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Spec Sheet - The Reynolds Company

1. rimer On Dela EN 4 Preset S000 Accum 17 i Dual Channel input Stop pcs Safety interiock Safety Function EMERGENCY STOP input Type EQUIVALENT ACTIVE HH Discrepancy Time Maec 250 Rester Type AUTOMATE Cold Start Type ALITOMATIC Channel A 1781E5 1 PTOGData 1 AENT 1 1 Pr SDatA Dual Channel Input Monib r DM ately Function USER DEFINED Input EQUI ALENT ACTIVE HGH Discrepancy Time 250 Channel AENT TAO 1 1 input Status AENT 1 LCombinedinputStatus 1 Reset AENT 1 1 PSData Channel B ATHESIPOTData 1 input 17S ES CombinecinputStatus 1 Gate_Lock_contacts Channel B AENT VL POSDeta 0 Iam P AENT 11 PtOdData ont Safety Fderock O1 Gael Gate Lock contacts O1 Contactos FP safety enable safety oua enable Configurable Recdundant Output CRORIT Safety Lontecborg Feedback Type HEGATIVE Feedback Resection Times Mec 25 0 Actuate zajety ipu enable Feedback 1 AENT 1 LPtOTDaA 1 Feachack 2 AENT 1 1 Pt 7Dat input Status AENT 1 LCombinedinpulstatus 1 Culput Status AENT 2L CombinedOuipulStalus 1 Reset AENT LPtOSDAMS 0 Safety Contactors O Sately_Contactors O2 If you wish to use software to programmatically cycle Channel A and Channel B on the DCSTL the following code is an example of how to
2. THINK SOME ET m WE a8 m lt d i i Ld ina Lo LL ob Safety Function Door Locking and Monitoring Products TLS3 GD2 GuardLogix Controller POINT Guard Safety I O Modules Safety Rating PLe Cat 4 to EN ISO 138491 2008 Rockwell Allen Bradley Rockwell Software Automation Table of Contents Introduction Important User Information Safety Function Realization General Safety Information Setup and Wiring Configuration Programming Falling Edge Reset Calculation of the Performance Level Verification and Validation Plan Additional Resources 15 19 19 21 24 Introduction This Safety Function application note explains how to wire configure and program a Compact GuardLogix controller and POINT Guard I O module to monitor and lock a TLS3 GD2 interlock switch mounted on a door If the gate is opened or unlocked or a fault is detected in the monitoring circuit the GuardLogix controller de energizes the final control device in this case a redundant pair of 100S contactors This example uses a Compact GuardLogix controller but is applicable to any GuardLogix controller This example uses a TLS3 GD2 interlock switch but is applicable to power to release locking switches with at least 2 N C door contacts and at least one N C lock contact Power to lock switches can utilize this document with one simp
3. Verify proper machine status indication and RSLogix 5000 safety application program indication While Running attempt to open the guard door The door should remain closed and locked Both contactors should remain energized and closed for a normal safe condition Verify proper machine status indication and RSLogix 5000 safety application program indication Repeat for all guard doors While Stopped attempt to open the guard door The door should be unlocked and able to be opened Both contactors should remain de energized and open for a normal safe condition Verify proper machine status indication and RSLogix 5000 safety application program 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 RSLogix 5000 safety application program indication Repeat for all guard doors Initiate Reset Command Both contactors should remain de energized Verify proper machine status indication and RSLogix 5000 safety application program indication 23 Abnormal Operation Verification The GuardLogix safety system properly responds to all foreseeable faults with corresponding diagnostics Door Monitoring and Lock Input Tests While Running remove the Door Monitor Channel 1 wire from the Safety 1 0 Both contactors should 1 de energize Verify proper machine status indicatio
4. I O Modules Follow these steps 1 RSLogix 5000 software create a new project 2 Inthe Controller Organizer add the 1768 ENBT module to the 1768 Bus 3 Select the 1768 ENBT module and click OK 4 Name the module type its IP address and click OK We used 192 168 1 8 for this application example Yours may be different ew Module 5 Add the 1734 AENT adapter by right clicking the 1768 ENBT module in the Controller Organizer and choosing New Module 9 68 1768 Bus 8 1 1768 ENBT A peer erm 2Port Twisted Pair Media 1738 Ethernet Adapter Twisted Pair Media 1738 Ethernet Adapter 2 Port Twisted Pair Media 1756 10 100 Mbps Ethernet Bridge Fiber Media 1756 10 100 Mbos Ethernet Bridge Twisted Pair Media Allen amp radey 1756 10 100 Mbps Ethernet Bridge 2 Port Twisted Pair Allen Gradiey 1756 10 100 Mbps Ethernet Bridge 2 Port Twisted Pair Allen Bradiey 1756 10 100 Mbps Ethernet Bridge Trasted Par Media Allen Bradley 1756 Ethernet Communicaton Interface Allen Bradey 1756 Ethernet Communicaton Interface Alen Bradiey 1756 10 100 Mbps Ethernet Bridge w Enhanced Web Serv aed 17 11 7 Name the module type its IP address and click OK We used 192 168 1 11 for this application example Yours may be different 8 Click Change 9 Set the Chassis Size as 3 for the 1734 AENT adapter and click OK Chassis size is the number of mo
