Rockwell Automation Allen-Bradley Compact GuardLogix 5370... Benutzerhandbuch

Application Technique

Door Locking and Monitoring with a 442G Access Box and an

Integrated Safety Controller Safety Function

Products: GuardLogix 5570 or Compact GuardLogix 5370 Controller, 442G Multifunctional Access Box, POINT Guard I/O Safety Modules

Safety Rating: Cat. 4, PLe 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

Guard Locking and Monitoring Safety Function 5

Safety Function Requirements 5

Functional Safety Description 6

Bill of Material 7

Setup and Wiring 7

Configuration 10

Programming 11

Calculation of the Performance Level 20

Verification and Validation Plan 22

Additional Resources 23

2Rockwell Automation Publication SAFETY-AT129B-EN-P - November 2018

Door Locking and Monitoring with a 442G Access Box and an Integrated Safety Controller Safety Function

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 identifya 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: Labelsmaybe onorinside theequipment,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-AT129B-EN-P - November 2018 3

Door Locking and Monitoring with a 442G Access Box and an Integrated Safety Controller Safety Function

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.

SafetyDistanceCalculations

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)

Topic Pages

Added section on accessing components of the safety function. 4

Updated available controller groups in the Bill of Material. 7

Attached the wiring schematic to this document. 9

Shortened the Configuration section because the Logix Designer project ACD is now attached to this document. 10

Added the SISTEMA file to this document. 20

The Verification and Validation Checklist is now attached tothis document as a spreadsheet. 22

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-AT129B-EN-P - November 2018

Door Locking and Monitoring with a 442G Access Box and an Integrated Safety Controller Safety Function

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.

Introduction

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

POINT Guard I/O™ module to lock and monitor a 442G Multifunctional Access Box (MAB) mounted on a power-to-

release door. If the door is opened or unlocked, or a fault is detected in the safety function, the GuardLogix controller

de-energizes the final control device, which in this safety function is a redundant pair of 100S contactors.

This example uses a 1756-L73S GuardLogix controller, but is applicable to any GuardLogix controller.

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 by using the actual products.

Access Componentsof the Safety Function

The component files (AutoCAD, EPLAN, ACD, SISTEMA, and Verification and Validation checklist) that are

attached to this document help you implement this safety function. To access these components, click the Attachments

link and right-click and save the component that you want to use. If the PDF file opens in a browser and you don't see

the Attachments link , download the PDF file and then reopen the file with the Adobe Acrobat Reader application.

Rockwell Automation Publication SAFETY-AT129B-EN-P - November 2018 5

Door Locking and Monitoring with a 442G Access Box and an Integrated Safety Controller Safety Function

SafetyFunctionRealization: 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 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.

Guard Locking and Monitoring Safety Function

This application technique includes one safety function: guard locking and monitoring.

Safety Function Requirements

This safety function makes sure that the hazard has stopped, and that safety output power has been removed, before the

gate is unlocked upon request. It also monitors the lock and door, and it drops output power if they unexpectedly change

state. If any fault occurs, such as loss of communications, output power to the safety actuators is dropped. While the door

is open, itsstatus is monitored to prevent unexpected startup while the door is open. When the door isclosed and locked,

hazardous motion and power to the motor do not resume until a secondary action (Reset button depressed) occurs.

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.

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-AT129B-EN-P - November 2018

Door Locking and Monitoring with a 442G Access Box and an Integrated Safety Controller Safety Function

Considerations for Safety Distance and Stopping Performance

Safety distance calculations are typically not required for safety functions that use a Power-to-release locking-gate switch.

The risk assessment determines if a safety distance calculation is required for your safety function that uses the

Multifunctional Access Box.

Based on the selection of a sensor subsystem, the risk assessment determines if a safety distance calculation is required.

Typically, a safety distance calculation is required if a non-separating sensor subsystem (such as a light curtain) is selected

for the safety function. If a safety distance calculation is required for this safety function, the following documents can be

referenced:

•GuardLogix 5570 and Compact GuardLogix 5370 Controller Systems Safety Reference Manual,

publication1756-RM099

•SafeBook 5– Safety related control systems for machinery, publication SAFEBK-RM002

•Safety Function: Light Curtain Products: Light Curtain GuardLogix Controller, publication SAFETY-AT056

Functional Safety Description

In this example, an unlock is requested by pressing an Unlock Request button on the MAB. The unlock request is sent

over a CIP Safety™ connection to the GuardLogix safety controller. The GuardLogix controller drops out the redundant

contactors, and the hazard coasts to a stop. The safety contactors (K1 and K2) are connected to a pair of safety outputs

on a safety output module (1734-OB8S). The I/O module is connected via CIP Safety over an EtherNet/IP™ network to

the safety controller. After the hazard stops (you must determine how to monitor for the hazard stopping in your

application), the GuardLogix commands the MAB to unlock the door, which allows entry to the hazard. Once the

operator has completed the routine and repetitive maintenance, the operator closes the door and extends the bolt via the

handle. If the door is closed and the bolt is extended, a Lock button on the MAB can be used to send a signal to the

GuardLogix controller to lock the door by de-energizing the lock solenoid. In this example, the lock is Power-to-release.

