Safety Function: Single-beam Area Access Control (AAC)
Contents
1. Not Used v None v Safety v None v v Safety x None gt a Not Used al None v Safety Pulse Test v 2 P Input Error Latch Time me ms Status Offline Cancel 4 Click OK 5 In the Controller Organizer right click the 1734 OB8S module and choose Properties Rockwell Automation Publication SAFETY AT112A EN P November 2013 Safety Function Single beam Area Access Control AAC 17 6 Click Output Configuration and configure the module as shown Typically contactor coils will not react to the pulse testing of the output wires If using a contactor that does react to the pulse test then disable the pulse testing This should not affect the overall safety rating if redundancy and monitoring are being utilized x General Connection Safety Module Info Output Configuration Point Operation Point Point Mode EEE GE VEGNE Not Used Not Used Dual Not Used Not Used Not Used Not Used NEN ERENENE Output Error Latch Time 1000 4 ms Status Creating Cancel Help 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 an area access control sensor The DCS instruction monitors dual input channels for consisten2. 1 1768 ENBT A ENBT JR an ener agii 1769 Bus Discover Modules BA 0 1768 1 Paste Ctrl V Print Rockwell Automation Publication SAFETY AT112A EN P November 2013 12 Safety Function Single beam Area Access Control AAC 7 Select the 1734 AENT adapter and click OK Catalog Module Discover Favorites Enter Search Text for Module Type Catalog Number 1738 AENT 1756 EN2F 1756 EN2T 1756 ENBT 1756 ENET 205 of 205 Module Types Found 16 Point 24 DC Output 2 Port 8 Point 24 DC Scheduled Output 2 Port 1734 Ethernet Adapter Twisted Pair Media 1734 Ethernet Adapter 2 Port Twisted Pair Media 1738 Ethernet Adapter Twisted Pair Media 1738 Ethernet Adapter 2 Port Twisted Pair Media 174 Ethernet Adapter 2 Port Twisted Pair Media 1732E 0B16M12R 1738 ENTR 1747 4AENTR 1753 L28BBBx GPLC 1600 1753 L32BBBx 84 GPLC 1756 10 100 Mbps Ethernet Bridge Fiber Media 1756 10 100 Mbps Ethernet Bridge Twisted Pair Media 1756 10 100 Mbps Ethernet Bridge 2 Part Twisted P 1756 10 100 Mbps Ethernet Bridge 2 Port Twisted P 1756 10 100 Mbps Ethernet Bridge Twisted Pair Media 1756 Ethernet Communication Interface 1756 EN2TR 1756 EN3TR Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Show Filt
3. Whether they are effectively monitored for faults e Whether they are properly specified and installed SISTEMA software calculates the MTTFd by using B10d data provided for the contactors along with the estimated frequency of use entered during the creation of the SISTEMA project The DCavg 99 for the contactors is selected from the Output Device table of EN ISO 13849 1 Annex E Direct Monitoring The CCF value is generated by using the scoring process outlined in Annex F of EN ISO 13849 1 The complete CCF scoring process must be performed when actually implementing an application A minimum score of 65 must be achieved Rockwell Automation Publication SAFETY AT 112A EN P November 2013 Safety Function Single beam Area Access Control AAC 23 Verification and Validation Plan Verification and validation play important roles in the avoidance of faults throughout the safety system design and development process EN ISO 13849 2 sets the requirements for verification and validation The standard calls for a documented plan to confirm all of 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 that the system meets the required Performance Level PLr specified The SISTEMA software is typically used to perform the calculations and assist with satisfying the requirements of EN ISO 13849 1 V
4. 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 the output devices are qualified by cycling their respective actuators Monitor the status in the RSLogix 5000 Controller Tags window Rockwell Automation Publication SAFETY AT112A EN P November 2013 Safety Function Single beam Area Access Control AAC 25 GuardLogix Single beam AAC Sensor Safety Function Verification and Validation Checklist continued Normal Operation Verification The GuardLogix safety system properly responds to all normal Start Stop AAC Sensor Input and Reset commands Initiate a Start command Both contactors energize for a normal machine run condition Verify proper machine status indication and RSLogix 5000 safety application program indication Initiate a Stop command Both contactors de energize for a normal machine Stop condition Verify proper machine status indication and RSLogix 5000 safety application program indication While the system is running interrupt the single beam area access control sensor Both contactors de energize and open for a normal safe condition Verify proper machine status indication and RSLogix 5000 safety application program indication Repeat for all sensors While the system is stopped interrupt the single beam area access control sensor and initiate a Start command Both contactors remain de e
