Safety Function - Rockwell Automation
Contents
1. CombinedinputStatus o Output Status AEM T 2 _CombinedOutputStatus g Feret SENT 2 POS Donki KARL 01 Senat FK IEZ We AEAMT 2 0 POG ata BENT 250 Pei Dats eS OE E CE red Falling Edge Reset ISO 13849 1 stipulates that instruction reset functions must occur on falling edge signals To comply with this requirement a One Shot Falling OSF instruction is used on the reset rung Then the OSF instruction Output Bit tag is used as the reset bit for the Output Enable rung Calculation of the Performance Level When properly implemented this door monitoring safety function can achieve a safety rating of Category 3 Performance Level d CAT 3 PLd according to ISO 13849 1 2008 as calculated by using the SISTEMA software PL calculation tool The Performance Level required PLr from the risk assessment for the safety functions in this application is PLd minimum and a structure of Cat 3 minimum A PFHd of less than 1 0 E 06 for the overall safety function is required for PLd 14 Rockwell Automation Publication SAFETY ATO60C EN P December 2014 Safety Function Door Monitoring The individual subsystem values are shown below Safety function Wy IFA Documentation PLr PL Subsystems E Stat Type Name PL PFH ish CCF score DCcavg MITTFd a Category Requirements of the category rE 56 Safety Gate 1 e 2A7E 8 65 fulfilled 99 High 100 High 4 fulfilled fa New v 5B Mechanical2. and program a Compact GuardLogix controller and POINT Guard I O module to monitor a Trojan 5 tongue interlock switch that is mounted on a door If the door is opened or a fault is detected in the monitoring circuit the GuardLogix controller de energizes the final control device in this case a redundant pair of 100S C contactors This example uses a Compact GuardLogix controller but is applicable to any GuardLogix controller This example uses a Trojan 5 tongue switch but is applicable to dual dry contact devices with at least two N C contacts The SISTEMA calculations shown later in this document would have to be re calculated using the actual products 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 y 2 Specification of character
3. Twisted Pair Allen Bradley 1756 EN3TR 1756 10 100 Mbps Ethernet Bridge 2 Port Twisted Pair Allen Bradley 1756 ENBT 1756 10 100 Mbps Ethernet Bridge Twisted Pair Media Allen Bradley 1756 ENET A 1756 Ethernet Communication Interface Allen Bradley 1756 ENET B 1756 Ethernet Communication Interface Allen Bradley 1756 EWEB A 1756 10 100 Mbps Ethernet Bridge w Enhanced Web Serv Allen Bradley x F Find Add Favorite By Category Favorites mei Heb 2 8 Rockwell Automation Publication SAFETY AT060C EN P December 2014 Safety Function Door Monitoring 7 Inthe New Module dialog box do the following a Name the module b Type its IP address c Click OK This example uses 192 168 1 11 as the IP address Yours can be different 8 Click Change x General Connection Module Info Internet Protocal Port Configuration Chassis Size Type 1734 AENT 1734 Ethernet Adapter Twisted Pair Media Vendor Allen Bradley Parent ENET Ethernet Address Name ent i Private Network 192 168 E H Descriptions iia Se eR E Host Name Module Definition Revision 31 Compatible Module Electronic eying Connection Rack Optimization 1 Chassis Size Status Creating Cancel Help 9 Set the Chassis Size at 3 for the 1734 AENT adapter and click OK z Revision 3 4 Electronic Keping Compatible Module cack Loti Connection Chassis Size IMPORTANT Cha
4. bridge wiEnnanced Web Serv Men Bre E Motion Other Rockwell Automation Publication SAFETY ATO60C EN P December 2014 7 Safety Function Door Monitoring 4 In the New Module dialog box do the following a Name the module b Type its IP address c Click OK New Module ey Type 1 68 ENBT 4 1766 10 1700 Mbps Ethernet Bridge Twisted Pair Media Vendor Allen Bradley Parent afer Address Host Name Name i ENET 152 168 1 g Host Mame Slot i Revision a f Electronic Keying Compatible Keping IY Open Module Properties Cancel Help This example uses 192 168 1 8 as the IP address Yours can be different 5 To add the 1734 AENT adapter in the Controller Organizer right click the 1768 ENBT module in the Controller Organizer and choose New Module LO Configuration i 1768 Bus ff 1 1768 ENBT A ENET E o 17 1769 bus 0 176i 6 Select the 1734 AENT adapter and click OK 1734 AENT 1734 Ethernet Adapter Twisted Pair Media Allen Bradley STAENTR 1734 Ethernet Adapter 2 Port Twisted Pair Media Allen ee 1738 AENT 1738 Ethernet Adapter Twisted Pair Media Allen Bradley 1738 AENTR 1738 Ethernet Adapter 2 Port Twisted Pair Media Allen Bradley 1756 EN2F 1756 10 100 Mbps Ethernet Bridge Fiber Media Allen Bradley 1756 EN2T 1756 10 100 Mbps Ethernet Bridge Twisted Pair Media Allen Bradley 1756 EN TR 1756 10 100 Mbps Ethernet Bridge 2 Port