The GuardLogix safety code monitors the status of the door by using the pre-certified safety instruction, Dual Channel

Input Stop with Test and Lock (DCSTL). The MAB provides a status bit that indicates that the door is closed, the bolt is

extended, and the bolt is locked. These status interlocks are monitored by the GuardLogix DCSTL.

When all safety input interlocks (the DCSTL is one of these interlocks) are satisfied, no faults are detected, and a safety

restart button on the MAB is pressed, a second GuardLogix certified function block called Configurable Redundant

Output (CROUT) controls and monitors feedback for a pair of 100S redundant contactors. The CROUT energizes

and de-energizes the contactors and monitors electromechanical feedback to make sure that both contactors operate

properly.

If a demand is placed on any other safety interlock, in this example it is the MAB E-stop, the redundant contactors are

dropped out. The Unlock Request button can then be used to request access to the hazard. The DCSTL safety

instruction makes sure that the hazard is stopped before the door is unlocked.

Rockwell Automation Publication SAFETY-AT129B-EN-P - November 2018 7

Door Locking and Monitoring with a 442G Access Box and an Integrated Safety Controller Safety Function

Bill of Material

This application technique uses these products.

Choose either the GuardLogix 5570 hardware list or the Compact GuardLogix 5370 hardware list.

Setup and Wiring

For detailed information on how to install and wire, refer to the publications that are listed in the Additional Resources.

Cat. No. Description Quantity

442G-MABH-R Handle for right-hand guard door 1

442G-MABRB-UR-E0JP4679 Lock/Bus module with E-stop, four buttons,and connector for enabling switch, power-to-release, right-hand1

100S-C09ZL23C Bulletin 100S-C safety contactors 2

1734-IB8S POINT Guard safety input module 1

1734-OB8S POINT Guard safety output module 1

1734-AENT 24V DC Ethernet adapter 1

1734-TB Module base with removable IEC screw terminals 4

Controller Cat. No. Description Quantity

GuardLogix 5570

1756-L71S

1756-L72S

1756-L73S

GuardLogix processor, 2.0 MB standard memory, 1.0 MB safety memory, or

GuardLogix processor, 4.0 MB standard memory, 2.0 MB safety memory, or

GuardLogix processor, 8.0 MB standard memory, 4.0 MB safety memory

1756-L7SP GuardLogix Safety Partner 1

1756-EN2TR ControlLogix® EtherNet/IP Module 1

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

1756-AA Four-slot chassis 1

Compact GuardLogix 5370

1769-L30ERMS

1769-L33ERMS

1769-L36ERMS

1769-L37ERMS

1769-L38ERMS

Compact GuardLogix processor, 1.0 MB standard memory, 0.5 MB safety memory, or

Compact GuardLogix processor, 2.0 MB standard memory,1.0 MB safety memory, or

Compact GuardLogix processor, 3.0 MB standard memory, 1.5 MB safety memory, or

Compact GuardLogix processor, 4.0 MB standard memory, 1.5 MB safety memory, or

Compact GuardLogix processor, 5.0 MB standard memory, 1.5 MB safety memory

1769-PA2 CompactLogix® Power Supply, 120V/240V AC 1

1769-ECR Right-end cap and terminator 1

8Rockwell Automation Publication SAFETY-AT129B-EN-P - November 2018

Door Locking and Monitoring with a 442G Access Box and an Integrated Safety Controller Safety Function

System Overview

The MAB and GuardLogix safety controller are connected over a CIP Safety connection.

The following status information is communicated from the MAB to the controller:

•Door/handle position, RFID technology (safety-rated status)

•Bolt position (safety-rated status)

•Lock status (safety-rated status)

•E-stop position (safety-rated status)

•Four push buttons (used for Unlock request/Lock request/resets in this safety function)

•RUN Mode

•MAB Faults

The following control information is communicated from the controller to the MAB:

•Fault resets

•Lock solenoid control (safety-rated control data)

•Four lights

•E-stop light

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

1734-OB8S safety output module. The contactors are wired in a redundant-series configuration. A feedback circuit is

wired through the K1 and K2 normally open contacts and back to an input on the 1734-IB8S module to monitor the

contactors for proper operation. The contactors cannot restart if the feedback circuit is not in the correct state.

The contactor feedback circuit is wired to the 1734-IB8S safety input module in this example. Feedback wiring to a

safety module is not required for functional safety. The feedback circuit could be wired to a standard input module.

The system has individual reset buttons for resetting faults and resetting safety outputs.

Rockwell Automation Publication SAFETY-AT129B-EN-P - November 2018 9

Door Locking and Monitoring with a 442G Access Box and an Integrated Safety Controller Safety Function

Electrical Schematic

For an electrical schematic in AutoCAD or EPLAN format, see the attached files.

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10 Rockwell Automation Publication SAFETY-AT129B-EN-P - November 2018

Door Locking and Monitoring with a 442G Access Box and an Integrated Safety Controller Safety Function

Network Architecture

The controller, EtherNet/IP connection, and MAB are shown in the controller organizer in the Logix Designer

application.

Configuration

The GuardLogix controller is configured by using the Studio 5000 Logix Designer® application. You must create a

project and add the POINT Guard I/O modules and the multifunctional access box. 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 used in your safety function

is the same controller used in your SISTEMA PL calculation.

Createa 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.

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)

GuardLogix 5570 Controller Organizer Compact GuardLogix 5370 Controller Organizer

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