Safety Automation

Safety Automation
A family of programmable safety solutions

ready to meet the most demanding applications
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Agenda
1. Family Overview
2. Product Features
3. Example Applications
4. Recognized Value
5. Future Plans
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Family Overview –
Safety logic controllers
Monitoring Programmable Integrated Safety I/O devices
safety relays safety controllers safety controllers  Safety rated I/Os
 Dual channel monitoring  Packaged safety  GuardLogix integrated  EtherNet/IP or
of the safety systems controller (SIL3) safety controller (SIL3) DeviceNet connectivity
 Comprehensive range  Programmable using for ControlLogix  Use with programmable
for your application RSNetworx software  Standard and safety and integrated safety
 Single function, modular  CIP safety over control in one platform controllers
of configurable versions DeviceNet and optional  CIP safety over  Devices include:
 Devices include: EtherNet/IP version for EtherNet/IP or  CompactBlock
 MSR100 - Single diagnostic comms DeviceNet GuardI/O
function safety  Communicates and  Communicates and  ArmorBlock
relays controls safety I/O controls safety I/O GuardI/O
 MSR200 – Modular  Devices include:  Devices include:  POINT GuardI/O
safety relay system  SmartGuard 600  GuardLogix PAC
 MSR300 –  GuardPLC
Configurable safety
relay system

Family Overview –
Safety logic controllers
 High-performance integrated safety GuardLogix
 CIP Safety on DeviceNet and EtherNet/IP
 Up to SIL 3 /Cat 4
 Project Level Integration
 Common Logix Hardware
 RSLogix 5000 Software
GuardPLC
 Ethernet Safety Integration
 EtherNet/IP Communications
 Discrete and Analog I/O
 Ideal for SIL 3 Process Applications
SmartGuard 600
 Simple Programmable Logic providing design flexibility
 Stand alone or networked with larger controllers
Flexibility
 CIP Safety on DeviceNet

 Standard EtherNet/IP communications
Price
Modular Safety Relays

 Modular I/0 Expansion
 DeviceNet
Safety System Complexity / Functionality

Variety of Safety Logic Solutions from simple stand-alone to the most demanding safety applications requiring integration

Integrated Safety - GuardLogix
 Standard control and safety control in one controller GuardLogix
 One common chassis
 Standard and safety control on common networks
 Single programming environment with RSLogix 5000
 ControlLogix Integrated Safety

 Dual Processor Solution (1oo2 Architecture)
 Up to Cat 4, SIL 3 Certification per IEC 61508
 EN 954-1 Category 4
 Certified Safety Application Instructions
 CIP Safety over DeviceNet and EtherNet/IP

GuardLogix Overview
A family of Programmable Safety Solutions …

Overview  Designed for a range of simple to complex control applications.
 Bring programmable flexibility to safety applications.
 Meet global safety standards.
 Reduce acquisition cost via common platform and programming tools

Key for both safe/standard control and visualization
 Improve time to troubleshoot by making diagnostic information available
Benefits
via the operator HMI
 Reduce downtime by designing flexible systems that match the safety
system behavior to the task being performed
 Speed system integration via pre integration of safe and standard control tasks
Safety fully integrated with standard Logix reduces cost, speeds development
and provides an environment to improve productivity

GuardLogix System Offering
Wide Variety of Network Connectivity Safety I/O RSLogix 5000 Programming &
Options  CompactBlock or Modular POINT Configuration Software
 Serial, EtherNet/IP, ControlNet &  On Machine or in Cabinet  Single Programming & Configuration
DeviceNet options.  Easy to install, diagnose & replace. Software across all Logix Standard and
 Wide-range of 3rd Party Network &  CIP Safety over EtherNet/IP Safety Controllers.
Device Integration Options. or DeviceNet  Multiple Programming Languages for
 Modbus & DF1 Master/Slave for RTU Multi-Discipline Control
applications  IEC61131-3 interface
 Program re-use across Logix Families
Simplifies Development
 Ethernet/IP for remote troubleshooting,
diagnostics, & repair.
 Network & Data Security Services
Unique Logix-based Features
  SIL 3 Safety with full standard control
Network Infrastructure products &
services. capabilities, no restrictions
 Safety is represented in it’s own specific
area, easy to see, easy to understand.
 All safety related functions protected by
Wide Range Of Motion & Drive Wide Range Of Operator Interface the system
Integration Options Options  Tag-based programming – self
 Simple Motion: Stepper, Servo via  Range of dedicated Panelview local documenting for standard and safety
DeviceNet, Analog or networked Operator Interface Units.  Run-time modifications & upgrades of
AC Drive.  Range of Industrial Computers with the standard without impacting safety
 Integrated Motion: Sercos flexibility in software & hardware
 Drive connectivity requirements.

