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Safety Solutions

Copyright © 2009 Rockwell Automation, Inc. All rights reserved.2 HOMEHOME

Safety. Is it a challenge for you?

Challenges• Has making your machines / process safer, raised issues

– Does it effect the performance of your equipment• Stopping when it shouldn’t stop? Nuisance tripping?

– Is it costing you too much?• Are you implementing too much safety?• Are you implementing a safety solution that causes issues• Managing additional safety suppliers costs your company

– Is safety limiting your ability to:• Run your machine productively and efficiently• Carry out maintenance tasks quickly and easily• Get your machines to your customer quickly

• Have incidents increased in your plant?– Are your safety measures applied correctly?– Is it costing you in personnel accident payments and disability payments

It is common knowledge that legislation requires safe operating environments within manufacturing.And working to standards is a good method to show you comply.But are you facing additional challenges you didn’t expect…


Working with Rockwell Automation

• An automation supplier that understands automation and safety… not just safety.– Helping you get performance you need… safely– Cost – helping you get the most from your investment– Legislation requirements – helping you achieve conformance

• A full range of services and solutions for safer automation– A comprehensive product portfolio (input / logic / actuation)– Safety services (assessments, validation, training etc)

• Integrating safety functions into standard automation solutions– Drives, PLC, I/Os, Motion, networks, programming software…– Simplifying your architecture– Lowering cost– Increasing performance



Integrated safety solutions

Integrated safety solutions

Integrated Architecture

1. Fault identification – visual ID

2. Fault identification – System diagnostics

3. Safe zone control – increased productivity

4. Safe zone control - maintenance

5. Simplified Design – Premier Integration

6. Optimizing lock out and tag out access

7. Simplifying line expansion

8. Remote access troubleshooting

11. Integrated safety - Reduce system complexity

10. Integrated Safety – Safe torque off

9. Cross beam muting – increase productivity

Rockwell Automation

Safety challenges and solutions

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12. Safe limited speed for maintenance

13. Zero speed access – reduced downtime

14. Safe acceleration and deceleration

SAFETYWWW

APPLICATIONKNOWLEDGE

LEGISLATION& STANDARDS

GUIDANCE

INDUSTRYSOLUTIONS

SAFETYSERVICES

FACTORYTALK™

NETLINX™ NETWORKS

HMI

INTEGRATED SAFETY SOLUTIONS

CONNECTION SYSTEMS

SAFETY LOGICCONTROLLERS

SAFETYINPUTS

SAFETYACTUATORS


Products – Safety input devices

Presence sensingsafety devices

• Detection of a person or moving object

• Passive safety interlocking option - no physical action required between the devices and the operator/object

• Devices include:– Safety light curtains– Safety laser scanners– Pressure sensitive mats– Pressure sensitive edging

Safety interlockswitches

Emergency stop &trip devices

Operatorinterface

• Physical Interlocking of guard doors or systems

• Opening the guard door activated the interlocks

• Non-contact or physical interlocking versions are available

• Versions to lock guard door closed available

• Key exchange systems

• Devices include:– Tongue operated interlocks– Hinge operated interlocks– Guard locking interlocks– Non-contact interlocks– Safety Limit Switches– Trapped key systems

• Devices used in the event of an emergency to stop a hazard

• Versions with push-button or rope (cable) pull actuation

• Devices include:– Emergency stop buttons– Cable pull safety switches

• Devices used to safety interact with applications

• Physical actuation of capacitive actuation

• Devices include:– Enabling grip switches– Two hand controls


Products – Safety logic controllers

Monitoringsafety relays

• Dual channel monitoring of the safety systems

• Comprehensive range for your application

• Single function, modular of configurable versions

• Devices include:– MSR100 - Single function

safety relays– MSR200 – Modular safety

relay system– MSR300 – Configurable sa

fety relay system

Programmablesafety controllers

Integratedsafety controllers

SafetyI/O devices

• Packaged safety controller (SIL3)

• Programmable using RSNetWorx software

• CIP safety over DeviceNet and optional EtherNet/IP version for diagnostic comms

