Safety Function - Rockwell Automation
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1. GuardLogix Modules Firmware Version 1768 L43S 1768 ENBT 1734 AENT GuardLogix Safety Controller CompactLogix Ethernet Bridge POINT 1 0 Ethernet Adapter POINT 1 0 Input Modules 1734 IB8S POINT 1 0 Output Modules 1734 0B8S GuardLogix Safety System Configuration and Wiring Verification Verify the safety system has been designed in accordance with the 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 5 Visually inspect the RSLogix 5000 application program to verify suitable safety certified instructions 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 f 5000 Controller Tags window Normal Operation Verification The GuardLogix safety system properly responds to all normal Start Stop Enabling and Reset Commands Init2. l FKIHKZFF iiris _ euii Jammi ROS Dorel HIHI od Falling Edge Reset OTS Duel Oran inp Shop Bos Tagy Foren LDT QURTAR fen Tra BULLET ACIM HOH HOFI Dimm ay T bees Y Prau Rasiat Typo AUTOMAN Coad miai Type ALC Pe eel A ABNT 1 Peale D Chane E BENT 10 Date Oo ing eu AENT 4 bCcenenedirut ia i Paget ADMIT 1 LPH IT Comtigunable bearda Guip CE Earl EIEI Feeda Type hESAM Fieci Pirkon Tiras Mirer eid BCA G Eoi Erai Fieni f SEMT 4 vraarteta er ea J 4DHT 4 Unos et Sis AENT O Giuria AENT i i Resa AHT Lead J SENT OAD MENT Oi Doe x lt gt 18 ISO 13849 1 stipulates that instruction reset functions must occur on falling edge signals To comply with this requirement add a One Shot Falling instruction to the rung immediately preceding the Cmd_Zone1_OutputEnable rung Then use the OSF instruction Output Bit tag as the reset bit for the following rung The Cnd_Zone1_OutputEnable is still used to enable the CROUT instruction The modified code appears below in rungs 1 and 2 Vike Donat Falingbdige Tanai LODI Iensl MIEP Dad Doia Cupia dopl HIKO Zee Minos Saleh Furcha LEHT CURT AR reat Typa POU ALENT ACTE HGH f Cincrepency Ting Mapt Ei Fipan Tyre AUTOMATIC Cold Shel Type BA aba TEZ Thira AETA InN a 0 Charateel Bi APT tol Ptr Caia mgar Sanus ENT 11 Conii Ha Coniguren Redundand Gutpat Rout Dore Ki Feedback Tepe NEGATIVE Feoi R
3. 1734 IB8S input module monitors OSSD1 and OSSD2 from the 440L light curtain If the Light Curtain is blocked OSSD1 and OSSD2 go LO and the controller will react by dropping out the safety contactors The 440L has onboard diagnostics to dynamically test the signal wiring for shorts to 24Vdc and channel to channel shorts If a fault occurs either or both OSSD1 and OSSD2 will be set LO and the controller will react by dropping out the safety contactors 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 block DCS in the controller will declare a fault Only after the fault is cleared and the light curtain is cycled blocked then unblocked 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 cannot 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 ar
4. 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 Stratix 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 12
5. be modeled as shown in the following safety related block diagram 1734 1885 1768 L43 1734 0885 Subsystem 1 Subsystem 2 Subsystem 3 20 Calculations are based on 1 operation of the light curtain per hour therefore 8 760 operations of contactors per year The measures against Common Cause Failure 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 SB Light Curtain GuardShield 440L Type 4 Single Safety PLC Compact GuardLogix 1 68 Cat MTTFd a DCavg 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
6. LISTEN SING SOLE Safety Function Light Curtain Products Light Curtain GuardLogix Controller Safety Rating PLe Cat 4 to EN ISO 13849 1 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 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 a 440L GuardShield light curtain If a demand is placed on the light curtain 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 440L GuardShield light curtain but is applicable to light curtains that pulse tests the OSSD1 and OSSD2 outputs 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 Installatio
7. Throughout this manual when necessary we use notes to make you aware of safety considerations gt IMPORTANT gt e 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 recognize 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 t
8. a 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 ATO56B EN E January 2013 Supersedes Publication SAFETY ATO56A EN E October 2012 Copyright 2013 Rockwell Automation Inc All Rights Reserved
