Rockwell Automation Allen-Bradley Guardmaster Dual-Input Safety... Benutzerhandbuch

Application Technique

Light Curtain with a Dual-input Safety Relay Safety Function

Products: Guardmaster Dual-input Safety Relay, GuardShield Light Curtain, 100S-C Safety Contactors

Safety Rating: Cat. 4, PLe to ISO 13849-1: 2015

Topic Page

Important User Information 2

General Safety Information 3

Introduction 4

Safety Function Realization: Risk Assessment 5

Stop Safety Function 5

Safety Function Requirements 5

Functional Safety Description 9

Bill of Material 10

Setup and Wiring 10

Configuration 12

Calculation of the Performance Level 13

Verification and Validation Plan 15

Additional Resources 15

2Rockwell Automation Publication SAFETY-AT168A-EN-P - February 2019

Light Curtain with a Dual-input Safety Relay 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 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-AT168A-EN-P - February 2019 3

Light Curtain with a Dual-input Safety Relay Safety Function

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)

IEC 62046:2018 (Application of protective equipment to detect the presence of persons)

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.

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.

4Rockwell Automation Publication SAFETY-AT168A-EN-P - February 2019

Light Curtain with a Dual-input Safety Relay Safety Function

Introduction

This safety function application technique explains how to wire and configure a Guardmaster® dual-input safety relay to

monitor a GuardShield™ light curtain. When an object intrudes into the light curtain field-of-view, the dual-input safety

relay de-energizes the final control devices, in this case, a pair of 100S-C safety contactors.

Access Components of 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-AT168A-EN-P - February 2019 5

Light Curtain with a Dual-input Safety Relay Safety Function

Safety Function Realization: Risk Assessment

The required Performance Level (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 per ANSI B11.19. Each safety product has its own rating and can be combined to create a

safety function that meets or exceeds the PLr.

Stop Safety Function

This application technique includes one safety function: a safety stop that is initiated by intrusion into the light curtain

field.

Safety Function Requirements

Interrupting the light curtain helps prevent hazardous motion by removal of power to the motor. The motor then coasts

to a stop (stop category 0). When the safety system is reset, hazardous motion and power to the motor do not resume

until a secondary action occurs (for example, pressing the start button). Faults at the light curtain, wiring terminals or

safety relay are detected before the next safety demand. The safe distance from the location of the light curtain to the

hazard must be established so that hazardous motion stops before the operator can reach the hazard. The safety function

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

Position the reset button outside of the hazardous area where it is possible to view the entire hazardous area.

The safety functions in this application technique each meet or exceed the requirements for category 3,

Performance Level d (cat. 3, PLd), per ISO 13849-1 and control reliable operation per ANSI B11.19.

ATTENTION: If it is not possible to view the entire hazardous area, additional safety-rated presence-sensing devices must be used to detect persons in that area,

for example, by using a laser scanner or safety mat inside the cell.

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

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Light Curtain with a Dual-input Safety Relay Safety Function

When a light curtain is used, additional mechanical protective devices must be installed so that hazardous machine

elements cannot be reached by personnel or material without first passing through the protective field of the light

curtain. For example, the entire rest of the hazardous cell must be surrounded by expanded metal fencing of sufficient

height or interlocked gates, including the area above and beneath the protective area of the light curtain, if it would

otherwise be possible for a person to access the hazard through these spaces.

The selection of light curtain model, protective height, resolution, and other specifications are dependent on the results

of the risk assessment for the specific application. See the relevant standards and the GuardShield Safety Light Curtain

User Manual, publication 450L-UM001, for additional information.

Safety Distance Calculation

A safety light curtain provides no physical barrier between a person and hazardous motion. The safety light curtain must

be installed at a sufficient distance from hazardous motion to make sure that someone putting a hand through the light

curtain cannot reach the hazard before it has stopped. This distance is referred to as the safety distance. The safety

distance (S or Ds) required varies from installation to installation and, therefore, must be calculated for each specific

application. This application example shows example calculations that are based on the formula from both the

international standard ISO 13855 and ANSI B11:19. The safety distance formula that is used is for a vertically installed

light curtain.

The safety distance (S) formula from ISO 13855:

S = (K x T) + C

S: minimum distance, mm (in.)

K: a parameter, mm (in.) per second, derived from data on approach speeds of the body or parts of the body

T: the overall stopping performance, in seconds, based on the machine stopping time plus the safety system total

reaction time

C: the intrusion distance, mm (in.)

