Safety Function - Rockwell Automation
Contents
1. 1734 Ethernet Adapter Twisted Pair Media Allen Bradley Communication PEPR 1734 Ethernet Adapter 2 Port Twisted Pair Media Allen Bradley Communication ial 1738 ENT 1738 Ethernet Adapter Twisted Pair Media Allen Bradley Communication 1738 4ENTR 1738 Ethernet Adapter 2 Port Twisted Pair Media Allen Bradley Communication 1747 AENTR 1747 Ethernet Adapter 2 Part Twisted Pair Media Allen Bradley Communication 1753 L28BBBx GPLC 1600 GuardPLC 1600 Allen Bradley Programmable Logi 1753 L32BBBx 84 GPLC GuardPLC 1800 Allen Bradley Programmable Logi 1756 EN2F 1756 10 100 Mbps Ethernet Bridge Fiber Media Allen Bradley Communication 1756 EN2T 1756 10 100 Mbps Ethernet Bridge Twisted Pair Media Allen Bradley Communication 1756 EN2TR 1756 10 100 Mbps Ethernet Bridge 2 Port Twisted P Allen Bradley Communication 1756 EN3TR 1756 10 100 Mbps Ethernet Bridge 2 Port Twisted P Allen Bradley Communication 1756 ENBT 1756 10 100 Mbps Ethernet Bridge Twisted Pair Media Allen Bradley Communication 1756 ENET 1756 Ethernet Communication Interface Allen Bradley ommunication 205 of 205 Module Types Found Add to Favorites I Close on Create Create Close Help i A Rockwell Automation Publication SAFETY AT108A EN P December 2013 Safety Function SensaGuard Non contact Interlock Switch 13 8 Name the module type its IP address and click OK For this application example we used 192 168 1 11 however your IP addre2. ollen bradley OMMA 1768 MO4SE 4 Axis SERCOS Interface Allen Bradley Motion 1768 MODULE Generic 1768 Module Allen Bradley Other i 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 New Module xj Type 1768 ENBT 4 1768 10 100 Mbps Ethernet Bridge Twisted Pair Media Vendor Allen Bradley Parent p Name Address Host Name Description IP Address z Host Name Slot BE Revision 4 Electronic Keying Compatible Keying 2 V Open Module Properties Cancel Help Rockwell Automation Publication SAFETY AT 108A EN P December 2013 12 safety Function SensaGuard Non contact Interlock Switch 6 Inthe Controller Organizer right click the Ethernet network and choose New Module Spee I O Configuration 1768 Bus El i 1 1768 ENBT A ENBT ng pepas P agii 1769 Bus Discover Modules Paste Ctrl Print 7 Select the 1734 AENT adapter and click OK Select Module Type Catalog Module Discovery Favorites Enter Search Text for Module Type Clear Filters Show Filters Catalog Number Description Vendor Categor 1732E 0B16M12R 16 Point 24 DC Output 2 Port Allen Bradley Digital aits 8 Point 24 DC Scheduled Output 2 Port Allen Bradley Digital
3. safety application program indication Additional Resources 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 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 RM095 GuardLogix 5570 Controller Systems Safety Reference Manual publication 1756 RM099 Safety Accelerator Toolkit for GuardLogix Systems Quick Start Guide publication IASIMP QS005 SensaGuard Integrated Latch Unique Coded Installation Instructions publication 10000121840 Ver 03 SensaGuard 18 mm Stainless Steel Barrel Installation Instructions publication 5056 181 05 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 Instru
4. 1734 IB8S 1768 L43S I 1734 OB8S Subsystem 2 Ie Subsystem 3 Rockwell Automation Publication SAFETY AT108A EN P December 2013 Safety Function SensaGuard Non contact Interlock Switch 23 Subsystems E stop Safety I O Compact GuardLogix and safety contactors modeled as shown below Documentation Per PL__ Subsystems 3 Library Name PL PFH 1 h CCF score DCavg 9 MTTFd a Category Requirements of t E New w SB POINT Guard I O 1734 IB8S e 1 34E 10 not relevant not relevant not relevant 4 fulfille vw SE POINT Guard I O 1734 OB8S e 1 38E 10 not relevant not relevant not relevant 4 fulfilles Edit vw SB Safety PLC Compact GuardLogix 1768 2 1E 10 not relevant not relevant not relevant 4 fulfille T Delete V SB Contactors 100s e 247E8 65 fulfilled 99 High 100 High 4 fulfille vw SB EStop e 2 47E 8 65 fulfilled 99 High 100 High 4 fulfille 4 PE b The E stop Performance Level is shown below Safety function W IFA Documentation PLr PL Subsystems Determine PL from subsystems Performance Level PL e PFH L h 49815 EStop FL PFH h 2 47E 8 Cat 4 MTTFd a 100 High DCavg 199 High LCF 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 sa
