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1. Motors create some of the most common hazards on a machine Removal of torque producing power is the only method of safe control for motors Dual contactors are the traditional method for safe removal of motor power Contactors must be oversized to increase life and reduce chances of welding Lots of additional wiring PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 23 Rockwell Automation Drive Safety External Safe Torque off Maximum amount of panel space required Multiple output contactors required for Cat 3 amp 4 Maximum amount of installation down time Tedious wiring Work increases with desired Category level Contactor welding may occur Lowest level of system reliability No Diagnostics equipment required 1769 L30ER CompactLogix 1 MB EtherNet IP Controller 1769 1016 CompactLogix 16 Pt 24VDC DI Module 1 69 OB8 CompactLogix 8 Pt 24VDC D O Module 1 69 OF4VI CompactLogix 4 Pt AJO VoltageModule 3 25A D6P0N104 3HP PowerFlex 523 AC Drive 6 100S C12D14BC 12 A Safety Contactor 3 440R D22R2 Guardmaster Dual Input Safety Relay 90 control terminations for contactors 4 safety input terminations 18 I O terminations for drives at 25 termination 36 extra power terminations for contactors Contro wiring Labor M PUBLIC Copyright 2014 Rockwell Automation Inc All Righ2. Allen Bradley Guedmartet Lat eu 1 ML ts t PP T m5 Sinn es P Ww E u SITE NR si i EN n ca Safety related control systems for machinery Principles standards and implementation SAFEBOOK 4 ell Automation V PUBLIC I Copyright 2014 Rockwell Automation Inc All Rights Reserved 52 Rockwell Automation Machine Safety Resources ANSI American National Standards Institute VVYVYV ansi org Explanation and Interpretation of Standards trom Rockwell Automation WWW ab com Product Catalogs Safety Products Principles Standards and Implementation Standards Information on Rockwell Automation Safety Solutions and Services www rockwellautomation com Solutions amp Services Safety Solutions Safety Functions User Manuals Safebook 4 and more literature rockwellautomation com Talk to Your Distributor Specialists and Rockwell Automation Specialists J PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 53
3. TN THINK SOLVE T60 Integrated Safety with Kinetix and PowerFlex drives g PUBLIC Rockwell Allen Bradley Rockwell Software Automation PUBLIC 5058 CO900G Copyright 2014 Rockwell Automation Inc All Rights Reserved Rockwell Automation Introduction Machine Safety Lifecycle Drive Safety Motor Safety Tools amp Services Copyright 2014 Rockwell Automation Inc All Rights Reserved Rockwell Automation Definition of Safety Safety Freedom from unacceptable risk Functional Safety Part of the safety of the machine and the machine control system which depends on the correct functioning of the safety related electrical control system other technology safety related systems external risk reduction facilities Copyright 2014 Rockwell Automation Inc All Rights Reserved 3 Rockwell Automation Evolution of Safety As our relationship to machines has changed so has society s emphasis for machine safety Properly designed safety never needs to be bypassed Lock Out Tag Out is still relevant but a alternative methods can boost KE E production without compromising safety Vy PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 4 Rockwell Automation Machine Safety Lifecycle Organizations Standards amp Guidelines Safety Org Stds amp Guidelines
4. 1 Risk Assessment 5 Manage Change amp Improve 4 Installation y Lae B F amp Validation AM q 3 Mitigation Design amp Verification PUBLIC I I l 5 Copyright 2014 Rockwell Automation Inc All Rights Reserved 5 i i i d IEC SO oF SY gt d d ia 9 ci EC E w X Wy B GIA A TUV UL c d wie Copyright 2014 Rockwell Automation Inc All Rights Reserved 6 Rockwell Automation Which Standards Apply Geographic Constraints Where are you and where will the machine system be located f you are an OEM be sure you ask your customer if they have any corporate safety requirements For the US You must meet OSHA requirements OSHA recognizes consensus standards NFPA 79 ANSI 2244 1 etc Internationally Use ISO and IEC standards Good news Most NFPA and ANSI standards can be related back to ISO and IEC standards Strong safety circuit design is consistent through all of the Standards though the terminology changes Copyright 2014 Rockwell Automation Inc All Rights Reserved Rockwell Automation Organization of Standards All functional safety standards are used to Three tier Structure of International safety Standards demonstrate compliance to global regional ms and some