• Communicates and controls safety I/O

• Devices include:– SmartGuard 600– GuardPLC

• GuardLogix integrated safety controller (SIL3) for ControlLogix

• Standard and safety control in one platform

• CIP safety over EtherNet/IP or DeviceNet

• Communicates and controls safety I/O

• Devices include:– GuardLogix PAC

• Safety rated I/Os• EtherNet/IP or DeviceNet

connectivity• Use with programmable and

integrated safety controllers

• Devices include:– CompactBlock GuardI/O– ArmorBlock GuardI/O– POINT GuardI/O


Products – Safety actuators

Safetycontactors

• Mechanically linked, positively guided contacts

• Feedback circuit for safety integrity

• Range of power ratings

• Devices include:– 100S Safety Contactors– 700S Safety Contactors– 109S Safety Contactors

PowerFlexAC drives

Kinetixintegrated motion

• PowerFlex AC drives with optional integrated safety functions

• Advanced safety functions in PowerFlex 750 series AC drives

• May replace the need for safety contactors

• Remove torque without powering down machine

• Restart machines faster

• Devices include:– PowerFlex 40P– PowerFlex 70– PowerFlex 700S– PowerFlex 755

• Kinetix 6000 with optional integrated safety functions

• Safe Torque Off and advanced safety

• Remove torque without powering down machine

• Restart machines faster

• Devices include:– Kinetix 6000– Kinetix 7000


Products – Connection systems / networks

‘Quick connect’connection systems

• Quick connect / disconnection systems

• Reduces installation time and simplifies troubleshooting

• Devices include:– Cordsets and patchchords– T-ports– Distribution boxes

CIP Safety overDeviceNet

CIP Safety overEtherNet/IP

• Open device level network• Standard and safety

communication across DeviceNet media

• Uses the proven Common Industrial Protocol (CIP)

• Provides, control, configure and data collection capabilities

• Devices include:– Physical media– Sensors, controllers and

actuators– Software

• Open device level network• Standard and safety

communication across EtherNet/IP media

• Uses the proven Common Industrial Protocol (CIP)

• Devices include:– Physical media– Sensors, controllers and

actuators– Software


GuardShield: Safety light curtains

• Allen-Bradley Guardmaster safety light curtains offer optimal safety while allowing for greater productivity and ergonomics on the work floor.

– Safety category 2 or 4– PNP Outputs (2 N.O. Safety + 1 N.O. Aux.)– 14 mm or 30 mm objects sensitivity (POC only)– Up to 18m sensing range– Fixed blanking — teachable (POC only)– Floating blanking — one or two beams (POC only)– Beam coding– External device monitoring (EDM)– Start/restart interlock– TUV approved

• Products include:– Point of Operation Control light curtains (POC)– Perimeter Access Control light curtains (PAC)– Area Access Control (AAC)– Micro-sized light curtains for when space is a premium


SafeZone: Safety laser scanners

• The SafeZone™ Multizone safety laser scanner provides flexible area guarding within hazardous cells.

– Vertical or horizontal mounting in stationary or mobile applications – Auto configured safety field using ambient contour– Angular scanning range 190°, Safety field range 5 m– Application resolutions of 30mm, 40mm, 50mm, 70mm, or 150 mm– Configurable samplings: 2-16 samplings before outputs switch off – Configurable restart delay: 2 to 60 sec– 7-segment diagnostic display – Application diagnostic output– CE and cULus marked, meets Category 3 per EN954, Type 3

IEC61496 and SIL2 per IEC61508


MatGuard: Pressure sensitive safety mat system

• Highest quality safety mat available today. This robust family of products withstands the force of a forklift driving over it, yet is sensitive enough to be triggered by the footstep of a 30kg person.

– Category 3 according to EN954-1 (ISO 13849-1) – Third party certification to EN 1760-1– Overall sensitivity including uniting strip– Rugged construction withstands the pressure of 4500psi– IP 67 vinyl construction resistant to most oils– 5-year warranty– Mat manager monitors the status of up to 8 mats individually


Safedge: Pressure sensitive edge system

• Pressure sensitive system can be applied along or around applications• Ideal for use in potential trapping or pinch points• Utilises durable rubber compound (conductive and non conductive)• Selection of cushion sizes: 5mm (0.2 in), 19mm (0.75 in) and 41mm (1.6 in)• Order parts and configure yourself or specify factory configured solution for you

application• Up to 50m lengths with min bend radius of 500mm (19.6 in)• Fully active corners• Utilizes safety controller