5. Add to Favorites I Close on Create Create Close Help hh Rockwell Automation Publication SAFETY AT108A EN P December 2013 Safety Function SensaGuard Non contact Interlock Switch 15 13 In the New Module dialog box name the device IB8S then click Change E New Module i x General Connection Safety Module Info Input Configuration Test Output Type 1734 IB8S 8 Point 24 DC Sink Input Vendor Allen Bradley Parent AENT Name fiBss Module Number 1 Description a jer Maa 3827 0414 76 8 p 6 17 2013 4 00 50 24 PM Module Definition Revision 14 Electronic Keying Compatible Module Configured By This Controller Input Data Safety Output Data Test Input Status Pt Status Status Creating Cancel Help The Module Definition dialog box appears 14 From the Output Data pull down menu choose None 15 Verify the Input Status is set to Combined Status Power and click OK Setting the output data to None means you cannot use the Test Outputs as standard outputs This saves one controller connection because we are using only the input connection Module Definition x Sene Revizion ho 13 Electronic Keping Compatible Module h onfigured By nput Data Output Data nput Status Combined Status Power 7 Cancel Help 16 Repeat steps 11 15 to add the 1734 OB8S safety output module with these exception
6. FP SafetyGate OutputEnable 4 Ame SafetyGate OutputEnable ROUT Configurable Redundant Output CROUT Gate_K1K2 Feedback Type POSITIVE Feedback Reaction Time Msec 500 Actuate SafetyGate OutputEnable 0 Feedback 1 AENT 1 LPI07Data 0 Feedback 2 AENT 1 1 Pt07 Data 0 Input Status AENT 1 1 CombinedlnputStatus 0 Output Status AENT 2 1 CombinedOutputStatus 0 Reset Fault Reset lt AENT 1 1 PI05Data gt 0 Enable K1 Enable K2 Gate KIK2 01 Gate K1K2 02 lt AENT 2 0 PI00Data gt lt AENT 2 0 Pt01 Data gt lt r T7 T mmmmmmmmm f Rockwell Automation Publication SAFET Y AT 108A EN P December 2013 20 Safety Function SensaGuard Non contact Interlock Switch Calculation of the Performance Level The required Performance Level PLr from the risk assessment is Category 3 Performance Level d CAT 3 PLd When properly implemented the safety functions described can achieve CAT 4 PLe according to EN ISO 13849 1 2008 as calculated by using the SISTEMA software PL calculation tool Calculations are based on each safety function being operated 5 times an hour 12 hours a day 365 days a year for a total of 21 900 operations a year The 100S contactors are used in both safety functions therefore their calculations are based on 43 800 operations per year The measures against Common Cause Failure CCF are quantified by using the scoring process outlined in Annex F
7. Instructions publication PN 46046 unique coded sensor SensaGuard 18 mm Plastic Barrel Provides detailed installation instructions for the Unique Coded Installation Instructions SensaGuard 18 mm plastic barrel unique coded publication PN 46045 sensor Safety Products Catalog publication Provides an overview of products product 5117 CAOQ01 specifications 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 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 SensaGuard 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 Cyberp
8. This is not required for functional safety These three inputs can be wired to a standard input module Rockwell Automation Publication SAFETY AT108A EN P December 2013 Safety Function SensaGuard Non contact Interlock Switch 7 Installation Refer to the installation instruction and user manuals for guidance on installing and maintaining the different parts of this system The size of the openings must prevent the operator from reaching the hazard Table O 10 in U S OHSA 1910 217 f 4 EN ISO 13854 Table D 1 of ANSI B11 19 Table 3 in CSA Z432 and AS4024 1 provide guidance on the appropriate distance a specific opening must be from the hazard Hazard Area Stop Switch Actuator Sliding Guard Guard Open Machine Stopped Guard Covering Switch RFID Non Contact Interlock Switches Non contact interlock switches based on Radio Frequency Identification RFID technology can provide a very high level of security against defeat by simple tools This technology can also be used to provide devices with unique coding for applications where security is paramount The use of RFID technology has many other important advantages RFID technology is suitable for use with high integrity circuit architectures such as Category 4 Performance Level e or SIL 3 RFID technology can be incorporated into devices with fully sealed IP69K enclosures manufactured from plastic or stainless steel When RFID technology is used for c
9. configured Discrepancy Time ms The automatic restart type allows the DCS output O1 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 instruction 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 you manually reset it 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 108A EN P December 2013 18 Safety Function SensaGuard Non contact Interlock Switch The two output tags from the CROUT instruction are used to
10. drive or motor to alert people that surfaces may reach dangerous temperatures 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 SAFETY AT108A EN P December 2013 Safety Function SensaGuard Non contact Interlock Switch 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 cccccc cece eecceeceeeeeeceeeeeeceeceeeceeesesseeceeeseeseesseeeeeeseesaes 3 POUCO OE 3 Safety Function Realization Risk Assessment rrarnnannnnnnannnnnnannnnrnnrvnnnnrnnnnnsnnnnnner 4 SensaGuard Switch Safety Function rrrarrnnrnnrrnnrnarnnnrnarnnnenarnnnnnaennerna