5. 0 u lS Fowertzx 3 Ime aisle Bin ini Sh innis U UUO an dh nt Geneva z iss pine Sp Module lato emet Poolaoci Matwod nsociated Pomes Coghailresa Genes Conrec EJ me Sync Module info Meet Stocoi Pod Corhguraon Memik amp avocialec ses Pot Vis Conserved Connection Nequerted Packet Conmecton Reaction Mar Ocas eer ire Network Due ma Integrated Motion and Safety configuration is identical in Logix Designer E PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 41 Rockwell Automation Logix Designer Configuration Add Safety drive to I O for application Module Definition Ba VO Configuration 5 1756 Backplane 1756 A7 Revision Ka 0 1756 L72S Safety Electronic Keying 1 1756 L7SP Safety Partit Select Connection Connection E B 3 1756 EN3TR Etherg Type mme TREE Ek Ethernet Verify Power Rating on Conn Safety only B 1756 ENSTR Etherenet Tag structure created for easy application monitoring Cancel 4 Scope WusSafety Show All Tags U ard WO WO U Dalm zs uje i U i U 8 op i Drive l_Motion_Safety 30 Reset x Complete and easy configuration for safety with Logix Designer PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved sale Torque oft Certification Kinetix 5500 and PowerFlex 52
6. Accelerator Toolkit Overview Rockwell Automation Details the integration of multiple safety functions Includes importable wiring diagrams logic and HMI files Designed for use with programmable safety controllers such as GuardLogix and SmartGuard 600 Available on DVD or as a download from the web iii TIT Ese 3 d imm u gt l loctin m nd I Safety Accelerator Toolkit re union il um tiae PETE II Emp 1 p i E PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 50 Rockwell Automation Rockwell Automation Safety Services Safety System Implementation Safety Circuit Design amp Review Safety Distance Calculations Control Reliable Safety Designs Safety Integration Services Safety System Requirements Consulting Services e Safety Summits to Drive Process LOTO Consulting Safety System Validation Validation Testing Documentation Conformity Audits Risk Hazard Assessment e Conformance Audits Risk Mitigation Consulting Hazard Assessment Risk Assessment e Safety Audit SIL Category Calculations Maintain amp Improve Safety System raining Services Preventive Maintenance Programs LOTO Consulting Vy PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 51 Rockwell Automation Safebook 4
7. C pu This Safety Output Logic Example controls the Network Safe Torque Off outputs of a Kinetix 5500 2198 Hxxx ERS2 drive The CROUT instruction is not needed since only a single output is need to be energized and diagnostics are already built into the module to go to safe state in the event of a fault Cmd Zone OutputEnable Drive 02 SO SafeTorqueOff Drive 02 Sl TorqueDisabled Drive 02 SI ResetRequired Drive 02 SO Reset Drive 02 Sl RunMode Drive 02 Sl ConnectionFaulted Drive 02 Sl SafetyFault Drive 02 SO SafeTorqueOff m s e E SafetyTask 5 3 Zonel nl e e Machine safety is configured in the safety task of Bl Inputs Blog Logix Designer mm Safety connections made through EtherNet IP E gt MainRoutine input e No additional wiring is required E Logic IE Outputs Safety Output Rung This Safety Output Logic Example controls the Network Safe Torque Off outputs of a Kinetix 5500 2198 Hxxx ERS2 drive The CROUT instruction is not needed since only a single output is need to be energized and diagnostics are already built into the module to go to safe state in the event of a fault Cmd_Zone_OutputEnable Drive 03 SO SafeTorqueOff Drive 03 SI TorqueDisabled Drive 03 SI ResetRequired Drive 03 SO Reset Drive 03 Sl RunMode Drive 03 Sl ConnectionFaulted Drive 03 SlI SafetyFault Drive 03 SO SafeTorqueOff done 2 This Safety Output Logic Example controls the Network Safe Torque Off outputs of a Kinetix
