Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Applying Midrange Safety Systems
Jul 06, 2015
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Applying Midrange Safety Systems
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Session Overview
Midrange safety applications pose unique challenges, and a range of
available safety control options. Find out how to get the most from your
midrange safety system selection. This session will review examples of
midrange applications, their challenges, the pros and cons of various
control options - including relays, programmable relays, and integrated
safety controllers – and how each can affect your development process.
2
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Midrange Safety Solution Discussion Points
1. Defining Rockwell Automation’s position in the safety market.
2. Defining what is a midrange system.
3. Defining of the types and kinds of machines in mid-range.
4. Basic understanding of how to leverage the Rockwell Automation
portfolio and safety tools to address safety in midrange systems.
5. Provide an understanding of the roadmap of Rockwell Automation’s
safety solutions in the midrange market.
6. Leveraging the best safety tools in the industry.
3
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Market Positioning
Midrange System
Safety Tools and support
4
Agenda
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
2012 Safety Market Share
5
Rockwell Automation is the Global Market Leader in Safety
Source: ARC Advisory Group
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Rockwell Automation has the broadest portfolio of Safety products
Global Safety Portfolio
6
Input Devices Logic Devices Output Devices Connectivity
Lig
ht C
urtain
Laser S
cann
er
Cam
era
No
n-C
on
tact (RF
ID)
Key In
terlock
Ple L
ockin
g
Trap K
ey
Mats
Ed
ges
En
ablin
g
Two
-Han
d P
B
Cab
le Pu
ll
E-S
top
Relays
Co
nfig
urab
le
PL
C H
igh
En
d
PL
C M
idran
ge
DIO
Co
ntacto
rs
Drives
Servo
Mo
tion
Valves
Ind
icators
Eth
erNet
DeviceN
et
Pro
fibu
s
cc link
Belo
w E
thern
et
Cab
les & D
istr. Blo
cks
Rockwell
+ + + + - - -
Encom
pass
+
Siemens + + +
Pilz + -
mu
te lamp
I/O
440G-LZ
PL e lock
440C-CR30
SW configurable
Relay
AoP - Premier
integration
CIP motoion
and CIP safety
drives
S7-1500
As of 2013
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Input Devices Logic Devices Output Devices Scalable
GuardShield
450L
Armor
GuardLogix
PowerFlex
527
Kinetix
5500
GuardMaster
440G-LZ
GuardMaster
EIP
GuardMaster
440C-CR30
Fu
nct
ion
alit
y
Machine Safety FY14 New Product Releases
7
CCW CCW
Scalable safety solution serving simple and complex applications
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Market Positioning
Midrange System
Safety Tools and support
8
Agenda
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Machinery Safety Complexity of Safety and Standard
10
Increasing demand of integration from low end to midrange to high end safety solutions!
Saf
ety
Co
mp
lexi
ty
(# z
on
es)
1
3
5
7
9
10+
Control Complexity
Midrange
require more than stand alone control
but need low cost solutions
• typically 50 to 200 I/O,
• have 2 to 4 zones of safety control,
• have 2 to 10 axis of motion control
• and 2-6 screens of visualization
Low End complexity:
Individual stand alone stations
• use Mirco controllers and
• simple safety relay solutions with
• little to no motion control.
High End Market
large, complex and integrated
• high I/O counts and complex safety needs
• multiple zones of control,
• distributed I/O,
• multiple axis of motion control
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Application and Product Segments
Food „n‟ Bev. Cutting, slicing
Packaging Wrapper
Food „n‟ Bev. Form Filling
Packaging Palletizer
Packaging Carton filling
Packaging Bottle labeling
Packaging Bottle labeling
Cost-effective Component Solutions Midrange Solutions Highly Integrated Solutions
Individual Station Safety Integrated Line Control Safety Module & Zone Control Safety
Simple connectivity 1 or 2 zones of control Local Status Indication
Advanced connectivity 2 to 5 zones
Increased interoperability
Integrated Safety Multiple zones of control
Safety includes complex machine control
Studio 5000 CCW Studio 5000
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
What is a Midrange System?
