integrated safety & powerflex driveguard on tour...up thru sil 3 /cat 4 • high performance •...

Integrated Safety &PowerFlexPowerFlexDriveGuardDriveGuard

Session AgendaAgenda

Session AgendaIntroduction to GuardLogix – Approx 15min

Hands-on lab – Approx 1.5 hrs

Topics to CoverContents

Topics to CoverIntroduction to GuardLogix

GuardLogix with ControlLogix Functionality

GuardLogix with RSLogix 5000 and Safe OFF

Safety I/O

G d i K B fiGuardLogix Key Benefits

Introduction to GuardLogixRSLogix 5000 SoftwareRSLogix 5000 Software • Function Block Diagram• Ladder Logicg• Structured Text• Sequential Function Chart • Certified Safety InstructionsIntegration with:• Motion

sequential control

process control

• Motion • Process • Safety

safety control

y• Drives control motion

controldrives control

Introduction to GuardLogix• High Performance Integrated Safety• Up through SIL 3 /Cat 4p g• Standard Logix – Rack, Power Supply and

Comms Modules• RSLogix 5000 Software• CIP Safety DeviceNet, ControlNet, EtherNet • Full Logix functionality + SIL 3 safety GuardLogix

• Packaged Safety Controllers• Up thru SIL 3 /Cat 4

• Full Logix functionality + SIL 3 safety

GuardPLC’s

g

• Up thru SIL 3 /Cat 4• High Performance• Discrete and Analog I/O• GuardPLC Ethernet & DeviceNet• Full IEC 1131 FB

C tifi d f t li ti i t tiS tG d 600 • Certified safety application instructions

• SmartGuard 600 / Ethernet /IP• Up through SIL 3 / Cat 4 programmable safety • 16 safety inputs / 8 safety outputs / 4 std outputs

SmartGuard 600

MSR300

• Safety Relays • Modular Expansion

MSR200

16 safety inputs / 8 safety outputs / 4 std outputs• Networked safety I/O expansion (CIP Safety on DeviceNet)

p• Configurable





Safety I/O


GuardLogix with ControlLogix FunctionalitySt d d C t l d S f t C t l i t ll• Standard Control and Safety Control in one controller

• Standard Controllers and Safety Controllers in a common chassiscommon chassis

• Standard Control and Safety Control on common networksnetworks

GuardLogix with ControlLogix Functionality• Modular rack based communications

– EtherNet/IP, ControlNet™, DH+, RIO, DeviceNet ™ and EWEB EtherNet/IP

– Controller Serial ASCII, DF1, and DH485– Mix and match network interfaces

Add as many or as few networks as needed– Add as many or as few networks as needed• Flexible networking

– Bridging and routing between messaging ControlNetRIO, DH+

networks across backplane w/o processorintervention

• 3rd Party Networks via Encompass Partners

DeviceNet

y p

GuardLogix with ControlLogix FunctionalityContinuous Task Scan Periodic Task Scan

Tim

e-sli

ce

esta

rt

Program 2

Program 1

Program 2

Program 1

5ms10ms

15ms...

Event Task Scan

Program 2

Program 1

InputMotion

Code...

PU O

verh

ead

T

Task

Aut

o-re Program 2

Program n

...

Program 2

Program n

...

Program 2

Program n

...

• Executes each program top to bottom

CP

Scan interrupted byperiodic and event tasks

Program ..n Program ..n

Depending on task priorityscan interrupted by

other periodic and event tasks

Program ..n

Depending on task priorityscan interrupted by

other periodic and event tasksExecutes each program top to bottom and then restarts

• Operates at the lowest priority on the controllerUses all CPU time left after other tasks

• Triggered automatically at a preset time interval

• Interrupts lower priority tasks and can be interrupted by higher priority tasks

• Triggered on arrival of input, consumed tag, motion operations, via another program, or a Windows Event for SofLogix5800

p

• Uses all CPU time left after other tasks execute

• Interrupted by operating system to perform processor and

be interrupted by higher priority tasks (15 Levels)

• Will time-slice on a 1ms basis with another task at the same priority level

for SofLogix5800• Priority same options as Periodic...• Captures fault for task overlap• Similar to PLC Peripheral Input

communications overhead• Traditional PLC Scan

• Captures fault for task overlap• Similar to PLC/SLC Selectable Timed

Interrupt (STI)

Interrupt (PII) or SLC Discrete Input Interrupt (DII)

GuardLogix with ControlLogix Functionality• Safety Task is a Periodic Task Periodic Task Scan• Safety Task is a Periodic Task• Safety Task executes in the GuardLogix Primary (L61S L62S L63S) and the

Periodic Task Scan

Program 2

Program 1.