Tongue operated interlock switches

• Ideal for interlocking of sliding, hinged and lift-off guard doors

• These devices require a physical actuator key to be inserted or removed from the switch for operation

• Positive actuation via direct opening contacts• Versions with metal and plastic housings for flexibility

and robustness• Small 25mm width versions for use in small spaces• A range of fixed, semi-flexible and fully flexible

actuators allow application flexibility• Versions with actuator holding force ≤ 40 N (9 lbs)• Conduit: Metric, ½ inch NPT and quick connect

versions available

• Note: These devices do not lock the guard


Hinge operated interlock switches

• Ideal for interlocking of hinged guard doors• Designed to fit onto the hinge or be the hinge-pin• Positive actuation via direct opening contacts• Small 25mm width versions for use in small spaces• Versions with 4 possible shaft positions – easy to install• Ideal where door misalignment or contaminants may cause issues• Versions with metal and plastic housings for flexibility and robustness• Conduit: Metric, ½ inch NPT and quick connect versions available



Guard locking interlock switches

• Ideal for interlocking of sliding, hinged and lift-off guard doors• Guard locking interlocks help keep guard door locked

closed until a safe machine condition exists• These devices require a physical actuator key to be

inserted or removed from the switch for operation• Positive actuation via direct opening contacts• Power to release and power to lock versions• Versions with actuator holding force ≤ 5000 N (1124 lbs)• Versions with metal and plastic housings for flexibility and robustness• A range of fixed, semi-flexible and fully flexible actuators allow application flexibility• Conduit: Metric, ½ inch NPT and quick connect versions available• Rotatable head: 4 possible actuator key entry slots (440G-MT and TLS-GD2)


Non-contact interlock switches

• Ideal for interlocking of sliding, hinged and lift-off guard doors• Requires no physical contact between the switch and

actuator to achieve operation• Small physical sizes, ideal where space is at a premium• Suitable for wash down thus ideal for hygiene sensitive

applications• Versions available with 25 mm assured sensing distances• Versions with and without control units

• SensaGuard family offer:– RFID coding for security integrity– Inductive technology for sensing– High tolerance to misalignment– Achieves Cat. 4 / SIL3 ratings even when wired in series– Visual diagnostics for ease of troubleshooting



Safety limit switches

• Comprehensive range of safety limit switches• These devices require physical actuation of the head

mounted actuator for operation• Positive actuation via direct opening contacts• Versions with metal and plastic housings for flexibility

and robustness• Snap-acting of slow-break/make contacts• A range of actuator types for application flexibility

– Roller plunger– Dome plunger– Lever operated– Offset hinge lever

• Conduit: Metric, ½ inch NPT, pre-wired and quick connect versions available


Prosafe trapped key systems

• Individually coded keys for high security• All stainless steel interlocking and coded parts• Replaceable code barrel assembly for key sequence

change-over or part replacement• The range includes:

– Power isolators (electrical, pneumatic etc)– Key exchange units– Interlocks (single and dual key)

• Bolt interlocks, access/chain interlocks,tongue interlocks, miniature valve interlocks

Based upon the premise that no one key can be in two places at once, key interlock systems can be configured to provide a predetermined sequence of events takes place or that hazards have been reduced before operators can become exposed to them


Emergency stop buttons

• Variety of operator sizes and contact configurations• Patented Self-Monitoring Contact Blocks (SMCB) monitors

if the contact block is correctly fixed to the mushroom actuator– IP2X finger-safe protection– Terminals identified with IEC-style markings– If the SMCB is separated from the E-stop operator

for any reason, the controller circuit will automatically open

• Twist to release, key release or pull to release options• Versions with LED mounted indication• Self configurable contact block


Cable (rope) pull safety switches

• The Lifeline family of cable-actuated emergency stop switches is ideal for installation along or around awkward machinery such as conveyors, and provides a continuous length of emergency stop access via the cable (rope)

– Unique cable grip system– System can be installed and commissioned quickly– Up to 300 mm of cable tension adjustment– IP67 stainless steel versions available– Cable span up to 125 m for standard models

and 75 m for stainless steel models– Switch mounted mushroom Emergency stop

button on Lifeline 4 versions– Visual rope tension indicator


Enabling grip switches

• Manually operated device used in conjunction with a start command• Safety function of the enabling grip switch has two parts