A machine with 50 to 200 standard I/O
A machine with 2 to 10 axis of integrated motion
A machine that has 2 to 4 zones of safety control
A machine that uses 4 to 6 screens of visualization
A machine utilizes multiple safety input and output device types
A machine that has a relatively small footprint
A machine that needs more control than a stand alone component solution can provide
A machine that needs to be a cost effective solution
Copyri
ght ©
2010
Rockw
ell
Autom
ation,
Inc. All
rights
reserv
ed.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Typical Midrange Applications
Sheet stacking systems
Integrated Shrink Wrapper Systems
Form Fill & Seal Machines
Plastic Injection Systems
Case Packer Systems Bottling & Capping systems
Box Erecting systems
Palletizers
De-Palletizers Integrated Oven Systems Material Handling Systems
Robotic Welding Systems
Automated Assembly Systems
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Safety Solutions for the Midrange Market
(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 14
Midrange safety solutions
CR30 ConfigurableSafety Relay with Micro 820 as
Ethernet bridge
SmartGuard600 safety controller
Simple Semi-complex and distributed
• The solutions above provide cost effective solutions that can meet any
application that a customer might have in the midrange market.
• All of these options have EtherNet communications capabilities that help with
diagnostics and integrated solutions.
Studio 5000
Expandable GuardMaster safety relays with E-net
Studio 5000
2015 CR30 w/Enet
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 15
Guardmaster® EtherNet/IP™ Network
Connectivity for Guardmaster Safety Relays to Ethernet Networks
Up to six GSRs supported by a single network interface
Optical Bus System
Optical Bus System
GSRs communicate seamlessly when mounted within 5mm of each other through the optical bus system
No need for extra wires or connectors
Ethernet
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Ease of Use Premier Logix integration
16
1. Set Private IP address with rotary switches (192.168.1.xxx)
3. Add Module Profile in Studio 5000 Logix Designer software
4. Monitor with logically named tags and structures!
2. Plug-in to EtherNet/IP Network
Configuration in one software package, Logix Designer!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Guardmaster® 440C-CR30 Safety Relay Software Configurable Safety Relay
Safety made Simple & Flexible • Supports four to ten safety input circuits and up to five safety output zones
• Flexible configuration allows you to re-engineer and rapidly integrate application without having to incur high costs of rewiring
• Innovative safety logic editor reduces the effort involved in setting up a safety system by minimizing manual input for a “best-in-class” configuration experience
Optimize Panel Space • 22 Safety I/O in a compact 110mm wide housing
• Expand by up to 16 standard I/O using front mounted plug-in slots that allow you to maintain the 110mm horizontal footprint
Part of the Connected Components Workbench™ Bundle • Preferred compatibility within the bundle
• Reduced supply chain costs
• One software supports Guardmaster 440C-CR30, Micro800 controllers, PowerFlex® drives, Kinetix™ 3 servo drives and PanelView™ Component terminals
Safety & Productivity • Embedded serial port for direct diagnostic communications to PanelView
Component terminals or Micro800™ controllers
• 16 user-configured status LEDs allow you to tailor indication to best suit your application
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Guardmaster ® 440C-CR30 Safety Relay Connection to Logix controller through Micro820™ Pass-through
Share diagnostics with Logix controller
Logix Controller
Use Micro820 for EtherNet/IP connectivity
• Embedded Serial Port on CR30 can be connected to the Micro820 with EtherNet/IP connectivity
Micro820
CR30
RS232 EtherNet/IP
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Stand Alone Safety Components for L2 Applications
Food ‘n’ Beverage Form Filling, sealing
Packaging Palletizer
Typical L1 or L2 Applications use:
• Standalone Safety
• Zoning and simple logic (AND/OR)
• Multiple safety input devices
• Diagnostics via Ethernet IP
• Logic requirement 3-5 safety inputs
• 2-4 safety zones
Studio 5000
Multiple relay system that is
configurable and expandable
and has multiple safety
functions
• Guardmaster Safety
Relays with Ethernet/IP
Gateway
Application Safety Function Solution
Safety Monitoring Function
• Combinations of door interlocks and