5ms10ms

15ms...

Primary (L61S, L62S, L63S) and the GuardLogix Safety Partner (LSP)

• Safety Task results are crossProgram ..n

..

Safety Task results are cross checked by both controllers (primary >< partner)

• Triggered automatically at a preset time interval

• Interrupts lower priority tasks and can be interrupted by higher priority tasks (15

– When checks are done and OK, safety output data is written to the safety

g p y (Levels)

• Will time-slice on a 1ms basis with another task at the same priority levelC t f lt f t k loutputs • Captures fault for task overlap

• Similar to PLC/SLC Selectable Timed Interrupt (STI)

Guardlogix with ControlLogix Functionality

Language LD (Std Task) FBD (Std Task) SFC (Std Task) STX (Std Task) LD + (Safety Task)

Instructions Set • Boolean• General & Trig Math• Timer / Counters• Table / Array

management

• General & Trig Math• Timer / Counters • Bit wise Logical• Advanced Process Blocks

Ad d D i Bl k

• Step / Action with full embedded STX

• Transition with Embedded STX comparisons

• Simultaneous and Select

• General & Trig Math• Timer / Counters• Bit wise Logical• Table / Array

management

• Certified Safety Instructions

– Boolean– Compare– Math/Conversionmanagement

• Diagnostic• Serial Port & Messaging• ASCII Manipulation• Specialty CPU control• Motion control blocks

• Advanced Drive Blocks Simultaneous and Select Branch

• Stop Element

management• Diagnostic• Serial Port & Messaging• ASCII Manipulation• Specialty CPU control• Motion control blocks

– Move Logical– Program Control– Timer / Counters

• Certified Safety Application Instructions

• Advanced Process Blocks• Advanced Drive Blocks

Editor Style • Graphical rungs• Unlimited rungs

• Graphical free form drawing

• Unlimited sheets

• Graphical free form drawing

• Unlimited Grid space

• Textual• Unlimited lines

• Graphical rungs• Unlimited rungs

Upload / Download • Full upload/Download • Full upload/Download • Full upload/Download • Full upload/Download• Comments included

• Full upload/Download

Editing • On/Off line rung level edits

• On/Off line routine edits • On/Off line routine edits • On/Off line routine edits • On/Off line rung level edits

Monitoring • Rung animationD l i i

• Output pin data value animation

• Active Step(s) AnimationA Di l S ll

• Tag watch paneC l i

• Rung animationD l i i• Data value animation

• Force statusanimation • Auto Display Scroll

• Branch/ trans force status• Context coloring • Data value animation

• Force status

Comments • Tag and Rung • Tag, Text Boxes • Tag, Text Boxes, and Embedded ST comments

• Multi-line and end of line embedded in text

• Tag and Rung


• ControlLogix Integrated SafetyGuardGuardLogixLogix

• ControlLogix Integrated Safety– Dual Processor Solution (1oo2 Architecture)

SIL 3 Certification per AS 62061– SIL-3 Certification per AS 62061– AS 4024 Category 4

P ith RSL i 5000– Programs with RSLogix5000– CIP Safety I/O on EtherNet or DeviceNet

• Standard CIP RoutingNo Special Media or Routers

Standard CIP Routing• Safety is in the end nodes

End to end safety using underlying

CIP SafetyCIP Safety

End to end safety using underlying standard servicesDevice Device

CIP ApplicationObjects

CIP ApplicationObjects

CIP ConnectionCIP Connection

CIP Safety Application

Objects

CIP Safety

CIP Safety Application

Objects

CIP Safety

DeviceNetTransport & Data

Link Layer

DeviceNetTransport & Data

Link Layer

EtherNet/IPTransport & Data

Link Layer

EtherNet/IPTransport & Data

Link Layer

CIP ConnectionCIP ConnectionCIP Routing ConnectionConnection

Link Layer Link Layer Link LayerLink Layer

DeviceNet Ethernet

Safety Specific Functions

What Makes Network Safety Safe???• Redundant CRCsRedundant CRCs

– CRC of the Safety Data– CRC of the inverted Safety Data

• Track the Age of Data– Time Stamp on the Data + CRC on the Time Stamp– Time Coordination message in the ACK from Consumer back to