– When continually actuated, machine can operate– When not actuated, switch initiates a stop command

• 3 position switch with middle position as actuated (safety contacts closed, machine run)• Gripping or releasing the enabling grip switch either way of the middle position will

generate a machine stop command• Versions available with:

– Machine jog / restart button– E-Stop mounted mushroom button

• Ideal for maintenance applicationswhere limited power has to be maintained


Two-hand control devices

• Ideal for machine control systems requiring two hand operation

• Internationally rated ergonomic touch buttons• Capacitive sensing - Zero force to operate• Diagnostic LED’s for status indication and

troubleshooting• Pre-wired or quick connection options• Robust design for use in demanding

environments


Minotaur MSR100: Single function safety relays

• For Applications up to Category 4 EN954-1,PLe EN ISO 13849-1 and SILCL 3 to EN IEC 62061

• Preferred units– MSR117/127/131: Basic function units.– MSR142: multiple outputs.– MSR144: expandable module.– MSR138: delayed outputs module - control stop to EN60204-1– MSR125H: 2-hand control module– MSR30/33/35/38: Solid state relays– MSR57P: Speed Monitoring Relay

• Safe Torque Off• Zero Speed Monitoring• Safe Limited Speed• Safe Stop to Cat 0, 1 or 2• Safe Maximum• Safe Acceleration and Deceleration• Door monitoring and control• Enabling grip switch control


Minotaur MSR200: Modular safety relay system

• Modular dual processor system– Modular – Expandable micro-processor system– Flexible – Guards, E-stops, safety mats, light curtains

• Safety Integrity– Individual input channels, 2 input channels per module

• Configuration– Inputs: 10 modules (22 inputs)– Outputs: 2 modules (instant and delayed versions)– Diagnostic display and communications module

• Economic– Reduced wiring cost – processors control logic.– Reduced inventory cost

• Ease of Installation– Wiring, interconnections, input and output expansion

• Compact– Smaller panel space required


Minotaur MSR300: Configurable safety relay system

• Modular MSR300 system– Logic configuration with multiple inputs– Control up to 3 independent output zones.

• Muting functionality for controlled access– Ideal for parts loading in robotic cells

• Output modules for three groups (zone control)– Each input module can be configured to switch one or more output groups

• Cat.4 EN 954-1, SIL3 IEC 61508 approvals• Configuration

– Inputs: 20 per base module– 3 independent output zones– DeviceNet module for diagnostic communication


SmartGuard 600 safety controller

• Ideally suited for applications:– Where a safety relay isn’t enough and a safety PLC is too much– Using: E-Stop, Safety Gate, Light Curtains, Two-hand Control,

Multi-zone Control

• 16 inputs, 8 outputs, 4 pulse test sources• Connectivity / Communications

– CIP Standard and Safety over DeviceNet– CIP Standard over EtherNet/IP (for diagnostics only)– USB port for configuration and programming

• Programmed via RSNetWorx for DeviceNet• Certified to Cat. 4, SIL3, PLe, UL NRGF, UL Class I Div 2

The SmartGuard 600 safety controller is a programmable safety controller designed for safety applications that require some complex logic, allowing for more advanced safety functionality


GuardPLC safety controllers and distributed I/O

Packaged safety controllers• GuardPLC 1600

– 20 digital inputs, 8 digital outputs

• GuardPLC 1800– 24 digital inputs, 8 digital outputs, 8 analog inputs

and 2 high speed counters

• Integrated 4-port Ethernet switch• EtherNet/IP connection to standard controller• Modbus or Profibus communication options

– Allows for direct connection to PanelViewand others

• GuardPLC distributed I/O blocks– A comprehensive range available– Digital and analog inputs and outputs

• Configured using RSLogix Guard PLUS software


GuardLogix - ControlLogix safety integration

• Standard control and safety control in one controller– One common chassis– Standard and safety control on common networks– Single programming environment with RSLogix 5000

• ControlLogix Integrated Safety– Dual Processor Solution (1oo2 Architecture)– SIL 3 Certification per IEC 61508– PLe according to EN ISO 13849– EN 954-1 Category 4 – Certified Safety Application Instructions– CIP Safety over DeviceNet and EtherNet/IP

