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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
GuardLogix Integrated Safety System
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2
Agenda
I talk a little more about Integrated
Safety
You ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Description
 Integrated safety is changing the way people...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Safety System Design Goals and
Challenges
Goal:
 Providin...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Questions
 How do I find the right mix of safety and prod...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Traditional Contemporary Safety
Solutions
 Turns machine ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
• Two diverse PLCs
• 1oo2 implementation
• From a Safety p...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Still Have Challenges…
 Additional hardware / programming...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
GuardLogix® Safety Integration Overview
 Logix Integrated...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
GuardLogix Features
 Some provide separation
 Some provi...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation between Safe and Standard Control
11
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation / Safety Task
 Safety task created whenever a
...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 13
Separation / Physical Memory
• GLX Primary Controller h...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Safety Task Scan
Safety Task is a Periodic Task
At perio...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation / Safety and Standard Tags
 Every controller t...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation / Safety I/O
 To create safety rated I/O tags,...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation / Unique Safety Protocol
 GuardLogix communica...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Separation / Safety Task Instructions
Instruction Category...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Dual Channel Application Instructions
 Next generation of...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Muting Suite and Safety Mat
 3 Certified Muting Instructi...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Metal Forming Instruction Suite
 BG Certified Mechanical ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integrate Safe and Standard Control
22
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integration / Mix standard and Safety I/O
 CIP and CIP Sa...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integration /Mapping Tool
 Standard tags can be directly ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integration / AOI Signature ID
 AOI functionality availab...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integration / Data Type added for P/C
 Connection_Status ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Integration made easy
27
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Ease of Integration / Standard Task
Operations Same as Con...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Ease of Integration /
Single Programming Tool
 The real b...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Ease of Integration / Studio 5000 Logix
Designer Safety En...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
GuardLogix Integrated Safety
 Integrated safety should re...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Improved Productivity via Safety System
Design
 Global Co...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
We care what you think!
 On the mobile app:
1. Locate ses...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
www.rsteched.com
Follow RSTechED on Facebook & Twitter.
Co...
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GuardLogix Integrated Safety System

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Integrated safety is changing the way people think of safety system design – safety systems that actually improve productivity. This presentation will discuss and demonstrate how simple an integrated safety system is to develop and maintain using RSLogix 5000. This presentation is geared toward beginner to intermediate users and anyone interested in understanding how integrated safety really works.

