A MEMBE R O F THE KENDALL GROUP

A MEMBE R O F THE KENDALL GROUP

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

SMART SAFETY SOLUTIONS Hardwired Safety SIL3/Ple (20-750-S) GuardLogix Controller SensaGuard Non-Contact Interlocks Stratix Switch Guardmaster Safety Relay Networked Safety SIL3/Ple (20-750-S3) SensaGuard Non-Contact

Interlocks PointGuard I/O Stratix Switch Eliminate field wiring and safety relays GuardLogix Controller 20-750-S4 Integrated Safety Functions Option Module Compact GuardLogix 5380 Controller +

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

0.3MB 16 Axis per controller 16 32 5069-L310ERMS2 1 MB 0.5MB

24 Axis per ms (50% CPU loading) 2 32 5069L320ERMS2(K)** 2 MB 1MB 40 5069L330ERMS2(K)**

3 MB 1.5MB 60 Yes 5069-L340ERMS2 4 MB 2MB 90

5 MB 2.5MB 120 Safety Memory Number of I/O (Class 0&1) connections Number of message (Class 3) connections Drive Safety Instructions 512* No Simplified to nodes

Integrated safety SIL CL3, Up to PLe Yes Yes 5069L350ERMS2(K)** Integrated safety SIL CL2, Up to PLd No Yes 5069-L380ERMS2 8 MB

4MB 150 10/100Mb 100/1000Mb 5069-L3100ERMS2 10 MB 5MB 180

10,000 128,000 5069-L306ERS2 0.6 MB 0.3MB 16 5069-L310ERS2 1 MB 0.5MB

24 Embedded Ethernet port Ethernet I/O (Class 0/1) Packets/Sec 1734 PointGuard I/O, 1732 ArmorBlock Guard I/ O Yes Yes 5069-L320ERS2(K)** 2 MB 1MB

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

Resources Guardmaster Safety Relay Wiring Examples https://literature.rockwellautomation.com/idc/groups/literature/documents/wd/safety-wd001_-en-p.pdf Safety Function Documents https:// www.rockwellautomation.com/en_NA/detail.page?pagetitle=Safety-Functions-Documents&content_type=tec h_data&docid=63726e09a2ea9f1d402c664bfb74acd6 Machinery SafeBook 5 https://literature.rockwellautomation.com/idc/groups/literature/documents/rm/safebk-rm002_-en-p.pdf Process SafeBook 1 https://literature.rockwellautomation.com/idc/groups/literature/documents/rm/safebk-rm003_-en-p.pdf Safety Automation Builder

https:// www.rockwellautomation.com/en_NA/capabilities/industrial-safety-solutions/overview.page?pagetitle=Safety -Automation-Builder&docid=ef863d3d3422316df38f212973b23076 RASWIN https:// www.rockwellautomation.com/en_NA/capabilities/industrial-safety-solutions/overview.page?docid=8122b63 8e50a4ef34f0610658ff6897e&pagetitle=RASWin-Software-Tool Sistema https://www.dguv.de/ifa/praxishilfen/practical-solutions-machine-safety/software-sistema/index.jsp Services Safety Services Website https:// www.rockwellautomation.com/en_NA/capabilities/industrial-safety-solutions/overview.page?pagetitle=Safety -Services&docid=4bfc96470a76212f5e13c402ada0f05a

For more information on Rockwell Services, contact your account manager or Phil Reece, who is our Kendall Services specialist at [email protected]

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