Transcription

Introduction to Safety PLCsGuardLogix & CIP SafetyJon RiemerSolution Architect – Safety & SecurityFunctional Safety Engineer (TÜV Rheinland)Cyber Security Specialist (TÜV Rheinland)PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.2018 Rockwell Automation TechED Event#ROKTechED

Agenda Basic Functionality Product Introduction Getting Started Programming Application Example Application TechniquesPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.2

Stand-Alone vs Integrated Safety Stand-Alone Safety Performs only safety tasks GSR Safety Relay 440C-CR30 Configurable Safety RelayIntegrated Safety Controller Performs both safety and standard tasks GuardLogix and Compact GuardLogixPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.3

Why Integrated Safety Benefits of Programmable Safety Solutions Flexibility Productivity Reduce Wiring Costs Zone Control Diagnostics Integration Reliability Expandability Security CertificationPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.4

GuardLogix – Redundant Safety Primary Processor Full Standard Logix Functionality (Everything) Isolated Safety Task (protected memory) Secondary Processor Fully isolated SafetyPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.5

SIL 3 Communications – CIP Safety CIP Safety SIL3 Safety Extensions SIL3 Certification per IEC 61508 Enables PLe and Category 4 for 13849CIP - SafetyCIP - StandardDIVERSITY - Standard & CRC Complemented data & Complemented CRCDUALITY - Standard and Complemented dataDIAGNOSTICS - Standard & Complemented CRC and TimingPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.CRC Cyclic Redundant Check6

CIP Safety – Safety Function: Light Curtain to ContactorsOK CIP Safety on EtherNet/IPStandard EtherNet/IPDiscrete HardwiringPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.7

CIP Safety – Safety Function: Light Curtain to Network Safe Torque OffOK toStopSTOCmdRunEtherNet/IPLCBlockedClearCIP Safety on EtherNet/IPStandard EtherNet/IPDiscrete HardwiringPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.8

Safety Processors – Scalable PLd or PLe ISO 13849-1:2015; Figure A.1PLdGuardLogix 5580 Compact GuardLogix 5380PLeAFC2019GuardLogix 5580With PartnerCompact GuardLogix 5380PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.GuardLogix 5570With PartnerCompact GuardLogix 5370Compact GuardLogix L4xS9

Compact GuardLogix 5380 ControllerWith or Without Motion High Performance CPU Optimized for faster safety reaction time Scalable Safety Level SIL CL2, Up to PLd SIL CL3, Up to PLe (Target 4/2019) 1-Gb Embedded Ethernet/IP Port Dual Port – Single or Dual IP Drive and Motion Safety Instructions New Drive Safety Instructions with Kinetix 5700 ERS4 drive Safe feedback scaling, Safe Stop 1, Safe Stop 2, SafeOperation Stop Safe Limited Speed, Safe Limited Position Safe Brake Control with external brake, Safe Direction Increased Scalability Standard memory options ranging from 0.6 MB - 10 MBList Price Starting At 1320PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. Safety memory options ranging from 0.3 MB - 5 MB Support for up to 180 EtherNet/IP nodes per controller Motion support for up to 32 axes per controller10

Ethernet Guard I/O - Family ComparisonFutureGuard I/O pact5000Flex5000DiscreteXXX12/20182019 (16ch)AnalogX20210.5 A / Ch1 A / Ch2019 (16ch)Sourcing/BP2 A / 9 (4ch)IP20PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.IP20IP67IP20IP2011

442G Multifunctional Access Box – CIP Safety Safety Functions Emergency Stop Guard Door Close Guard Door Lock Monitoring Guard Door Lock Enabling Switch Input Cat4/PLe RFID: door position, bolt position, lock status Dual Port Ethernet (M12) Dual Port 24VDC (M12)80% reductionin wiring vsdiscretePUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.12

CIP Safety - Drive PortfolioFutureCIP SafetyDrive PlatformsSafe Torque Off HardwireNetworkSafe 3PF755S4ERSXXXXXERS2XXXXXSpeedXXPositionXXSafety I/OPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.4I / 2O13

GuardLogixCIP Safety on Ethernet/IPCIP SafetyEtherNet/IPFuturePUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.14

GuardLogix Safety Task-Time Based-Ladder Safety I/O Configuration Safety Instruction PalettesPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.15

Safety: I/O ConfigurationGuardLogix-Program all I/O as Single Input and Outputs-Suggest Point StatusPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.16

Safety: Certified Application Instructions Example: TÜV Certified DSC Provides the same functionality as: 16 rungs of logic 2 Timers 5 Latching coils 3 One shots Significant glue logic Results Significant reduction in memory usageMuch easier maintenancePUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.17

Safety: GuardLogix Safety InstructionsGuardLogixDCS – Dual Control StopRedundant Input Monitor- with advanced diagnosticsUsage: E-stop, Guard Door Cls, Safety Prox, etc.F1 Online HelpPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.18

Safety: GuardLogix Safety InstructionsGuardLogixCROUT – Configurable Redundant OutputRedundant Output- with advanced diagnosticsUsage: Electro-mechanical outputs: Contactor, Guard Door Lk, etcF1 Online HelpPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.19

HMI – DCS FaceplateHMI Diagnostics – Normal ConditionFor the Operator: (Global PB)GuardLogix Standard Instruction:For the Troubleshooter: (Pop-up)PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.20

HMI – CROUT FaceplateHMI Diagnostics – Normal ConditionFor the Operator: (Global PB)GuardLogix Standard Instruction:For the Troubleshooter: (Pop-up)PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.21

HMI – CROUT FaceplateHMI Diagnostics – Fault ConditionFor the Operator: (Global PB)For the Troubleshooter: (Pop-up)PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.22

Safety Event Tracking Identify issues related to the use of Safety systems Actionable KPI’s Monitor Safety Systems at the Machine Safety System Testing and Reliability TestingStop Time DegradationPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.23

GuardLogixTypical ApplicationE-stop 1LockedGuardDoor 1OperatorEntry Key1 Safety zone with integrated safety logic Multiple zones requiring supervisory control Zones with shared hazardsE-stop 2LockedGuardDoor 2OperatorEntry Key2Robot Zone 1Robot Zone 2Grinder 1Grinder 2Conveyor 5OperatorEntry Key 5Robot Zone 3OperatorEntry Key 6LockedGuardDoor 5Robot Zone 4Grinder 3Conveyor 4Robot 2Conveyor 3Conveyor 2Conveyor 1Robot 1Grinder 4Conveyor 6Robot 3 Key Specification Steps:1) I/O Count: determine location and platform2) Determine zone unique considerations – before programmingE-stop 3LockedGuardDoor 3OperatorEntry Key 3PUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.Robot 4E-stop 4LockedGuardDoor 4OperatorEntry Key424

Speed Control System – Now: CompactGuardLogix and Kinetix 5700 5380 Compact GuardLogix Multifunction Access Box - CIP Enabling SwitchKinetix 5700 ERS4Motion and SafetyEtherNet/IPVPL Motor with SIL2/PLdsafety rated encoderPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.25

Safety Application Technique Fully documented safety functions:Google: Literature LibrarySearch: safety-at GuardLogixPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.26

ToolsSafety Functions LibraryEach safety function includes: System descriptions of operationsBill of materialElectrical drawingsSISTEMA calculationsVerification & validation plansReview Safety Application TechniquePUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.27

Questions?www.rockwellautomation.comPUBLIC Copyright 2018 Rockwell Automation, Inc. All Rights Reserved.2018 Rockwell Automation TechED Event#ROKTechED