9. ake into consideration safety distance calculations which are not part of the scope of this document Functional Safety Description Hazardous motion is interrupted or prevented by interrupting the light curtain The light curtain LC1 is wired to a pair of safety inputs on a Safety Input module SI1 The safety contactors K1 amp K2 are connected to a pair of safety outputs on a Safety Output module SO1 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 Light Curtain using the pre certified safety instruction Dual Channel Input Stop DCS 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 the Light Curtain is blocked the contactors drop out When the Light Curtain is unblocked and the reset button is pressed the contactors are energized Bill of Material This application example uses these components Catalog Number Description Quantity Horton nonin i ma e anag Me won Eeo Ma mist mC nnn co i oe a O _ ae mis operon e EN ete Setup and Wiring For detailed information on installing and wiring refer to the product manuals listed in the Additional Resources System Overview The
10. ation Test Output Type 17344885 8 Point 24V DC Sink Input Vendor Allen Bradley Parent AEMT Name flees ModuleNumber 1 nti J Satety Network JEE Description ane 3987 _0408_012E il i 4 27 2012 2 50 30 62 PM 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 14 15 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 OB8S Note this module will be in slot 2 and select Combined Status Readback Power for Input Status definition 16 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 El Module Properties AENT 1 1734 IB8S 1 1 General Connection Safety Module Info Input Configuration Test Output 3 Click Input Configuration and configure the module as shown Inputs 0 1 are the Light Curtain Inputs 4 5 are the reset buttons Input 7 is contactor monitoring c
11. ck to Run Mode all contactors should remain de energized Verify proper machine status indication and RSLogix 5000 safety application program indication 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 i While Running remove the contactor feedback from the Safety 1 0 All contactors should remain 2 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 24 Additional Resources For more information about 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
12. e 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 Safe Distance Calculation The user will need to perform a calculation using this formula to determine the distance between the light curtain and the hazard The user will need to use values based on their application rather than the example calculation shown here S K T C K 63 inches per second constant from B11 19 1990 T stopping time C Depth Penetration Factor 1 inch for 14mm resolution from documentation Stopping time T for this example is a summation of the following a Light Curtain delay 25ms from documentation b 1734 IB8S module delay 16ms from documentation c Input Module Connection delay d Safety Controller delay Safety Task Watchdog Safety Task Period e Output Module Connection delay f 1734 OB8S delay 6ms from documentation g Contactor response time 15ms from documentation h Actual Machine stop time assume 900ms for this example C The Input Module connection delay defaults to 4 x RPI If we assume a RPI of 10ms the maximum delay 40ms E The Output Module connection delay defaults to 3 x RPI If we assume a RPI of 10ms the maximum delay 30ms The worst case reaction time may be calculated assuming there is only a single fault in the control system This means that only the higher of the two connection delay valu
13. eacts Prive esc ta chess md Fore Dupi rahi Q Posdback 1 ABTA iP 0 Feedback 7 AENT TIPTE Q nol igus SENT 1 Comiirepain pet Stats Q Tuit iaig AEMT 2 i Coerdnrlsubpe al babr Q Feja BENT Paha g fo a AENT 2 O FiDets 6AENT DO PHa _ i 19 Calculation of the Performance Level When configured correctly this Light Curtain emergency stop 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 isrequired for PLd The individual subsystem values are shown below Safety function Documentation PLr PL Subsystems 2 Library Name PL PF IHL CCE score v sp EME 34E 10 s nt J New SB POINT Guard 1 0 1734 0885 e 1 3 10 4 fulfilled w SB Salety PLC Compact GuardLogi 1768 21E 10 rant N aa alaaa mew nakaa 4 fulfilled 4 Edi SB Contactors 1005 e 247E8 65 fulfilled 99 High 100 High 4 fulfilled tal Delete t SB Light Curtain GuardShield 440L Type 4 Single 317 9 rent aapa nov nada rey aapa 4 fulfilled The overall safety function value is shown below Safety function IFA Documentation PL PL Subsystems Determine PL trom subsystems Performance Level IPL fe PFH ish 2836 8 The LC safety function can