GuardGuardLogixLogix


CompactBlock Guard I/O

• Compact, space saving safety I/O blocks• Communication via CIP Safety over DeviceNet or EtherNet/IP• Easy migration between DeviceNet and EtherNet versions

– Common I/O circuits– Common interface and Logix profiles– Common set of terminal blocks

• IP20 rated package for use in cabinet• Programmed via RSLogix 5000 v16 or later


ArmorBlock Guard I/O

• Same functionality as CompactBlock Guard I/O– Control Flash compatible– Shock rated to 30g, tested to 50g– Improved temperature range to -20°C to 60°C

• IP67 rated package for use on machine• Simplified Installation: a single M12 cable connects to

dual-channel devices on inputs and outputs, using quick disconnects

• Compatible with quick disconnect standard sensors and safety devices

• Same input and output M12 pins as standard ArmorBlock• Can connect dual or single channel devices• 180mm x 70mm housing• Separate Input and Output Power via mini connector


POINT Guard I/O

• Integrated safety and standard control into 1734 POINT I/O product line• POINT I/O provides high density and granularity to optimize your design

– POINT standard (grey) I/O available in 2,4, and 8 point module densities– POINT Guard I/O (red) safety modules available

• 1734-IB8S - 8 Point Safety Sink Input• 1734-OB8S - 8 Point Safety Source Output

• For use with GuardLogix® and SmartGuard™600• Logix 5000 used to configure both standard and safety functions over EtherNet/IP• Compact design: combining safety + standard POINT I/O saves panel space• Certified to Category 4, SIL 3, PLe• Compatible with other POINT I/O products:

– 1734-AENT and 1734-AENTR– 1734-PDN and 1734D– 1734 terminal blocks (all except 1734–TB3)– Can be used with other POINT I/O modules, including:

• Digital, analog, specialty, and Encompass products

• Electronic over current protection of all outputs


Safety contactors

• Safety Contactors provide either mechanically linkedor mirror contacts, which are required in feedbackcircuits for modern safety applications

• Mechanically linked (positively guided) contacts are linked together thereby preventing the re-closing ofthe N.C. contacts if a N.O. contact has welded

• This helps to protect personnel from unintendedmachine starts and loss of the safety function

• Suitable for use in safety categories B…4• Protective cover to prevent manual operation


PowerFlex AC drives with optional integrated safety

• Safety functionality is available as an optional integrated feature• Power can be maintained to the drive after a demand on the safety function

– The DC bus is not discharged– Reduces wear on drive increasing life– Quicker restart times for higher productivity

• Simplified circuit with less wiring• Input or output contactors may not be required

• Standard Safe Torque Off available in:– PowerFlex 40P, 70, 700S, 755

• Advances safety functions available in:– PowerFlex 755 and subsequent 750 series

• Advances safety offers:– Safe Torque Off– Zero Speed Monitoring– Safe Limited Speed– Safe Stop to Cat 0, 1 or 2

– Safe Maximum– Safe Acceleration and Deceleration– Door monitoring and control– Enabling grip switch control


Kinetix integrated motionwith optional integrated safety

• Safety functionality is available as an optional integrated feature• Power can be maintained to the drive after a demand on the safety function

– The DC bus is not discharged– Reduces wear on drive increasing life– Quicker restart times for higher productivity

• Simplified circuit with less wiring• Input or output contactors may not be required

• Standard Safe Torque Off available in:– Kinetix 6000 and 7000

• Advances safety functions available in next release of:– Kinetix 6000

• Advances safety offers:– Safe Torque Off– Zero Speed Monitoring– Safe Limited Speed– Safe Stop to Cat 0, 1 or 2

– Safe Maximum– Safe Acceleration and Deceleration– Door monitoring and control– Enabling grip switch control


Connection systems

• Comprehensive range of cables, cordsets, patchcords,Y-cables, distribution boxes and receptacles

• Connect your devices quickly and seamlessly• Simplify system complexity• Reduce wiring channels• Speed up machine build time• Increased diagnostics to assist troubleshooting• Replace devices quickly and easily• Large range of safety devices supported


CIP Safety over DeviceNet

• DeviceNet is a simple, open networking solution that reduces the cost and time required to wire and install industrial automation devices, while providing interchangeability of like components.

