Guard Door Locking Safety Function
Contents
1. software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Safety Function Realization Risk Assessment The performance level required is the result of a risk assessment and refers to the amount of the risk reduction to be carried out by the safety related parts of the control system Part of the risk reduction process is to determine the safety functions of the machine For the purposes of this document the assumed required performance level PLr for each Safety Function is PLe Category 4 A safety system that achieves PLe Category 4 or higher can be considered control reliable Guard Locking Interlock Safety Function This application note includes two Safety Functions 1 Prevention of access to hazardous motion in the guarded area 2 Emergency stop of hazardous motion initiated by an E Stop button This system provides a Stop Category 0 stop power is removed and the hazardous motion coasts to a stop NHP Safety Reference Guide gt Safety Function Documents GSR 6B 32 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Safety Functional Requirements Access to hazardous motion is prevented by using an interlocked guard door with guard locking Once motor power has been removed the guard d2. two adjoining safety relays in the system All contactors should de energize Verify proper machine status indication and safety relay LED indication Repeat for all safety connections This test is not applicable for single relay circuits While Running turn the logic rotary switch on the safety relay All contactors should remain de energized Verify proper machine status indication and safety relay LED indication Repeat for all safety relays in the system Safety Contactor Output Tests While Running remove the contactor feedback from the safety relay All contactors should remain energized Initiate a Stop Command followed by a Reset Command The relay should not restart or reset Verify proper machine status indication and safety relay LED indication NHP Safety Reference Guide gt Safety Function Documents GSR 6B 42 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 GSR Door Monitoring Safety Function Verification and Validation Checklist cont GENERAL MACHINERY INFORMATION Machine Name Model Number Machine Serial Number Customer Name Test Date Tester Name s Schematic Drawing Number Guardmaster Safety Relay Model Safety Wiring and Relay Configuration Verification Visually inspect the safety relay circuit is wired as documented in the schematics O Visually inspect the safety relay rotary switch setting
3. 2 While Running short the Channel 1 of the safety relay to 24VDC Both contactors should de energize Verify proper machine status indication and safety relay LED indication Repeat for Channel 2 While Running short the Channel 1 of the safety relay to OVDC Both contactors should de energize i Verify proper machine status indication and safety relay LED indication Repeat for Channel 2 While Running short Channels 1 amp 2 of the safety relay Both contactors should de energize Verify proper machine status indication and safety relay LED indication GSR Logic Solver Tests While Running turn the logic rotary switch on the safety relay All contactors should remain de energized Verify proper machine status indication and safety relay LED indication Repeat for all safety relays in the system While Running remove the single wire safety connection between two adjoining safety relays in the system All contactors should de energize Verify proper machine status indication and safety relay LED indication Repeat for all safety connections This test is not applicable for single relay circuits Safety Contactor Output Tests While Running remove the contactor feedback from the safety relay All contactors should remain energized Initiate a Stop Command followed by a Reset Command The relay should not restart or reset Verify proper machine status indication and safety relay LED indication NHP Safety Reference Guide
4. 849 1 The complete CCF scoring process must be done when actually implementing an application A minimum score of 65 points must be achieved A CCF of 65 was entered for practical purposes in each case for this application example Verification and Validation Plan Verification and Validation play an important role in the avoidance of faults throughout the safety system design and development process ISO EN 13849 2 sets the requirements for verification and validation It calls for a documented plan to confirm all the Safety Functional Requirements have been met Verification is an analysis of the resulting safety control system The Performance Level PL of the safety control system is calculated to confirm it meets the Required Performance Level PLr specified The SISTEMA software tool is typically utilized to perform the calculations and assist with satisfying the requirements of ISO 13849 1 Validation is a functional test of the safety control system to demonstrate that it meets the specified requirements of the safety function The safety control system is tested to confirm all of the safety related outputs respond appropriately to their corresponding safety related inputs The functional test should include normal operating conditions in addition to potential fault inject of failure modes A checklist is typically used to document the validation of the safety control system Prior to validating the GSR Safety Relay system