5. install a Rockwell Automation industrial system Provides information on safety products available from Rockwell Automation Provides declarations of conformity certificates and other certification details Provides details on how to model safety functions in the SISTEMA tool 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 20 Rockwell Automation Publication SAFETY ATO60C EN P December 2014 Safety Function Door Monitoring Notes Rockwell Automation Publication SAFETY ATO60C EN P December 2014 21 Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature For more information on Safety Function Capabilities visit http marketing rockwellautomation com safety en safety functions Allen Bradley Compact GuardLogix CompactLogix GuardLogix LISTEN THINK SOLVE POINT Guard I O POINT I O Rockwell Automation Rockwell Software RSLogix Stratix 2000 and Trojan are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies EtherNet IP is a trademark of the ODVA Rockwell O
6. 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 equipment 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 gt gt gt 2 Rockwell Automation Publication SAFETY ATO60C EN P December 2014 Safety Function Door Monitoring 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 assessment can require additional circuitry to reduce the risk to a tolerable level Safety circuits must take into consideration safety ATTENTION Perform a risk assessment to make sure all task and hazard combinations have been identified and addressed The risk distance calculations which are not part of the scope of this document Introduction This safety function application technique explains how to wire configure
7. 0 module network connection and allow time to reestablish communication Verify the Connection Status Bit in the RSLogix 5000 safety application program Repeat for all safety 1 0 connections 3 While the system is running switch the controller out of Run mode All contactors should de energize Return the key switch back to Run mode All contactors should remain de energized Verify proper machine status indication and RSLogix 5000 safety application program indication Safety Contactor Output Tests Initiate a Start command Both contactors should energize for a normal machine run condition Verify proper machine status indication and RSLogix 5000 safety application program indication 2 While the system is running remove the contactor feedback from the safety I 0 All contactors should remain energized Initiate a Stop command and attempt a Reset command The system should not restart or reset Verify proper machine status indication and RSLogix 5000 safety application program indication While the system is running short the contactor feedback to the safety 1 0 All contactors should remain energized Initiate a Stop command and attempt a Reset command The system should not restart or reset Verify proper machine Status indication and RSLogix 5000 safety application program indication Rockwell Automation Publication SAFETY ATO60C EN P December 2014 19 Safety Function Door Monitoring Additional Resources These docum
8. 8S safety output module name the module OB8S choose slot 2 and choose Combined Status Readback Power for Input Status definition Module Definition x Series fa Revision h E Electronic Keying Compatible modue Configured By This Controller Input Data None Lalle Output Data Safet Input Status Data Format Integer e Heb Configure the 1 0 Modules Follow these steps to configure the POINT Guard I O modules Rockwell Automation Publication SAFETY AT060C EN P December 2014 11 Safety Function Door Monitoring 1 In the Controller Organizer right click the POINT Guard I O 1734 IB8S module and choose Properties 2 Click Test Output and configure the module as shown El Module Properties AENT 1 1734 IB8S 1 1 General Connection Safety Module Info Input Configuration Test Output o Puse Test a o Pulse Test gt ANN TO and T1 are being used to pulse test the Trojan 5 switch channels T2 is being used to pulse test the contactor feedback circuit 3 Click Input Configuration and configure the module as shown OW Module Properties AENT 1 1734 IB8S 1 1 General Connection Safety Module Info Input Configuration Test Output Point Operation Input Delay Time ms Point Discrepancy Point Mode tee O Single O af Safety Pulse Test j 0 a a 1 a Safety
9. Application Technique Allen Bradley Safety Function Door Monitoring Products Trojan 5 Switch GuardLogix Controller Safety Rating CAT 3 PLd to ISO 13849 1 2008 mom ar Topic Page Important User Information 2 General Safety Information 3 Introduction 3 Safety Function Realization Risk Assessment 3 Interlock Safety Function 4 Safety Function Requirements 4 Functional Safety Description 4 Bill of Material 5 Setup and Wiring Configuration 6 Programming 13 Calculation of the Performance Level 14 Verification and Validation Plan 17 Additional Resources 20 USE NE THINK SOILME Rockwell Allen Bradley Rockwell Software Automation Safety Function Door Monitoring 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 impai