• Reduces wiring and installation cost– Labor and hardware expense

• Reduces start-up time– Minimizes wiring errors– Makes it easier to “stage” sub-systems– Allocate resources to next job quickly

• Significantly reduce downtime and total cost of ownership with the aid of diagnostics, Auto Device Replacement, and other time- and cost-saving features

• Run standard and safety applications on the same wire• It’s an open network

– Specification maintained by Open DeviceNet Vendor Association (ODVA)• Control, configure, and collect data on a single network• Pre- and post-sales tools available for system planning and configuration


CIP Safety over EtherNet/IP

• EtherNet/IP based on the standard Ethernet architecture, is an industrial open networking solution that reduces the cost and time required to wire and install industrial automation devices, while providing interchangeability of like components

• Reduces wiring and installation cost– Labor and hardware expense

• Reduces start-up time– Minimizes wiring errors– Makes it easier to “stage” sub-systems– Allocate resources to next job quickly

• Significantly reduce downtime and total cost of ownership with the aid of diagnostics, Auto Device Replacement, and other time- and cost-saving features

• Run standard and safety applications on the same wire• It’s an open network

– Specification maintained by Open DeviceNet Vendor Association (ODVA)• Control, configure, and collect data on a single network• Pre- and post-sales tools available for system planning and configuration


Conventional solution – Fault identification


Challenges and costs associated with this scenario ?

Conventional safety solution

1. Production stops. Why?2. Manually locate the relevant guard or zone3. Establish the reason for the trip

- Is it a Mechanical or Electrical fault4. Was it avoidable?5. Confirm / repair the problem, reset and start process

(Minutes……….Hours……..Days ??)

Unplanned downtime due to guard door misalignmentMaintenance activity is reactive rather than proactiveNo diagnostic capabilityMeeting production targets are not under control !!


Contemporary safety solution


Benefits to your business

Contemporary Safety Solution1. Production did not stop due to warning and diagnostics functions provided by simple

visual identification2. Production loss ZERO !!

Unplanned downtime reduced to a minimum Production targets can be met consistently Where required pro-active maintenance can be scheduled to avoid further issues and

downtime Fact based decisions can be made due to Diagnostic data available


Conventional solution – Fault identification



Conventional safety solution

1. Production stops. Why?2. Manually locate the relevant guard or zone3. Establish the reason for the trip

- Is it a Mechanical or Electrical fault4. Was it avoidable?5. Confirm / repair the problem, reset and start process

(Minutes……….Hours……..Days ??)

Unplanned downtimeMaintenance activity is reactive rather than proactiveNo diagnostic capabilityMeeting production targets are not under control !!





Contemporary Safety Solution1. Production did not stop due to warning and diagnostics functions provided through

Integrated Architecture2. Production loss ZERO !!

Unplanned downtime reduced to a minimum Production targets can be met consistently Streamlined architecture reduces system complexity allowing simpler maintenance and

flexibility to change Where required pro-active maintenance can be scheduled to avoid further issues and

downtime Fact based decisions can be made due to Diagnostic data available


Conventional solution – Zone control for productivity



Conventional safety solution?

1. Production has to stop to allow loading of parts 2. Robot would need to be homed if light curtain is tripped without controlled machine stop3. One loading zone allows limited parts to be loaded

Limited productivity due to repeated machine stops for parts loadingUnnecessary downtimeSafety was applied without looking at the ‘Function’ of the machine





Contemporary Safety Solution1. Production does not stop when parts are being loaded 2. Zone control technique used to increased productivity3. The ‘Function’ of the machine used in applying a safety solution

Downtime due to restocking is reduced to a minimum Production targets can be met consistently Machine and operator interaction streamlined Safety is designed into the machine and operator interfaces Start-up routines minimised


Conventional solution – Zone control for maintenance




1. All production cells stop for individual robot maintenance2. A demand on the safety function will stop the whole cell3. Physical guarding required to protect the cell4. No detection of personnel inside the cell5. Power isolation required for access

Multi-robot downtime is costly!!Productivity impactedNo partial power for robot jogging / teaching





Contemporary Safety Solution1. Whole production cell did not stop for individual robot maintenance2. Safe limited speed and zone control techniques used3. The ‘Maintenance Mode Function’ of the machine is identified and considered when

applying the safety solution 4. Space saving achieved as no physical guarding required