5. accomplish this Whenever the lock feedback goes LO for one scan Channel A and Channel B are logically dropped out to satisfy the DCSTL requirements to cycle the gate For the rest of the time the two door monitoring contacts drive the state of Channel A and Channel B 18 Gate Lock contacts C1 ansi OpenGateSimulation AENT 1 LPt00Osta Channel c gt 1 1 101 Channel DCSTL Dual Channel Input Stop Vath Test And Lock DCSTL Gate Ot Safety Function SAFETY GATE input Type EQUIVALENT ACTIVE HIGH TC9 Discrepancy Time 250 Restart Type AUTOMATIC FULC2 Cold Start Type AUTOMATIC Channel A ChannelA FP 0 Channel Channel 0 Test Request test request 1 Unlock Request unlock request Q4 Lock Feedback Gate Lock contacts O1 ia Hazard Stopped hazard stopped 0 Input Status AENT 1 CombinedinputStatus 1 Reset AENT 1 1 PtOSData 04 Gate ULC AENT 2 O PtO7Data Pe ee he Jo lll BA 19 Falling Edge Reset ISO 13849 1 stipulates that instruction reset functions must occur on falling edge signals To comply with this requirement a One Shot Falling instruction is used on the reset rung Then the OSF instruction Output Bit tag is used as the reset bit for the Output Enable rung AENT 1 1 Pi4Diate OSF j One Shot Falling Storage B Ouiput Reset Reset Safety QGale O1 Lock QI Safely Contactors FP safety oufp
6. the safety contactors and 5 seconds later the hazard stopped tag is set HI This causes the DCSTL instruction to set the ULC output which energizes output 7 and unlocks the gate Your application needs to determine the proper way to generate the hazard stopped tag There are two 2 lock monitoring contacts on the TLS3 GD2 switch yet there is only one 1 lock feedback tag required for the DCSTL instruction The DCM instruction is used to monitor both lock contacts and its output used for the DCSTL lock feedback tag The DCSTL DCM and DCS instructions monitor their respective dual channel inputs for consistency Equivalent Active High and detect faults when the inconsistency is detected for longer than the configured Discrepancy Time ms The automatic restart type allows the DCSTL and DCS outputs O1 to reset automatically after a demand The manual action typically required for safety is provided in rung 6 to reset the safety output enable 16 Input Status typically represents the channel status of the two input channels In this example the Combined Input Status bit goes LO if any of the 8 input channels on the 1734 IB8S module has a fault In this example the DCSTL DCM and DCS reset acts as a fault reset Even when configured for automatic restart a reset is required to recover from a fault The outputs O1 of the DCSTL DCM and DCSD instructions are used as a safety interlock in the seal in rung to dr
7. unlock the door by applying power to the guard lock While the door is open it is monitored to confirm 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 gt IMPORTANT gt gt 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 loss Identifies information that is critical for successful application and understanding of the product ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and rec
8. GuardLogix System Safety Reference Manual 1756 RM093 Verify the safety application program has been designed in accordance with the GuardLogix Application Instruction Safety Reference Manual 1756 RM095 Visually inspect the safety system network and 1 0 is wired as documented in the schematics Visually inspect the RSLogix 5000 program to verify that the safety system network and 1 0 module configuration is configured as documented 1 2 3 4 Visually inspect the RSLogix 5000 application program to verify suitable safety certified instructions 5 are utilized The logic is readable understandable and testable with the aid of clear comments All input devices are qualified by cycling their respective actuators Monitor the status in the RSLogix 5000 Controller Tags window All output devices are qualified by cycling their respective actuators Monitor the status in the RSLogix 5000 Controller Tags window Normal Operation Verification The Safety Relay system properly responds to all normal Start Stop Estop Lock and Reset Commands Initiate a Start Command Both contactors should energize for a normal machine run condition Verify proper machine status indication and RSLogix 5000 safety application program indication Changes Modifications Initiate a Stop Command Both contactors should de energize immediately for a normal machine Stop condition After the preset time delay verify the door unlocks