11. input devices are qualified by cycling their respective actuators Monitor the status in the RSLogix 5000 Controller Tags window All output devices are qualified by cycling their respective actuators Monitor the status in the RSLogix 5000 Controller Tags window Rockwell Automation Publication SAFETY AT108A EN P December 2013 26 Safety Function SensaGuard Non contact Interlock Switch GuardLogix SensaGuard Safety Function Verification and Validation Checklist continued Normal Operation Verification The GuardLogix safety system properly responds to all normal Start Stop E stop and Reset commands Test Step 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 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 open the moveable door 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 SensaGuard switches safety application program indication While the system is running press the E stop button Both contactors de energize and open for a normal safe condition Ver
12. perform the calculations and assist with satisfying the requirements of EN ISO 13849 1 Validation 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 108A EN P December 2013 Safety Function SensaGuard Non contact Interlock S
13. 00 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 the keyswitch back to Run mode All contactors remain de energized Verify proper machine status indication and RSLogix 5000 safety application program indication Rockwell Automation Publication SAFETY AT108A EN P December 2013 Safety Function SensaGuard Non contact Interlock Switch 29 GuardLogix SensaGuard Safety Function Verification and Validation Checklist continued Safety Contactor Output 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 5000 safety application program indication While the system is running short the contactor feedback to the safety I O module 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
14. 4 safety Function SensaGuard Non contact Interlock Switch Safety Function Realization Risk Assessment The required performance level PLr 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 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 Mi SensaGuard Switch Safety Function The safety system described in this application has two safety functions e Safety related stop function initiated by the SensaGuard switch e Emergency stop initiated by actuation of an E stop button This system executes a Stop Category 0 stop Power is removed and motion coasts to a stop Safety Function Requirements When the moveable door is opened for access the SensaGuard switch sends signals to the safety controller to de energize outputs stopping the hazardous moti
15. B Module base with removable IEC screw terminals 4 1734 IB8S POINT Guard I O safety input module 1 1734 OB8S POINT Guard I O safety output module 1 1783 US05T Stratix 2000 unmanaged Ethernet switch 1 Any 440N Z SensaGuard product can be used in this application Rockwell Automation Publication SAFETY AT108A EN P December 2013 6 safety Function SensaGuard Non contact Interlock Switch Setup and Wiring For detailed information on installing and wiring refer to the product manuals listed in the Additional Resources System Overview The 1734 IB8S input module monitors two output signal switching devices OSSD from the SensaGuard switch If the moveable door is opened the SensaGuard switch turns off its two PNP outputs OSSD Safety A and OSSD Safety B and the safety controller reacts by turning off the two safety outputs This removes 24V DC from the coils of the two safety contactors whose contacts open removing power to the motor The motor coasts to a stop Stop Category 0 The SensaGuard switch OSSD outputs Safety A and Safety B turn on once the door is closed The SensaGuard switch monitors its internal circuitry and its OSSD outputs for faults When a fault in the internal circuitry or an output is detected the SensaGuard switch responds by turning off its OSSD outputs The pulse test outputs TO and T1 wired to the 1734 IB8S input module are run through the two N C contacts of the E stop to inputs I2 and I3 respecti
16. Cancel 4 Click OK 5 In the Controller Organizer right click the 1734 OB8S module and choose Properties Rockwell Automation Publication SAFETY AT108A EN P December 2013 Safety Function SensaGuard Non contact Interlock Switch 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 Mi Module Properties AENT 2 1734 OB8S 1 1 General Connection Safety Module Info Output Configuration Point Mode 0 Dual Safety Pulse Test Y Safety Pulse Test x Dual Not Used Not Used l Not Used Not Used Dual Not Used Not Used Leet tees Output Error Latch Time 100 ms Status Offline Cancel Apply 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 the DCS instruction is being used to monitor a SensaGuard switch and an E stop button The DCS instruction monitors dual input channels for consistency Equivalent Active High and detects and traps faults when the inconsistency is detected for longer than the