Published in: Technology, Business

GuardLogix Integrated Safety System

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION GuardLogix Integrated Safety System
  2. 2. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2 Agenda I talk a little more about Integrated Safety You ask some more questions You ask some questions I talk a little about Integrated Safety You give me a good review
  3. 3. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Description  Integrated safety is changing the way people think of safety system design - safety systems that actually improve productivity. This session will discuss and demonstrate how simple an integrated safety system is to develop and maintain using Rockwell Software® Studio 5000. This session is geared toward beginner to intermediate users and anyone interested in understanding how integrated safety really works. 3
  4. 4. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety System Design Goals and Challenges Goal:  Providing a machine that is safe to install / operate / maintain  Comply to appropriate standards (ISO 13849-1:2006, IEC 62061, …) Challenge:  Deliver a safe, compliant system without compromising the production capability and flexibility of the overall system.  Deliver a system with capability for expansion and upgrading.  Deliver a system with global support capability  Deliver a system with adaptability and scalability  Design for Recovery - Minimize MTTR – Downtime or Service time 4
  5. 5. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Questions  How do I find the right mix of safety and productivity?  How does that machine need to act to be productive and safe? Asking these two questions is relatively new… 5
  6. 6. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Traditional Contemporary Safety Solutions  Turns machine off  Hardwired Diagnostics  Inter-connect relays for logic 6 Hardwired Auxiliary Inputs Safety Relay Configurable Safety Relay Stand-alone Safety PLC E-Stop #1 E-Stop #5 E-Stop #3 E-Stop #2 E-Stop #4 Out Feed Conveyor In Feed Conveyor  Some zone control  Hardwired Diagnostics  “Programs with a screwdriver”  Multi-zone control  Comms link for Diagnostics  Programs with separate software
  7. 7. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. • Two diverse PLCs • 1oo2 implementation • From a Safety perspective, this is a good design • Costly, complex, highly engineering system • Difficult to design, develop, test, and maintain • Requires cross-wiring, cross-checking, extensively programmed diagnostics Ch A Ch B Early Safety System Designs 7
  8. 8. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Still Have Challenges…  Additional hardware / programming for Safety System Diagnostics  Additional equipment to specify, purchase, hold as spare parts, …  Multiple software programming environments  Extra time to develop  Extra time to troubleshoot  Extra time to maintain  Additional training for maintenance personnel or for end customer 8 What if we used a single PLC for Safe and Standard Control?
  9. 9. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. GuardLogix® Safety Integration Overview  Logix Integrated Safety  Dual Processor Solution (1oo2 Architecture)  SIL-3 Certification per IEC 61508  ISO 13849 Performance Level e (Category 4)  Programs with Studio 5000 Logix Designer  Safety I/O on Ethernet/IP 9
  10. 10. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. GuardLogix Features  Some provide separation  Some provide integration  Some just make integration „easier‟ 10
  11. 11. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Separation between Safe and Standard Control 11
  12. 12. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Separation / Safety Task  Safety task created whenever a GuardLogix safety controller is selected 12
  13. 13. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 13 Separation / Physical Memory • GLX Primary Controller has separate • Physical Memory for Standard Task Control • Physical Memory for Safety Task Control • Safety Signature • Memory for Safety Task • Read Only • No Forcing • No Online editing • No Offline editing • Safety Lock • Prevents deletion of safety signature • Password protection
  14. 14. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety Task Scan Safety Task is a Periodic Task At period rate, Primary „wakes up‟ Partner Safety input data „frozen‟; does not change during scan Primary sends raw input data to Partner Both Primary and Partner execute safety logic to completion using the frozen safety input data Safety Task results are cross checked by both controllers (primary >< partner) If results are OK, Primary and Partner each build half of the safety output data packet, and then packet is written to the safety outputs 14
  15. 15. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Separation / Safety and Standard Tags  Every controller tag has a class; either „standard‟ or „safety‟  Safety tags can only be used within safety task  Cannot „drive‟ or „control‟ a safety output tag in standard task 15
  16. 16. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Separation / Safety I/O  To create safety rated I/O tags, you need to use safety rated I/O modules  Safety I/O data automatically mapped into safety memory  CompactBlock™ I/O (1791)  ArmorBlock® (1732)  POINT Guard I/O™ (1734) 16
  17. 17. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Separation / Unique Safety Protocol  GuardLogix communicates to standard I/O modules using CIP protocol  GuardLogix communicates to safety I/O modules using CIP Safety protocol  CIP Safety Protocol  Data is sent twice (redundancy)  One regular / One inverted (diversity)  Every packet is time stamped (diagnostics)  Protect against misuse; standard module data cannot appear in safety tags 17
  18. 18. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Separation / Safety Task Instructions Instruction Category Supported Instructions  Array/Shift  Bit XIC, XIO, OTE, OTL, OTU, ONS, OSR, OSF,  Compare LIM, MEQ, EQU, NEQ, LES, GRT, LEQ, GEQ  Compute/Math  File Misc. COP  Filter  For  Input/Output GSV, SSV  Math Conversion ADD, SUB, MUL, DIV, MOD, SQR, NEG, ABS  Move/Logical MOV, MVM, AND, OR, XOR, NOT, CLR,  Program Control JMP, LBL, JSR, RET, SBR, TND, MCR, AFI, NOP  Select/Limit  Sequencer  Special  Statistical  Timer/Counter TON, TOF, RTO, CTU, CTD, RES  Only certified instructions available for safety task  Only certified instructions in Partner firmware 18
