dupline specialist seminar 2005 1jens neigaard duplinesafe

1

Dupline Specialist Seminar 2005Dupline Specialist Seminar 2005

Jens Neigaard

DuplineSafeDuplineSafe

2


Jens Neigaard

To seek approval for Dupline as a Safety Bus To seek approval for Dupline as a Safety Bus according to:according to:

• EN61508 (SIL 3) EN61508 (SIL 3) Functional safety of electronic systems Functional safety of electronic systems

• EN954-1 (Cat 4) EN954-1 (Cat 4) Safety related parts of control systemsSafety related parts of control systems

• EN81–1 (Cat 4) EN81–1 (Cat 4) Elevator safety normElevator safety norm

DuplineSafe IdeaDuplineSafe Idea

3


Jens Neigaard

• We have existing customers demanding itWe have existing customers demanding it

• We have new potential customers demanding itWe have new potential customers demanding it

• The approvals will open new markets for DuplineThe approvals will open new markets for Dupline

• The general image of Dupline will be improvedThe general image of Dupline will be improved

• Synergy with the Safety Product GroupSynergy with the Safety Product Group

• The trend in the Fieldbus market is going in this The trend in the Fieldbus market is going in this direction- and we must continue to develop our direction- and we must continue to develop our technology to keep pacetechnology to keep pace

Why do we need these approvals ?Why do we need these approvals ?

4


Jens Neigaard

Dupline has some unique features which make the Dupline has some unique features which make the system very suitable for certain safety applications:system very suitable for certain safety applications:

• Dupline can handle long distancesDupline can handle long distances

• Dupline is noise immune and reliableDupline is noise immune and reliable

• Dupline is simple Dupline is simple

• Dupline modules can be powered from the busDupline modules can be powered from the bus

• Dupline input module can be ATEX approvedDupline input module can be ATEX approved

How can we compete with open Safety Buses How can we compete with open Safety Buses like ProfiSafe, SafetyBus and ASI-Safety ?like ProfiSafe, SafetyBus and ASI-Safety ?

5


Jens Neigaard

Traditional safety circuit with series wired Traditional safety circuit with series wired NC ContactsNC Contacts

Problems:• Shorted contacts create an undetected loss of safety function

• No diagnostics• Resistance in contacts becomes a problem

over time

0 VDC

24 VDC

0 VDC

24 VDC

Contactor

Contactor

Safety Relay

6


Jens Neigaard

0 VDC

24 VDC

0 VDC

24 VDC

Contactor

Contactor

Safety Relay Problems:• Wiring cost• Limited number of inputs• Lack of flexibility

Traditional parallel wired safety circuitTraditional parallel wired safety circuit

7


Jens Neigaard

The DuplineSafe SolutionThe DuplineSafe Solution

• Standard Dupline Channel GeneratorStandard Dupline Channel Generator• Buspowered Safety Input ModulesBuspowered Safety Input Modules• Configurable Safety Relay Output Configurable Safety Relay Output

module module • Diagnostic information via PLC, PC orDiagnostic information via PLC, PC or Text Text DisplayDisplay• Up to 63 safety signals on one Up to 63 safety signals on one Dupline busDupline bus

Safety Output module

Contactor

Tx

Tx

Tx

Tx

Safety Input modules

Contactor

PLC/ PC/ Text Display

Gateway Profibus-DP or Modbus

Channel Generator

0 VDC

24 VDC

0 VDC

24 VDC

8


Jens Neigaard

DuplineSafe vs. series wired safety circuitDuplineSafe vs. series wired safety circuit

• The risk of a dangerous short circuit The risk of a dangerous short circuit is much lower because all short is much lower because all short

circuits on the bus are either circuits on the bus are either detected detected or have no impact on safety functionor have no impact on safety function

• Only risk is input leads, but these are Only risk is input leads, but these are very short due to the vicinity of the very short due to the vicinity of the input moduleinput module

• Precise diagnostics which can be Precise diagnostics which can be read from a PLC, PC or Text Displayread from a PLC, PC or Text Display• No problems with contact resistance No problems with contact resistance

due to short input leadsdue to short input leads

Safety Output module

Contactor

Tx

Tx

Tx

Tx


Contactor



Channel Generator

0 VDC

24 VDC

0 VDC

24 VDC

9


Jens Neigaard

DuplineSafeDuplineSafe vs. Parallel wired safety circuit vs. Parallel wired safety circuitSafety Output module

Contactor

Tx

Tx

Tx

Tx


Contactor



Channel Generator

0 VDC

24 VDC

0 VDC

24 VDC

• Reduced wiring costReduced wiring cost• Higher number of inputs possibleHigher number of inputs possible (up to 63 input modules)(up to 63 input modules)• Higher flexibility for enhancement Higher flexibility for enhancement

of a systemof a system

10


Jens Neigaard

Communication ConceptCommunication Concept

• The synchronization channel is toggling every Dupline cycle (controlled by safety output module)

• The status of each input is transmitted is on 2 different Dupline channels

• The transmission is dynamic with the bits toggling every Dupline cycle

• When the input contact is closed, channel 1 follows the sync channel, channel 2 is reverse. When the input contact is

open it is the opposite

11


Jens Neigaard

Communication ConceptCommunication Concept

SafetyInput

Programminginterface

Processor# 2

Powersupply # 1

Duplineinterface

Duplineprotection

Powersupply # 2

Duplineinterface

Processor# 1

Deact. Act. Deact. Act. Deact.