Planned/unplanned downtime for maintenance effects only specific cell Production targets can be met consistently Integrated safety used to achieve productivity and flexibility Intelligent zone control used to maximise uptime and availability Minimal physical guarding required allowing personnel and machine flexibility and

safety


Conventional solution – Programming and startup



Conventional safety solution?1. Requires multiple software tools to configure the PLC, drive, I/O, motion and safety

functions2. Remapping of defined data for each software tool: e.g., logic/descriptive tag names,

data types, etc.3. Program configurations stored in separate files4. Potential errors in programming

Time consuming with higher potential for errorsProgramming knowledge of multiple environmentsOperator / maintenance personnel have to be trained in multiple environments





Contemporary Safety Solution1. One programming environment for safety, drive, I/O, motion and PLC2. Auto generation of descriptive tag names/data for control and visualisation3. Program configuration stored in one location

Potential programming errors reduced to a minimum Simple to access and edit information Diagnostic, fault, alarm and event management are integral to RSLogix 5000

programming environment Reduce development time and complexity


Conventional solution – Lock out and Tag out




1. Multiple energy sources in different locations have to be locked out2. If padlocks used there maybe multiple keys which could reduce lockout system integrity3. Potential not to lockout all energy sources4. No enforced sequence of events has to take place to gain access to potentially

hazardous area

Can be time consuming to isolate all power sources!!Lockout could be removed if multiple maintenance / personnel working which could cause a potentially hazardous risk!!Bypassing safety lockout routine can be done





Contemporary Safety Solution1. Utilization of a Prosafe trapped key system enforces a sequence of events to take place

before access is allowed to guarded area2. One location to isolate all power sources!!3. Keys can be used to ensure no restart is possible – operator / maintenance person can

keep the key with him/her

Enforces a standardized sequence for safety integrity Reduces time to lockout all power sources Reduces complexity and potential for bypassing Individually coded keys increase safety integrity Trapped key systems can be configured to achieve the correct ‘Functional Access’ to

an application


Conventional solution – Expanding your production




1. Production expansion requires individual programming2. Multiple programming software / integrators required3. System complexity increases with expansion

Time consuming and inflexible!!Can lead to a very costly and complex production facility!!Software revision management can be difficult and costly





Contemporary Safety Solution1. Single programming environment allows for flexibility2. Application code reuse, simplified along with revision management3. Common networks such as EtherNet/IP or DeviceNet allow safety and automation

control on one network, reducing system complexity4. Integrating safety control into automation devices to achieve flexibility through

standardised solutions

Flexible automation solution with integrated safety can be easily replicated quickly and efficiently

Single programming environment for ease of use in factory expansion when adapting to changing market conditions


Conventional solution – Remote troubleshooting




1. Web access is limited to the overall application2. No access to devices such as drives, safety devices, motion controllers (unless

extensive code is developed in the PLC)3. Site visit may be required to change or troubleshoot applications

Time consuming and expensive to troubleshootDowntime while maintenance contractor arrives from another locationMaintenance person does not know what has happened before arriving so can not predict required actions or hardware needed





Contemporary Safety Solution1. Diagnostic information accessible down to device level2. Remote high level support for local maintenance personnel3. Simple issues solved quickly without need for installation visit4. Less on-site personnel required allowing for flexible deployment of resources across

multiple sites

Reduced downtime and simplified troubleshooting Required actions identified remotely allowing maintenance personnel to prepare in

advance of installation visit No extensive code required in PLC


Conventional solution – Cross beam muting




1. Manual operator interaction required2. Potential of operator to access guarded area to keep production moving3. Productivity limited to operator efficiency at different times of day4. Operator error can result in production waste5. Production limited to access time to filling station

Can be costly to have personnel working at multiple stationsProduction is reliant on operator productivity and competencyPhysical labour can result in operator injuries with associated costsThe safety function of the interlocked guard door makes the application safer but limits productivity





Contemporary Safety Solution1. Light curtain with cross beam muting function used to increase access speed to filling

station2. No manual interaction required3. Automated loading and unloading helps increase productivity4. Personnel can not access guarded area without tripping the light curtain