8. Rockwell Automation Inc All Rights Reserved 13 Rockwell Automation Performing Risk Assessments How TT GL C li in EL M Chances How Bad How Often E Frequenc Important to remember What is the operating mode Who is interacting with the machine When in the lifecycle is this activity What has already been done for protection Copyright 2014 Rockwell Automation Inc All Rights Reserved 14 Rockwell Automation Functional Requirements Basic Concepts Functional Safety Specifications outline how a safety system responds from system inputs to control system outputs Functional safety specifications should address the following items All modes of operation Auto Manual Jog All machine interactions Jam removal Cleaning Set up Adjustment Speed control and monitoring Safe speed Safe stop etc Drive control Braking Accel Decel Special safety functions Blanking Muting Zone Control Keep them as simple as possible M Copyright 2014 Rockwell Automation Inc All Rights Reserved 15 Functional Requirements Basic Concepts Rockwell Automation Safety functions should always be written as Input Interlocks Sensors E stops Light Curtains Logic Safety Logic Relays Safety Controllers Output Contactors Drives Below is an example of a simple Functional Safety System using a simple door
9. complete drawing a bill of material and SISTEMA calculation Safety Connected Components Building Blocks The Connected Components Building Blocks provide users with pre designed safety solutions that have panel drawings wiring diagrams programs HMI screens and start up manuals make the design and integration of safety systems quick and easy Safety Solutions Toolkit The Safety Solutions Toolkit is a tool that presents all safety related product launches presentations videos amp animations literature event archives and many other additional resources that the Rockwell Automation Safety Solutions program provides Safety Accelerator Toolkit a The Safety Accelerator Toolkit provides easy to use system design programming and diagnostic tools to assist you in the rapid development and deployment of your safety systems using GuardLogix Compact GuardLogix or SmartGuard 600 Controllers Guard I O and Safety Devices The toolkit includes a risk assessment and system design guide hardware selection guide CAD drawings safety logic routines and operator status and diagnostic faceplates Pro Safe Trapped Key Builder The Pro safe Trapped Key Builder tool allows you to build safety solutions using a broad range of trapped key switches and devices that can isolate pneumatic hydraulic and electrical sources in a systematic repeatable process Pro safe builder is linked to ProposalWorks to allow users to generate complete Bi
10. interlock a safety relay and safety contactors Output Copyright 2014 Rockwell Automation Inc All Rights Reserved 16 Mitigation Design amp Verification Basic Concepts Rockwell Automation Mitigation Design Which products are used How components are wired Where they are placed on the machine Code is written Verification Determine if the implementation meets the requirements Perform PL or SIL calculations at this time SISTEMA can be used when ISO 13849 1 is the standard to verify Copyright 2014 Rockwell Automation Inc All Rights Reserved 17 Rockwell Automation Mitigation Design amp Verification SISTEMA for ISO 13849 1 Mii SISTEMA Safety Integrity Software Tool for the Evaluation of Machine Applications v1 1 4 Developed and maintained DY a dhan o Sha 7 vena we neutral and well respected Safety function IFA PR GSA DI EStop AND LC E nar a ele vue Fe i i T T n u H WPR fr SISTEMA Safety Integrity Software Tool for the Evaluation of Machine Applications v1 1 4 I EI xi organization specializing in Pre B Tw New 3 Open B Save Close Project Hii Library Report e Help F Wizard R HI MELAKA Subsystem A IFA UNC lona da e y t E amp Projects il SVS em 4 ee eee Documentation P