GuardLogix Controller Features
Catalog 1756-L61S 1756-L62S 1756-L63S 1756-LSP

User Memory Standard – 2MB Standard – 4MB Standard – 8MB NA
Safety – 1MB Safety – 1MB Safety – 3.75MB
Non-Vol. Memory Coming in RSLogix 5000 V18
Standard I/O Total
(max) Digital I/O = 128,000, Analog I/O = 4,000, I/O total = 128,000
Safety I/O Total (max) Digital Safety I/O = 2,000

Communication Ports 1 RS-232-C
Expandable
Communications DeviceNet, ControlNet, EtherNet
Integrated Motion Full ControlLogix functionality without restrictions

Controller Tasks 15 Standard Tasks, 1 Safety Task
Programming Standard Control - Relay Ladder Logic, Function Block Diagram, Structured Text and SFC
Languages Safety Ralated Control – Relay Ladder Logic, Safety Application Instructions
Certifications UL 1998, NRGF, CSA Class I Div 2 Hazardous, CE, C-Tick, FM, TÜV-certified for Functional Safety up to SIL
3 (IEC 61508, 62061) and ISO 13849 PLe and Cat. 4
Programming Standard Control - Relay Ladder Logic, Function Block Diagram, Structured Text and SFC
Languages Safety Ralated Control – Relay Ladder Logic, Safety Application Instructions
Scaleable Control for virtually any Control Application!

Programmable Safety - SmartGuard 600
Catalog 1752-L24BBB 1752-L24BBBE

User Memory 256 Instructions 256 Instructions
Digital Inputs 16 16
Digital Outputs 8 8
Other I/O Type 4 Pulse Test or standard 4 Pulse Test or standard

outputs outputs
• CompactBlock Guard I/O •CompactBlock Guard I/O
Expansion DIO • ArmorBlock Guard I/O •ArmorBlock Guard I/O
• Point Guard I/O •Point Guard I/O
• EtherNet/IP
• DeviceNet
Built-in • DeviceNet
• CIP Safety on DeviceNet
Communication Ports • CIP Safety on DeviceNet
• USB
• USB
Programming Function Block Function Block
Languages
Programming RSNetWorx for DeviceNet RSNetWorx for DeviceNet
Software
Ideal for Small-Mid-Range Machine Safety Applications!

Programmable Safety –
GuardPLC 1600 & 1800
Catalog 1753-L28BBBM 1753-L28BBBP 1753-L32BBBM-8A 1753-L32BBBM-8A

250kB user program 250kB user program 250kB user program 250kB user program
User Memory
250kB user data 250kB user data 250kB user data 250kB user data
Digital Inputs 20 20 24 24
Digital Outputs 8 8 8 8
8 analog inputs 8 analog inputs
Other I/O Type - -
2 high speed counters 2 high speed counters
• GuardPLC I/O on • GuardPLC I/O on • GuardPLC I/O on • GuardPLC I/O on
Expansion DIO Ethernet Ethernet Ethernet Ethernet
• EtherNet/IP • EtherNet/IP • EtherNet/IP • EtherNet/IP
Built-in • GuardPLC Ethernet • GuardPLC Ethernet • GuardPLC Ethernet • GuardPLC Ethernet
Communication Ports • Modbus RTU Slave • Profibus Slave • Modbus RTU Slave • Profibus Slave
• ASCII • ASCII • ASCII • ASCII
Programming Function Block Function Block Function Block Function Block
Languages
Programming RSLogix Guard PLUS RSLogix Guard PLUS RSLogix Guard PLUS RSLogix Guard PLUS
Software
Ideal for Safety Applications Requiring Analog (BMS, ESD, …)!

Safety I/O - CompactBlock Guard I/O
 Compact, space saving safety I/O blocks
 Communication via CIP Safety over DeviceNet or EtherNet/IP
 Easy migration between DeviceNet and EtherNet versions

 Common I/O circuits
 Common interface and Logix profiles
 Common set of terminal blocks
 IP20 rated package for use in cabinet
 Programmed via RSLogix 5000 v16 or later

Safety I/O - ArmorBlock Guard I/O
 Same functionality as CompactBlock Guard I/O
 Control Flash compatible
 Shock rated to 30g, tested to 50g
 Improved temperature range to -20°C to 60°C
 IP67 rated package for use on machine
 Simplified Installation: a single M12 cable connects to

dual-channel devices on inputs and outputs,
using quick disconnects
 Compatible with quick disconnect standard sensors

and safety devices
 Same input and output M12 pins as standard ArmorBlock
 Can connect dual or single channel devices
 180mm x 70mm housing
 Separate Input and Output Power via mini connector