10. Fault Exclusion d 0 wt relevent not relevant not relevoni 4 fulfilled 5B Safety 1 0 1734 1685 e 225E 10 notrelevont not relevant 3 fulfilled 2 vo 56 Safety PLC Compact GuardLogix 1768 e 2 1E 10 t not relevan t refewant 4 fulfilled G vy 5B Safety V0 1734 0885 e 229E 10 notrelevent not relevant not relevant 4 fulfilled w SE Contactors 2 47E 8 65 fulfilled 99 High 100 High 4 fulfilled The overall safety function value is shown below Safety function W IFA Docu mentation Pir PL Subsystems Determine PL from subsystems Performance Level PL d PFH l h 5E 8 The door monitoring safety function can be modeled as shown in the following safety related block diagram Input Fault Exclusion Logic Logic Logic Output _ p o es pnl l ON l a G p a A y y a y a M a Trojan 5 K1 1005 C S1 Fault Exclusion 1734 IB8S 1768 L435 1734 0B8S Trojan 5 S2 Subsystem 1 I l Subsystem 2 I l Subsystem 3 I Subsystem 4 I l Subsystem 5 Subsystem 6 b oae ee a a a ae a ere a en eee eee a o a b e he a Calculations are based on one operation of the safety guard door per hour therefore 8760 operations of contactors per year The measures against Common Cause Failure CCF are quantified using the scoring process outlined in Annex F of ISO 13849 1 For the purposes of the PL calculation the required score of 65 needed to fulfi
11. Pulse Test 1 gt of 0S 2 Single 0 a Not Used v None v o lt 3 i Not User None gt j o 4 Single 0 af Safety v None oz oz 5 Safet x None 02 02 6 Single 0 Not Used 7l None _ 02 02 7 W z Safety Pulse Test 0a ay Input Error Latch Time 1 oH ms Status Offline Cancel Apply Help IMPORTANT Inputs 0 1 are the Light Curtain Inputs 4 5 are the reset buttons Input 7 is contactor monitoring circuit Recall that input 7 is being sourced from Test Output 2 4 Click OK 5 In the Controller Organizer right click the POINT Guard I O 1734 OB8S module and choose Properties 12 Rockwell Automation Publication SAFETY ATO60C EN P December 2014 Safety Function Door Monitoring 6 Click Output Configuration and configure the module as shown DE Module Properties AENT 2 1734 OBBS 1 1 General Connection Safety Module Info Output Configuration a Safety Pulse Test Safety Pulse Test Not Used Not Used a Not Used Not Used Output Error Latch Time 1000 4 ms Status Offline Cancel Apply Help 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 7 Click OK Programming The Dual Channel Inp
12. al publication 1756 RM093 2 Verify that the safety application program is designed in accordance with the GuardLogix Application Instruction Safety Reference Manual publication 1756 RM095 3 Visually inspect the safety system network and verify that the 1 0 is wired as documented in the schematics 4 Visually inspect the RSLogix 5000 program to verify that the safety system network and 1 0 module configuration is configured as documented 5 Visually inspect the RSLogix 5000 application program to verify that suitable safety certified instructions are used The logic must be readable understandable and testable with the aid of clear comments All input devices are qualified by cycling their respective actuators Monitor the Status in the RSLogix 5000 Controller Tags window 7 All output devices are qualified by cycling their respective actuators Monitor the status in the RSLogix 5000 Controller Tags window Normal Operation Verification The GuardLogix safety system properly responds to all normal Start Stop Enable and Reset commands Initiate a Start command Both contactors should energize for a normal machine run condition Verify proper machine status indication and RSLogix 5000 safety application program indication Initiate a Stop command Both contactors should de energize for a normal machine Stop condition Verify proper machine status indication and RSLogix 5000 safety application program indication 3 While
13. ents contain additional information concerning related products from Rockwell Automation Resource Compact GuardLogix Controllers User Manual publication 1768 UM002 POINT Guard 1 0 Safety Modules User Manual publication 1734 UM013 GuardLogix Controller Systems Safety Reference Manual publication 1756 RM093 GuardLogix Safety Application Instruction Set Reference Manual publication 1756 RM095 Safety Accelerator Toolkit for GuardLogix Systems Quick Start Guide publication IASIMP QS005 Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Rockwell Automation Safety Products Catalog available from the Product Catalogs link at http www ab com Product Certifications website http www ab com The SISTEMA Cookbook 4 available at http www dguv de ifa Praxishilfen Software SISTEMA SISTEMA Kochb C3 BCcher index 2 jsp Description Provides information on how to configure operate and maintain Compact GuardLogix controllers Provides information on how to install configure and operate POINT Guard 1 0 modules Contains detailed requirements for how to achieve and maintain safety ratings with the GuardLogix controller system in an RSLogix 5000 project Provides detailed information on the GuardLogix Safety Application Instruction Set Provides a step by step guide on how to use the design programming and diagnostic tools in the Safety Accelerator Toolkit Provides general guidelines on how to