5. GSR SAFETY FUNCTION DOCUMENTS Guard Door Locking Safety Function Lid a Lit VW Lit De Lit Li Lit CK gt Lit Li lt L UN en Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Table of Contents Introduction 030 Important User Information 830 Safety Function Realization 630 General Safety Information BT Bill of Material O32 Electrical Schematic 038 Configuration nu O34 Calculation of the Performance Level 635 Verification and Validation Plan O9 Additional Resources 6 42 AB Authorised uw Distributor NHP Safety Reference Guide gt Safety Function Documents GSR 6B 31 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Introduction This Safety Function application note explains how to wire configure and integrate a GSR DI and EMD to monitor a TLSZR GD2 and prevent access while hazardous motion is present in the guarded area An E Stop safety function is also integrated into the safety system The GSR DI monitors the TLSZR GD2 and E Stop to detect any faults in their operational state or faults in the circuits The GSR DI and EMD monitor their internal circuits for any faults Faults will not lead to the system performing its
6. d safety relay LED indication Repeat for all guard doors While Stopped with the guard door open initiate a Start Command Both contactors should remain de energized and open for a normal safe condition Verify proper machine status indication and safety relay LED indication Repeat for all door locks Initiate Reset Command Both contactors should remain de energized Verify proper machine status indication and safety relay LED indication Abnormal Operation Verification The Safety Relay system properly responds to all foreseeable faults with corresponding diagnostics Door Monitoring Input Tests While Running remove the Channel 1 wire from the safety relay Both contactors should de energize Verify proper machine status indication and safety relay LED indication Repeat for Channel 2 While Running short the Channel 1 of the safety relay to 24VDC Both contactors should de energize Verify proper machine status indication and safety relay LED indication Repeat for Channel 2 While Running short the Channel 1 of the safety relay to OVDC Both contactors should de energize Verify proper machine status _ indication and safety relay LED indication Repeat for Channel 2 While Running short Channels 1 amp 2 of the safety relay Both contactors should de energize Verify proper machine status indication and safety relay LED indication GSR Logic Solver Tests While Running remove the single wire safety connection between
7. ducts TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Calculation of the Performance Level cont The prevention of access to hazardous motion in the guarded area Safety Function can be modeled as below OUTPUT E Stop 1 B2 E2 The Functional Safety data for the GSR DI Logic subsystem is Monitoring Safety Relay GSR DI NHP Safety Reference Guide gt Safety Function Documents GSR 6B 38 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Calculation of the Performance Level cont The Functional Safety data for the EMD Logic subsystem is SE Monitoring Safety Relay GSR EMD MTTFd al Pey ty DCavg 17 NHP Safety Reference Guide gt Safety Function Documents GSR 6B 39 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Calculation of the Performance Level cont Emergency stop of hazardous motion initiated by an E Stop button Safety Function can be modeled as below INPUT LOGIC OUTPUT Sub System ___ Sub System 2 __ Sub System3 The Functional Safety data for the E Stop Input subsystem is OF 65 tis The Functional safety data for the GSR DI Logic subsystem is SE Monitorin
8. e two channels of the E Stop to inputs 12 and S22 respectively A loose wire a shorted contact 800F 1YP3 Tiise 46 Releace Om Nor lllumninated 2 NC 1 a short to 24V a short to OV or a cross fault between the a channels will be detected by the DI 440G TZS21UPRH GuardLock RFID Door Monitoring Power to Release 1 The TLSZRisa fully self monitoring device When faults are Cat No Description Quantity 800F 1 Hole Enclosure E Stop Station Plastic PG 800F Push Button Metal Guarded Blue R Metal detected the TLSZR responds by turning off both its OSSD SOUEM GOIIMAIO Mi Tareh Mount 1 N 0 Contact s Reset outputs 800F 2 position Key Selector Switch Right Key The GSR DI monitoring both the E Stop and the TLSZR outputs 800FM KM22MX11 1 Removal 1 N 0 1 N C Gate Release responds to any faults or demands from the devices by de oe Guardmaster Safety Relay 2 Dual Channel Universal energizing its safety contacts removing power from the coils of Inputs 1 N C Solid State Auxiliary Outputs the redundant 100S safety contactors K1 and K2 At the same Guardmaster Safety Relay Expansion Module Single time via the Single Wire Safety SWS connection the GSR DI 440R EM4R2D Wire Safe is 1 starts the EMD 30 second delay off function The hazardous only input N A Auxiliary Outputs motion coasts to a stop in no more than 20 seconds 100S C09ZJ23C 2 After the 30 second delay the EMD de energizes it safety contacts removing powe