Safety I/O - POINT Guard I/O
 Integrated safety and standard control into 1734 POINT I/O product line
 POINT I/O provides high density and granularity to optimize your design
 POINT standard (grey) I/O available in 2,4, and 8 point module densities
 POINT Guard I/O (red) safety modules available
 1734-IB8S - 8 Point Safety Sink Input
 1734-OB8S - 8 Point Safety Source Output
 For use with GuardLogix®, SmartGuard™ and Guard PLC™
 Logix 5000 used to configure both standard and safety functions over EtherNet/IP
 Compact design: combining safety + standard POINT I/O saves panel space
 Certified to Category 4, SIL 3, PLe
 Compatible with other POINT I/O products:

 1734-AENT and 1734-AENTR
 1734-PDN and 1734D
 1734 terminal blocks (all except 1734–TB3)
 Can be used with other POINT I/O modules, including:
 Digital, analog, specialty, and Encompass products
 Electronic over current protection of all outputs

Safety actuators
Safety contactors PowerFlex Kinetix
 Mechanically linked, positively AC drives integrated motion
guided contacts  PowerFlex AC drives with optional  Kinetix 6000 with optional
 Feedback circuit for safety integrity integrated safety functions integrated safety functions
 Range of power ratings  Advanced safety functions in  Safe Torque Off and advanced
 Devices include: PowerFlex 750 series AC drives safety
 100S Safety Contactors  May replace the need for safety  Remove torque without powering
 700S Safety Contactors contactors down machine
 109S Safety Contactors  Remove torque without powering  Restart machines faster
down machine  Devices include:
 Restart machines faster  Kinetix 6000
 Devices include:  Kinetix 7000
 PowerFlex 40P
 PowerFlex 70
 PowerFlex 700S
 PowerFlex 755

Safety input devices
Presence sensing Safety interlock Emergency stop & Operator interface
safety devices switches trip devices  Devices used to safety
 Detection of a person or  Physical Interlocking of  Devices used in the interact with
guard doors or systems
moving object  event of an emergency applications
Opening the guard door
 Passive safety activated the interlocks to stop a hazard  Physical actuation of
interlocking option - no  Non-contact or physical  Versions with push- capacitive actuation
interlocking versions are  Devices include:
physical action required button or rope (cable)
available
between the devices pull actuation  Enabling grip switches
 Versions to lock guard
and the operator/object door closed available  Devices include:  Two hand controls
 Devices include:  Key exchange systems  Emergency stop

 Safety light curtains  Devices include: buttons
 Tongue operated
 Safety laser scanners  Cable pull safety
interlocks
 Pressure sensitive  Hinge operated switches
mats interlocks
 Pressure sensitive  Guard locking
edging interlocks
 Non-contact interlocks
 Safety Limit Switches
 Trapped key systems

Integrated Safety in the Tire Industry
Tire Wind-up / Let-off Machine Application Safety Challenges
 The RMA (Rubber Manufacturers Association) recognized
wind-up/let-off applications as the most dangerous area in
Tire Manufacturing
Let-off  An industry recommendation was made that this should be a
▼ safety focus area for all global manufacturing plants
Wind-up ►  Operators must continuously monitor the process and initiate
the load and unload process manually
 Significant industry OSHA Reportables on these applications
Cartoner Machine
 Increase reliability through standardization
 Each plant could have 50 – 100 machines
Safety Architecture Benefits of Implemented Solution

 Flexible and modular solution that is integrated to new designs
or retrofitted to existing machines.
 Globally acceptable solution for all facilities
 Implementation resulted in going from “worst facility” to best
facility relative to safety record.
 61% Safety Record improvement in 1 year
 OSHA reportables cut in half in 1 year. 60% in 2 years
 Project return on investment in 4 months. Does not include
indirect savings.

Integrated Safety in Metal Forming
Mechanical Press Integrated Safety Application Safety Challenges
 Ease of use has historically been a problem. Press safety
systems were often completely isolated and different than the
press automation system. Difficult to maintain and difficult to
troubleshoot.
 Complying with Press Safety standards. Often these
standards make safety systems complex and difficult to deal
with. GuardLogix is certified to EN 692 for Europe (BG), ANSI
B11.19, and RIA 15.06 for North America.
 Co ordination between press automation and press safety
systems. GuardLogix provides the best integration currently
available on the market today.

 Flexible and modular solution that is easy to use in new
designs or retrofitted to existing machines.
 Globally acceptable solution for all facilities
 Improved productivity, easier and quicker maintenance
 Common system reduces training and other support costs,
reduces spares, improves operations.
 GuardLogix being part of integrated architecture means it’s
easy to use in existing or new manufacturing facilities.