9. POINT Guard Safety Output Module 1783 US05T Stratix 2000 Unmanaged Ethernet Switch Setup and Wiring For detailed information on installing and wiring refer to the product manuals listed in the Additional Resources System Overview The 1734 IB8S input module monitors two door channels and two lock channels of the TLS3 GD2 The 1734 IB8S module can source the 24VDC for all these channels to dynamically test the signal wiring for shorts to 24VDC and channel to channel shorts If a fault occurs either or both channels will be set LO and the controller will react by dropping out the safety contactors Only after the fault is cleared and the gate is cycled will the function block reset Shorts to OV DC and wire off will be seen as an open circuit by the 1734 IB8S input module and the controller will react by dropping out the safety contactors If the inputs remain discrepant for longer than the discrepancy time then the function blocks in the controller safety task will declare a fault Only after the fault is cleared and the gate is cycled will the function block reset The final control device in this case is a pair of 100S safety contactors K1 and K2 The contactors are controlled by a 1734 OBS safety output module The contactors are wired in a redundant series configuration A feedback circuit is wired through the N O contacts and back to an input on the 1734 IB8S module to monitor the contactors for proper operation The contactors c
10. ailure CCF are quantified using the scoring process outlined in Annex F of ISO 13849 1 For the purposes of the PL calculation the required score of 65 needed to fulfill the CCF requirement is considered to be met The complete CCF scoring process must be done when implementing this example TLS3 GD2 Interlock Switch 100 High 99 High 65 fulfilled 21 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 ch
11. air of safety outputs on a Safety Output module 501 The I O module is connected via CIP Safety over an EtherNet IP network to the Safety Controller SC1 The safety code in SC1 monitors the status of the gate using the pre certified safety instruction Dual Channel Input Stop with Test and Lock DCSTL When all safety input interlocks are satisfied no faults are detected and the reset push button is pressed a second certified function block called Configurable Redundant Output CROUT controls and monitors feedback for a pair of 100S redundant contactors In summary when a demand is placed on a safety interlock the contactors drop out Five seconds later the gate unlocks When the door is closed and locked and the reset button is pressed the contactors are energized Bill of Material Catalog Number Description Quantity 440G 127181 TLS3 GD2 Power to Release Safety Interlock Switch 800F Reset Push Button Metal Guarded Blue R SUD SOITAN Metal Latch Mount 1 N O Contact S Standard 100S C09ZJ23C Bulletin 100S C Safety Contactors 800F Mushroom Operators Twist to 800FP MT44PX02 Release 40mm Round Plastic Type 4 4X 13 66 Red 2 N C Contacts CompactLogix EtherNet IP Bridge Module rper NEN Power Supply 120 240 VAC Input 3 5 A 24V DC Right End Cap Terminator 24V DC Ethernet Adapter Module Base with Removable IEC Screw Terminals POINT Guard Safety Input Module 1734 0885
12. annot restart if the feedback circuit is not in the correct state The system has individual reset buttons for resetting faults and safety outputs Note that the reset buttons and the contactor feedback circuit are all wired to the 1734 IB8S module in this example This is not required for functional safety These three 3 inputs could be wired to a standard input module In this example the gate solenoid is controlled by a safety output This is not required for functional safety The solenoid could be controlled by a standard output If the solenoid were to fault LO the gate will never unlock a rather safe state If the solenoid were to fault HI the gate will unlock but unless the motion stopped input is HI the DCSTL instruction in the safety task will declare a fault and drop out its output For these reasons the solenoid is not a part of the safety function Electrical Schematic 24Vdec Ber Safety Interlock that requests unlock not shown Og Q4 e COM e COM e eg OF Configuration The Compact GuardLogix controller is configured by using RSLogix 5000 software version 17 or later You must create a new project and add the I O modules Then configure the I O modules for the correct input and output types A detailed description of each step is beyond the scope of this document Knowledge of the RSLogix programming environment is assumed Configure the Controller and Add