17. ISEN THINK SOME Application Technique Safety Function SensaGuard Non contact Interlock Switch Products SensaGuard Switch GuardLogix Controller Safety Rating CAT 4 PLe to EN ISO 13849 1 2008 Rockwell Allen Bradley gt Rockwell Software Automation 2 safety Function SensaGuard Non contact Interlock Switch 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 Automation Inc cannot a
18. L120D Recoverable actuator 1 is in sensing range Actuator 2 is in sensing range Actuator 3 is in sensing range Actuator 4 is in sensing range ay j 7 lette eis OSSDs Fault Switch 1 is functioning properly Switch 2 is functioning properly Switch 3 has fault Switch 4 is functioning properly ek sS ea are OSSDs are energized to 24V DC OSSDs are energized to 24V DC See table below Red status Series inputs are 0V DC 7 Off Green status indicator is ON Green status indicator is ON nce OPE sn pb WDC RER Green status indicator is flashing to ES i indicate series inputs are not 24V Green status indicator is flashing c to indicate series inputs are not 24V DC Rockwell Automation Publication SAFETY AT108A EN P December 2013 10 Safety Function SensaGuard Non contact Interlock Switch Status Indicators Troubleshooting Not Powered NA Red Not Safe Output Off ue Safe Output On rie Green Power up Test Shock 24V DC on safety outputs de oa Flashing yellow and red wire Indicator Red 1 Hz Flash Recoverable Fault Recoverable Fault Check that safety Flashing 4 Hz Flash Nonrecoverable Fault outputs are not shorted to GND 24V DC or each other Cycle power Safe output on sensor is Readjust the distance between the reaching maximum sensing actuator and the sensor until output distance status is green Configuration Configure the Controller and Add I O Modules The Compact GuardLogix controller is configured by usin
19. 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 module 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 module 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 repeat for channel 2 While the system is running short channels 1 and 2 of the safety I O module 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 channel 2 wiring GuardLogix Controller 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 module and the controller All contactors de energize Verify proper machine status indication and I O connection status in the RSLogix 50
20. ction 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 detailed installation instructions for the SensaGuard coded sensor Provides detailed installation instructions for the SensaGuard coded sensor Rockwell Automation Publication SAFETY AT108A EN P December 2013 30 safety Function SensaGuard Non contact Interlock Switch Resource Description SensaGuard Rectangular Flat Pack Provides detailed installation instructions for the Installation Instructions publication SensaGuard 18 mm stainless steel barrel 10000182958 Ver 00 sensor SensaGuard Rectangular Flat Pack Provides detailed installation instructions for the Installation Instructions publication SensaGuard rectangular flat pack sensor 15056 179 Ver 04 SensaGuard 18 mm Plastic Barrel Provides detailed installation instructions for the Installation Instructions publication SensaGuard 18 mm plastic barrel sensor 75056 180 3 SensaGuard Rectangular Flat Pack Provides detailed installation instructions for the Unique Coded Installation Instructions SensaGuard rectangular flat pack unique coded publication PN 46047 sensor SensaGuard 18 mm Stainless Steel Provides detailed installation instructions for the Barrel Unique Coded Installation SensaGuard 18 mm stainless steel barrel
21. drive the contactor outputs on the 1734 OB8S module DCS 0 Dual Channel Input Stop DCS Gate_SG1 Safety Function SAFETY GATE Input Type EQUIVALENT ACTIVE HIGH Discrepancy Time Msec 250 Restart Type AUTOMATIC Cold Start Type AUTOMATIC Channel amp AENT 1 1 Pt00Data 0 Channel B AENT 1 1 Pt01 Data 0 Input Status AENT 1 1 CombinedlnputStatus 0 Faut_Reset 1 Dual Channel Input Stop DCS Gate_Estop 01 3 Safety Function EMERGENCY STOP Input Type EQUIVALENT ACTIVE HIGH FP Discrepancy Time Msec 250 Restart Type AUTOMATIC Cold Start Type AUTOMATIC Channel amp AENT 1 1 Pt02Data 0 Channel B AENT 1 1 Pt03Data 0 Input Status AENT 1 1 CombinedinputStatus 0 Reset Faut_Reset lt AENT 1 1 PI05Data gt 0 Safety_Reset sAENT 1 1 Pt04Data gt wrk_gate_ONS Gate 5G1 01 Gate_Estop 01 Gate_KiK2 FP SafetyGate OutputEnable 2 vm UDE e eu SafetyGate OutputEnable ROUT 3 Configurable Redundant Output CROUT Gate_K1K2 Feedback Type POSITIVE Feedback Reaction Time Msec 500 Actuate SafetyGate OutputEnable 0 Feedback 1 AENT 1 1 PI07Data 0 Feedback 2 AENT 1 1 Pt07 Data 0 Input Status AENT 1 1 CombinedlInputStatus 0 Output Status AENT 2 1 CombinedOutputStatus 0 Reset Fault Reset lt AENT 1 1 PI0SData gt Enable K1 Enable K2 Gate K1K2 01 Gate K1K2 02 lt AENT 2 0 PI00Data gt lt AENT 2 0 Pt01 Data gt 4 End Rockwell Automation Publication SAFET Y AT 108A EN P December 2013 Saf