11. 2014 Rockwell Automation Inc All Rights Reserved PUBLIC 31 Rockwell Automation Integrated Safety on EtherNet IP GuardLogix Integrated Safety System Controller cab PointGuard A id Safety I O tilii id dd ii d Stratix 5700 Industrial Ethernet switch Integrated Safety Enhances Machine Performance and Flexibility Vy PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 32 GuardLogix for Safety and Motion Control SIL3 PLe Safe Torque off Dual Ethernet connection for Safety and Motion Motion and Safety Monitoring By GuardLogix Sa s Bha U 1 E El 1 EX mE ls GuardLogix allows machine flexibility for Motion and Safety Copyright 2014 Rockwell Automation Inc All Rights Reserved PUBLIC safety Zoning in Logix Designer Safety Output Rung This Safety Output Logic Example controls the Network Safe Torque Off outputs of a Kinetix 5500 2198 Hxxx ERS2 drive The CROUT instruction is not needed since only a single output is need to be energized and diagnostics are already built into the module to go to safe state in the event of a fault Cmd_Zone_OutputEnable Drive 01 SO SafeTorqueOff Drive 01 Sl TorqueDisabled Drive 01 SI ResetRequired Drive 01 SO Reset Drive 01 Sl ConnectionFaulted Drive 01 Sl SafetyFault Drive 01 SO SafeTorqueOff X
12. 5500 2198 Hxxx ERS2 drive The CROUT instruction is npt needed since only a single output is need to be energized and diagnostics are already built into the module to go to Safe state TIT tT vrara Cmd_Zone_OutputEnable Drive 04 S80 SafeTorqueOff Drive 04 Sl TorqueDisabled Drive 04 SI ResetRequired Drive 04 SO Reset ET Drive 04 Sl RunMode Drive 04 SI ConnectionFaulted Drive 04 SI SafetyFault Drive 04 SO SafeTorqueOff p 3 M PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved Programmatically change the safety zones in Logix Designer Rockwell Automation mt LITT Zone 1 Zone 2 x UR Rockwell Automation afety Zoning in Logix Designer Safety Output Rung This Safety Output Logic Example controls the Network Safe Torque Off outputs of a Kinetix 5500 2198 Hxxx ERS2 drive The CROUT instruction is not needed since only a single output is need to be energized and diagnostics are already built into the module to go to safe state in the event of a fault Cmd_Zone_OutputEnable Drive 01 50 SafelorqueOff Drive 01 SI TorqueDisabled Drive 01 SI ResetRequired Drive 01 SO Reset iue 01 SI ConnectionFaulted Drive 01 Sl SafetyFault Drive 01 50 SafeTorqueOff This Safety Output Logic Example controls the Network Safe Torque Off outputs of a Kinetix 5500 2198 Hxxx ERS2 drive Th built into the module to go to safe state in the event of a fault C
13. 7 Rockwell Automation TUV Rheinland Approved Integrated safety with EtherNet IP se PLe CAT3 per ISO 13849 1 se SIL3 per IEC EN 61508 EN 62061 and EN 61800 5 2 4 Stop Category 0 EN 60204 Table 3 Performance levels PL Speed Average probability of dangerous failure per hour im Stopping Time 3x 10 5 ta c 10 1077 to 1075 10 to 107 NOTE Besides ihe average probability of dancerous talure per hour offer measures arg also necessary to achieve a PL Increased safety rating using Kinetix 5500 with Integrated Safety Copyright 2014 Rockwell Automation Inc All Rights Reserved 43 PUBLIC Drive Safety Diagnostics Automation Integrated Safety Drive PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 44 Drive Safety Functions Reset Function amp Feedback Circuits Rockwell Automation Network integration gives access to the drive status Apply these to Indicator Lights or HMI screens for z PES One Our faster troubleshooting PFS45 i PF525 PF525 amp b amp amp EG ase OG Last Faut T Fault Description M Fault Action Check safety input signals If not Both of the safety inputs Safety 1 using safety verify and tighten Safety Open Safety 2 are not enabled jumper for VO terminals 51 52 and St Configure with t105 Safety Open E
14. L Category MTTFd DCavg CCF Blocks w PR GSA DIS 2 Estop AND SWL EM Example 2 wv PR Input Sub System w PR K300 amp Contactor SF Name ft Determine MTTFd value from blocks C Enter MTTFd value directly Simplified entry of safety related reliability information R PR Project SF Safety Function raaes nission time u Vendor libraries reduce work to s Bi SISTEMA Safety Integrity Software Tool for the Evaluation of u i S a Machine Applications aili n d CrI ti Ca d ala PFH 17h 2 Projectname K300 amp Contactor i Cat i n MTTFd a i File date 17 02 2011 Report date 29 06 2011 Checksum 030b26805dd97cd54b303c519c07f89a DCava PR Project name K300 amp Contactor E CCF i Reduce risk of mistakes in por Dangerouspointimachine Documentation calculations i S m i a File name CADocuments and Settingsibjmaherimy i EA DocumentsiSISTEMA ProjectsiK300 amp Contactor ssm E u E E Version of software 1 1 4 a D Ca VI ew O Sd e y Version of standard ISO 13849 1 2006 1SO 13849 2 2003 Checksum 030b26805dd87cd545h303c5198c07f89a fu n Cti O n S Options 7 Use DC intermediate levels for calculation of PFH more precise O Raise the MTTFd capping for Category 4 from 100 to 2500 years Status green Automatic report generation for EE Contain
