Allen-Bradley GuardLogix 5570 Manuale utente

Application Technique

Original Instructions

Enabling Switch with an Integrated Safety Controller and a POINT

Guard I/O Safety Module Safety Function

Products: GuardLogix 5570 or Compact GuardLogix 5370 Controller, POINT Guard I/O Safety Module, 440J Enabling Switch,

440K Interlock Switch

Safety Rating: Cat. 3, PLd to ISO 13849-1: 2015

Topic Page

Important User Information 2

Summary of Changes 3

General Safety Information 3

Introduction 4

Safety Function Realization: Risk Assessment 5

Enabling Switch Safety Function 5

Safety Function Requirements 5

Functional Safety Description 5

Bill of Material 6

Setup and Wiring 7

Configuration 10

Programming 11

Calculation of the Performance Level 13

Verification and Validation Plan 15

Additional Resources 16

2Rockwell Automation Publication SAFETY-AT125C-EN-P - February 2022

Enabling Switch with an Integrated Safety Controller and a POINT Guard I/O Safety Module Safety Function Application Technique

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this

equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and

wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried

out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application

of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements

associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the

examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in

this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

Labels may also be on or inside the equipment to provide specific precautions.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,

which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may

reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication SAFETY-AT125C-EN-P - February 2022 3

Enabling Switch with an Integrated Safety Controller and a POINT Guard I/O Safety Module Safety Function Application Technique

Summary of Changes

This publication contains new and updated information as indicated in the following table.

General Safety Information

Contact Rockwell Automation to learn more about our safety risk assessment services.

Safety Distance Calculations

Non-separating safeguards provide no physical barrier to prevent access to a hazard. Publications that offer guidance for calculating

compliant safety distances for safety systems that use non-separating safeguards, such as light curtains, scanners, two-hand controls, or

safety mats, include the following:

EN ISO 13855:2010 (Safety of Machinery – Positioning of safeguards with respect to the approach speeds of parts of the human body)

EN ISO 13857:2008 (Safety of Machinery – Safety distances to prevent hazardous zones being reached by upper and lower limbs)

ANSI B11:19 2010 (Machines – Performance Criteria for Safeguarding)

Separating safeguards monitor a movable, physical barrier that guards access to a hazard. Publications that offer guidance for calculating

compliant access times for safety systems that use separating safeguards, such as gates with limit switches or interlocks (including

SensaGuard™ switches), include the following:

EN ISO 14119:2013 (Safety of Machinery – Interlocking devices associated with guards - Principles for design and selection)

EN ISO 13855:2010 (Safety of Machinery – Positioning of safeguards with respect to the approach speeds of parts of the human body)

EN ISO 13857:2008 (Safety of Machinery – Safety distances to prevent hazardous zones being reached by upper and lower limbs)

ANSI B11:19 2010 (Machines – Performance Criteria for Safeguarding)

In addition, consult relevant national or local safety standards to assure compliance.

Topic Page

Updated the Bill of Material. 6

Replaced the Electrical Schematic diagram. 9

Added a graphic that depicts the I/O configuration. 10

Replaced the SISTEMA screen shots. 13…14

IMPORTANT This application example is for advanced users and assumes that you are trained and experienced in safety

system requirements.

ATTENTION: Perform a risk assessment to make sure that all task and hazard combinations have been identified and

addressed. The risk assessment can require additional circuitry to reduce the risk to a tolerable level. Safety circuits must

consider safety distance calculations, which are not part of the scope of this document.

ATTENTION: While safety distance or access time calculations are beyond the scope of this document, compliant safety

circuits must often consider a safety distance or access time calculation.

4Rockwell Automation Publication SAFETY-AT125C-EN-P - February 2022

Enabling Switch with an Integrated Safety Controller and a POINT Guard I/O Safety Module Safety Function Application Technique

Introduction

This safety function application technique explains how to wire, configure, and program a Compact GuardLogix® controller and POINT Guard

I/O™ module to monitor an enabling switch. The operator squeezes the enabling switch to the middle position to bypass the primary, safety-

door interlock. This action allows the Compact GuardLogix controller to energize the final control device, in this case, a redundant pair of

100S contactors. The actual safety function that uses an enabling switch is beyond the scope of this document. The safety function may

require speed monitoring, direction monitoring, force monitoring, or additional monitoring to reduce hazard to a tolerable level while using

the enabling switch.