22. ety Function SensaGuard Non contact Interlock Switch 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 Cmd_Zone1_OutputEnable rung then use the OSF instruction Output Bit tag as the reset bit for the following rung The Cmd Zone1l OutputEnable is still used to enable the CROUT instruction The modified code appears below in rungs 1 and 2 DCS Dual Channel Input Stop DCS Gate_SG1 Safety Function SAFETY GATE Input Type EQUIVALENT ACTIVE HIGH Discrepancy Time Msec 250 Restart Type AUTOMATIC Cold Start Type AUTOMATIC Channel A AENT 1 1 Pt00Data 0 Channel B AENT 1 1 Pt01 Data 0 Input Status AENT 1 1 CombinedinputStatus 0 Reset Fault Reset lt AENT 1 1 PI05Data gt Dual Channel Input Stop DCS Gate_Estop Safety Function EMERGENCY STOP Input Type EQUIVALENT ACTIVE HIGH Discrepancy Time Msec 250 Restart Type AUTOMATIC Cold Start Type AUTOMATIC Channel amp AENT 1 1 P102Data FP 0 Channel B AENT 1 1 PI03Data 0 Input Status AENT 1 1 CombinedinputStatus 0 Reset Fault Reset lt AENT 1 1 Pt05Data gt 0 Safety Reset lt AENT 1 1 P104Data gt OSF One Shot Falling Storage Bit vyrk gate OSF SB 3 Output Bit vyrk FallingEdge OB 3 Vyrk FalingEdge Gate 5G1 01 Gate Estop 01 Gate KIKZ2
23. fety evaluations include the following e How frequently they are operated e Whether they are effectively monitored for faults e Whether they are properly specified and installed SISTEMA software calculates the MT TFd by using B10d data provided for the contactors along with the estimated frequency of use entered during the creation of the SISTEMA project This application example presumes that the E stop is operated or tested at least once per day for a total of 365 times a year The DCavg 99 for the contactors is selected from the Output Device table of EN ISO 13849 1 Annex E Direct Monitoring The DCavg 99 for the E Stop is selected from the Input Device table of EN ISO 13849 1 Annex E Cross Monitoring Rockwell Automation Publication SAFETY AT108A EN P December 2013 24 Safety Function SensaGuard Non contact Interlock Switch 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
24. g RSLogix 5000 software version 17 or later You must create a new project and add the I O modules Then configure the I O modules for the correct input and output types A detailed description of each step is beyond the scope of this document Knowledge of the RSLogix programming environment is assumed 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 d Click OK x Vendor Allen Bradley Type 17681435 CompactLogix53435 Safety Controller DE Revision We Cancel bo Redundancy Enabled Help Mame Description Ehassie Type Slot 0 4 Safety Partner Slot lt mberral gt Create In C RSLogix FOOO Projects Browse Rockwell Automation Publication SAFETY AT108A EN P December 2013 Safety Function SensaGuard Non contact Interlock Switch 11 3 In the Controller Organizer right click 1768 Bus and choose New Module E E 1 0 Configuration Sea 1765 Bus f d 0 New Module a g 1769 E Discover Modules 6 or EA Paste Ctrl Print 4 Choose the 1768 ENBT module and click OK Select Module Type Gass Catalog Module Discovery Favorites Show Filters bol WED DO F JU MDD Nemet bidd A d
25. ify proper machine status indication and safety relay status indicator indication Repeat for all E stop buttons While the system is stopped press the E stop button and initiate a Start command Both contactors remain de energized and open for a normal safe condition Verify proper machine status indication and safety relay status indicator indication Repeat for all E stop buttons Initiate a Reset command Both contactors remain de energized Verify proper machine status indication and RSLogix 5000 safety application program indication While the system is stopped and the door is open initiate a Start command Both contactors remain de energized and open for a normal safe condition Verify proper machine status indication and RSLogix 5000 Rockwell Automation Publication SAFETY AT108A EN P December 2013 Safety Function SensaGuard Non contact Interlock Switch 27 GuardLogix SensaGuard Safety Function Verification and Validation Checklist continued Abnormal Operation Validation The GuardLogix safety system properly responds to all foreseeable faults with corresponding diagnostics E stop Input Tests Test Step Validation Pass Fail Changes Modifications While the system is running remove the channel 1 wire from the safety I O module 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 wi