15. ations 4 safety input terminations at 25 termination PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 26 Rockwell Automation Drive Safety Functions Safe Torque off Hardwired vs Integrated Hardwired Safety e Drive based monitoring e Safety relay for input devices Discrete safety wiring Integrated Safety e Controller based monitoring e Guard Point I O input devices e Communication via EtherNet IP Copyright 2014 Rockwell Automation Inc All Rights Reserved 27 Ll Ms i Control Wiring Labor M PUBLIC Drive Safety Integrated Safe Torque off Advanced level of diagnostics Specific information on what component faulted experienced safety demand and why Lowest level of panel space required No contactors No safety relays Lowest amount of installation time No bothering with small terminals Fewer user manuals to read Low opportunity for wiring error level of reliability Only EtherNet IP cable required mi oci required 1769 L30ERMS Compact GuardLogix Controller 3 25C D6P0N104 SHP PowerFlex 527 AC Drive 1734 AENTR POINT I O Dual Port Network Adaptor 1734 IB8S 8 Channel Safety Sinking Input Module 1734 IB8 24V DC 8 Channel Sink Input Module A RA DA DM Z a Julius O 20 Ji t MOC Mike con Inc All Rights Reserved 28 Rockwell Automation Drive Safety Fu
16. ed safety functions SF Name Mame fa ste d 0 CU m e n tati O f penile jin Reached PLe PFH 1h 5 6E 8 Status green PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 18 Installation amp Validation Basic Concepts Rockwell Automation Follow through with the Mitigation Design Induce faults to validate system Use ISO 13849 2 for techniques such as Table D 9 shown below Fault exclusion All contacts remain in the energized None position when the coil is de energized e g due to mechanical fault All contacts remain in the de ener gized position when power is applied e g due to mechanical fault open circuit of coil Contact will not open Contact will not close Simultaneous short circuit between Simultaneous short circuit can be The creepage and clearance the three terminals of a change over excluded if remarks are taken into distances are dimensioned to at contact account least IEC 60664 1 with at least pollution degree 2 overvoltage Short circuit between two pairs of Short circuit can be excluded if Ba category III contacts and or between contacts remarks are taken into account and coil terminal Conductive parts which become loose cannot bridge the insula tion between contacts and the coil Simultaneous closing of normally simultaneous closing of contacts can Positively driven or mechani open and normally closed contacts be excluded if re
17. lls of Materials BOM Copyright 2014 Rockwell Automation Inc All Rights Reserved 47 safety Function Library Overview Rockwell Automation Building Blocks approach to safety Combine blocks together for more complex functions gt Available for GuardLogix controller or as GuardMaster relay solutions Rs E ay Each one includes 5 System descriptions of operations MGE Parts lists NE MORIR e eN Erin e Electrical drawings S STE MA calcu lations Pap qes rore OT ee EMER Verification 4 Validation plans as mE PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 48 Safety Automation Builder Overview Rockwell Automation Use Safety Automation Builder to Layout machine hazards and access points Define safety functions and select safety products Export data to SISTEMA for analysis Beer cena Outputs of Safety Automation Builder include S Bill of Materia E Lc Conceptual safety layout drawings SISTEMA project files Safety Automation Builder and SISTEMA tools must be used in conjunction with each other to provide this output Proposal Generate s414808 4 148 08 nx Loxll azren Lock nid s nd lu aa ce nly stati Push Suttors PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 49 safety