This example is applicable to any GuardLogix controller. This example uses a 440J interlock switch with an integrated jog button, but is

applicable to solutions that use enabling switch technology in combination with a manual button.

The Safety Integrity Software Tool for the Evaluation of Machine Applications (SISTEMA) calculations that are shown later in this document

would have to be recalculated using the actual products.

Use Sample Project Files

Sample project files (AutoCAD, EPLAN, ACD, SISTEMA, and Verification and Validation checklist) are attached to this document to help you

implement this safety function.

To access these files, follow these steps.

1. If you are viewing the PDF file in a browser and do not see the Attachments link , download the PDF file and open it in the Adobe

Acrobat Reader application.

2. Click the Attachments link .

3. Right-click and save the desired file.

4. Open the file in the appropriate application.

Rockwell Automation Publication SAFETY-AT125C-EN-P - February 2022 5

Enabling Switch with an Integrated Safety Controller and a POINT Guard I/O Safety Module Safety Function Application Technique

Safety Function Realization: Risk Assessment

The Performance Level required (PLr) is the result of a risk assessment and refers to the amount of the risk reduction to be conducted by the

safety-related parts of the control system. Part of the risk reduction process is to determine the safety functions of the machine. In this

application, the Performance Level that is required by the risk assessment is category 3, Performance Level d (cat. 3, PLd), for each safety

function. A safety system that achieves cat. 3, PLd, or higher, can be considered control reliable. Each safety product has its own rating and

can be combined to create a safety function that meets or exceeds the PLr.

Enabling Switch Safety Function

This application technique includes one safety function: removal of power from the hazard when the safety system detects that the operator

does not have the enabling switch in the middle position, or the door switch is open.

Safety Function Requirements

Functional safety requires the continuous actuation of a three-position enabling switch to enable power to the motor. The handheld device

provides power to the motor when squeezed to the middle position. When the operator releases or fully squeezes the switch, power to the

motor is removed. Faults at the enabling switch, wiring terminals, or safety controller are detected before the next safety demand. The

safety function in this example is capable of connecting and interrupting power to motors rated up to 9 A, 600V AC.

The safety function in this application technique meets or exceeds the requirements for Category 3, Performance Level d (Cat. 3, PLd), per

ISO 13849-1 and control reliable operation per ANSI B11.19.

Functional Safety Description

In this example, power to the motor is enabled if the safety door is closed, or if the operator opens the door and squeezes an enabling switch

to the middle position. Both the door switch and enabling switch are wired to a pair of safety inputs on a safety input module (SI1).The safety

contactors (K1 and K2) are connected to a pair of safety outputs of a safety output module (SO1). The I/O module is connected via CIP Safety™

technology over an EtherNet/IP™ network to the safety controller (SC1). The safety code in SC1 monitors the status of the door and enabling

switch by using pre-certified safety instructions. Dual Channel Input Stop (DCS) is used for the door and Dual Channel Input Start (DCSRT) is

used for the enabling switch, as this device is a safety device that starts a safety output. When all safety input interlocks are satisfied and no

faults are detected, a certified function block called Configurable Redundant Output (CROUT) controls and monitors feedback for a pair of

100S redundant contactors.

From: Risk Assessment (ISO 12100)

1. Identification of safety functions

2. Specification of characteristics of each function

3. Determination of required PL (PLr) for each safety function

To: Realization and PL Evaluation

6Rockwell Automation Publication SAFETY-AT125C-EN-P - February 2022

Enabling Switch with an Integrated Safety Controller and a POINT Guard I/O Safety Module Safety Function Application Technique

Bill of Material

This application technique uses these products.

Choose one of the following safety-controller hardware groups.

Cat. No. Description Quantity

440J-N21TNPM-NP Enabling switch with button 1

440K-T11090 Trojan™ 5 standard safety interlock switch 1

800FM-G611MX10 800F Reset push button - metal, guarded, blue, R, metal latch mount, one normally open contact, standard 2