14. es shown above needs to be included in the Time calculation For this example 40 ms is used and the 30 is excluded If you wish to account for multiple faults occurring at the same time use both values in the calculation D the safety controller delay is a combination of the safety task period plus the safety task watchdog The watchdog accounts for the possibility that the safety code runs right up to but does not trip the watchdog The safety task period accounts for the possibility that the asynchronous scan just ended when the input changed state For this example lets assume Safety Task Period 10ms Safety Task Watchdog 5ms So to calculate T add the following Light Curtain delay 25ms 1734 IB8S module delay 16ms Higher of Input Output Module Connection delay 40ms Safety Controller delay 10 5 15ms 1734 OB8S delay 6ms Contactor response time 15ms Measured actual machine stop time 900ms This makes the total stop time T 1017ms S K T C 63 1 017 1 65 071 inches Given this example the light curtain must be placed 65 inches from the hazard Safe Distance Calculation to 13855 C S KxT C minimum distance in millimeters mm K is a parameter in millimeters per second mm s derived from data on approach speeds of the body or parts of the body is the overall stopping performance in seconds is the intrusion distance in mm In this Application Note the values a
15. 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 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 and the GuardLogix Application Instruction Safety Reference Manual 1756 RM095 GuardLogix Light Curtain 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 Controller Name Safety Signature ID Safety Network Number s RSLogix5000 Software Version Safety Control System Modules
16. iate 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 for a normal machine Stop condition Verify proper machine status indication and RSLogix 5000 safety application program indication While Running interrupt the light curtain 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 While Stopped interrupt the light curtain and inititate 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 light curtains 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 Light Curtain Input Tests While Running remove the Channel 1 wire from the Safety 1 0 Both contactors should de energize 1 Verify proper machine status indication and RSLogix 5000 safety application program indication Verify unable to reset and re
17. ircuit 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 BB Module Properties AENT 1 1 T34 IBBS 1 1 a a lalalala alallala fea feos fers ate Jeo fea f fe q EE L Satety Pulse Test 2 Inout Emo Latch Time 1 m Staue Offline ok caret Apply Hep 4 Click OK 5 Inthe Controller Organizer right click the 1734 OB8S module and choose Properties 6 Click Output Configuration and configure the module as shown The electromechanical coil on the contactor can be pulse tested without reacting to the brief LO pulse E Module Properties AENT2 1734 085 1 1 General Connection Safety Module Info Output Configuratioe Gately Pure Test Satety Pulse lect 4 F E A J i j lale lalalala Output Eater Lateh Time 1000 44 me Status Dline Cancel Apc Heb 7 Click OK Programming The Dual Channel Input Stop DCS instruction monitors dual input safety devices whose main function is to stop a machine safely for example an E stop light curtain or safety gate In this example it is being used to monitor a light curtain The DCS instruction monitors dual input channels for consistency Equivalent Active High and detects and traps faults when the inconsi
18. mmunication Interface 1756 Ethernet Communication Interface Aller ae 1756 10 100 Mbps Ethernet Bridge w Enhanced Web Serv Allen Bradley z 12 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 BB Sew Poduke General Connection Module Info Intemet Protocol Port Configuration Chassis Size Type T7M AENT 1734 Ethemet Adapter Twisted Fair Media Vendor Aler Bradley Patent ENBT none fe Depew ipti t m a EJ M Module Definition Revision a Electronic Keying Compatible Module Connection Rack Optimization Chassis Size 1 Status Creating Cancel Help 9 Set the Chassis Size as 3 for the 1734 AENT adapter and click OK Chassis size is the number of modules 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 Revision 3 13 Electronic Keying Compatible Module ChasssSze 10 In the Controller Organizer right click the 1734 AENT adapter and choose New Module EJ Trends j 1 0 Configuration E 176s us E E 1 1766TA T gs Ethernet 1766 EN5T A ENST 1734 AENT A AENT 12 In the New Module dialog box name the device IB8S and click Change EB ew Module General Connection Safety Module Info Input Configur
19. n 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 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