26. nnnernnennenner 4 Safety Function Requirements arrnrrnanrnnrvanrnnrnannnnrnannannnarnannnurnnnenannnnnnnnnnnennennnener 4 Functional Safety Description rrrnrnnrnanrnnrvanrnarnnnrrannnnnnnrnannnnnnannnnnannneenannnnennsnnnenn 5 Biror Nr 5 EUP AIG Aa 0 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 ccccccccccecceeceeeeeeceeeeeeceeeeeeseeeeeeseeeaeeeaes 20 Verification and Validation PI an ccccccccccecceecceeeeeseeeeeeceeceeeeeeceeeseeseeseeseeeseeeas 24 Additional 5 CSOUNC CS scar Sacer totes etacsabyadanie aA O aAa EnEn NNE 29 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 both an E stop button and a SensaGuard switch When the moveable door is opened the E stop button is actuated or a fault is detected in the monitoring circuit the safety 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 SensaGuard switch and an E stop button The SISTEMA software PL calculation tool calculations shown later in this document must be re calculated if different products are used Rockwell Automation Publication SAFETY AT108A EN P December 2013
27. nt not relevant not relevant 4 fulfilled i vw SE POINT Guard I O 1734 OB8S e 1 38E 10 not relevant not relevant not relevant 4 fulfilled Edit V SB Safety PLC Compact GuardLogix e 2 1E 10 not relevant not relevant not relevant 4 fulfilled XT Delete 5B Contactors 1005 e 247E8 65 fulfilled 99 High 100 High 4 fulfilled vw SE Interlock Switch SensaGuard e 1 12E 9 It relevant not relevant not relevant 4 fulfilled TT SensaGuard Safety Function Subsystem 1 GE Interlock Switch SensaGuard PL E PFH 1h 11 12E 9 Cat 4 MTT Fd a saa DCavg 4 cant atest CEF AN SN SensaGuard Safety Function Subsystem 2 SE POINT Guard 170 1734 1885 FL PFH T k 1 34E 10 Lat 4 MTT Fd a can naia DLavg 8 natalis CCF SO Aen Rockwell Automation Publication SAFETY AT108A EN P December 2013 22 safety Function SensaGuard Non contact Interlock Switch SensaGuard Safety Function Subsystem 3 Safety PLC Compact GuardLogi 1768 PL E PFH ih 21E 10 Cat 4 MTTFd a arna DCavg E ar nnana CLF Aue sr SensaGuard Safety Function Subsystem 4 POINT Guard 170 1734 0685 PL PFH Th 1 1 39E 10 Cat 4 MTTFd a amina DCavg E ar nnan CEF yt ESN SensaGuard Safety Function Subsystem 5 GE Contactors 1005 PL E PFH 1 h 2 47E 8 Cat 4 MTTFd a 100 High DCavg 2 199 High CCF 65 fulfilled The E Stop safety function is represented below E stop 1
28. oding and inductive technology for sensing a large sensing range and tolerance to misalignment can be achieved typically 15 25 mm This means that these devices can provide very stable and reliable service combined with high levels of integrity and security over a wide range of industrial safety applications The SensaGuard switch interlocks use RFID technology Rockwell Automation Publication SAFETY AT108A EN P December 2013 8 Safety Function SensaGuard Non contact Interlock Switch Electrical Schematic 24V DC z Safety Reset Fault Reset E T l IO 1 14 15 SensaGuard ene Fi z G White Aux Contact 666 64 Mr 3 1 co COM COM COM TO T1 T2 T3M 24V DC COMMON 1734 IB8S 4 Stainless steel models have an ok additional green wire that should be Y Y terminated to the power supply ground 06 A COM COM COM 2 COM COM COM 1734 OB8S Rockwell Automation Publication SAFETY AT108A EN P December 2013 Typical Wiring Diagrams Description Plastic Stainless Steel ae 3 Shield 2 24V DC 8 HAMN SG Ar Aux A pest ies TR oe 4 Safety B Kon 7 Ground 7 Ground 5 Safety A KZ 5 Safet ewe 6 Safety B y OF 6 Safety B 8 pin Cordset Safety A 889D F8AB Red Safety A Safety A a Safety B Safety B Aux A Aux A 24V DC Gnd Gnd NA Shield Replace symbol with 2 2 m 5 5 m or 10 10 m for standard cable lengths Green wire only applies to the stainless steel model X
29. of EN 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 performed when implementing this example The subsystem values are shown below Project W IFA Documentation Safety functions New 2 Edit SE SensaGuard Safety Function S w SF EStop Safety Function lal Delete The overall safety project Performance Level is shown below Safety function w IFA Determine PL from subsystems Performance Level PL e PFH L h 463E 8 This safety System includes two safety functions a SensaGuard safety function and an E stop safety function The two safety functions can be represented in block diagrams Rockwell Automation Publication SAFETY AT108A EN P December 2013 Safety Function SensaGuard Non contact Interlock Switch 21 The SensaGuard safety function can be modeled as shown in the following safety related block diagram SensaGuard 1734 IB8S 1768 L43S 1734 OB8S Subsystem 1 Subsystem 4 Subsystem 5 Subsystem 2 Subsystem 3 Subsystems SensaGuard Safety I O Compact GuardLogix and safety contactors modeled as shown below Safety function OG IFA Documentation Per PL Subsystems 2 Library Name PL PFH 1 h CCF score DCavg Po MTTFd a Category Requirements of the ca ED New vw SB POINT Guard I O 1734 1885 e 1 34E 10 not releva