For the purposes of this example, we use the following values:

K = 2000 mm (78.74 in.) per second; or, when S > 500 mm (19.69 in.), K =1600 mm (63 in.) per second (when

using the latter, a minimum S of 500 mm (19.69 in.) must be used)

T = 405 ms [300 ms (machine stopping time) + 15 ms (light curtain) + 45 ms (DIS relay) + 45 ms (K1 and

K2 contactors)]

IMPORTANT: The specific machine stopping time must be measured for each application.

C = 0 mm (0 in.) [8 x (d-14) but not less than 0 where d is the resolution of the light curtain (d=14 mm (.55 in.))]

S = (K x T) + C = 2000 mm (78.74 in.) per second x 0.405 s + 0 mm (0 in.) = 810 mm (31.89 in.)

IMPORTANT An example calculation is shown in this document, but you must perform a final calculation for your specific application based on the safety system

specification as well as the machine stopping time.

Rockwell Automation Publication SAFETY-AT168A-EN-P - February 2019 7

Light Curtain with a Dual-input Safety Relay Safety Function

Since 810 mm (31.89 in.) > 500 mm (19.69 in.), we repeat the calculation using K = 1600 mm (63 in.) per second

S = (K x T) + C = 1600 mm (63 in.) per second x 0.405 s + 0 mm (0 in.) = 648 mm (25.51 in.)

IMPORTANT: If the calculation of S results in a value less than 500 mm (19.69 in.)) when using K = 1600 mm

(63 in.) per second, a safety distance of 500 mm (19.69 in.) must be used.

The light curtain must not be mounted closer than 648 mm (25.51 in.) from the hazardous motion being guarded

against.

The safety distance (Ds) formula from ANSI B11:19 is only slightly different and results in a similar distance, as follows:

Ds = K x (Ts + Tc + Tr + Tbm) + Dpf

K: the 'standard' hand speed of 63 in. (1600 mm) per second

Ts: the stop time of the machine

Tc: the response time of the safety system

Tr: the response time of the presence sensing device

Tbm: additional time allowed for the brake monitor (if any) to compensate for variations in normal stopping time

Dpf: the distance a 'standard' hand could possibly move through the light curtain before it is detected. This value

is a fixed value that is based on the light curtain resolution.

For the purposes of this example, we use the following values:

K = 63 in. (1600 mm) per second

Ts = 300 ms (0.3 seconds) for the purposes of this application example.

IMPORTANT: The specific machine stopping time must be measured for each application.

Tc = 90 ms = 45 ms (DIS relay) + 45 ms (K1 and K2 contactors)

Tr = 15 ms (light curtain)

Tc + Tr = 90 + 15= 105 ms = 0.105 seconds

Tbm = 0 (No brake is used in this application.)

Dpf = 1 in. (25.4 mm)

Ds = 63 x (0.3 + 0.09 + 0.015 + 0) + 1 = 26.5 in. (673.1)

The light curtain must not be mounted closer than 26.5 in. (673.1 mm) from the guarded hazard.

IMPORTANT For Point of Operation Control Light Curtain applications, the machine stopping time is critical.The machine must be capable of stopping in a short period

of time. In the example, we use a machine stopping time of 300 ms.The machine must stop within 300 ms every time to be able to use this number. By

comparison, if the stopping time was 500 ms, the safety distance would be 968 mm (38.1 in.).The light curtain would need to be mounted 320 mm

(12.6 in.) farther away from the hazard because it takes 0.2 seconds longer to stop. It is very important to understand the effect that stopping time has on

the safety distance.

8Rockwell Automation Publication SAFETY-AT168A-EN-P - February 2019

Light Curtain with a Dual-input Safety Relay Safety Function

Minimum Distance from Reflecting Surfaces

The infrared light from the sender may be reflected off shiny surfaces and be received by the system receiver. If this

condition occurs, it can result in an object not being detected when it enters the GuardShield sensing field. For

information about how to install and wire a GuardShield light curtain, see GuardShield Safety Light Curtain User

Manual, publication 450L-UM001.

All reflecting surfaces and objects (for example, material bins) must, therefore, be located at a minimum distance (A)

from the protective field of the system.

Minimum Distance “A” from Reflective Surfaces (Top View)

Minimum Distance “A” from Reflective Surfaces (Side View)

The minimum distance (A) depends on the distance (D) between the sender and the receiver. Follow these steps to

determine the minimum distance from the reflecting surfaces.

