applying midrange safety systems

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Applying Midrange Safety Systems


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


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


Market Positioning

Midrange System

Safety Tools and support

4

Agenda


2012 Safety Market Share

5

Rockwell Automation is the Global Market Leader in Safety

Source: ARC Advisory Group


Rockwell Automation has the broadest portfolio of Safety products

Global Safety Portfolio

6

Input Devices Logic Devices Output Devices Connectivity

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Trap K

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Mats

Ed

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ablin

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Two

-Han

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Cab

le Pu

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top

Relays

Co

nfig

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PL

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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


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


Market Positioning

Midrange System


8

Agenda


Machinery Safety Complexity of Safety and Standard

10

Increasing demand of integration from low end to midrange to high end safety solutions!

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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


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


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.


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

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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


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!


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


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


Stand Alone Safety Components for L2 Applications

Food ‘n’ Beverage Form Filling, sealing


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


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 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


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


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


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


Market Positioning

Midrange System


24

Agenda


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!

http://safetyroi.avidcom.com/







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. 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


• 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


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




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!


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


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