13. dules that will be inserted in the chassis The 1734 AENT adapter is considered to be in slot 0 so for one input and one output module the chassis size is 3 Module Definition 12 10 In the Controller Organizer right click the 1734 AENT adapter and choose New Module 12 In the New Module dialog box name the device IB8S and click Change Sew Module General Connection Salety Module Info Input Configueation Test Output Type 17344885 8 Point 24V DC Sink Inpul Vendor Allen Bradey Patent AENT Name 885 Module Humber Description 040 4 27 2012 250 3062 PM Moheban Sene A Change Elector Keying Compatible Module Configured By Tris Controller Staur Creating Cancel 13 When the Module Definition dialog box opens change the Output Data to None and verify the Input Status is Combined Status Power and click OK Setting the output data to None means that you cannot use the Test Outputs as standard outputs and we are not doing that in this example Note this saves one 1 controller connection because we are only using the input connection 13 Module Definition 14 Close the Module Properties dialog box by clicking OK 15 Repeat steps 10 14 to add the 1734 OB8S safety output module Name the module 85 Note this module will be in slot 2 and select Combin
14. ecklist is typically used to document the validation of the safety control system Validation of software development is a process in which similar methodologies and techniques that are used in hardware development are deployed Faults created through poor software development process and procedure are systemic in nature rather than faults associated with hardware which are considered as random Prior to validating the GuardLogix Safety System it is necessary to confirm the safety system and safety application program have been designed in accordance with the GuardLogix System Safety Reference Manual 1756 RM093 the GuardLogix Application Instruction Safety Reference Manual 1756 95 22 GuardLogix Door Monitoring with Safety Lock 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 Controller Name Safety Signature ID Safety Network Number s RSLogix5000 Software Version Safety Control System Modules GuardLogix Modules Firmware Version GuardLogix Safety Controller 1768 1435 CompactLogix Ethernet Bridge 1768 ENBT POINT 1 0 Ethernet Adapter 1734 AENT POINT 1 0 Input Modules 1734 1 85 0 Output Modules 1734 0885 GuardLogix Safety System Configuration and Wiring Verification Verify the safety system has been designed in accordance with the
15. ed Status Readback Power for Input Status definition I Module Definition 14 Configure the I O Modules Follow these steps to configure the POINT Guard I O modules 1 In the Controller Organizer right click the 1734 IB8S module and choose Properties 2 Click Test Output and configure the module as shown TO and T1 are being used to pulse test the TLS3 GD2 channels T2 is being used to pulse test the contactor feedback circuit 3 Click Input Configuration and configure the module as shown Inputs 0 1 are the TLS3 GD2 door monitoring contacts Recall that inputs 0 1 are being sourced from test outputs 0 1 Inputs 2 3 are the lock monitoring contacts They are also being sourced from test outputs 0 1 Inputs 4 5 are the reset buttons Input 7 is the contactor monitoring circuit Recall that input 7 is being sourced from Test Output 2 Note that there really is no difference when an input channel is configured for safety or standard It is used more for documentation B Module Properties ABST 1 1734 1885 1 1 Safety Pulse Tes Pulse Test 2 Satety Pulina Cnt Pulse Tres 0 af Not Lined f Pulse Test 25 ERES s 19 Enoe Latch Tine 10002 4 Click OK 5 Inthe Controller Organizer right click the 1734 OB8S module and choose Properties 15 6 Click Output Configuration and configure the module a
16. ive the output enable tag If any of the three 3 outputs drop out so does the output enable and it will remain off until a manual reset action is carried out The Configurable Redundant Output CROUT instruction controls and monitors redundant outputs Essentially this instruction verifies that feedback follows the safety outputs appropriately For the negative feedback used in this example if the outputs are HI the feedback should be LO and vice versa In this example the feedback has 500ms to change to the proper State Since only a single feedback circuit is being used the feedback tag is used for both Feedback 1 and 2 The two 2 output tags from the CROUT instruction are used to drive the contactor outputs on the 1734 OB8S module AK SIL Dual Channel input Stop Wilh Test And Lock DESIL Gae Safety Function SAFETY GATE Type EQUIVALENT ACTIVE HGH TE Discrepancy Tine htec 250 Reetart AUTOMATIC ULC Coi Seri Type AUTOMATIC Channel 11 Priest j 1 Channel B MENT 1 1 Phi Data 1 Pieces lesi renees Request uniock Lock Feedback Gale Lock contacts Oi Hazard Stopped hazard stopped inpul Status AENT 1 1 Combinedinpad status Reset SENT 11 PlOSDta Gate ULC AENT 2 0 POT Date Safety interiock C unlock request ARENT 2OPtOUDaS AENT SO Daia
17. le change in the ladder logic This example assumes that the jumpers in the TLS3 GD2 switch have been removed and that separate feedback is available for both the lock and the door The SISTEMA calculations shown later in this document would have to be re calculated using the actual products 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 diagra