5. and Validation Checklist General Machinery Information Machine Name Model Number Customer Name Test Date Tester Name s Schematic Drawing Number Controller Name Safety Signature ID Safety Network Number s RSLogix 5000 Software Version Safety Control System Modules GuardLogix Modules Firmware Revision GuardLogix Safety Controller 1768 L43S CompactLogix EtherNet Bridge 1768 ENBT POINT I O EtherNet Adapter 1734 AENT POINT I O Input Modules 1734 IB8S POINT I O Output Modules 1734 OB8S GuardLogix Safety System Configuration and Wiring Verification Test Step Pass Fail ChangesiModifications Verify that the safety system has been designed in accordance with the GuardLogix System Safety Reference Manuals listed in the Additional Resources Verify that the safety application program has been designed in accordance with the GuardLogix Application Instruction Safety Reference Manuals listed in the Additional Resources Visually inspect the safety system network and I O and verify that it is wired as documented in the schematics Visually inspect the area access control and verify that it is wired as documented Visually inspect the RSLogix 5000 program to verify that safety systems network and I O module configurations are configured as documented Visually inspect the RSLogix 5000 application program to verify suitable safety certified instructions are utilized The logic is readable understandable and testable with the
6. 95 GuardLogix 5570 Controller Systems Safety Reference Manual publication 1756 RM099 Safety Accelerator Toolkit for GuardLogix System Quick Start Guide publication IASIMP QS005 Area Access Control Safety Single Beam User Manual publication 440L UMO002 Safety Product Catalog publication 5117 CAQ01 Description Provides information on configuring operating and maintaining Compact GuardLogix controllers Provides information on installing configuring and operating POINT Guard I O modules Provides detailed requirements for achieving and maintaining safety ratings with the GuardLogix and Compact GuardLogix controller systems Provides detailed information on the GuardLogix Safety Application Instruction Set Contains detailed requirements for achieving and maintaining safety ratings with the GuardLogix 5570 controller system Provides a step by step guide to using the design programming and diagnostic tools in the Safety Accelerator Toolkit Provides information on configuring operating and maintaining Area Access Control Safety Single Beam Light Curtains Provides data and guidance concerning safety principals standards component data and application examples 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 Rockwell Aut
7. Application Technique Safety Function Single beam Area Access Control AAC Products Single beam Area Access Control Sensors GuardLogix Controllers Safety Rating CAT 4 PLe to EN ISO 13849 1 2008 ISEN THINK tubs Rockwell 7 Allen Bradley gt Rockwell Software Automation 2 Safety Function Single beam Area Access Control AAC Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired 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 Auto
8. Compatible Module 7 configured By This Controller F nput Data Safety Output Data Mone C nput Status ombined Status PFower ata Format 18 Repeat steps 13 17 to add the 1734 OB8S safety output module with these exceptions e Name the module OB8S e Set the module to slot 2 e Set the Input Status to Combined Status Feedback Power Rockwell Automation Publication SAFETY AT112A EN P November 2013 16 Safety Function Single beam Area Access Control AAC Configure the 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 CH Module Properties AENT 1 1734 IB8S 1 1 General Connection Safety Module Info Input Configuration Test Output Co Pulse Test M a Pulse Test x 2 Pulse Test 7 3 Click Input Configuration and configure the module as shown e Input Points 0 1 are the single beam area access control AAC e Input Points 4 5 are the Reset buttons e Input Point 7 is the contactor monitoring circuit Input Point 7 is being sourced from Test Output 2 OE module Properties AENT 1 1734 IB8S 1 1 General Connection Safety Module Info Input Configuration Test Output Point Operation Point ae Point Mode Type Se Source Of gt On On gt Off 0 Single 0 Safety Pulse Test v 0 03 04 1 v Safety Pulse Test y 1 gt 0 0 I Input Delay Time ms