18. mark is taken into cally linked contacts are account used see IEC 60947 5 1 2003 Annex L M PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 19 Manage Change amp Improve Basic Concepts Rockwell Automation OEMs End Users Maintain designs to latest Maintain designs to latest standards standards Perform Risk Assessments Perform Risk Assessments whenever designs are improved whenever designs are improved Add value through documentation Expect documentation from OEMs Look for feedback from customers Thoroughly document any changes from original machines Provide feedback to OEMs and governing bodies PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 20 Rockwell Automation Machine Safety Lifecycle Organizations Standards amp Guidelines Safety Org Stds amp Guidelines 1 Risk Assessment 5 Manage Change amp Improve 4 Installation o Lee B F amp Validation AM q 3 Mitigation Design amp Verification PUBLIC I I l 5 Copyright 2014 Rockwell Automation Inc All Rights Reserved 21 Rockwell Automation Introduction Machine Safety Lifecycle Drive Safety Motor Drive Safety Tools amp Services Copyright 2014 Rockwell Automation Inc All Rights Reserved 22 AC Motor Safety Basic Concepts and Contactors Rockwell Automation
19. md Zone OutputEnable Drive 03 SO SafeTorqueOff Drive 03 Sl TorqueDisabled Drive 03 SI ResetRequired Drive 03 SO Reset Drive 03 Sl RunMode Drive 03 Sl ConnectionFaulted Drive 03 Sl SafetyFault Drive 03 50 SafeTorqueOff c E SafetyTask ge eom Local Tags Machine safety IS configured In the safety task of Eh MainRoutine pur Logix Designer H Logic a e Cut paste Axis from one zone to another Parameters and Local Tags BbMainRoutn e Safety connection to the drive via EtherNet IP H Inputs Bio e No additional wiring is required H Outputs Safety Output Rung This Safety Output Logic Example controls the Network Safe Torque Off outputs of a Kinetix 5500 2198 Hxxx ERS2 drive The CROUT instruction is not needed since only a single output is need to be energized and diagnostics are already built into the module to go to safe state in the event of a fault Cmd Zone OutputEnable Drive 02 SO SafeTorqueOff Drive 02 Sl TorqueDisabled Drive 02 SI ResetRequired Drive 02 SO Reset Drive 02 SO SafeTorqueOff This Safety Output Logic Example controls the Network Safe Torque Off outputs of a Kinetix 5500 2198 Hxxx ERS2 drive The CROUT instruction is not needed since only a single output is need to be energized and diagnostics are already built into the module to go to safe state in the event of a fault Cmd Zone OutputEnable Drive 04 SO SafeTorqueOff Drive 04 Sl TorqueDisabled Drive 04 SI ResetRequired Dri
20. n Fault Em CLR Faults PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 45 Rockwell Automation Introduction Machine Safety Lifecycle Integrated Safety Motor Drive Safety Tools amp Services Copyright 2014 Rockwell Automation Inc All Rights Reserved 46 Rockwell Automation Safety Tools Connected Components BB Safety Solutions Toolkit Safety Accelerator Toolkit Pro Safe Builder v PUBLIC Rockwell Automation Safety Return On Investment Tool Find out how to quantify the savings and productivity gains from safety investments The Rockwell Automation Safety Return On Investment Tool accounts for improved safety reduced claims improved productivity and other issues unique to safety applications Safety Functions Program The Safety Functions Program is building block approach to designing safety systems Each building block has a complete documentation package that includes a description of each safety function an electrical schematic a bill of material a SISTEMA verification calculation and a verification and validation plan Safety Automation Builder The Safety Automation Builder software package that allows users to import images of their machines Users can identify hazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigate the risk This gives the customer a