14. fault Restore channel 1 and repeat for channel 2 18 Rockwell Automation Publication SAFETY ATO60C EN P December 2014 Safety Function Door Monitoring While the system is running short channel 1 of the safety 1 0 to OV DC Both contactors should de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify that the system cannot be reset and restarted with the fault Restore channel 1 and repeat for channel 2 4 While the system is running short channels 1 and 2 of the safety 1 0 Both contactors should de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify that the system cannot be reset and restarted with the fault Restore channel 1 and 2 wiring While the system is running short channel 1 to Test Source 1 of the safety 1 0 Open the guard door Both contactors should de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify that the system cannot be reset and restarted with the fault Restore channel 1 and repeat for channel 2 GuardLogix Controller and Network Tests While the system is running remove the Ethernet network connection between the safety 1 0 and the controller All contactors should de energize Verify proper machine status indication and 1 0 connection status in the RSLogix 5000 safety application program 1 2 Restore the safety 1
15. istics of each function y 3 Determination of required PL PLr for each safety function To Realization and PL Evaluation Rockwell Automation Publication SAFETY AT060C EN P December 2014 3 Safety Function Door Monitoring Interlock Safety Function This safety function is the removal of power from the hazard when the safety system detects that the door has been opened Safety Function Requirements Opening of a guard door stops and prevents hazardous motion by removal of power to the motor When the door is closed hazardous motion and power to the motor does not resume until a secondary action Start button depressed occurs Faults at the door interlock switch wiring terminals or safety controller are detected before the next safety demand The safety function in this example is capable of connecting and interrupting power to motors rated up to 9A 600V AC The safety function in this application technique meets or exceeds the requirements for Category 3 Performance Level d CAT 3 PLd per ISO 13849 1 and control reliable operation per ANSI B11 19 Functional Safety Description Hazardous motion is interrupted or prevented by opening the door The switch is wired to a pair of safety inputs of a safety input module SI1 The safety contactors K1 and K2 are connected to a pair of safety outputs on a safety output module SO1 The I O module is connected via CIP Safety protocol over an EtherNet IP network to the safet
16. ll the CCF requirement is considered to be met The complete CCF scoring process must be performed when implementing this example Rockwell Automation Publication SAFETY AT060C EN P December 2014 15 16 Safety Function Door Monitoring The Trojan 5 switch uses a single tongue actuator for door monitoring and locking Due to the inherent strength and simplicity of the actuator design Fault Exclusion FE for this single mechanical actuator is applied in accordance with ISO 13849 Parts 1 amp 2 EB Trojan 5 Door Switch Fl PFH M1 shi 2 Ca PFH dwt MTTFd T eF les fulfilled Rockwell Automation Publication SAFETY AT060C EN P December 2014 Safety Function Door Monitoring Verification and Validation Plan Verification and validation play an important role in the avoidance of faults throughout the safety system design and development process ISO EN 13849 2 sets the requirements for verification and validation It calls for a documented plan to confirm all the safety functional requirements have been met Verification is an analysis of the resulting safety control system The performance level PL of the safety control system is calculated to confirm it meets the required performance level PLr specified The SISTEMA software tool is typically used to perform the calculations and assist with satisfying the requirements of ISO 13849 1 Validation is a functional test of the safety control system to demonstra
17. monitors the two channels of the Trojan 5 switch If the door is opened these two channels open and the controller reacts by dropping out the safety contactors The POINT Guard I O 1734 IB8S module can source the 24V DC for both channels to dynamically test the signal wiring for shorts to 24V DC and channel to channel shorts If a fault occurs either or both channels are set to 0 low and the controller reacts by dropping out the safety contactors Only after the fault is cleared and the door is cycled does the function block reset Shorts to OV DC and wire off are seen as an open circuit by the POINT Guard I O 1734 IB8S input module and the 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 with Test DCST in the controller declares a fault Only after the fault is cleared and the door is cycled does the function block reset The final control device in this case is a pair of 100S C safety contactors K1 and K2 The contactors are controlled by a POINT Guard I O 1734 OB8S safety output module The contactors are wired in a redundant series configuration A feedback circuit is wired through the N C auxiliary contact and back to an input on the POINT Guard I O 1734 IB8S module to monitor the contactors for proper operation The contactors cannot restart if the feedback circuit is not in the correct state Rockwell Au
