A MEMBE R O F THE KENDALL GROUP Functional Safety Overview Requirements Product Solutions Standards Safety Life Cycle Industrial Safety Safe Off/Speed Safety Integration Application Examples Safety Wiring Diagrams Safety Function Documents
RASWIN OSHA Occupational Safety and Health Administration In the United States, one of the main drivers of industrial safety is the Occupational Safety and Health Administration (OSHA). OSHA was established in 1971 by an Act of the U.S. Congress. Article 5 of the Act sets the basic requirements. Each employer shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees; and shall comply with occupational safety and health standards promulgated under this Act. OSHA 1910 ANSI NFPA
Global Standards ISO (International Organization for Standardization) ISO generates standards for designing, manufacturing and using machinery more efficiently, safer and cleaner. For more information, visit the ISO website: www.iso.org. IEC (International Electrotechnical Commission) The IEC prepares and publishes international standards for electrical, electronic and related technologies. For more information, visit the IEC website: www.iec.ch EN Harmonized European Standards Their use is voluntary but designing and manufacturing equipment to them is the most direct way of demonstrating compliance with the EHSRs of the Machinery Directive. http://ec.europa.eu/growth/single-market/european-standards/ Categories US Standards
Both US and International standards require a systematic approach for safety system development which starts with a risk assessment! So which method is right for you? ISO 13849 Method P1 ANSI/RIA TR15.306 Method F1 S1 F2
OR F1 S2 F2 P2 P1 P2 P1 P2 P1 P2 aa bb bb
cc cc dd dd ee Either is OK as long as you are following a risk assessment and risk reduction method! SAFEBOOK 5 Standards (EN) ISO 13849-1 and IEC/EN 62061 Both standards produce similar results but use different methods. (EN) ISO 13849-1 PLr Less complex manufacturing machinery IEC/EN 62061 SIL Typically more complex machine safety systems Safety Standards
1. (EN) ISO 12100 Safety of machinery General principals for design Risk assessment and risk reduction 2. (EN) ISO 13849-1 Safety of machinery - Safety related parts of control systems 3. IEC/EN 61508 Functional safety of safety related electrical, electronic and programmable electronic control systems 4. IEC/EN 62061 Safety of machinery - Functional safety of safety related electrical, electronic and programmable electronic control systems 5. IEC 61511 Functional safety - Safety instrumented systems for the process industry sector Safety Standards Standard Types A Ge
n for eral de prin As sign cipl ses & e sm Risk s en t B B1 Ge ne r
As al Sa pe f cts ety Sp ec 7 85 nces 13 EN Dista y fet Sa &2 9-1 ol
84 ontr 3 1 C EN fety ems Sa Syst 0 & 12 14 ign EN des tion s ard truc Gu ons c 0 8 5 t op
S 13 EN ency nt e g r m e p Em equi B2 S Pr peci o a
De tecti l vic ve es i al sa fet y fea C tur e
sf or i nd i vi du al ma ch i ne gro
u 100 12 EN ps er 10 10 Pap EN and s ng ine nti ch Pri Ma n tio
21 19 duc EN pro d s ate tem tom sys Au 93 ars e 2/6 69 d Sh / N n E a ical
s n e ss cha lic Pre me drau hy g 1 20 ldin EN Mou s n tio chine ec Inj Ma Dont forget about OSHA 1910 standard.
Safety Life Cycle 5. Operate, Maintain and Improve 1. Detailed operational specification Required maintenance schedule Preventive maintenance schedule Assessment Identifies Task & Hazards Pairs Follow the Safety Life Cycle!
2. Functional Safe System Requiremen 4. Installation and Validation Final site assembly Commissioning Validation Final Assessment Validation 3. Design and Verification Circuit & Component Selection Safety System Design Design Verification Guarding design Outlines functional
requirements of the safety system Traditional Safety Single or dual channel No Annunciation Safety Relays Are Confusing Accidental estop, cable pull or door vibration Traditional Solutions Take it to another level Take it to another level Take it to another level
Top Level - Components Top Level - Components - GuardLink Top Level Components Top Level - Components 32 nodes 2 Channel Safety Relay for a total of 64 nodes 35uS response time Taps 5 & 8 pin, EM and SS CIP Safety Available Now! Available Someday
Greatness of CompactLogix 5380 PUBLIC = Integrated with safety Compact GuardLogix 5380 Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 39
Compact GuardLogix 5380 Controller Integrated Architecture Single Controller for Standard and Safety Control Single Software for Standard and Safety Control No Extra Time For Data Integration Design Flexibility saves time Same look and feel; speeds up application building Better diagnostics, Easy data sharing up to HMI
Single Controller for Standard and Safety Control No special network or gateways for I/O Ability to mix and match with standard I/O PUBLIC Capable and flexible Certified Safety instructions (More than 100) Also facilitates to create your own (Add-On Instruction Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.