30. on by removing power to the motor The system cannot be reset while the moveable door is open Once the door is closed and the Reset button is pressed and released a separate action the electrical circuit is re established and the machine is ready to start Pressing the E stop button stops the hazardous motion by removing power to the motor by the use of two safety contactors Releasing the E stop button does not restart the hazardous motion Pressing and releasing the Reset button after the E stop button has been reset and all faults are cleared prepares the machine for Rockwell Automation Publication SAFETY AT108A EN P December 2013 Safety Function SensaGuard Non contact Interlock Switch 5 normal operation ready to run The machine runs after the Start button is pressed A fault at the SensaGuard switch E stop wiring terminals or safety controller is detected before the next safety demand The safety system described in this application technique is capable of connecting and interrupting power to motors rated up to 9 A 600V AC The safety functions in this application technique each meet or exceed the requirements for Category 3 Performance Level d CAT 3 PLd per EN ISO 13849 1 and control reliable operation per ANSI B11 19 Functional Safety Description The SensaGuard switch and the E stop button are wired to pairs of safety inputs of a safety input module S11 The safety contactors K1 and K2 are connected to a pai
31. ort Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication SAFETY AT108A EN P December 2013 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in U S A
32. r of safety outputs of a safety output module S01 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 SensaGuard switch and E stop button by 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 button is pressed and released a second pre certified function block called Configurable Redundant Output CROUT controls and monitors feedback for a pair of 100S redundant contactors Bill of Material This application uses these products 440N Z21SS2HN SensaGuard plastic rectangular 2 x PNP 0 2 A max safety output 6 in pigtail 8 pin micro M12 margin indication 889D F8AB 2 DC micro M12 female straight 8 pin PVC cable yellow unshielded 24AWG 2 m SOOFP MT44PX02S 800F non illuminated mushroom operators twist to release 40 mm round plastic red plastic latch mount 0 N O contacts 2 N C contacts self monitoring 800F 1YP3 800F 1 hole enclosure E stop station plastic PG twist to release 40 mm non illuminated 2 N C contacts 100S CO9EJ23C Bulletin 100S C safety contactors 9 A 24V DC 2 1768 ENBT CompactLogix EtherNet IP bridge module 1 memory 0 5 Mb safety memory 1768 PA3 Power supply 120 240V AC input 3 5 A 24V DC 1 1769 ECR Right end cap terminator 1 1734 AENT 24V DC Ethernet adapter 1 1734 T
33. s name the module OB8S set the module to slot 2 and set the Input Status to Combined Status Feedback Power Rockwell Automation Publication SAFET Y AT 108A EN P December 2013 16 safety Function SensaGuard Non contact Interlock Switch 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 lolx General Connection Safety Module Info Input Configuration Test Output Point Point Mode ua Pulse Test Pulse Test v Pulse Test 7 Not Used v Status Offline Cancel Apply Help 3 Click Input Configuration and configure the module as shown e Input Points 0 1 are the SensaGuard e Input Points 2 3 are E stop buttons e Input Points 4 5 are the Reset buttons e Input Point 7 is the contactor monitoring circuit Inputs Point 2 and 3 are being sourced from Test Output 0 and 1 respectively Input Point 7 is being sourced from Test Output 2 E Module Properties AENT 1 1734 IB8S 1 1 ioj x General Connection Safety Module Info Input Configuration Test Output Point Operation Input Delay Time ms Test Source off 0n On Off z Safety Pulse Test v Safety Pulse Test vil Safety Pulse Test vi Input Error Latch Time 1004 ms Status Offline OK
34. ss can be different Ml New Module x General Connection Module Info Internet Protocol Port Configuration Chassis Size Type 1734 AENT 1734 Ethernet Adapter Twisted Pair Media Vendor Allen Bradley Parent NE Ethernet Address Name AENT Private Network 192 168 1 114 Description a Wa IP Address Host Name i eeeusgesevensvenenenevonsvesewone S lot 0 Y M Module Definition ueeseseeeosoesoscSsseosossosesseoo Revision 31 Electronic Keying Compatible Module Connection Rack Optimization Chassis Size 1 Status Creating OK Cancel Help 9 Click Change The Module Definition dialog box appears 10 From the Chassis Size pull down menu choose 3 and click OK Chassis size is the number of modules that are 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 xX Sene lA 3 1 gt Electronic Keying Compatible Module Connection rack Ontinizaion d Chassis Sze E Revizion Rockwell Automation Publication SAFETY AT108A EN P December 2013 1 4 S afety Function SensaGuard Non contact Interlock Switch The confirmation screen will be displayed Click Yes to accept the changes RSLogix 5000 i x 4 These changes will cause module data types and properties to change Da