Producer

• Safety Network Number• Safety Network Number– Provides unique identifier for each network within the safety

system – When combined with the local device address (MACID),

provides unique device addressing

1Copyright © 2005 Rockwell Automation, Inc. All rights





Safety I/O


GuardLogix with RSLogix 5000G ardLogi Controllers in • GuardLogix Controllers in Selection Dialog

– 1756-L61S– 1756-L61S– 1756-L63S

• Safety Partner Automatically • Safety Partner Automatically Assigned to the next Slot - Right of the Safety Controller– 1756-LSP

GuardLogix with RSLogix 5000

• RSLogix5000– Safety Task automatically created with tools that restrict y y

user to Safety functions– Single controller view

• Standard Control Task(s)– Same functionality that exists today with ControlLogix

(V16)

• Safety Control - Safety Task– Restricted set of features and functionsRestricted set of features and functions– Safety Certified Standard Instructions– Safety Certified Application Instructions– Security (Safety Task Signature, Locking)– Safety I/O automatically mapped into safety memory

Guardlogix with RSLogix 5000• Safety

Controller Status

• Safety Instruction P l ttPalette

• Periodic SafetyPeriodic Safety Task

• Routine Information Box with Class

• Watermark

GuardLogix with RSLogix 5000• 49 Safety Certified Instructions49 Safety Certified Instructions

– Subset of standard ladder logic instruction set

• Safety Certified Application Instructions– Dual Channel Suite

• 6 Instructions– Metal Forming Suite

• 10 Instructions– Muting Suite

GuardLogix with RSLogix 5000• Safety Task operates in 1 of 2 statesy p

– Standard behavior (Safety signature does not exist)– SIL 3 Safety behavior (Safety signature exists)y ( y g )

• Safety Task - Standard– User actions same as standard task

Forcing online editing memory write are allowed– Forcing, online editing, memory write are allowed.

• Safety Task - Safety– Safety Logic and data is protected– NO FORCES– NO ONLINE EDITING– SAFETY MEMORY READ ONLY

• Safety Signature– A 64 bit unique number

• Calculated by GuardLogix Firmware

Recent NFPA79 Change to Emergency StopPrevious NFPA 79 Emergency Stop Requirements

M t B A C t 0 O 1 StNormal

Start/Stop

– Must Be A Category 0 Or 1 Stop.– The Final Removal Of Power Must Be By Electromechanical Components.

• Drives Do Not Qualify as an Electromechanical Component.– Current Standard Allows Electronic Safety Devices in E-Stop String.

Safe-off (EN954-1/AS4024, Category 3)– Must Be A Category 0 Or 1 Stop– Single Fault Does Not Lead to Loss of Safety Function– Reset of Safety Function Cannot Cause Hazardous Operation Emergency Reset of Safety Function Cannot Cause Hazardous Operation– Safety Categories Are Often Confused with Stop Categories

NFPA 79 2007 & IEC/AS 60204-1 Emergency Stop Requirements

Emergency Stop

9 00 & C/ S 60 0 e ge cy Stop equ e e ts– Approved with an August 17 2006 effective date.– Must Be A Category 0 Or 1 Stop.– Final removal of power is still to be by means of electromechanical components except:

• Where drives or solid state outputs are used which are designed for safety related functions according to relevant safety standards for routine maintenance operations.

Recent change to NFPA79 Makes Safety Drives the productivity choice

2

p oduct ty c o ce

Rockwell Safety Drive Solutions– PowerFlex 40PPowerFlex 40P

• Safe-off Option• Certified to Category 3 per EN954-1

– PowerFlex 70• Safe-off Option on Enhanced Control• Certified to Category 3 per EN954-1• 600V Only: Safety Function Approved to Category 3 per EN954-1

– PowerFlex 700L• Safe-off Option• Certified to Category 3 per EN954-1

S– PowerFlex 700S • Safe-off Option on Phase II w/Expanded Cassette• 208/480V F1-6: Certified to Category 3 per EN954-1• 600V F5 6: Certified to Category 3 per EN954 1• 600V F5-6: Certified to Category 3 per EN954-1• 480V F9-13: Safety Function Approved to Category 3 per EN954-1• 600V F1-4 & 690V F9-13: Safety Function Approved to Category 3 per EN954-1

2





Safety I/O


Safety I/OSafety modules appear• Safety modules appear directly on the I/O Config Tree within RSLogix 5000g– DeviceNet Safety I/O

looks like I/O on ControlNet or EtherNetControlNet or EtherNet I/P

• Safety tags areSafety tags are automatically created

• Safety module configuration is owned by GuardLogix.