E-Stops, light Curtains
• Typically wired in series for one safety
circuit
Safety control (output) function
• Partial Shutdown of multiple zones
• Combinations of delayed and
instantaneous shut down
+
+ + +
Packaging Carton filling and erector
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Stand Alone Safety Components for L2 to L4
Applications
Typical L2 to L4 Applications use:
• Zoning and enhanced logic
(AND/OR) between multiple diverse
safety functions
• Diagnostics via Communication
interfaces
• 3+ zones
Application Safety Function Solution
Safety Monitoring Function
• Multiple diverse safety function
• Typically low number of logical series
connection within safety circuits
• Specialty functions required such as
Safe operation mode selection via
Key switches in combination with
enabling switches to monitor operator
position, Muting and Two Hand
control
Safety control (output) function
• Partial Shutdown of multiple zones
• Locking functions
+
+
+ +
Packaging Palletizer
Packaging Carton filling and erector
Food ‘n’ Beverage Bottle labeling
+
+
440C-CR30 configurable safety relay
• Up to 5 Zone control can be
achieved by CR30
Integrated Safety:
• If a large amount of complexity is
needed for both standard and safety
systems, (motion) and machine is
made up of many sections over a
large distance then cGLX with
PointGuard I/O provides the
appropriate level of control.
Studio 5000
2015 CR30 w/Enet
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Close gap below Ethernet for small scale safety application with simple logic
Component Safety Systems
21
Safety Relays
GSR
• Screw-driver configuration
• Local diagnostics
• Hardwired
• Aux or NO for Diagnostics
Safety components and push-buttons
Safety Relays
• Gateway devices for
more granular
diagnostics of safety
relay
• Advanced diagnostics
to reduce downtime and
troubleshooting
Configurable safety Relay
• Configurable relay
integrated with CCW
• Embedded serial
communication
• Compatible with selected
Micro800 plug-ins
GSR830 EtherNet/IP Connectivity
0 1 2 3 45 6 7 8 9
0 1 23 4 5
PWR
RUN
FAULT
LOCK
COM
440C-CR30
• Integration with Logix
systems for diagnostics
• And configuration
Today Increasing diagnostics and flexibility
Studio 5000
CCW
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Focus is: On-machine and scaled safety
Integrated Safety Systems
22
In Cabinet Mid-Range
On-machine Dnet Safety I/O
1756-L7yS
In-Cabinet Enet Safety I/O
On-Machine
On-machine Enet/IP Safety I/O
Armor GLX
Compact
GuardLogix
1768-L4xS
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integrated Safety
Premier Integration
Machine Safety Connected Enterprise across all platforms
23
Safety scales and data flows in all architectures
Saf
ety
Co
mp
lexi
ty
(# z
on
es)
1
3
5
7
9
10+
Micro 800 L1 to L3 L4 to L7
Control Complexity
440C-CR30 with
2080-ENET
CompactLogix ControlLogix
GSR with GSR-ENET
GuardLogix Compact GuardLogix
Connected Components
440C-CR30
AFC!
Enet
2015
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Market Positioning
Midrange System
Safety Tools and support
24
Agenda
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Safety Return-On-Investment Tool Find out how to quantify the savings and productivity gains from safety investments. The Rockwell Automation Safety Return-On-Investment Tool accounts for improved safety, reduced claims, improved productivity, and other issues unique to safety applications.
Safety Functions
Safety Functions Program The Safety Functions Program is building block approach to designing safety systems. Each building block has a complete documentation package that includes a description of each safety function, an electrical schematic, a bill of material, a SISTEMA verification calculation and a verification and validation plan.
SAB Safety Automation Builder The Safety Automation Builder software package that allows users to import images of their machines. Users can identify hazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigate the risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation.
Safety Accelerator
Toolkit
Safety Accelerator Toolkit This toolkit provides easy to use system design, programming, and diagnostic tools to assist you in the rapid development and deployment of your safety systems using GuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, and Safety Devices. The toolkit includes a risk assessment and system design guide, hardware selection guide, CAD drawings, safety logic routines, and operator status and diagnostic faceplates.