35. ssume 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 lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence ATTENTION Identifies information about practices or circumstances that can 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 ARC FLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc 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
36. ta 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 11 In the Controller Organizer right click the PointlO 3 Slot Chassis and choose New Module Bae KO Configuration fi 1766 Bus lB 1 1768 ENBT A ENBT i l Ethernet fl 1768 ENBT A ENBT PT LE bw FE 0 17 a i 1769 Bus B 0 1768 1435 cGLX1 Discover Modules EA Paste Ctrl Print 12 Expand Safety select 1734 IB8S module and click OK Catalog Module Discovery Favorites Clear Filters Show Filters Catalog Number R5232 ASCII Interface Module 1734 2324SC Allen Bradley Specialty 1734 4854SC R5485 ASCII Module Allen Bradley Specialty 1734 8CFG 8 Point 10v 28v DC Self Configuring Allen Bradley Digital 1734 8CFGDL 8 Point 10V 28v DC Self Configuring DeviceLoaix Allen Bradley Digital 1734 42 2 Point 120 AC Input Allen Bradley Digital 1734 144 4 Point 120 AC Input Allen Bradley Digital 1734 1B82 2 Point 10 28 DC Input Sink Allen Bradley Digital 1734 1B4 4 Point 10 28 DC Input Sink Allen Bradley Digital 1734 IB4D 4 Point 10 28Y DCInput w Diagnostics Sink Allen Bradley Digital 1734 E 2 2 Channel Analog Voltage Input Allen Bradley Analog 1734E4C 4 Channel Analog Current Input Allen Bradley Analog 1734 1E8C 8 Channel Analog Current Inout Allen Bradley 50 of 50 Module Types Found
37. th a fault Restore channel 1 and repeat for channel 2 While the system is running short channel 1 of the safety I O module 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 module 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 repeat for channel 2 While the system is running short channels 1 and 2 of the safety I O module Both contactors de energize Verify proper machine status indication an RSLogix 5000 safety application program indication Verify that the system is unable to reset and restart with a fault Restore channel 1 and channel 2 wiring Rockwell Automation Publication SAFETY AT108A EN P December 2013 28 Safety Function SensaGuard Non contact Interlock Switch GuardLogix SensaGuard Safety Function Verification and Validation Checklist continued SensaGuard Input Tests Test Step Validation Pass Fail Changes Modifications While the system is running remove the channel 1 wire from the safety I O module Both contactors de energize Verify proper machine status indication
38. vely When the E stop is pressed and released these circuits are interrupted The safety controller reacts by turning the safety contacts off This removes power from the 100S contactor coils and removing 24V DC from the coils of the two 100S contactors whose contacts open removing power to the motor The motor coasts to a stop Stop Category 0 Shorts to OV DC and wire off are seen as an open circuit by the 1734 IB8S input module and the safety controller reacts by dropping out the safety contactors If the inputs remain discrepant for longer than the discrepancy time then the function block Dual Channel Input Stop DCS in the safety controller declares a fault Only after the fault is cleared and the SensaGuard switch or E stop inputs are cycled door opened then closed or push and release the button is the function block reset The final control devices are a pair of 100S safety contactors K1 and K2 The contactors are controlled by a 1 34 OB8S safety output module The contactors are wired in a redundant series configuration A feedback circuit is wired through the N C contacts and back to an input on the 1734 IB8S 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 The Reset buttons and the two contactor feedbacks circuit are all wired to the 1734 IB8S module in this example
39. witch 25 GuardLogix SensaGuard 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 10 Safety Network Number s RSLogix 5000 Software Version Safety Control System Modules GuardLogix Modules 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 Firmware Revision GuardLogix Safety System Configuration and Wiring Verification Test Step Pass Fail Changes Modifications 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 reference manuals listed in the Additional Resources See the I O is wired as documented in the schematics dl configured as documented Visually inspect the RSLogix 5000 program to verify that safety system network and I O module configuration is configured as documented Visually inspect the RSLogix 5000 application program to verify that suitable safety certified instructions are used The logic is readable understandable and testable with the aid of clear comments All
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