21. national community These standards do recognize the international community Copyright 2014 Rockwell Automation Inc All Rights Reserved 9 Rockwell Automation Type A amp Type B Standards International ISO 12100 Safety of Machinery General Principles for Design Risk Assessment and Risk Reduction ISO 13849 1 safety of Machinery Safety Related Parts of Control Systems Part 1 General Principles for Design Replaced EN 954 in 2008 Simple devices including electromechanical devices Common Terms Categories structure Diagnostic Coverage DC Performance Levels PL Probability of Dangerous Failure per Hour PFH Copyright 2014 Rockwell Automation Inc All Rights Reserved 10 Rockwell Automation Going Between Standards ANSI B11 19 amp ISO 13849 1 While the requirements of Other Categories and control reliability are not directly Performance Levels per EN ISO comparable to the requirements 13849 1 and Safety Integrity of ISO 13849 1 1999 or Levels SILs per IEC 61508 and EN ISO 13849 1 2008 for the IEC 62061 can also satisfy the purposes of this standard requirements of this sub clause complying with Category 3 or 4 depending on the design and or Performance Level d or construction fault exclusions e at a minimum will satisfy installation and maintenance of the requirements of control the safety related function and a reliability documen
22. nctions Integrated Safe Torque off Rockwell Automation Safety Message Producer to Consumer Data Section yy Normal data 9 gt Duality Inverted data isal gt Diagnostics Time Stamp Section AR E Diversity Capable of SIL3 PLe Independent of network media Wired and wireless Works across many different networks EtherNet IP CIP Safety Packet provides Duality Diagnostics and Diversity M PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved Rockwell Automation Introduction Machine Safety Lifecycle Integrated Safety Motor Drive Safety Tools amp Services Copyright 2014 Rockwell Automation Inc All Rights Reserved 30 Rockwell Automation Integrated Safety on EtherNet IP Module Definition l Revision z IS Electronic kepi Competiote adul l Motion PLC RACK x Safety JO PLC RACK Connection Motion and Sahety Motion and 5 ale Power Structure immi I Verily Power Rating on Ca Satety on Cancel Help ETAP ETAP ETAP LLLI LTTTITI DLR ili DLR LLI aii AEN Sa ti M w A kon wa E u Ej Peery EJ wy P o4 5 9 an us m mre ot JF V a V ue nm d n mre Lom 5500 te n mre i netix 5500 L ve 5500 Flexibility vvith standard connection configurations Copyright
23. s Limited Detailed Integration Very little controller integration Seamlessly part of controller Manual operation for Maintenance Automatic device configuration replacement Application Space Only for specific problems Easily customized for anything Code Validation Must be repeated every time simplified through code re use Increasing customer value by integrating safety into the architecture Vv PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 39 Integrated Safety Features and Benefits Rockwell Automation Perform SIL3 PLe Safe Torque off Complete project integration in Logix safety functions over EtherNet IP Designer of control safety and motion connection Increased flexibility and modularity of Reduction in wiring of safety circuit system design and safety zoning Fewer number of components Detailed diagnostics to assist in required commissioning and troubleshooting Safety system validation through safety related faults code reuse safety zone configuration change Reduction in cabinet space without changing hardware requirements Integrated Safety Enhances Machine Performance PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved Rockwell Automation Common User Experience for Safety ri PowerFlex amp 527 Kinetix amp 5500 Module Properties edt P owerfes 22 5TO OP Safety LD Ho lO edd 8 Moduls Orngertui en t Q1S8 en ER 2
24. ted risk assessment Right out of ANSI B11 19 E6 1 PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 11 Rockwell Automation Summary of Standards Standards are there to help you by taking the guesswork out of your safety system design Use Type C standards when you can otherwise use Type A amp Type B Don t be afraid to ask for help to understand them There are a lot of good interpretations online My recommended desert island standards ANSI B11 0 ANSI B11 TR3 or ISO 12100 ANSI B11 19 ISO 13849 1 amp 2 IEC 60204 1 or NFPA 79 Use the standards to your advantage Copyright 2014 Rockwell Automation Inc All Rights Reserved 12 Principles of Risk Assessments Risk Reduction Rockwell Automation Risk assessment based on defined limits and intended use of the machine Hierarchy of Protective Measures Inherently sale design JE Fixed guards Complementary protective measures Awareness signs signals ui waming devices user manual nie Fuck banoi Personal protective equipment Some can be implemented by the Mm machine builder Some rely on the end users E organization Uso of personal protective equipment Training etc Step 1 Inherently safe design measures Safeguarding and complementa Residual risk f afterall E protective E PUBLIC Copyright 2014
