise hazardous atmospheres may be encountered.

Designed to ATEX Directive 100a in accordance with EN50021:1999, a hazardous area annunciator offers all the features and benefits of a safe area annunciator.

A hazardous area Annunciator offering all the features and benefits of a safe area Annunciator from RTK Instruments RTK Instruments' NEX7250 Alarm Annunciator is a feature rich annunciator suitable for use in Zone 2 hazardous areas and designed to Type 'n' standards. Designed to ATEX directive 100a in accordance with EN50021:1999, the NEX7250 is based on the field-proven Series 725 Annunciator. Systems are available in a range of sizes and formats from 2 to 120 windows, in a choice of three different window sizes and six colours.

Windows are illuminated by ultra-bright, ultra reliable LEDs.

As with all RTK's range of Annunciators, ASIC technology is used in the NEX7250 to maximise reliability.

This multi-redundant design ensures no single point can cause failure.

The standard unit comprises a wall mounting steel enclosure with hinged plexiglass viewing window sealed to IP54.

Options include panel mounting versions or stainless steel enclosures.

The NEX7250 is fully field-programmable for all standard ISA sequences plus a range of options.

Units are equipped with dual common alarm and dual horn relays as standard.

Options for RS485 serial interface and individual repeat relays per channel are also available.

RTK Instruments, as major suppliers of industrial alarm systems and components for safe and hazardous area, can also supply complete alarm systems and help with all industrial alarm applications.

Modular safety controller gains a number of extra safety functions, new standard automation control functions and improved diagnostics to help minimise plant downtime.

Several major enhancements are incorporated in the latest version of the Configurator software for the Pilz PNOZmulti modular safety controller. Version 5 gains a number of extra safety functions, new standard automation control functions and improved diagnostics to help minimise plant downtime in the event of a safety-related stoppage. Additional safety functions in the drag-and-drop Configurator enable users to create safety-related control systems that utilise safety mats, safety gates with interlocks, pushbuttons, limit switches, key switches, foot switches and light curtains with muting functions.

For those who use the PNOZmulti to perform standard automation control functions, version 5 of the Configurator enables the cascading output from the PNOZmulti to be used as an output for standard control functions.

Pilz has recently announced the PVIS expanded diagnostic concept and version 5 of the Configurator can be used to create the error messages and set up the PVIS diagnostics when a compact PMImicro diag diagnostic display is connected to the PNOZmulti controller.

Any customers who have bought a licence for the PNOZmulti Configurator software since 1 January 2006 are entitled to a free upgrade.

Please contact Pilz to request more information about the PNOZmulti Configurator version 5, or visit the Pilz Web site.

Type 4 light curtains in accordance with EN/IEC 61496-1 and -2, include finger and hand detection in safety-related control circuits conforming to the requirements of Category 2 or 4 of EN 954-1.

Pilz Automation Technology's new PSENopt range of safety light barriers is being launched with the introduction of new standard light curtains that are available from stock on short delivery times (typically ten days or less). These units are all Type 4 light curtains in accordance with EN/IEC 61496-1 and -2, with models available for finger and hand detection in safety-related control circuits conforming to the requirements of Category 2 or 4 of EN 954-1. Light curtains for finger detection are offered with protected field heights ranging from 150mm to 1200mm, and units for hand detection are offered with protected field heights of 150mm to 1650mm.

Operating ranges are 0.2m to 6m and 0.2m to 15m for the finger and hand detection light curtains, respectively.

All of the light curtains in this standard range benefit from an integral alignment guide, feedback loop monitoring, semiconductor outputs and a user-settable manual/automatic reset facility.

The Standard range will be available from August 2006.

Further products in the PSENopt range to be launched in the coming months include single-beam infrared and laser light barriers, as well as light curtains with various additional functions.

For example, some can be connected together in a cascaded master/slave arrangement to provide enhanced protection around hazardous machinery, while others benefit from fixed or floating blanking.