1. Determine the distance, (D) in meters, between the sender and receiver.

2. Read the minimum distance, (A) in millimeters, from the graph.

Rockwell Automation Publication SAFETY-AT168A-EN-P - February 2019 9

Light Curtain with a Dual-input Safety Relay Safety Function

Minimum Distance “A”from Reflective Surfaces (D= Distance Between Receiver and Transmitter)

A = Minimum distance to reflective surfaces

D = Distance between transmitter and receiver

Note: Formula: A [mm] = tan 2.5° x D = 43.7 × D [m]

The effective aperture angle for the 450L-B GuardShield system is ±2.5° at a mounting distance of ≥ 3.0 m (9.8 ft).

Calculate the minimum distance to reflective surfaces depending on the distance between the transmitter and the

receiver, with an aperture angle of 2.5°, or take the appropriate value from Ta bl e 1.

Functional Safety Description

Hazardous motion is stopped or prevented by interrupting the field of view of the light curtain. The 450L light curtain is

connected to the DIS safety relay. The safety outputs of the DIS relay control the power to the 100S-C contactor coils.

Whenever the DIS relay de-energizes the safety contacts, hazardous motion coasts to a stop (stop category 0). The DIS

relay monitors the status of the 100S-C output contactors via mechanically linked auxiliary contacts and does not reset

unless both sets of the main motor contacts are open. After clearing the light curtain, once all safety input signals are

correct, no faults are detected, and the reset push button is pressed (for 0.25…3.0 seconds) and released, the DIS relay

turns ON its safety outputs, providing power to the contactor coils.

Table 1 - Minimum Distance “A”for Various Distances “D” Between Transmitter and Receiver

Distance between Transmitter and Receiver

[(Range D) [m (ft)]

Minimum Distance “A”

[mm (in.)]

0.3...3.0 (0.98...9.8) 135 (5.31)

4.0 (13.1) 175 (6.88)

5.0 (16.4) 220 (8.66)

6.0 (19.6) 265 (10.43)

7.0 (22.9) 310 (12.2)

10.0 (32.8) 440 (17.32)

10 Rockwell Automation Publication SAFETY-AT168A-EN-P - February 2019

Light Curtain with a Dual-input Safety Relay Safety Function

Bill of Material

Select a GuardShield safety light curtain and its accessories.

Select the following safety relay.

Select the following contactors.

Setup and Wiring

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

System Overview

When an object, such as the hand of the operator, interrupts the light curtain, the light curtain turns its two OSSD

outputs OFF. These signals are connected to the safety input terminals of the DIS safety relay. When the OSSD outputs

of the light curtain turn OFF, the safety relay responds by turning OFF its own redundant safety outputs. This action

removes the 24V signal from the coils of the two safety contactors whose main motor contacts then open, thus removing

power from the motor. This action causes the motor to coast to a stop (stop category 0). Stopped is the safe state.

Light Curtain Cat. No. Description Quantity

440L GuardShield

440L-P4JL0640YA

GuardShield safety light curtain, res 14 mm (.55 in.), protective height 640 mm (25.20 in.), 64 beams,

integrated laser alignment, DC Miro QD (M12) connectors, order as pair, includes both transmitter and

receiver

889D-F4NC-5

Cordset, DC Micro QD (M12), female, straight, 4-pin, PVC cable, red, unshielded, 22 AWG, IEC color coded,

for transmitter, 5 m (16.4 ft)

Note: The transmitter can also use the 5-pin cordset 889D-F5NC-5.

889D-F5NC-5 Cordset, DC Micro QD (M12), female, straight, 5-pin, PVC cable, red, unshielded, 22 AWG, IEC color coded,

for receiver, 5 m (16.4 ft) 1

450L GuardShield

450L-B4FN0600YD GuardShield safety light curtain, res 14 mm (.55 in.), protective height 600 mm (23.62 in.) 2

450L-APR-ON-5 Receiver 5-pin plug-in 1

450L-APT-PW-5 Transmitter 5-pin plug-in 1

889D-F5NC-5 Cordset, DC Micro QD (M12), female, straight, 5-pin, PVC cable, red, unshielded, 22 AWG, IEC color coded,

no connector, 5 m (16.4 ft) 2

450L-ALAT-C Optional 450L-B laser alignment tool bracket 1

440L-ALAT Optional laser-alignment tool 1

Safety Relay Cat. No. Description Quantity

DIS 440R-D22S2

Guardmaster dual-input safety relay (GSR-DI), two dual channel inputs, four solid-state outputs (two for

high capacitance loads), and one solid-state auxiliary contact.

Note: This is the preferred relay for higher operating cycles.

Cat. No. Description Quantity

100S-C09EJ23BC Safety contactor, 9 A, 24V DC electronic coil, bifurcated auxiliary contacts 2

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