Safety IOSIL 3 & Category 4 Certified for use, by TUV UL Listed for Functional Safety -

NRGF.E256621

Key Features

Safety I/OKey Features

Configurable Standard Outputs, Removable terminal blocks,DIN Rail mountable

Product CharacteristicsConfigurable Standard Outputs

• Use for standard control• Use for standard control • Use as an input’s pulse test source

Safety I/O

Safety I/O• Eliminate need for IO panels• Eliminate need for IO panels• Simplify design/installation time using devices with quick

disconnectdisconnect• Many safety devices directly connect to ArmorBlock Guard

I/O

Safety I/O• CompactBlockTM Guard I/OTMCompactBlock Guard I/O• Same as new 1791DS DeviceNet CompactBlock Guard

IO productsBi P l O t t ti– Bi-Polar Outputs option

• Ethernet/IP Support– Set node number with software or rotary switchesSet node number with software or rotary switches

• IP20 Products:– #1 - 1791ES-IB8XOBV4 - 8 inputs, 4 Bipolar

8 l / d doutputs, + 8 pulse test / standard outputs– #2 – 1791ES-IB16 - 16 inputs, 0 outputs, +

16 pulse test / standard outputs• CIP Safety Guard I/O Modules on

EtherNet/IP supported in RSLogix 5000 V16

Safety I/O

RSLogixRSView

GuardLogix

GuardLogix

GuardLogix

SmartGuard 600SmartGuard 600

CIP Safety – EtherNet I/PCIP Safety – EtherNet I/PCIP Safety – ControlNetCIP Safety – DeviceNet





Safety I/O






Safety I/O

G dL i K B fiGuardLogix Key Benefits

GuardLogix Key BenefitsOne Single Programming Environment for DiscreteOne Single Programming Environment for Discrete, Motion, Drives, Safety, and Process

“Pure Tag-based” Control Environment

B tt I t t d M ti S f t d D iBetter Integrated Motion, Safety, and Drives

Better Integrated Ethernet SolutionBetter Integrated Ethernet Solution

GuardLogix Key Benefits• Safety and Standard One Project• Safety and Standard, One Project

– Upload / Download one project (including safety task)– Safety Data available to Standard Task (Read Only)y ( y)– Passing of Standard Data to Safety Task– Leverage existing hardware

• Chassis Power Supplies Comm’s etc• Chassis, Power Supplies, Comm s, etc.

• SIL 3 Safety Task– Certified Safety and Safety Application Instructionsy y pp

• Ladder Programming– SIL 3 Compact Block Safety I/O on DeviceNet Safety

O li Off li Editi d F i ( h U l k d)– On-line, Off-line Editing and Forcing (when Unlocked)– On-line Program Monitoring (Locked or Unlocked)– Safety Tags provide data security

3





Safety I/O

G dL i K B fiGuardLogix Key Benefits

Safety Resources @ Rockwell• Web ResourcesWeb Resources

– CIP Safety Overviewwww.odva.orgWhit P S f t N t k– White Paper - Safety Networkswww.odva.org/10_2/CIPWhite_paper_English.pdf

– Rockwell Automation Safety Certificationsk ll i / d / ifi i / f /www.rockwellautomation.com/products/certification/safety/

– Safety Home Pagewww.ab.com/safety

– Safety Librarywww.ab.com/safety (left navigator – click on Safety Library)

• Collateral• Collateral– Safety Now – new February 2006 issue

Order Publication No. SAFETY-BR001D-EN-PS f t O i B h till i t k– Safety Overview Brochure – still in stockOrder Publication No. SAFETY-BR008A-EN-P

Questions

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integrated safety & powerflex driveguard on tour...up thru sil 3 /cat 4 • high performance •...

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