  19. 19. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Dual Channel Application Instructions  Next generation of certified application instructions  DCS is base instruction (Stop)  Stop with Test  Stop with Test & Lock  Stop with Test & Mute  Monitor  Start  Focused on three main safety “Functions”  Start  Stop  Monitor  Easier to use  Functions are built into the instructions  Test & Unlock Request  Hazard Stopped  Input Status  Reduces testing & validation effort  Better diagnostics 19
  20. 20. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Muting Suite and Safety Mat  3 Certified Muting Instructions  Two Sensor Asymmetrical  Two Sensor Symmetrical  Four Sensor Bidirectional  Safety for Conveyor related applications  Light Curtains  Laser Scanners  Safety Mat Instruction  Eliminates the need for a safety mat controller.  Directly connect safety mats to safety input modules. 20
  21. 21. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Metal Forming Instruction Suite  BG Certified Mechanical Press Application Instructions  EN 692  ANSI B11.1  CSA Z142.02  10 Metal Forming Instructions  Crankshaft Position Monitor  Clutch Brake Inch Mode  Clutch Brake Single Stroke Mode  Clutch Brake Continuous Mode  Camshaft Monitor  Main Valve Control  Auxiliary Valve Control  Manual Maintenance Valve Control  Two Hand Run Station  8 Position Mode Selector 21
  22. 22. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Integrate Safe and Standard Control 22
  23. 23. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Integration / Mix standard and Safety I/O  CIP and CIP Safety protocols can reside on same network  Ethernet/IP  DeviceNet  Can mix & match standard and safety Point I/O modules in the same rail Differences between CIP and CIP Safety are at the protocol level, so you can communicate to standard and safety modules via Netlinx 23
  24. 24. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Integration /Mapping Tool  Standard tags can be directly mapped to safety tags  The Safety tag can then be used in safety task  This mapped safety tag must still be considered non-safety data 24
  25. 25. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Integration / AOI Signature ID  AOI functionality available for use within Safety Routines  Only safety tags / instructions are allowed  Safety Signature added to easily verify that AOI downloaded properly.  Signature ID represents CRC of binary code in memory  Reduces test and validation effort  Test once and then simply verify signature on each re use.  Transportable between GuardLogix projects  SIL integrity is maintained  Uses the same procedures as standard side AOI‟s  Compatible with all future AOI enhancements (Library ease of use features, etc.)  Provides users significant benefits  Helps enforce consistent behavior  Reduces the risk of users creating custom logic 25
  26. 26. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Integration / Data Type added for P/C  Connection_Status data type added to support P/C Safety tags  Only UDTs can be used for P/C safety tags  First member must be CONNECTION_STATUS 26
  27. 27. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Integration made easy 27
  28. 28. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Ease of Integration / Standard Task Operations Same as ControlLogix® • Executes each program top to bottom and then restarts • Operates at the lowest priority on the controller • Uses all CPU time left after other tasks execute • Interrupted by operating system to perform processor and communications overhead • Traditional PLC Scan • Triggered automatically at a preset time interval • Interrupts lower priority tasks and can be interrupted by higher priority tasks (15 Levels) • Will time-slice on a 1ms basis with another task at the same priority level • Captures fault for task overlap • Similar to PLC/SLC Selectable Timed Interrupt (STI) • Triggered on arrival of input, consumed tag, motion operations, via another program, or a Windows Event for SoftLogix™ 5800 • Priority same options as Periodic... • Captures fault for task overlap • Similar to PLC Peripheral Input Interrupt (PII) or SLC Discrete Input Interrupt (DII) Continuous Task Scan Periodic Task Scan CPUOverheadTime-slice TaskAuto-restart Scan interrupted by periodic and event tasks Program 2 Program 1 Program ..n ... Program 2 Program 1 Program ..n ... 5ms 10ms 15ms ... Depending on task priority scan interrupted by other periodic and event tasks Event Task Scan Program 2 Program 1 Program ..n ... Input Motion Code ... Depending on task priority scan interrupted by other periodic and event tasks 28
  29. 29. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Ease of Integration / Single Programming Tool  The real benefit is related to software familiarity  The more safety is the same as standard, the easier it becomes  Can program both safety and standard tasks using Rockwell Software® Studio 5000  Data structures remained the same  How I/O is handled remained the same  How communications are handled remained the same 29 RSLogix™ 5000 V1…16,17,18,19,20 Studio 5000 Logix Designer™ V21,22,23,24,25,…
  30. 30. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Ease of Integration / Studio 5000 Logix Designer Safety Environment  Safety Controller Status  Safety Instruction Palette  Periodic Safety Task, Programs, Program scoped safety tags, Routines  Safety I/O  Safety Watermark 30
  31. 31. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. GuardLogix Integrated Safety  Integrated safety should reduce system development costs  Ease of use is the primary factor  Directly correlates to speed, less wasted time and effort  Common software reduces acquisition costs, but the real benefit is related to software familiarity.  The more safety is the same as standard, the easier it becomes  How data is used in the system  How I/O is handled  How controller interlocking is done  Standard, Safety or both  How communications are configured and operate 31
  32. 32. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Improved Productivity via Safety System Design  Global Compliance – design scalable applications that meet global requirements.  Reduce Design Time – safety can not continue to be an added cost solution, it must deliver value.  Reduce Installation Cost and Start-up Time – leverage existing investments and architecture. Safety = Productivity = Profitability Modern Safety Practices are Enabling a Fundamental Change in How Safety is Viewed in Manufacturing 32
  33. 33. 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!!
  34. 34. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Thanks for Attending

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