Applying Midrange Safety Systems
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Applying Midrange Safety Systems

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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 ...

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.

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Applying Midrange Safety Systems Applying Midrange Safety Systems Presentation Transcript

  • 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 LightCurtain LaserScanner Camera Non-Contact(RFID) KeyInterlock PleLocking TrapKey Mats Edges Enabling Two-HandPB CablePull E-Stop Relays Configurable PLCHighEnd PLCMidrange DIO Contactors Drives ServoMotion Valves Indicators EtherNet DeviceNet Profibus cclink BelowEthernet Cables&Distr.Blocks Rockwell + + + + - - - Encompass + Siemens + + + Pilz + - mutelamp 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 Functionality 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! SafetyComplexity(#zones) 1357910+ 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 SafetyModule & 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 5000CCW 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
  • 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 FunctionSolution 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 FunctionSolution 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 4 5 6 7 8 9 0 1 2 3 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 SafetyComplexity(#zones) 1357910+ 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. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Thank you for participating!
  • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 33 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Questions?