9. Subsystem 2 l Subsystem 3 l Subsystem 4 Subsystem 5 Single beam Area Access Control Sensor Safety Function Subsystem 1 Safety Single Beam 440L H T PL PFH Oh 1 43E 8 Cat 4 MTTFd a ani nna DCavg E Ar nnana CLF Aut sr Single beam Area Access Control Sensor Safety Function Subsystem 2 SE POINT Guard 170 1734 IBSS FL E PFH T k 1 34E 10 Lat 4 MTTFd a arnar DLavg 4 act aster CCF AA seen Single beam Area Access Control Sensor Safety Function Subsystem 3 Safety PLC Compact GuardLogm 1768 ek PFH fh 2 1E 10 Cat 4 MTTFd a can nania DLavg 4 state CEF oy SN Rockwell Automation Publication SAFETY AT112A EN P November 2013 21 22 Safety Function Single beam Area Access Control AAC Single beam Area Access Control Sensor Safety Function Subsystem 4 EE POINT Guard 120 1734 0B85 FL PFH T k 1 38E 10 Cat 4 MTTFd a can naia DLavg 4 at Anaan CCF sen Single beam Area Access Control Sensor Safety Function Subsystem 5 Contactors 1005 PL PFH 1 h 2 47E 9 Cat 4 MTTFd a 100 High DCavg 199 High CEF 65 fulfilled Because these are electro mechanical devices the safety contactors data includes the following e Mean Time to Failure dangerous MTTFd e Diagnostic Coverage DCavg e Common Cause Failure CCF Electro mechanical devices functional safety evaluations include the following e How frequently they are operated e
10. able the CROUT instruction The modified code appears below in rungs 1 and 2 DCS 0 Dual Channel Input Stop DCS AAC 1 Safety Function SAFETY GATE Input Type EQUIVALENT ACTIVE HIGH FP Discrepancy Time Msec 250 Restart Type AUTOMATIC Cold Start Type AUTOMATIC Channel A AENT 1 1 PI00Data 1 Channel B AENT 1 1 Pt01 Data 1 Input Status AENT 1 1 CombinedInputStatus 1 Reset AENT 1 1 PI05Data 0 AENT 1 1 PI04Data OSF 1 One Shot Falling Storage Bt ACC_OSF SB 3 Output Bit OSF Safety1 OB OSF Safety1 AAC 101 ACC CROUT1 FP ACC_OutputEnablet 2 EE rrr ACC OutputEnableti ROUT 3 Configurable Redundant Output CROUT ACC_CROUT1 Feedback Type NEGATIVE Feedback Reaction Time Msec 500 Actuate ACC OutputEnablei 1 Feedback 1 AENT 1 LPIO7Data Feedback 2 AENT 1 NE AENT 1 PE Output Status REEE AENT 1 PR 0 Input Status Reset ACC_CROUT1 01 ACC_CROUT1 02 AENT 2 0 Pt00Data AENT 2 0 Pt01Data eee End Rockwell Automation Publication SAFETY AT 112A EN P November 2013 20 Safety Function Single beam Area Access Control AAC Calculation of the Performance Level The Performance Level required from the risk assessment is Category 3 Performance Level d CAT 3 PLd When properly implemented the safety function described here can achieve a CAT 4 PLe according to EN ISO 13849 1 2008 as calculated by using the SISTEMA software PL calculation tool Calculations a
11. alidation is a functional test of the safety control system to demonstrate that the system meets the specified requirements of the safety function The safety control system is tested to confirm that all of the safety related outputs respond appropriately to their corresponding safety related inputs The functional test includes normal operating conditions in addition to potential fault injection of failure modes A checklist is typically used to document the validation of the safety control system Validation of software development is the process in which similar methodologies and techniques that are used in hardware development are deployed Faults created through poor software development processes and procedures 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 that the safety system and safety application program have been designed in accordance with the GuardLogix System Safety Reference Manuals publication 1756 RM093 GuardLogix 5560 and Compact GuardLogix controllers and 1756 RM099 GuardLogix 5570 controllers and the GuardLogix Application Instruction Safety Reference Manual publication 1756 RM095 Rockwell Automation Publication SAFETY AT 112A EN P November 2013 24 Safety Function Single beam Area Access Control AAC GuardLogix Single beam Area Access Control AAC Sensor Safety Function Verification
12. ction time can be calculated by assuming there is only a single fault in the control system This means that only the higher of the two connection delay values shown above needs to be included in the Time calculation For this example 40 ms is used and the 30 ms is excluded To account for multiple faults occurring at the same time use both values in the calculation Rockwell Automation Publication SAFETY AT112A EN P November 2013 8 Safety Function Single beam Area Access Control AAC In this application technique example the values are the following K 1600 mm s T 1029 ms C 850 mm with reference to the multi beam formula S 1600 x 1 029 850 2496 4 Conclusion The single beam area access control sensor must not be mounted closer than 2496 4 mm 98 3 in from the hazardous motion being guarded against The above calculation is based on the following mounting consideration with two separate beams deduced from the risk assessment for reduction of the risk DOmm DOmm T Transmitter R Receiver M Mirror With reference to the EN ISO 13855 2010 Appendix E standard for two beam applications the mounting heights are 400 mm and 900 mm from the ground or panel level which correspond to adequate risk reduction and application practice Thus in applying the multiple separated beam the formula S 1600 T 850 mm is used According to EN ISO 13855 2010 Appendix E the two beam application of the lowe