Connected Components
BB
Connected Components Building Blocks These building blocks are tools that help customers develop safety solutions that utilize component class safety solutions. These building blocks include sample programs, electrical schematics and configuration document that help in the
ProSafe Builder
ProSafe Builder The ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safety applications with a tool that generate a bill of material and system configuration schematic/map.
The broadest suite of safety tools in the industry!
Rockwell Automation invested in safety tools to
help customers be compliant and safe!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Qty Catalog Number Description DS List Ea Typical Delivery
1 445L-P4E0600FP Micro 400 Safety Light Curtain, Pair, Res 30mm, Pt Ht 600mm E8 $ 1,220.00 Preferred
2 445L-AC8RJ5 M12 to RJ45, 5 meter E8 $ 26.30 Preferred
1 440R-ACABL2 Ribbon cable 10 pin for 2 extenstion E8 $ 36.46
1 440R-P226AGS-NNR MSR42 Multi function Controller for GuardShield Light Curtains E8 $ 507.00 Preferred
1 440R-D22R2
Guardmaster Safety Relay, 2 Dual Channel Universal Inputs, 1 N.C. Solid State Auxiliary Outputs E8 $ 402.99 Preferred
1 100S-C37EJ14BC MCS 100S-C Safety Contactor, 37A, 24V DC (w/Elec. Coil), Bifuracated Contact B7 $ 411.07
1 1754-L28BBB GuardPLC 1200 - Packaged Safety Controller, 28 I/O D5 $ 6,120.60
1 1753-DNSI GuardPLC DeviceNet Safety Scanner D5 $ 1,141.30
2 1753-IB16 Digital Input Module, 16 Inputs, 24V DC D5 $ 1,787.70 Preferred
Complete Safety System Layout
Performance Level Verification
Complete Bill of Material
SAB – Leaves customers with conceptual layout drawings,
design verification reports and complete bills of materials!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 27
The industries only return on investment tool for safety projects!
What is the Safety ROI Calculator Tool?
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Copyright © 2010 Rockwell Automation, Inc. All rights reserved. 28
Simplified Wiring
Preconfigured Logic Quick Start Manual
Preconfigured HMI
Risk Assessment,
Design Methods
Compliance and
Safety Accelerator Toolkit Development Tools and Quick Start Guide
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
• Safety Functions include GSR relay solutions and GuardLogix solutions.
• The initial 6 Safety Functions will launch October 1st
• E-stop
• Light Curtains
• Two hand control
• Enabling Switch
• Guard-locking switches
• Door interlocks
• 18 additional Safety Functions will be added in the near future.
Introducing… The Safety Functions Library
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Rockwell Automation Service & Support! Assessments
Arc Flash Analysis
Hazard Risk LOTO HAZOP
Validation Safety circuit
analysis Machine stop time
services Conformance
audits Safety system
validation
Compliance Consulting CE conformance Functional safety
(ex. ISO 13849-1 and IEC 62061, ISO, ANSI, IEC, CE, OSHA, NFPA, CSA, AS )
200+ Safety Professionals Available Globally 100+ Machinery Safety Certified Resources 80+ Process Safety Resources Over 200 Training Courses for help customers develop competency
30 + RA Safety Professionals 3 RA Safety Partners – 20 Resources
4 Safety Professionals
20+ RA Safety Professionals 12 RA Safety Partners – 24+ Resources
20+ Safety Professionals
6 Safety Professionals
5 Safety Professionals
5 Safety Professionals
Training TUV Certification Risk Assessments Safety Standards Safety Products Arc Flash LOTO
Integration / Start Up
Circuit/logic design Installation Arc flash
remediation MCC Arc Flash
upgrades Project
Management
Remediation Solutions Complete
Turnkey Systems
The most complete suite of safety services in the industry!
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
If Something Is Moving, Safety Is Required!
Safety Summary
31
Rockwell Automation is #1 in Machine Safety
Safety is no longer a niche – it is becoming a standard feature
Safety is on every machine
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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