20. re K 1600mm per second t Sum of Light Curtain delay 25ms 1734 IB8S module delay 16ms Higher of Input Output Module Connection delay 40ms Safety Controller delay 10 5 15ms 1734 OB8S delay 6ms Contactor response time 15ms Measured actual machine stop time 900ms This makes the total stop time T 1017ms C 8 d 14 but not less than 0 where d is the resolution of the light curtain S 1600 x 1 017 8 14 14 The light curtain must not be mounted closer than 1628 mm approx 64 in from the hazardous motion being guarded against Electrical Schematic 24Vde 24Vide COMMON Configuration There are dip switches in the 400L light curtain These can remain in the factory default position Receiver Factory Settings Switch Switch Function Default Setting Description 1 Mode Activation Combination activates one of the following modes Guard Only Start Interlock Ooa Guard Only 2 Restart Interlock o woo 4 OFF Disabled 5 OFF Switches 5 amp 6 cannot be activated On at the same time 6 OFF 7 Disabled i Transmitter Factory Settings Switch Switch Function Default Setting Description 1 Set Beam Coding OFF Disabled Machine Test Signal OFF OFF Signal High Active No connection or connect normally open ON Signal Low Active Connect N C The Compact GuardLogix controller is configured by using RSLogix 5000 software version 17 or later You mu
21. st 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 10 11 Configure the Controller and Add I O Modules Follow these steps 1 In RSLogix 5000 software create a new project 1768L435 CompactLogi53435 Safety Contoller LE edundaney Enabled PATS Weg EUA Set artnet Sot lt irnerria 2 Inthe Controller Organizer add the 1768 ENBT module to the 1768 Bus i SS Se E B 63 1 0 Configuration a 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 4 F l New Module xj 5 Add the 1734 AENT adapter by right clicking the 1768 ENBT module in the Controller Organizer and choosing New Module BS I O Configuration B a 1768 Bus Bef g 1768 j a R73 Ethernet Adapter 2 Port Twisted Pair Media 1738 Ethernet Adapter Twisted Pair Media 1736 Ethernet Adapter 2 Port Twisted Pair Media 1756 10 100 Mbps Ethernet Bridge Fiber Media 1756 10 100 Mbps Ethernet Bridge Twisted Pair Media 1756 10 100 Mbps Ethernet Bridge 2 Port Twisted Pair A 1756 10 100 Mbps Ethernet Bridge 2Port Twisted Pair 1756 10 100 Mbps Ethernet Bridge Twisted Pair Media 1756 Ethernet Co
22. start with fault Restore Channel 1 and repeat for Channel 2 While Running short Channel 1 of the Safety 1 0 to 24VDC Both contactors should de energize 2 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 Channel 1 of the Safety 1 0 to OVDC Both contactors should de energize 3 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 Channels 1 amp 2 of the Safety 1 0 Both contactors should de energize 4 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 1 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 RSLogix 5000 safety application program Repeat for all Safety 1 0 connections While Running switch the controller out of Run Mode All contactors should de energize Return key 3 switch ba
23. stency is detected for longer than the configured Discrepancy Time ms The automatic restart type allows the DCS output 01 to reset automatically after a demand The manual action typically required for safety is provided in rung 1 to reset the safety output enable 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 has a fault In this example the DCS reset acts as a fault reset Even when configured for automatic restart a reset is required to recover from a fault The output 01 of the DCS is used as a safety interlock in the seal in rung to drive the output enable tag If the DCS output drops 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 AENT II FEHCi gt Fk il ORS Pie LCDI Dap
24. 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 Specification of characteristics of each safety function Determination of required PL PLr for each safety function To Realization and PL Evaluation Emergency Stop Safety Function Emergency stop by actuation of a light curtain Point of Operation Control There is no muting function in this example Safety Function Requirements Interrupting the light curtain will stop and prevent hazardous motion by removal of power to the motor Upon resetting the light curtain hazardous motion and power to the motor will not resume until a secondary action start button depressed occurs Faults at the light curtain wiring terminals or safety controller will be detected before the next safety demand The safe distance location of the light curtain 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
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