13. cy Equivalent Active High and detects and traps faults when the inconsistency 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 low 0 if any of the eight 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 remains 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 high 1 the feedback is low 0 and vice versa In this example the feedback has 500 ms to change to the proper state Because only a single feedback circuit is being used the feedback tag is used for both Feedback 1 and 2 Rockwell Automation Publication SAFET Y AT 112A EN P November 2013 18 Saf
14. d prevents hazardous motion by removing power to the motor When the sensor is reset the motor does not resume until a secondary action occurs the Reset button is pressed and released A fault at the sensor wiring terminal or safety controller is detected before the next safety demand The safe distance location of the sensor must be established such that hazardous motion must be stopped before the user can reach the hazard This distance is called the Safety Distance and is addressed later in this application technique The safety function in this example is capable of connecting and interrupting power to motors rated up to 9 A 600V AC The safety function in this application technique meets or exceeds the requirements for Category 3 Performance Level d CAT 3 PLd per EN ISO 13849 1 and control reliable operation per ANSI B11 19 Rockwell Automation Publication SAFETY AT112A EN P November 2013 Safety Function Single beam Area Access Control AAC Functional Safety Description An interruption of the single beam from the transmitter is detected by the receiver and motion is stopped Hazardous motion is prevented from restarting while the beam is interrupted Bill of Material This application uses these products 1585 Ethernet cables 4 conductors RJ45 straight 1585J M4TBJM 2 male standard RJ45 straight male teal robotic TPE UL CMB CMX CUL CMG standard TIA 568 B 1783 US05T Stratix 2000 switch unmanaged 5 c
15. e used Rockwell Automation Publication SAFETY AT112A EN P November 2013 4 Safety Function Single beam Area Access Control AAC 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 In this application the performance level required PLr by the risk assessment is Category 3 Performance Level d CAT 3 PLd for each safety function A safety system that achieves CAT 3 PLd or higher can be considered control reliable Each safety product has its own rating and can be combined to create a safety function that meets or exceeds the PLr From Risk Assessment ISO 12100 1 Identification of safety functions 2 Specification of characteristics of each function 3 Determination of required PL PLr for each safety function To Realization and PL Evaluation ba Single beam Area Access Control Sensor Safety Function The safety system described in this application has one safety function safety related stop by actuation of the single beam area access control sensor This system executes a Stop Category 0 stop Power is immediately removed and motion coasts to a stop Safety Function Requirements The interruption of the single beam area access control sensor stops an
16. epeat for channel 2 While the system is running short channels 1 and 2 of the safety I O Both contactors de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Repeat for channel 2 Verify that the system is unable to reset and restart with a fault Restore channel 1 and channel 2 wiring Rockwell Automation Publication SAFETY AT112A EN P November 2013 26 Safety Function Single beam Area Access Control AAC GuardLogix Single beam AAC Sensor Safety Function Verification and Validation Checklist continued GuardLogix Control and Network Tests Test Step Verification and Validation Pass Fail Changes Modifications While the system is running remove the Ethernet network connection between the safety I O and the controller All contactors de energize Verify proper machine status indication and I O connection status in the RSLogix 5000 safety application program Restore the safety I O module network connection and allow time to re establish communication Verify the state of the Connection Status Bit in the RSLogix 5000 safety application program Repeat for all safety I O connections While the system is running switch the controller out of Run mode All contactors de energize Return controller keyswitch back to Run mode All contactors remain de energized Verify proper machine status indication and RSLogix 5000 safety application program indication Safety Contactor Ou