9. g Safety Relay GSR DI PFH 1 h 4 Ct MTTFd a araea DCavgl NHP Safety Reference Guide gt Safety Function Documents GSR 6B 40 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Calculation of the Performance Level cont The Functional Safety data for the 100S Output subsystem is SE Safety Contactors PL fe 2 47E 8 Ca 1100 High 39 High 65 fulfilled Note that the E Stop 100S contactor and 7OOHPS relay data includes MTTFd DCavg and CCF data This is because these are electromechanical devices Electromechanical devices functional safety evaluations include how frequently they are operated whether they are effectively monitored for faults and properly specified and installed SISTEMA calculates the MTTFd using B10d data provided for the contactors along with the estimated frequency of use entered during the creation of the SISTEMA project This application example presumes that the E Stop is operated or tested once per day or 365 times a year The DCavg 99 for the contactors was selected from the Output Device table of EN ISO 13849 1 Annex E Direct Monitoring The DCavg 99 for the E Stop was selected from the Input Device table of EN ISO 13849 1 Annex E Cross Monitoring The CCF value is generated using the scoring process outlined in Annex F of ISO 13
10. gt Safety Function Documents GSR 6B 43 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Additional Resources For more information about the products used in this example refer to these resources Document Pub No Description Guard Locking Switch Installation Instructions How to install commission operate and maintain the 440G TZS21UPRH Guardmaster Safety Relay Installation Instructions How to install commission operate and maintain the 440R D22R2 Safety Relays Guardmaster Safety Relay Troubleshooting Guide How to troubleshoot the 440RD22R2 Safety Relays Guardmaster Expansion Relay Installation Instructions How to install commission operate and maintain the 440R EM4R2D Expansion Relay Guardmaster Expansion Relay Troubleshooting Guide How to install commission operate and maintain the 440R EM4R2D Expansion Relay Safety Products Catalog Overview of Safety products product specifications and application examples GuardShield Type 4 User Manual How to install operate and maintain the 440L Safety Light Curtains Next Generation Guardmaster Safety Relays Functional descriptions guidance and wiring for Safety Relays Heavy Duty Guard Interlock Switch Installation Instructions How to install configure commission operate and maintain MT GD2 Interlock Switches Trojan T15 Interlock Switch Installation Instructions How to install confi
11. gure commission operate and maintain Trojan T15 Interlock Switch Safety Interlock Switches Brochure Overview of Interlock Switches Guardmaster Safety Relay SI Installation Instructions How to install configure commission operate and maintain GSR SI Safety Relays Guardmaster Safety Relays Selection Guide Overview of Guardmaster Safety Relays RightSight Photoelectric Sensor Installation Instructions How to install commission operate and maintain 42EF Photoelectric Sensors MSR42 Control Module User Manual How to install commission operate and maintain MSR42 Systems MSR45E Safety Relay Expansion Module User Manual How to install commission operate and maintain the MSR45E Expansion Module SensaGuard Integrated Latch Unique Coded Installation Instructions How to install commission operate and maintain the SensaGuard Touch Button and Guard Installation Instructions How to install and mount the 8007 Touch Button Zero Force Touch Buttons Family Brochure Brochure that describes all 800Z Palm Buttons MSR12T Safety Relays Installation Instructions How to install configure commission operate and maintain the MSR 12T Safety Relays Guardmaster Safety Relay Installation Instructions How to install commission operate and maintain the 440R S12R2 Safety Relays NHP Safety Reference Guide gt Safety Function Documents GSR es 6B 44 Safety Function Document Disclaimer The information contained in this and any related publications is intended a
12. hed Stow Start Circuit 5 NHP Safety Reference Guide gt Safety Function Documents GSR 6B 35 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Configuration Configure the DI he following procedure sets the function Of the device 1 Start configuration overwrite with power off turn rotary switch to position 0 and unit is powered up After power up test PWR LED will flash red 2 Set configuration turn rotary switch to position 27 IN 1 LED blinks new setting NOTE Position is set when PWR LED is solid green B Lock in configuration by cycling unit power 4 Conhguration must be confirmed before operation A white space on face of device is provided to record unit setting Logic 2 L12 OR IN 1 AND IN 2 LOGIC 9 z Cd Configure the EMD The following steps describe timing configuration Both switches need to be set LED B1 indicates position of RANGES and Logic IN of TIME 1 Start configuration overwrite with power off turn rotary switch RANGE to position 0 and power unit up After power up test PWR LED will flash red 2 Set configuration turn rotary switch to desired position both RANGE 3 and TIME 10 B1 and Logic IN LED blink new setting NOTE Position is set when PWR LED is solid green 3 Lock in configuration by cycling