Increased productivity Increased integrity of safety system Reduced potential of injury and associated costs The safety solution allows an increase in productivity by adopting a ‘Functional Safety’

approach to the application


Conventional solution – Reduce start-up cycle time




1. Demand on the safety function initiates stop and removes power to drive2. Start-up cycle time maybe considerable

Cycling power to the drive reduces operational lifetime of the driveLoss of production efficiency due to recurring start-up timesComplex start-up routines may have to be followedPossible loss of communications





Contemporary Safety Solution1. Demand on the safety function initiates a stop. The drive remains powered but in a

Safe Torque Off state with motor unable to start2. No start-up routine needed. Process can begin immediately

Drive operational lifetime maintained Minimum loss of production Less confusion and stress for operator No start-up routine needed Communications active throughout safety initiated routine


Conventional solution – Reduce system complexity




1. All control functions located in one cabinet2. Automation control and safety control are independent3. Utilisation of traditional connection solutions4. Cabinets built for specific control purpose

Large control cabinet requiring premium spaceMultiple wiring tracks increase fault possibilities and application complexityMaintenance and troubleshooting can be difficultLengthy installation, commissioning and testing





Contemporary Safety Solution1. Integration of automation control and safety control allows for smaller cabinet footprint2. Distribution of control functions and devices around the machine3. Utilisation of quick connection methods and standard networks such as EtherNet/IP and

DeviceNet carry control and safety data4. Local control of functions on the machine

Reduces installation time and simplifies complexity Simplifies troubleshooting and maintenance Reduces required control cabinet size and associated space costs Re-useable solutions and flexibility of system configuration


Conventional solution – Safe speed for maintenance




1. Total power removal required to carry out maintenance / cleaning2. Access only allowed into guarded zone if machine at stand-still 3. Operator has to leave the guarded area, close guard door and power up to partially

rotate the application to carry out maintenance / cleaning4. The safety system is effective but is not designed to assist in ‘Maintenance Function’

Can be time consuming to carry out basic maintenance procedurePotential of maintenance personnel to bypass safety system to achieve quicker maintenance procedureFunctional Safety assessment did not cover maintenance procedure





Contemporary Safety Solution1. ‘Functional Maintenance’ procedure considered in deployment of an integrated safety

solution to help, not hinder maintenance tasks2. Partial power-up under monitored ‘Safe Limited Speed

with Safe Direction’ allows personnel the flexibility to efficiently carry out maintenance procedures

3. Deployment of ‘Safe-speed technology’ either through dedicated MSR57P Speed Monitoring Relay or optional integrated in PowerFlex 750 series AC drive

Maintenance procedures carried out efficiently Machine downtime kept to a minimum Desire to bypass safety system no longer necessary Safety solution helps increase flexibility


Conventional solution – Zero speed access




1. Rotating hazardous motion not monitored for stand-still2. Access to guarded area only allowed after a pre-determined time even if the hazard no

longer exists3. Delay in access time could be considerable4. Does not utilise ‘Functional Safety’ assessment to aid operator and machine interaction

Can impact productivity as downtime can be considerableDoes not benefit from frequent access requirementsCan frustrate operator causing attempt to bypass safety functions





Contemporary Safety Solution1. Instant access to guarded area allowed as soon as hazardous motion has stopped2. The ‘Function’ of the machine considered when applying safety3. Deployment of ‘Safe-speed technology’ either through dedicated MSR57P Speed

Monitoring Relay or optional integrated in PowerFlex 750 series AC drive

Reduces machine downtime Allows quick operator and machine interaction safely Adopts Functional Safety standards to allow flexibility Integrated safety and automation technologies reduce system complexity


Conventional solution – Safe acceleration/deceleration




1. Acceleration and deceleration controlled and monitored by PLC2. Safety solution will shutdown application if fault detected 3. No safe acceleration or deceleration options4. Applications may start or stop too quickly

Can cause application usability issuesSafe shutdown is power off and could cause potential swingingRiding comfort is uncomfortable on embarking and disembarking Application not under controlled condition





Contemporary Safety Solution1. Safety monitoring of applications acceleration and deceleration2. Helps protect against runaway condition or deceleration excess3. Deployment of ‘Safe-speed technology’ either through dedicated MSR57P Speed

Monitoring Relay or optional integrated in PowerFlex 750 series AC drive

Protects assets from damage Can be retrofitted to existing applications

Education

0 safety presentation master v1