17. ers Digital Digital Communication Communication al Communication Communication Communication Programmable Logi Programmable Logi Communication Communication Communication Communication Communication ommunication Add to Favorites I Close on Create 8 Name the module and type its Ethernet address Create Close Help pr For this application example we used 192 168 1 11 however your IP address can be different General Connection Module Info Internet Protocol Port Configuration Chassis Size Type 1734 AENT 1734 Ethemet Adapter Twisted Pair Media Vendor Allen Bradley Parent ENBT Private Network 192 168 1 1 Status Creating 9 Click Change The Module Definition dialog box appears ik anse its Rockwell Automation Publication SAFETY AT 112A EN P November 2013 Safety Function Single beam Area Access Control AAC 13 10 From the Chassis Size pull down menu choose 3 Chassis size is the number of modules that are inserted in the chassis The 1734 AENT adapter is considered to be in slot 0 therefore for one input and one output module the chassis size Is 3 x Serie lA a Revision J 1 Electronic Keying Compatible Module Chassis Size Bd Cancel Help 11 Click OK The confirmation screen is displayed RSLogix 5000 i x These changes will cause module data types and properties
18. ety Function Single beam Area Access Control AAC The two output tags from the CROUT instructions are used to drive the contactor outputs on the 1734 OB8S module DCS 0 Dual Channel Input Stop DCS AAC 1 01 Safety Function SAFETY GATE Input Type EQUIVALENT ACTIVE HIGH FP3 Discrepancy Time Msec 250 Restart Type AUTOMATIC Cold Start Type AUTOMATIC Channel 4 AENT 1 1 PI00Data 1 Channel B AENT 1 1 Pt01 Data 1 Input Status AENT 1 1 CombinedlnputStatus 1 Reset AENT 1 1 PI05Data 0 AENT 1 1 Pt04Data ONS Safety1 AAC 1 01 ACC_CROUT1 FP ACC OutputEnable1 1 Eons ACC_OutputEnable1 ROUT 2 Configurable Redundant Output CROUT ACC CROUT1 Feedback Type NEGATIVE Feedback Reaction Time Msec 500 Actuate ACC OutputEnable1 Feedback 1 AENT 1 Gre Feedback 2 AENT 1 inas Input Status AENT 1 EE Output Status EE Reset AENT 1 pe 0 ACC_CROUT1 01 ACC CROUT1 02 AENT 2 0 Pt00Data AENT 2 0 P101Data 3 rr End Rockwell Automation Publication SAFETY AT 112A EN P November 2013 Safety Function Single beam Area Access Control AAC 19 Falling Edge Reset EN ISO 13849 1 stipulates that instruction reset functions must occur on falling edge signals To comply with this requirement add a One Shot Falling OSF instruction to the rung immediately preceding the ACC_OutputEnable1 rung Then use the OSF instruction Output Bit tag as the reset bit for the following rung The ACC_OutputEnable is still used to en
19. ew The 1734 IB8S input module monitors the inputs from the single beam area access control sensor The sensor provides two N C outputs which open when an object interrupts the sensor s field of view These two N C contacts are monitored by test pulses TO and T1 provided by the input module which are configured to test the circuit of I0 and 11 These test pulses are the source of the 24V DC for the circuit By periodically dropping the 24V DC to OV DC it is possible to detect cross channel faults shorts to an external 24V DC and shorts to OV DC These faults and shorts are seen as an open circuit by the input and are detected by either the hardware if configured to detect discrepancy errors or by the appropriate safety function block in the application code Upon detection of an intrusion of the sensor the pair of 100S safety contractors K1 and K2 are de energized The contactors are controlled by a 1734 OBS output module and a wired in series The contactors are tested on start up for faults The start up test is accomplished by using a Configurable Redundant Output CROUT instruction to monitor the feedback circuit into input 7 17 before the contactors are energized These de energized contactors remove power to the motor causing the motor to coast to a stop Stop category 0 The contactors are re energized when the sensor blockage is removed the sensor resumes its normal state and the Reset button is pressed and released The s
20. mation 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 Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss 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 IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions 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 ARC FLASH HAZARD Labels may be on or inside the eq
21. n Bradley Type 1768 1435 CompactLogix53435 Safety Controller OK I Redundancy Enabled Help Name cGLX Description a lt none gt Clot 0 Safety Partner Slot lt mternal Create In C ARSLogix 5000Projects Browse 3 Inthe Controller Organizer right click 1768 Bus and choose New Module E E 10 Configuration ef 1755 Bus of Mew Module a g 1769 E Discover Modules A Faste Ctrl Print Rockwell Automation Publication SAFETY AT112A EN P November 2013 Safety Function Single beam Area Access Control AAC 11 4 Select the 1768 ENBT module and click OK Catalog Module Discovery Favorites Show Filters Y Communication DO T WED DO E UL MOD ne el oud ae SHler olradicy T p 1768 MO4SE 4 Axis SERCOS Interface Allen Bradley Motion 1768 MODULE Generic 1768 Module Allen Bradley Other 2 6 of 6 Module Types Found Add to Favorites I Close on Create Create Close Help pr 5 Name the module type its IP address and click OK For this application example we used 192 168 1 8 however your IP address can be different Type 1769 ENET 24 1768 10100 Mbps Ethernet Bridge Twisted Par Media Address Host Name Revisor i Electronic Keying Compatible Keying 7 Open Module Properties Help 6 In the Controller Organizer right click the Ethernet network and choose New Module 110 Configuration 1768 Bus 5