100S-C09EJ23C Bulletin 100S-C - safety contactors 2

1734-AENT 24V DC Ethernet adapter 1

1734-TB Module base with removable IEC screw terminals 4

1734-IB8S POINT Guard I/O safety input module 1

1734-OB8S POINT Guard I/O safety output module 1

Controller Cat. No. Description Quantity

GuardLogix 5570

1756-L71S GuardLogix processor, 2.0 MB standard memory, 1.0 MB safety memory

11756-L72S GuardLogix processor, 4.0 MB standard memory, 2.0 MB safety memory

1756-L73S GuardLogix processor, 8.0 MB standard memory, 4.0 MB safety memory

1756-L7SP GuardLogix Safety Partner 1

1756-EN2TR ControlLogix® EtherNet/IP bridge, 10/100 Mbps, 2-port, twisted-pair media 1

1756-PA72 Power supply, 120/240V AC input, 3.5 A @ 24V DC 1

1756-A7 Seven-slot ControlLogix chassis 1

Compact GuardLogix 5370

1769-L30ERMS Compact GuardLogix processor, 1.0 MB standard memory, 0.5 MB safety memory

1769-L33ERMS Compact GuardLogix processor, 2.0 MB standard memory, 1.0 MB safety memory

1769-L36ERMS Compact GuardLogix processor, 3.0 MB standard memory, 1.5 MB safety memory

1769-L37ERMS Compact GuardLogix processor, 4.0 MB standard memory, 1.5 MB safety memory

1769-L38ERMS Compact GuardLogix processor, 5.0 MB standard memory, 1.5 MB safety memory

1769-PA4 Power supply, 120V/240V AC input, 2.0 A @ 24V DC 1

1769-ECR Right-end cap and terminator 1

GuardLogix 5580(1)

1756-L81ES GuardLogix Processor, 3 MB standard memory, 1.5 MB safety memory

1756-L82ES GuardLogix Processor, 5 MB standard memory, 2.5 MB safety memory

1756-L83ES GuardLogix Processor, 10 MB standard memory, 5 MB safety memory

1756-L84ES GuardLogix Processor, 20 MB standard memory, 6 MB safety memory

1756-PA72 Power supply, 120/240V AC input, 3.5 A @ 24V DC 1

1756-A7 Seven-slot ControlLogix chassis 1

Rockwell Automation Publication SAFETY-AT125C-EN-P - February 2022 7

Enabling Switch with an Integrated Safety Controller and a POINT Guard I/O Safety Module Safety Function Application Technique

Setup and Wiring

For detailed information on how to install and wire the products in this application technique, refer to the publications that are listed in

Additional Resources.

System Overview

The POINT Guard I/O safety input module monitors the contacts of both the enabling switch and the door interlock switch.

The input module can source the 24V DC for all channels to dynamically test the signal wiring for shorts to 24V DC and channel-to-channel

shorts. If a fault occurs, either or all channels are set low (0), and the controller reacts by dropping out the safety contactors. Only after the

fault is cleared and the faulted input device is cycled, does the function block reset.

Compact GuardLogix 5380–

SIL 2

5069-L306ERS2 Compact GuardLogix processor, 0.6 MB standard memory, 0.3 MB safety memory

5069-L306ERMS2

5069-L310ERMS Compact GuardLogix processor, 1.0 MB standard memory, 0.5 MB safety memory

5069-L310ERMS2

5069-L320ERS2 Compact GuardLogix processor, 2.0 MB standard memory, 1.0 MB safety memory

5069-L320ERMS2

5069-L330ERS2 Compact GuardLogix processor, 3.0 MB standard memory, 1.5 MB safety memory

5069-L330ERMS2

5069-L340ERS2 Compact GuardLogix processor, 4.0 MB standard memory, 2.0 MB safety memory

5069-L340ERMS2

5069-L350ERS2 Compact GuardLogix processor, 5.0 MB standard memory, 2.5 MB safety memory

5069-L350ERMS2

5069-L380ERS2 Compact GuardLogix processor, 8.0 MB standard memory, 4.0 MB safety memory

5069-L380ERMS2

5069-L3100ERS2 Compact GuardLogix processor, 10.0 MB standard memory, 5.0 MB safety memory

5069-L3100ERMS2

1606-XLP72E Compact power supply, 24…28V DC, 72 W, 120/240V AC input 1

Compact GuardLogix 5380 -

SIL 3

5069-L306ERMS3 Compact GuardLogix processor, 0.6 MB standard memory, 0.3 MB safety memory

5069-L310ERMS3 Compact GuardLogix processor, 1.0 MB standard memory, 0.5 MB safety memory

5069-L320ERMS3 Compact GuardLogix processor, 2.0 MB standard memory, 1.0 MB safety memory