18. ms No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or 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 required performance level 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 is Category 4 PLe From Risk Assessment ISO 12100 Identification of safety functions opecification of characteristics of each safety function Determination of required PL PLr for each safety function To Realization and PL Evaluation Guard Locking Interlock Safety Function The safety function is the removal of power from the hazard when the safety system detects that the door has been opened or that the lock has been energized Safety Function Requirements Access to hazardous motion is prevented by using an interlocked guard door with guard locking Once motor power has been removed the guard door 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
19. n and RSLogix 5000 safety application program indication Verify unable to reset and restart with fault Restore Channel 1 and repeat for Channel 2 While Running short the Door Monitor Channel 1 of the Safety 1 0 to 24VDC Both contactors should 2 de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify unable to reset and restart with fault Restore Channel 1 and repeat for Channel 2 While Running short the Door Monitor Channel 1 of the Safety 1 0 to OVDC Both contactors should 3 de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify unable to reset and restart with fault Restore Channel 1 and repeat for Channel 2 While Running short the Door Monitor Channels 1 amp 2 of the Safety 1 0 Both contactors should 4 de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify unable to reset and restart with fault Restore Channel 1 amp 2 wiring While Running short Channel 1 to Test Source 1 of the Safety 1 0 Open the guard door Both contactors 5 should de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify unable to reset and restart with fault Restore Channel 1 and repeat for Channel 2 While Running remove the Lock Monitor Channel 1 wire from the Safety 1 0 Both contactors should de energize Ve
20. ognize the consequence SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures General Safety Information Contact Rockwell Automation to find out more about our safety risk assessment services IMPORTANT This application example is for advanced users and assumes that you are trained and experienced in safety system requirements ATTENTION A 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 take into consideration safety distance calculations which are not part of the scope of this document Functional Safety Description In this example unlock is requested by placing a demand on a safety input interlock The demand on the safety input drops out the redundant contactors and the motion coasts to a stop After a five second delay to allow the motion to completely stop the gate unlocks The TLS3 GD2 switch is wired to two pairs of safety inputs on a Safety Input module SI1 One pair is the lock monitoring contacts and the other is the door monitoring contacts The safety contactors K1 amp K2 are connected to a p
21. rify proper machine status indication and RSLogix 5000 safety application program indication Verify unable to reset and restart with fault Restore Channel 1 and repeat for Channel 2 While Running short the Lock Monitor Channel 1 of the Safety 1 0 to 24VDC Both contactors should 7 de energize Verify proper machine status indication RSLogix 5000 safety application program indication Verify unable to reset and restart with fault Restore Channel 1 and repeat for Channel 2 While Running short the Lock Monitor Channel 1 of the Safety 1 0 to OVDC Both contactors should de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify unable to reset and restart with fault Restore Channel 1 and repeat for Channel 2 While Running short the Lock Monitor Channel 1 amp 2 of the Safety 1 0 Both contactors should de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify unable to reset and restart with fault Restore Channel 1 amp 2 wiring While Running remove the Ethernet network connection between the Safety 1 0 and the controller All contactors should de energize Verify proper machine status indication and 1 0 Connection Status in the RSLogix 5000 safety application program Restore the Safety 1 0 module network connection and allow time to reestablish communication 2 Verify the Connection Status Bit in the RSLogi