22. nergized and open for a normal safe condition Verify proper machine status indication and RSLogix 5000 safety application program indication Initiate a Reset command Both contactors remain de energized Verify proper machine status indication and RSLogix 5000 safety application program indication Abnormal Operation Validation The GuardLogix safety system properly responds to all foreseeable faults with corresponding diagnostics Single beam Area Access Control Sensor Tests Test Step Validation Pass Fail Changes Modifications While the system is running remove the channel 1 wire from the safety I O Both contactors de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify that the system is unable to reset and restart with a fault Restore channel 1 and repeat for channel 2 While the system is running short channel 1 of the safety I O to 24V DC Both contactors de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify that the system is unable to reset and restart with a fault Restore channel 1 and repeat for channel 2 While the system is running short channel 1 of the safety I O to OV DC Both contactors de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify that the system is unable to reset and restart with a fault Restore channel 1 and r
23. omation Publication SAFETY AT 112A EN P November 2013 28 Safety Function Single beam Area Access Control AAC For more information on Safety Function Capabilities visit discover rockwellautomation com safety Rockwell Automation Allen Bradley Rockwell Software Compact GuardLogix POINT Guard I O POINT I O CompactLogix Stratix 2000 RSLogix and LISTEN THINK SOLVE 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 AT112A EN P November 2013 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in U S A
24. opper ports 1768 ENBT EtherNet IP bridge module 1768 L43S CompactLogix L43 safety processor 2 0 Mb standard memory 0 5 Mb safety memory 1768 PA3 Power supply 120 240V AC input 3 5 A 24V DC 1769 ECR Right end cap terminator 1734 AENT EtherNet IP twisted pair media I O adapter 1734 IB8S POINT Guard I O safety module 8 point input module 1 compatible with terminal bases with 8 terminations POINT Guard I O safety module 8 safety sourcing 1734 OB8S output module compatible with terminal bases with 8 terminations 1734 TBS Module bases with removable IEC spring terminals 4 quantity 10 1794 PS13 85 264V AC to 24V DC 1 3 A power supply 1 Single beam sensor 0 70 m range terminal chamber with cable gland PG13 5 thread Single beam sensor 0 5 20 m range 24V DC terminal chamber with cable gland PG13 5 thread 440L T4F2070 Q 440L R4F0020 Q 440L AMIRR2 440L AMIRR2 glass corner mirror 45 angle 0 30 m 2 1005 C09ZJ23C MCS 100S C safety contactor 9 A 24V DC 2 800F push button metal guarded blue R metal latch 800FM G611MX10 mount 1 N O contact O N C contacts standard standard pack quantity 1 Rockwell Automation Publication SAFETY AT112A EN P November 2013 5 6 Safety Function Single beam Area Access Control AAC Setup and Wiring For detailed information on installing and wiring refer to the product manuals listed in the Additional Resources System Overvi
25. re based on the safety function being operated once an hour 24 hours a day 365 days a year for a total of 8760 operations a year The 100S contactors are used in the safety function therefore their calculations are based on 17 520 operations per year Documentation Ptr PL Subsystems J Library Name PL PFH 1 h CCF score DCavg 5 MTTFd a Category Requirements of the category E New w S POINT Guard I O 1734 1885 e 1 34E 10 not relevant not relevant not relevant 4 fulfilled vw SB POINT Guard I O 1734 0B85 e 1 38E 10 not relevant not relevant not relevant 4 fulfilled Edit V SB safety PLC Compact Guard e 2 1E 10 not relevant not relevant not relevant 4 fulfilled x SB Contactors 1005 e 2 47E8 65 fulfilled 99 High 100 High 4 fulfilled Delete vw SB safety Single Beam 440L R T e 1 43E 8 not relevant not relevant not relevant 4 fulfilled The overall Safety Function Performance Level is shown below IFA Safety function Documentation Subsystems Determine PL from subsystems Performance Level PL e PFH h 3 94E 3 Rockwell Automation Publication SAFETY AT112A EN P November 2013 Safety Function Single beam Area Access Control AAC The Safety Function can be represented in block diagrams i I i I I I I i i I I i i i I i I i I i 1734 IB8S I 1768 L43S i 1734 OB8S i I I I I I I i I i i i l i i I I i l i I i I Subsystem 1