18. ollows the safety outputs appropriately For the negative feedback used in this example if the outputs are 1 high the feedback should be 0 low 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 SAFETY ATO060C EN P December 2014 13 Safety Function Door Monitoring The two output tags from the CROUT instruction are used to drive the contactor outputs on the POINT Guard I O 1734 OB8S module DEST 0 Qual Channel laput Stop With Test DEST Zamet _ Coane Oi Satety Function SAFETY GATE Input Type EQUIVALENT ACTIVE HIGH T Bitorepanay Time Meteo 2 Restart Typa AUTOMATIC FP Cold Stad Type AUTOMATIC Channel SENT 4 1 Peoot ata E Channel B HEAT 121 F 041 bata a T n Reguert T en_S atety_ aie ii cs Input Stator BENT A CombinadinputStaiue i E Reset SENT 121 P50 ata D E AEMT dsl JPRS oe SF i f One Shot Falling Storage Bit Wk_foned_OSF 6 QOviput Bit Wik Sonel _FalingEdge DE 3 Vok_Zone1_F alliangedge Zone _ Dsoro1 Zone _MiKS FP Ceid_ztone1_Outbnable oo aas i Cmd donei OuvwiEnable CROUT Contigurable Redundant Quotpat CAOUT Z m l IKZ Feedback Type HEGATIVE Feedback Reaction Time irec SA uctu ate Cmd foned_ Outen abia a Feedback 1 AENT TPO ate Feedback AEM tse Data D input Status SENT 21 1
19. red In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited 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 gt gt IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to
20. ssis 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 Rockwell Automation Publication SAFETY AT060C EN P December 2014 9 Safety Function Door Monitoring B I O Configuration 1768 Bus B 1 1768 ENeT A ENET Begs Ethernet 11 In the Select Module dialog box do the following a Expand Safety b Select the 1734 IB8S module c Click OK Select Module 8 Point 24V DC Sink Input 8 Point 24V DC Source Output Ada Pavionte 10 Rockwell Automation Publication SAFETY ATO60C EN P December 2014 Safety Function Door Monitoring 13 When the Module Definition dialog box opens change the Output Data to None and verify the Input Status is Combined Status Power 14 Click OK Module Definition x Series fa x Revision fi 1 Electronic Keying Compatible Module Configured By This Controller v Input Data Safet M Output Data None Input Status Combined Status Power M Data Format Integer const ee IMPORTANT Setting the output data to None means that you cannot use the Test Outputs as standard outputs This saves one controller connection because we are only using the input connection 15 Close the Module Properties dialog box by clicking OK 16 Repeat steps 10 15 to add the POINT Guard I O 1734 OB
21. te that it meets the specified requirements of the safety function The safety control system is tested to confirm all of the safety related outputs respond appropriately to their corresponding safety related inputs The functional test should include normal operating conditions in addition to potential fault inject of failure modes A checklist is typically used to document the validation of the safety control system Validation of software development is a process in which similar methodologies and techniques that are used in hardware development are deployed Faults created through poor software development process and procedure are systemic in nature rather than faults associated with hardware which are considered as random Prior to validating the GuardLogix Safety System it is necessary to confirm that the safety system and safety application program have been designed in accordance with the GuardLogix System Safety Reference Manual publication 1756 RM093 and the GuardLogix Application Instruction Safety Reference Manual publication 1756 RM095 Verification and Validation Checklist General Machinery Information Test Date C C C C C e E C E a E e a Rockwell Automation Publication SAFETY AT060C EN P December 2014 17 Safety Function Door Monitoring GuardLogix Safety System Configuration and Wiring Verification 1 Verify that the safety system is designed in accordance with the GuardLogix System Safety Reference Manu