5069-L330ERMS3 Compact GuardLogix processor, 3.0 MB standard memory, 1.5 MB safety memory

5069-L340ERMS3 Compact GuardLogix processor, 4.0 MB standard memory, 2.0 MB safety memory

5069-L350ERMS3 Compact GuardLogix processor, 5.0 MB standard memory, 2.5 MB safety memory

5069-L380ERMS3 Compact GuardLogix processor, 8.0 MB standard memory, 4.0 MB safety memory

5069-L3100ERMS3 Compact GuardLogix processor, 10.0 MB standard memory, 5.0 MB safety memory

1606-XLP72E Compact power supply, 24…28V DC, 72 W, 120/240V AC input 1

(1) If your PLr is SIL 3/PLe, use a GuardLogix 5580 controller with a safety partner, cat. no. 1756-L8SP.

Controller Cat. No. Description Quantity

8Rockwell Automation Publication SAFETY-AT125C-EN-P - February 2022

Enabling Switch with an Integrated Safety Controller and a POINT Guard I/O Safety Module Safety Function Application Technique

Shorts to 0V DC (and wire off) are seen as an open circuit by the safety input module, and the controller reacts by dropping out the safety

contactors. If the inputs remain discrepant for longer than the discrepancy time, then the function block (DCS or DCSRT) in the controller

declares a fault. Only after the fault is cleared and the faulted input device is cycled, does the function block reset.

The final control device in this case is a pair of 100S safety contactors, K1 and K2. The contactors are controlled by a POINT Guard I/O safety

output module. The contactors are wired in a redundant-series configuration. A feedback circuit is wired through the normally closed

contacts and back to an input on the safety output module to monitor the contactors for proper operation. The contactors cannot restart if

the feedback circuit is not in the correct state.

The system has a reset button for resetting faults. There is a jog button on the enabling switch that the control system uses to start motion.

The reset button, the jog button, and the contactor feedback circuit are all wired to the safety input module in this example. This

configuration is not required for functional safety. These inputs could be wired to a standard input module.

Rockwell Automation Publication SAFETY-AT125C-EN-P - February 2022 9

Enabling Switch with an Integrated Safety Controller and a POINT Guard I/O Safety Module Safety Function Application Technique

Electrical Schematic

For an electrical schematic in AutoCAD or EPLAN format, see the attached files. For instructions on how to access the attachments, see Use

Sample Project Files on page 4.

Safety Reset

Fault Reset

Jog Switch

Safety

Interlock

Switch

DC COM

24V DC - Class 2

10 Rockwell Automation Publication SAFETY-AT125C-EN-P - February 2022

Enabling Switch with an Integrated Safety Controller and a POINT Guard I/O Safety Module Safety Function Application Technique

Configuration

The safety controller is configured by using the Studio 5000 Logix Designer® application. You must create a project and add the POINT Guard

I/O modules. A detailed description of each step is beyond the scope of this document. Knowledge of the Logix Designer application is

assumed.

For a Studio 5000 Logix Designer project file that you can import into your own project, see the attached ACD file. The attached ACD file

includes a GuardLogix 5570 controller, but if you choose a Compact GuardLogix 5370 controller, you can change the controller in the Logix

Designer program. Make sure that the controller that is used in your safety function is the same controller used in your SISTEMA PL

calculation.

Create a Project with a GuardLogix Controller

If you are not using the attached ACD file, follow these steps to create a project.

1. In the Logix Designer application, create a project with a GuardLogix controller that includes the following:

• A connection to an Ethernet network

GuardLogix 5570 controllers require the use of an Ethernet communication module, but

Compact GuardLogix 5370 controllers have Ethernet ports.

• Time Synchronization enabled on the controller and any Ethernet communication modules, if used

2. Set the IP Address for the controller or any Ethernet communication modules, if used.

3. Add a POINT I/O™ Ethernet adapter module to your project.

4. Add POINT Guard I/O modules to your project.

5. Configure the modules properly for your application.

See Additional Resources for more information regarding I/O modules.

Minimum Logix Designer Application Version Product

20 GuardLogix 5570 controller

28 Compact GuardLogix 5370 controller (1769-L30ERMS, 1769-L33ERMS, 1769-L36ERMS)

31 Compact GuardLogix 5370 controller (1769-L37ERMS, 1769-L38ERMS)

I/O Configuration from the Controller Organizer

in the Logix Designer application

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