26. rrannnnrner 4 Safety Function Requirements r rrnnrnannnnrnanrnnrnanrnnrnannannnarnannnnrnnnenannnnnnnnnnnenennnnenee 4 Functional Safety Description rrrnrnnrnanrnnrvanrnarnnnrrannnnnnnrnannnnnnannnnnannneenannnnennsnnnenn 5 Biror Nr 5 EUP AIG VAIN SE NR NN S se 6 OAT UN NO EE EE ated eioaeee cence 10 POO AU NG EEE EEE 17 Calculation of the Performance LeVel ccccccceccecceeceeeseeceeeeeceeeeeeseeeeeeeeeseeenees 20 Verification and Validation PI an cccccceccecceecceeeeeeseeeeeeceeceeeeeeseeeseeseeseeseeegeeees 23 Additional RC SOUNCC Ss caed acetic totes etaccadsadanie EA RAEE a O sews TAE EnB N 2 Introduction This safety function application technique explains how to wire configure and program a Compact GuardLogix controller and POINT Guard I O module to monitor a single beam area access control sensor If a demand is placed on the single beam sensor or a fault is detected in the monitoring circuit the GuardLogix controller de energizes the final control devices 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 single beam area access control sensor with the pulse train output from the POINT Guard I O module for monitoring and detection of fault The SISTEMA Software PL Calculation Tool calculations shown later in this document must be re calculated if different products ar
27. second mm s derived from data on approach speeds of the body or parts of the body T Overall stopping performance in seconds C Intrusion distance in millimeters mm In this example stopping time T is a summation of the following Variable Value Single beam area access control delay time 22 ms from product documentation 1734 IB8S delay 16 ms from documentation Input Module Connection delay Safety Controller delay e Safety Task Watchdog e Safety Task period Output Module Connection Delay 1734 OB8S delay 6 ms from product documentation Contactor response time 15 ms from product documentation Actual Machine stop time assume 900 ms for this example The Input Module connection delay defaults to 4 x requested packet interval RPI If we assume a RPI of 10 ms the maximum delay 40 ms 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 the following assumptions were made e Safety Task Period 10 ms e Safety Task Watchdog 5 ms e Therefore the T in this example is 1029 ms The Output Module connection delay defaults to 3 x RPI If we assume a RPI of 10 ms the maximum delay 30 ms The worst case rea
28. st height of 400 mm can be used only when the risk assessment allows Rockwell Automation Publication SAFETY AT112A EN P November 2013 Safety Function Single beam Area Access Control AAC 9 Electrical Schematic Input Circuit 24V Circuit Fault Reset Reset 400L F4F0020Q 1734 IB8S Receiver 400L T4F2070Q Transmitter on Output Circuit 1734 OB8S K1 and K2 are the safety contactors Rockwell Automation Publication SAFETY AT112A EN P November 2013 10 Safety Function Single beam Area Access Control AAC Configuration The 440L single beam area access control sensor needs no settings only alignment of the transmitter and receiver is necessary The Compact GuardLogix Controller is configured by using RSLogix 5000 software version 17 or later First 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 I O Modules 1 In RSLogix 5000 software create a new project 2 Choose a controller a From the Type pull down menu choose 1768 L435 CompactLogix 5343S Safety Controller b From the Revision pull down menu choose the appropriate revision for the controller In the Name box type an appropriate name for the controller Click OK x Vendor Alle
29. t 10 28 DCInput w Diagnostics Sink Allen Bradley Digital 1734 E 27 2 Channel nalog Voltage Input Allen Bradley Analog 1734 JE4C 4 Channel Analog Current Input Allen Bradley Analog 1734 1E8C 8 Channel naloa Current Inout Allen Bradley 50 of 50 Module Types Found Add to Favorites I Close on Create Create Close Help E New Module l xj General Connection Safety Module Info Input Configuration Test Output Type 1734 IB8S 8 Point 24 DC Sink Input Vendor Allen Bradley Parent AENT Name less Module Number 1 Description 7 Safety Network Ip ania 3827 0414 76E8 6 17 2013 4 00 50 24 PM Module Definition Series Revision 1 1 Electronic Keying Compatible Module Configured By This Controller Input Data Safety Output Data Test Input Status Pt Status Status Creating Cancel Help Rockwell Automation Publication SAFET Y AT 112A EN P November 2013 Safety Function Single beam Area Access Control AAC 15 The Module Definition dialog box appears 16 From the Output Data pull down menu choose None 17 Verify that the Input Status is set to Combined Status Power and click OK Setting the output data to None means the Test Outputs cannot be used as standard outputs This saves one controller connection because we are using only the input connection Module Definition x Serez Revizion 1 v 1 Electronic Keping