13. it is necessary to confirm the GSR Relay has been wired and configured in accordance with the Installation Instructions NHP Safety Reference Guide gt Safety Function Documents GSR 6B 41 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 GSR Door Monitoring Safety Function Verification and Validation Checklist GENERAL MACHINERY INFORMATION Machine Name Model Number Machine Serial Number Customer Name Test Date Tester Name s Schematic Drawing Number Guardmaster Safety Relay Model Safety Wiring and Relay Configuration Verification Visually inspect the safety relay circuit is wired as documented in the schematics a Visually inspect the safety relay rotary switch settings are correct as documented ae Normal Operation Verification The safety relay system properly responds to all normal Start Stop Estop and Reset Commands Initiate a Start Command Both contactors should energize for a normal machine run condition Verify proper machine status indication and safety relay LED indication Initiate a Stop Command Both contactors should de energize for a normal machine Stop condition Verify proper machine status indication and safety relay LED indication While Running open the monitored guard door Both contactors should de energize and open for a normal safe condition Verify proper machine status indication an
14. oor will remain closed and locked for a predetermined amount time to confirm the hazardous motion is stopped At such time the operator is allowed to unlock the door by applying power to the guard lock using the key switch While the door is open it is monitored to prevent an unexpected start up Upon closing of the door hazardous motion and power to the motor will not resume until a secondary action start button depressed occurs Faults at the door interlock switch wiring terminals or safety controller will be detected before the next safety demand The stop time of the machine must be established such that the hazardous motion must be stopped before the user can reach the hazard The safety function in this example is capable of connecting and interrupting power to motors rated up to 9A 600VAC The safety function will meet the requirements for Category 4 Performance Level e Cat 4 PLe per ISO 13849 1 and SIL3 per IEC 62061 and control reliable operation per ANSI B11 19 Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or Circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic boss Identifies informalion thal is critical for successful IMPORTANT application and understanding of the product ATTENTION identifies information about p
15. r from the coil of interposing relays K3 ae 2 and K4 With K1 K2 K3 and K4 de energized 24V is available at 700 HN123 J the gate release key switch Turning the key switch to the right energizes the solenoid of the TLSZR unlocking the gate The key 700 HN119 Retainer Clip K3 amp K4 2 can be removed when in the right position Once the key is Control Tower Stack Light Pre Assembled 10 cm removed the gate cannot be locked nor the system reset 855EP G24Y3L5 Pole Mount with Cap Gray Housing 24V AC DC Full 1 The gate must be closed the key inserted and turned to the left Voltage Green Steady LED Amber Flashing Light locking the gate before the reset button will function The key cannot be removed when in the Left position Setup and Wiring In this example the hazardous motion has ceased before access to the guarded area can occur In essence there is no danger For detailed information on installing and wiring refer to the product manuals listed in the Additional Resources NHP Safety Reference Guide gt Safety Function Documents GSR 6B 34 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Electrical Schematic Etionand Guardlockino oa Gate Open Gute Untocked ri PPOs is Lig EMD LTI TLSER GT Ae TdT LIP RH CH OR D RZ L LILI KSI GJOFWKMZIMET Left Position External Swiic
16. ractices or circumstances that can lead to personal injury or death property damage or economic ines Attentions help you identify a hazard avoid a hazard and recognize ihe Cons quence equipment for example a drive or molor to alert people that dangerous vollage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or molor to alert people that surfaces may reach dangerous tamperatures SHOCK HAZARD Labels may be on or inside the General Safety Information Contact Rockwell Automation to find out more about our safety risk assessment services This application example is for advanced users and assumes that you are trained and experianced in safety system requirements IMPORTANT ATTENTION risk assessment should be performed to make sure all task and hazard combinations have been identified and addressed The risk assessment may require additional circuitry to reduce the risk to a tolerable level Safety circuits must lake into consideration safety distance calculations which are not part of the scope of this document Functional Safety Description In this application example the access gate is locked during normal operation The GSR DI uses pulse checking to monitor the E Stop for actuation and faults The TLSZR monitors itself for faults lock status and gate actuation When a fault is detected or the gate is unlocked or open the TLSZR turns off both its OSSD outp