40 Compact GuardLogix Controllers Compact GuardLogix 5370 Integrated Motion on EtherNet/IP up to 16 axes @ 2 axis /ms Integrated safety up to SIL 3, PLe CAT 4 versions Minimizes hardware in the control cabinet with placement directly on the machine Multiple disciplines Helps protect against dust and water with IP67-rated wash down protection Conformal coated versions
Flexible and scalable Compact GuardLogix 5380 Integrated Motion on EtherNet/IP up to 32 axes @ 32 axis/ms 1 gigabit (Gb) embedded Ethernet port enables high-speed I/O and motion control for up to 180 nodes Integrated safety up to SIL 2, PLd CAT 3 versions Conformal coated versions One common design environment Enhanced security features PUBLIC
Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 41 Compact GuardLogix 5380 Controller Whats NEW SCALABLE HIGH PERFORMANCE Scalable Safety Level Multi-core CPU SIL CL2, Up to PLd 1oo1
Optimized for faster safety reaction time SIL CL3, Up to PLe 1oo2 (Future) PUBLIC INCREASED SAFETY I N T E G R AT I O N Networked Safety Functions with drives and Motion By using safety instructions in the safety task Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.
42 Compact GuardLogix 5380 Controller High Performance CPU Optimized for faster safety reaction time Scalable Safety Level SIL CL2, Up to PLd 1oo1 SIL CL3, Up to PLe 1oo2 (Future release) 1-Gb Embedded Ethernet/IP Port Integrated Safety on EtherNet/IP, I/O and Safety Devices IEC 61800-5-2 Safety Instructions New Drive Safety Instructions with Kinetix 5700 ERS4 drive Safe feedback scaling, Safe Stop 1, Safe Stop 2, Safe Operation Stop
Safe Limited Speed, Safe Limited Position Safe Brake Control with external brake, Safe Direction Increased Scalability PUBLIC Standard memory options ranging from 0.6 MB - 10 MB
Safety memory options ranging from 0.3 MB - 5 MB Support for up to 180 EtherNet/IP nodes per controller Motion support for up to 32 axes per controller Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 43 Scalable Safety Level SCALABLE
Up to PLd (Cat. 3) SIL CL2 1oo1 Architecture First in scalable Safety Performance Levels (PLs) and Safety Integrity Levels (SILs) for machine safety The risk assessment is the key to defining the safety requirements Right Sizing can create compliant designs Up to PLe (Cat. 4) SIL CL3 1oo2 Architecture PUBLIC
Optimized for cost and performance Help achieve the safety, cost and timing targets for each project Just the right amount of safety for your unique application Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 44
Compact GuardLogix 5380 Performance & Features C OM PA R I S O N S SPECIFICATIONS Overall performance 5370S 5380S CATALOG NUMBER STANDARD MEMORY SIZE SAFETY
MEMORY SIZE TOTAL # OF CONTROLLER ETHERNET/IP NODES* 1x 5x-20x 0.5 1.5 MB 0.3 - 5 MB 5069-L306ERMS2 0.6 MB
40 Networked STO for Drives (CIP Mode/IO Mode) Yes Yes 5069-L330ERS2(K)** 3 MB 1.5MB 60
Networked STO for Kinetix (CIP Mode) Yes Yes 5069-L340ERS2 4 MB 2MB 90 Integrated safety SIL CL3, Up to PLe Yes
Yes 5069-L350ERS2(K)** 5 MB 2.5MB 120 Integrated Up to coated PLd **Catalog withsafety K addedSIL canCL2,
be conformal No Yes 5069-L380ERS2 8 MB 4MB 150 V31 5069-L3100ERS2
10 MB 5MB 180 Logix Designer V28+ * Connection Node : 1 or more 1756-ENxT modules required for EtherNet/IP connections 1 Data size = 32bits / 1-DINT PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.
45 Safety-AT and WD Examples Safety-Wiring Diagrams - GSR Safety Function Documents GSR and PLC RASWIN RASWIN RASWIN RASWIN RASWIN
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