30. to change Data will be set to default values unless it can be recovered From the existing module properties verify module properties before Applying changes Change module definition 12 Click Yes to accept the changes 13 In the Controller Organizer right click the PointlO 3 Slot Chassis and choose New Module Ba IO Configuration fi 1766 Bus lB 1 1768 ENBT A ENBT Ex Ethernet L 1768 ENBT A ENBT HC i OE en 6G 0 17 a i 1769 Bus fen mel 0 1768 L435 coLx1 Discover Modules g Paste Ctrl Print Rockwell Automation Publication SAFETY AT112A EN P November 2013 14 Safety Function Single beam Area Access Control AAC 14 Expand Safety select the 1734 IB8S module and click OK Select Module Type 7 Catalog Module Discovery Favorites Enter Search Text for Module Type Clear Filters Show Filters Catalog Number Description Venda Categor a 1734 232A5C R5232 ASCII Interface Module Allen Bradley Specialty 1734 4854SC R5485 ASCII Module Allen Bradley Specialty 1734 8CFG 8 Point 10 28 DC Self Configuring Allen Bradley Digital 1734 8CFGDLX 8 Point 10 28v DC Self Configuring DeviceLogix Allen Bradley Digital 1734 142 2 Point 120 AC Input Allen Bradley Digital 1734 44 4 Point 120 AC Input Allen Bradley Digital 1734 1B2 2 Point 10 28 DC Input Sink Allen Bradley Digital 1734 IB4 4 Point 10 28 DC Input Sink Allen Bradley Digital 1734 1B4D 4 Poin
31. tput Tests Test Step Verification and Validation Pass Fail Changes Modifications Initiate a Start Command Both contactors energize for a normal machine run condition Verify proper machine status indication and RSLogix 5000 safety application program indication While the system is running remove the contactor feedback from the safety I O module All contactors remain energized Initiate a Stop command followed by a Reset command The system does not restart or reset Verify proper machine status indication and RSLogix 5000 safety application program indication While the system is running short the contactor feedback to the safety I O All contactors remain energized Initiate a Stop command and attempt a Reset command The system does not restart or reset Verify proper machine status indication and RSLogix 5000 safety application program indication Rockwell Automation Publication SAFETY AT112A EN P November 2013 Safety Function Single Beam Area Access Control AAC 27 Additional Resources Refer to these publications for more information about related products from Rockwell Automation Resource Compact GuardLogix Controllers User Manual publication 1768 UM002 POINT Guard I O Safety Modules Installation and User Manual publication 1734 UM013 GuardLogix Control Systems Safety Reference Manual publication 1756 RM093 GuardLogix Safety Application Instruction Set Reference Manual publication 1756 RM0
32. uipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE Rockwell Automation Publication SAFET Y AT112A EN P November 2013 Safety Function Single beam Area Access Control AAC 3 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 Perform a risk assessment to make sure all task and hazard combinations have been identified and addressed The risk assessment can 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 Table of Contents Important User Information 2sscssicicncrsvecdacsasahcunseersandardentnvecteaswes tone pecdiossiwndsereansavenaeeeeds 2 General Safety Information rrarrarrnarranerarnnnvnnrrannnnrrannnnnnaannnenurnnanneennanneenuanneennannee 3 POUCO OE 3 Safety Function Realization Risk Assessment rrannnannnnnnannnnnrnnnnnrnnrnnnnnernnnnnennnnnner 4 Single beam Area Access Control Sensor Safety Function r rrrrarrnrrrarnnr
33. ystem is designed so that no single fault results in the safety system failing to perform its safety function A single fault is detected before the next demand on the safety system The system cannot be reset until the fault is corrected The Reset button and the contactor feedback circuit are wired to the input module This is not required for functional safety The Reset button can be wired to a standard input module Installation Refer to the installation instruction and user manuals listed in the Additional Resources for guidance on installing and maintaining the different parts of this system A single beam area access control sensor provides no physical barrier between personnel and the hazardous motion The sensor must be installed at a sufficient distance from the hazardous motion to make sure that an operator putting a hand through the beam cannot reach the hazard before hazardous motion has stopped This distance is referred to as the Safety Distance Rockwell Automation Publication SAFETY AT112A EN P November 2013 Safety Function Single beam Area Access Control AAC 7 Safe Distance Calculation The Safety Distance Ds required varies from installation to installation and therefore must be calculated for each specific application In this application technique the formula from EN ISO 13855 is used Formula S Kx T C Symbol Definition S Minimum distance in millimeters mm K Parameter in millimeters per
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