17. s a guide only Every care has been taken to ensure that the information given is accurate at time of publication Neither NHP nor any of the manufacturers portrayed in this and any related publications accept responsibility for any errors or omissions contained therein nor any misapplications resulting from such errors or omissions Risk assessments should be conducted by authorized persons The purchaser and installer are responsible for ensuring the safety system s incorporating these products complies with all current regulations and applicable standards Products are subject to change without notice and may differ from any illustration s provided All products offered for sale are subject to NHP standard Conditions of Sale a copy of which is available on application NHP Safety Reference Guide gt Safety Function Documents GSR 6B 45
18. s are correct as documented O Normal Operation Verification The safety relay system properly responds to all normal Start Stop Estop and Reset Commands Initiate a Start Command Both contactors should energize for a normal machine run condition Verify proper machine status indication and safety relay LED indication Initiate a Stop Command Both contactors should de energize for a normal machine Stop condition Verify proper machine status indication and safety relay LED indication While Running press the E Stop pushbutton Both contactors should de energize and open for a normal safe condition Verify proper machine status indication and safety relay LED indication Repeat for all E Stop pushbuttons While Stopped press the E Stop pushbutton initiate a Start Command Both contactors should remain M de energized and open for a normal safe condition Verify proper machine status indication and safety relay LED indication Repeat for all E Stop pushbuttons Initiate Reset Command Both contactors should remain de energized Verify proper machine status indication and safety relay LED indication Abnormal Operation Verification The Safety Relay system properly responds to all foreseeable faults with corresponding diagnostics E Stop Input Tests While Running remove the Channel 1 wire from the safety relay Both contactors should de energize Verify proper machine status indication and safety relay LED indication Repeat for Channel
19. safety functions on demand stopping the hazardous motion The system cannot be reset once the safety function has been performed until the fault has been corrected Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or
20. unit power 4 Configuration must be confirmed before operation A white space on face of device is provided to record unit setting Set for 30 second OFF Delay RANGE i XJ 6 5 TIME o 3 es Ty Cres 4 5 7 5 NHP Safety Reference Guide gt Safety Function Documents GSR 6B 36 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Calculation of the Performance Level When configured and installed properly the two Safety Functions of this safety system prevention of access to hazardous motion in the guarded area and emergency stop of hazardous motion initiated by an E Stop button can achieve a Safety rating of PLe Cat 4 according to EN ISO 13849 1 2008 As calculated using the SISTEMA tool Door Monitoring and Locking Project Project Ww IFA rE d te r Piscertond moen alter ESropedhe there ma be oho permi Prevention of acces after Stony efaa here ia be eon Ge eed di daryo Pe ar iT Prevention of access to hazardous motion in the guarded area Safety Function Safety function Documentation Ps F Subsystem Emergency stop of hazardous motion initiated by an E Stop button Safety Function Safety function NHP Safety Reference Guide gt Safety Function Documents GSR 6B 37 Safety Function Documents Door Locking and Monitoring Pro
21. uts The GSR DI de energizes the redundant safety contactors K1 and K2 removing power to the hazardous motion upon actuation of the E Stop or the TLSZR turning off its OSSD outputs The hazardous motion coasts to a stop in a maximum of 20 seconds Stop Category 0 The EMD delays power to the access gate release key switch while the hazardous motion is running in normal operation and for 30 seconds after power is removed from the hazardous motion in response to actuation of the E Stop Once power is provided to the gate release key switch via K1 K2 and K3 NC aux contacts turning the key to the right energizes the solenoid unlocking the TLSZR GD2 and the gate may be opened The operator removes the key so that the gate cannot be locked nor the system reset with the operator in the hazardous area The system cannot be reset until the gate is closed and locked by inserting the key and turning it to the left and the E Stop is released The Reset button must be pressed for more than a quarter second and less than three seconds A shorter press will be ignored a longer press will be ignored NHP Safety Reference Guide gt Safety Function Documents GSR 6B 33 Safety Function Documents Door Locking and Monitoring Products TLSZR GD2 Guardmaster Safety Relays Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Bill of Material System Overview The GSR DI monitors the E Stop by running its 11 and S21 pulsed outputs through th
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