Sync. 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0

Ch. A 0 1 0 1 1 0 1 0 1 1 0 1 0 1 0 1 1 0 1 1 0 1 0Ch. B 1 0 1 0 0 1 0 1 0 0 1 0 1 0 1 0 0 1 0 0 1 0 1

12


Jens Neigaard

Duplinechannel

generator

Standardinput

Standardoutput

Safetyinput

Safetyrelay

output

Standard Dupline modules Safety modules

Dupline bus

The Safety Modules

- Can operate on existing Dupline system

- Can be used together with standard Dupline modules

Combined SolutionsCombined Solutions

13


Jens Neigaard

The DuplineSafe The DuplineSafe ApprovalApproval

Approval according to:• IEC 61508-SIL3• EN954-1 Cat. 4

Pending:• EN81-1

Approved Products:• Safety Input Module (GS75102101)• Safety Relay Output module(GS38300143)

14


Jens Neigaard

The ProductsThe Products

GS75102101GS75102101

15


Jens Neigaard


GS38300143GS38300143

16


Jens Neigaard


GS73800080GS73800080

17


Jens Neigaard


GS38910125GS38910125

18


Jens Neigaard


GSTI50GSTI50

19


Jens Neigaard


GTD50GTD50

20


Jens Neigaard

Safety rules / info in GS38300143 DatasheetSafety rules / info in GS38300143 Datasheet

21


Jens Neigaard


22


Jens Neigaard


23


Jens Neigaard

Safety info / rules in GS38300143 DatasheetSafety info / rules in GS38300143 Datasheet

24


Jens Neigaard

Safety data for approved productsSafety data for approved products

25


Jens Neigaard

Application exampleApplication example

26


Jens Neigaard

AdvantagesAdvantages

27


Jens Neigaard

AdvantagesAdvantages

28


Jens Neigaard

Target ApplicationsTarget Applications

0 VDC

24 VDC

0 VDC

24 VDC

Contactor

Contactor

Safety Relay REPLACEMENT OF SERIES WIRED EMERGENCY STOP SYSTEMS:• Much safer• Diagnostics reduce downtime• Several safety relays at different positions can

react on the same safety switch

29


Jens Neigaard


Application requirements to our advantage• Long distances• Widespread safety switches• No local power supply available at safety switches• High reliability / noise immunity demanded• Simplicity in design, installation and commissioning demanded• Frequent system changes

Application requirements to our disadvantage• Ultra-fast reaction-time needed (not needed for buttons / pull-wire)• Advanced safety functions needed (e.g. Safety PLC with programmable logic functions)

• Open system specified

30


Jens Neigaard


Application examples• Long bulk material conveyors

• Tunnels• Mines• Stone Mills• Power Plants• Cement Factories

• Conveyors used in sorting systems• Airports• Postal systems

• Automated Logistics Systems• Wood Works• Cranes (sliding contacts)• Automatic door systems (e.g. big stock facility)• Elevators (when EN81-1 approval is ready)• Chemical plants (especially when ATEX approval is ready)

31


Jens Neigaard

CompetitorsCompetitors

• Safetybus-P (Pilz)• ProfiSafe (Siemens)• ASI-Safety at work (Siemens, Schneider, Turck ..)• Interbus Safety (Phoenix)• Devicenet Safety (Rockwell)• SafeEthernet (HIMA)

32


Jens Neigaard

Sales Tools / PromotionSales Tools / Promotion

DuplineSafe FlyerDuplineSafe Flyer

33


Jens Neigaard


Exhibition PanelsExhibition Panels

34


Jens Neigaard


Demo SuitcaseDemo Suitcase

35


Jens Neigaard

Sales Tools / Promotion Sales Tools / Promotion

Application NotesApplication Notes

36


Jens Neigaard


Dupline.comDupline.com

37


Jens Neigaard


Advertisement / PosterAdvertisement / Poster

38


Jens Neigaard

Future DevelopmentsFuture Developments

EN81-1 approval (open PCB version)• Visit elevator companies to discuss

• Applicability of concept• Reaction time• Number of I/O’s• Interfacing• Mechanical solution

• Payback issues• Pricing• Determine target customers / elevator types

• Expected time of approval: Q2 2006• We could be the first EN81-1 approved Safety Bus

39


Jens Neigaard

Master ModulePLCPowerSupply 1

24 VDCRS232/485

Safety Tx

Safety Tx

I/O-module

I/O-module

Contactor for Power/ Motor

0 VDC24 VDC

Safety Monitor

Push Buttons

Lamps

1’st floor

2’nd floor

Push Buttons

Lamps

DuplineSafe for Elevators – combined solutionDuplineSafe for Elevators – combined solution

40


Jens Neigaard


ATEX approval• We could be the first on the market with an

IEC 61508 approved Safetybus with Bus-powered IS input modules

• ATEX approved Channel Generator needed• ATEX approval not needed for Output Module• A close cooperation with AUSTDAC is needed in

this project• Expected time of approval: Q2/(Q3) 2006

41


Jens Neigaard


General improvements (phase 2)• Option to program Release-delay in the Safety

Output module• Option to make a ”safety-only” system where un-used

channels are monitored for activity• Approval from TUV that DuplineSafe Repeater can

be used• Mounting bracket for the Safety Input Module• Improved quality of programming adaptor connectors• Expected time of availability: Q2 2006

42


Jens Neigaard


• ProfiSafe Gateway ?• Two-input DIN-rail module ?

dupline specialist seminar 2005 1jens neigaard duplinesafe

Documents