22. s shown The electromechanical coil on the contactor outputs 0 1 can be pulse tested without reacting to the brief LO pulse Output 7 is the TLS3 GD2 locking solenoid BB Module Properties 1734 0885 1 1 Genma Correction Madule into Output i 2 zl zi Output Emor Latch Tee 10002 m 7 Click OK Programming The Dual Channel Input Stop with Test and Lock DCSTL instruction monitors and locks dual channel safety devices whose main function is to stop a machine safely For example a safety gate with locking solenoid When the unlock request goes HI the DCSTL instruction waits for the Hazard Stopped input to go HI and then turns on the ULC unlock command output At the same time the output O1 goes LO to indicate that the gate is no longer protecting the hazard The Lock Feedback should go LO indicating the gate is indeed unlocked The operator can now open the gate Note that the DCSTL requires that the door monitors Channel A and Channel B cycle at this time or a fault occurs when restart is attempted This cycle can be done by opening or closing the gate or can be done in software as shown later in this section In this example the unlock request is generated by placing a demand on the safety interlock being controlled by the DCS instruction For your application all that is required is that unlock request be set LO The demand on the safety interlock drops out
23. the products used in this example refer to these resources Resource Compact GuardLogix Controllers User Manual Publication 1768 UM002 POINT Guard 1 0 Safety Modules Installation and User Manual Publication 1734 UM013 GuardLogix Controller Systems Safety Reference Manual Publication 1756 RM093 GuardLogix Safety Application Instruction Set Reference Manual Publication 1756 RM095 Safety Accelerator Toolkit for GuardLogix Systems Quick Start Guide Publication IASIMP QS005 Safety Products Catalog Description Provides information on configuring operating and maintaining Compact GuardLogix controllers Provides information on installing configuring and operating POINT Guard 1 0 Modules Contains detailed requirements for achieving and maintaining safety ratings with the GuardLogix controller system Provides detailed information on the GuardLogix Safety Application Instruction Set Provides a step by step guide to using the design programming and diagnostic tools in the Safety Accelerator Toolkit You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative For More Information on Safety Function Capabilities visit discover rockwellautomation com safety Rockwell Automation Allen Bradley GuardLogix RSLogix 5000 CompactLogix Strati
24. ul enable 3 safety oupi enable Calculation of the Performance Level When configured correctly this Door Monitoring and Locking safety function can achieve a safety rating of PLe Cat 4 according to EN ISO 13849 1 2008 The Functional Safety Specifications of the project call for a Performance Level on PLd minimum and a structure of Cat 3 minimum A PFHd of less than 1 0 E 06 for the overall safety function is required for PLd The individual subsystem values are shown below Safety function IFA Documentation Pir Subsystem w 5B POINT Gusid I O 17244885 T 3ME 10 FK fell ina FRA eei ae 4 C New 58 POINT Guard 1 0 1734 0885 ii 0 PAY andina 4 w PLC Compact Gusdlog 1768 21E 10 T w 5B Contactors 1005 e 2478 5 53 High 100 High hited TLS GD2 Interlock Sich zATES 33 High 1060 High overall safety function value is shown below Safety function W IFA PL arms Permane Level PF rss The Guard Door Monitoring and Locking safety function can be modeled as shown in the following safety related block diagram 20 Calculations are based on 1 operation of the safety guard door per hour therefore 8 760 operations of contactors per year The measures against Common Cause F
25. x 2000 and POINT Guard I O are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication SAFETY AT061B EN E January 2013 Supersedes Publication SAFETY ATO61A EN E October 2012 Copyright 2013 Rockwell Automation Inc All Rights Reserved
26. x 5000 safety application program Changes Modifications Repeat for all Safety 1 0 connections While Running switch the controller out of Run Mode All contactors should de energize Return key switch back to Run Mode all contactors should remain de energized Verify proper machine status indication and RSLogix 5000 safety application program indication Changes Modifications Initiate a Start Command Both contactors should energize for a normal machine run condition Verify proper machine status indication and RSLogix 5000 safety application program indication While Running remove the contactor feedback from the Safety 1 0 All contactors should remain energized Initiate a Stop command and attempt a Reset command The system should not Restart or Reset Verify proper machine status indication and RSLogix 5000 safety application program indication While Running short the contactor feedback to the Safety 1 0 All contactors should remain energized 3 Initiate a Stop command and attempt a Reset command The system should not Restart or Reset Verify proper machine status indication and RSLogix 5000 safety application program indication While Stopped remove the safety output to the door lock The door should remain locked and all contactors should remain de energized Verify proper machine status indication and RSLogix 5000 safety application program indication Additional Resources 24 For more information about

Spec Sheet - The Reynolds Company

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