The new PSENopt electrosensitive protective devices will supersede the existing PSENopt products as they become available.

An option pod with keyswitch for the amGard range of modular safety gate switches ensures an operative can only enter a hazardous area - such as a robotic cell - when it is safe.

Safety specialist Fortress Interlocks has introduced an option pod with keyswitch for the company's amGard range of modular safety gate switches. The option pod ensures an operative can only enter a potentially hazardous area when it is safe. It prevents inadvertent restart of the machinery while they are in there, and a second pod inside the area can be used to initiate safe robot programming using the key.

amGard combines both trapped key and gate switch technology to control access to equipment protected by safety guarding.

Removal of the key from the pod selects machine stop at the end of a run down cycle.

When the solenoid within the connected gate switch has been energized access can be gained.

The operator takes the safety key into the hazardous area preventing restart.

Inside the guarded area a robot's teach mode can be initiated by insertion of the key into a second pod.

This overrides the circuits that operate the robot and enables the separate circuits that allow safe teaching.

Reverse robot or machine start is only possible when the key is released from the programming pod, the door safely closed, and the key inserted into the pod onto the guarding door.

The amGard range consists of modular units, providing maximum flexibility.

Customized interlock systems can be created to individual specifications using standard products.

The modular functionality means amGard can easily be configured to accommodate the latest safety standards and be updated in the future * Fortress Interlocks at IMTS 2006, Chicago, USA, September 6-13, Booth D-4077.

An access and control product enables modules - mechanical trapped key interlocks, electrical safety gate switch interlocks, and simple machine controls - to be integrated in one unit.

Industrial safety specialist Fortress Interlocks will be showcasing its revolutionary, new access and control product, eGard, at IMTS 2006, USA. Also on display will be the company's successful mGard range of modular, mechanical interlocks, and the AmGard range of modular safety gate switches. eGard enables a selection of modules including mechanical trapped key interlocks, electrical safety gate switch interlocks, and simple machine controls to be integrated in one unit.

Easy to install, eGard can be customized for every application, providing a single source of gate access hardware.

The mGard range of Door Module, Exchange Module and Bolt Module offers flexible, mechanical solutions to safeguarding dangerous machines and hazardous processes, with up to 39,000 different sequences possible.

AmGard uses both modular trapped key and gate switch technology to control access, providing maximum flexibility.

An explosion proof safety gate switch - certified UL (E61730) and CSA (LR57327) - is designed to control access to machinery and process lines operating in potentially explosive environments.

Industrial safety specialist Fortress Interlocks has introduced an explosion proof safety gate switch certified UL (E61730) and CSA (LR57327). Designed to control access to machinery and process lines operating in potentially explosive environments, it is also ingress protected to NEMA 1, 3, 4, 6, 7, 9 and 13. The switch is suitable for Category 1 and 2 all Groups environments such as those found in the chemical and petrochemical, paint, pharmaceutical, flour, powders and mining industries.

The Stop XP is a heavy duty explosion protection safety gate switch, available with either a handle actuator (AmStop XP) or tongue actuator (AtStop XP), for use on both hinged and sliding doors.

As well as UL and CSA approvals it complies with the European ATEX Directive, meeting the Hazardous locations designation: EExd IIC T6 category II2 GD, SIRA 00ATEX 1037x.

Sealed to NEMA 1, 3, 4, 6, 7, 9 and 13 and IP67 as defined in IEC 529 it is protected against corrosion, water, dust and oil.

The Stop XP features a tamper proof locking mechanism, dual channel safety circuitry and is suitable for high risk Category 4 applications.

It is manufactured from stainless steel and zinc alloys for trouble free operation.

The Stop XP is part of Fortress' range of amGard products.

amGard combines both trapped key and gate switch technology to control access to equipment protected by safety guarding.

amGard includes solenoid-controlled locks specifically for machines with run-down cycles.