22. the system is running open the monitored guard door Both contactors should de energize and open for a normal safe condition Verify proper machine status indication and RSLogix 5000 safety application program indication Repeat for all guard doors While the system is stopped with the guard door open initiate a Start command Both contactors should remain de energized and open for a normal safe condition Verify proper machine status indication and RSLogix 5000 safety application program indication Repeat for all guard doors Initiate a Reset command Both contactors should 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 Interlock Switch Input Tests While the system is running remove the channel 1 wire from the safety 1 0 Both contactors should de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify that the system cannot be reset and restarted with the fault Restore channel 1 and repeat for channel 2 2 While the system is running short channel 1 of the safety 1 0 to 24V DC Both contactors should de energize Verify proper machine status indication and RSLogix 5000 safety application program indication Verify that the system cannot be reset and restarted with the
23. tomasyon Ticaret A Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y Istanbul Tel 90 216 5698400 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 ATO60C EN P December 2014 Supersedes Publication SAFETY ATO60B EN P January 2013 Copyright 2014 Rockwell Automation Inc All rights reserved Printed in the U S A
24. tomation Publication SAFETY ATO60C EN P December 2014 5 Safety Function Door Monitoring The system has individual reset buttons for resetting of faults and safety outputs The reset buttons and the contactor feedback circuit are all wired to the POINT Guard I O 1734 IB8S module in this example This is not required for functional safety These three inputs could be wired to a standard input module Electrical Schematic 24V DC Safety Reset Fault Reset 1734 IB8S 24V DC Common 1734 0B8S Configuration The Compact GuardLogix controller is configured by using RSLogix 5000 software version 17 or later You must create a new project and add the I O modules Then configure the I O modules for the correct input and output types A detailed description of each step is beyond the scope of this document Knowledge of the RSLogix 5000 programming environment is assumed Configure the Controller and Add 1 0 Modules Follow these steps to configure the controller and to add I O modules 6 Rockwell Automation Publication SAFETY ATO60C EN P December 2014 Safety Function Door Monitoring 1 In RSLogix 5000 software create a new project Hew Controller E Redundancy Enabled esd l E E Communications i i 1768 CNB A 1768 ControlNet Bridge Allen Bradley 3 Controlet Bridge Redundant Mediz Allen Bradle 8 10 100 Mbps Ethernet Bridge TwistedPair Media Allen Bradley SS TESEWER A l os IUPIU0 Mops EMemet
25. ut Stop with Test DCST instruction monitors dual input safety devices whose main function is to stop a machine safely for example a safety gate When a test function is requested programmatically or manually the operation of the machine is halted until a proper cycle of the safety gate occurs The DCST instruction monitors dual input channels for consistency 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 DCST output O1 to reset automatically after a demand The manual action typically required for safety is provided in rung 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 to 0 low if any of the 8 input channels on the POINT Guard I O 1734 IB8S module have a fault In this example the DCST reset acts as a fault reset Even when configured for automatic restart a reset is required to recover from a fault The output O1 of the DCST 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 a manual reset action is carried out The Configurable Redundant Output CROUT instruction controls and monitors redundant outputs Essentially this instruction verifies that feedback f
26. y controller SC1 The safety code in SC1 monitors the status of the door by using the pre certified safety instruction Dual Channel Input Stop with Test DCST When all safety input interlocks are satisfied no faults are detected and the reset button is pressed a second certified function block called Configurable Redundant Output CROUT controls and monitors feedback for a redundant pair of 100S C contactors In summary when the door is opened the contactors drop out When the door is closed and the Reset button is pressed the contactors are energized 4 Rockwell Automation Publication SAFETY ATO60C EN P December 2014 Safety Function Door Monitoring Bill of Material This application uses these products 1768 ENBT CompactLogix EtherNet IP bridge 1 1768 L43S Compact GuardLogix processor 2 0 MB standard memory 0 5 MB safety memory 1 1768 PA3 Power supply 120 240 V AC input 3 5 A 24V DC _ _ 1769 ECR Right end cap terminator 1734 AENT 24V DC Ethernet adapter A 1734 TB Module base with removable IEC screw terminals 1734 IB8S POINT Guard 1 0 safety input module 1734 OB8S POINT Guard 1 0 safety output module 1783 US05T Stratix 2000 unmanaged Ethernet switch _ _ _ _ Setup and Wiring For detailed information on installing and wiring refer to the publications listed in the Additional Resources on the back cover System Overview The POINT Guard I O 1734 IB8S input module
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