25. times national legal reguirements ops 18 12100 01 2 a Three types of Standards pov 15914121 E A Standards Type B Machinery Standards B1 Sedewiorese enne basic concepts weder CI principles for design un uum i general aspects mem NET B Standards Standard for iy two hand souis 3851 Lc Gone B1 safety distances surface mE dd temps noise TypeA Fundamental safety standards applicable to all iu brani e MON ptm nenne DRE Un EE Standard for switches IECB0D47 B2 components or devices concepts principles for design and general aspects ENGOS4T Type BY Standards applicable to a wide range of machinery proof equipment 77 oe E C Standards i eee sia monos vertical standards covering a single eee ME o E type of machine or group of teteeingdeceerpessure senate devices f r mom ENED machines ncm Semdariforjecion ENZO Use A and B standards to create C Type Detailed standards applicable loa spacific machine Standard for industrial 18910218 stand ards or a particular group of machines robot ENT775 PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 8 Rockwell Automation Type A amp Type B Standards North America ANSI B11 0 General Requirements and Risk Assessment ANSI B11 19 Performance Criteria for Safeguarding These two standards can get you most of the way with most safety applications in North America These are not recognized by the inter
26. ts Reserved 24 Rockwell Automation Drive Safety Safe Torque off Remove torque by preventing the Inverter from synchronized switching Gate Control Circuitry creates EtherNet IP contro waveforms to Inverter By disabling the Gate Control Circuitry the Inverter cannot create torque at the motor oafety Control removes signals to Enable and Power of the Gate Control Circuitry Components have excellent reliability in a dual channel configuration PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved 25 Rockwell Automation Drive Safety Hardwired Safe Torque off Low level of panel space required Diagnostics Basic fault information Drive detects something is wrong 440R also reports faults in components but reasons for safety demand require further investigation Moderate amount of installation time Significantly improved level of reliability No contactors required Fewer opportunities for installation error B Mp required 1769 L30ER CompactLogix 1 MB EtherNet IP Controller 3 25B D6PON104 PowerFlex 525 AC Drives 1783 BMS06SL Stratix 5700 6 Port Managed Switch 1734 AENTR POINT I O Dual Port Network Adaptor 1734 IB8 24V DC 8 Channel Sink Input Module 1734 OBA 24V DC 4 Channel Source Output Module A40R ENETR GSR Ethernet Interface 440R D22R2 Guardmaster Dual Input Safety Relay 8 safety termin
27. ve 04 SO Reset Drive 04 SI RunMode Drive 04 Sl ConnectionFaulted Drive 04 SI SafetyFault Drive 04 SO SafeTorqueOff Programmatically change the safety zones in Logix Designer M PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved GuardLogix for Safety and Motion Control Zone 1 Zone 2 P s EE OO E NEN UNE DJ ma F Ra Ge U 1 an mu G 1 al a a i aaa as EE E Machine flexibility for modular design configuration and safety zoning PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved Machine flexibility with separated control for Motion and Safety PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved safety Reaction Time Explanation Rockwell Automation e L Hardwired Safety vs Integrated Safety Light Curtain MSR delayed output Light Curtain Integrated HW Drive 9 d Safety reaction En Drive time 10ms reaction son ww w q I time 10ms x Use Safety reaction time tool to calculate system reaction time M PUBLIC Copyright 2014 Rockwell Automation Inc All Rights Reserved eo parsor s MAI Configuration opecific to each device Unified in controller Wiring to Drive Often intensive wiring Reduced or eliminated Diagnostic
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