Integrated Safety in Printing
Printing Press Integrated Safety Application Safety Challenges
 Deadline-driven reliability - 1.5 hours from electronic file
receipt to papers on the street.
 Flexibility to produce runs ranging from 800 to 70,000 copies,
printing between four and 120-page papers, in full colour are
also chief considerations.
 Multiple, mechanically linked presses with multiple clutch
configurations that allow operation as either one complete or
two individual presses, depending on production demand.
Actual configuration must be known and matched to mitigate
Operator hazard.

 Press capacity improved threefold.
 Production color flexibility provided for full color or black
w/accent.
 Improved reliability and operator safety with controlled
shutdowns and clutch-point verification.
 Plant never missed a day’s production during upgrade.

GuardLogix Family Customer Value
Maintain Upgrade Specify/Conversion
 Security privileges for Safety Task to  Compatible with existing DeviceNet and  Risk Assessment consulting to assist in
control access and change rights EtherNet/IP networks maximizing safety and productivity goals
 Integration with RS Asset Center allows for  Existing ControlLogix applications can be  World-wide local expertise
easy management of validated programs reused in GuardLogix
and security privileges
Purchase
 Reduce cost by fully integrating safe and standard
control into a single platform
 Compliance with global safety standards enables
Validate Customer
single platform to cover global applications.
 Electronic signature for easy
verification of Safety Task
Automation
 Safety Task Lock/Unlock to prevent Life-Cycle Acquire
unauthorized changes to validated  2-3 day order to shipment targets
safety application code  Manufacturing sites worldwide for rapid sourcing &
distributing.
 >700 sales distribution & support partners worldwide.
Program
Troubleshoot & Commissioning  Safety accelerator with sample code and
Install
 Safety I/O and Networks enable safety Visualization Faceplates for key safety
 Safety on standard network reduces the home run
diagnostic data to be viewed by operators applications simplifies application development.
 Transparency of data between safe and wiring traditionally associated with Safety relays
and maintenance for rapid troubleshooting  Safety accelerator with wiring diagrams for many
standard tasks reduces system integration time
and recovery and complexity and improved diagnostics. safety circuits to speed application development
Goal: Enable the rapid deployment of safety solutions that improve

safety and productivity while reducing complexity and life cycle costs
GuardLogix Customer Recognized Value
Customer Application Challenges Customer Value

Kurt G. Joa Inc.  Cost Containment “Pressure from international regulatory statutes will make integrated safety
 Modular Design resulting in reduced Engineering technology all but mandatory.”
Paper Converting and quick customer response
Machines  Contemporary technology solution for
“future proof” design – Kevin Zeinemann, Manager of Electrical Engineering Division
 Integrated Discrete, Motion and Safety Curt G. Joa, Inc.
Quigg International  Integrated Solution for Press, Safety and “One of the most unique challenges of this project was the need to integrate
Motion Press, Motion and Safety Control into one system.
Press System Integrator
 Common hardware and software resulting in GuardLogix solves this problem by being part of an Integrated Control
Canada reduction of Engineering cost Architecture that simplifies programming and configuration and improves
 Reduced Maintenance and Training Costs system reliability.
 Improve Press Productivity – Joe Quigg, Vice President at Quigg International
 Reduction in traditional equipment cost
 Reduction of Operator Interaction with the equipment

Smorgen Steel “GuardLogix will enable us to seamlessly incorporate this application into our
 Ease of Maintenance based on standardized hardware control system – once again, we’ll be able to develop conventional and safety
Steel Product and software control concurrently”
Manufacturer  Integrated Safety Solution for control, networks and Drives – Wayne Pearse, Project Electrical Superintendent. Smorgon Steel
Australia  Improved diagnostics

Machine and Process Safety
Machine Safety Market Leaders 2007 sales data. Source ARC Broadest Portfolio
2007 Mkt.
Machinery Vendor Share
Safety Sick #1
$1.8B Rockwell Automation 9.4%

Siemens #3
Omron #4
Pilz #5
Process Safety Market Leaders 2007 sales data. Source ARC Most Scalable
2007 Share
Process Vendor
Invensys / Triconex #1
Safety
Rockwell Automation 13.1%
$1.4B
Honeywell #3
Yokogawa #4
ABB #5
Rockwell Automation: The world leader in the $3B+ Safety Market

GuardLogix Key Drivers
Industry Drivers Challenges and Trends RA Offering Response
Product  Achieving safety goals while

 Integration of safety into standard platforms
to reduce both cost and space
Cost driving down life cycle cost
(Logix, POINT, EtherNet/IP, etc.)
Global Safety  Deploy solutions that conform  Conformance to key global standards.
Standards to global safety standards with  Safety simplification tools to assist in the
minimal regional changes development of safety applications
Conformance
 Safety consulting services to assist with the

proper design and deployment of safety
Productivity  Achieve safety goals while
improving plant productivity
solutions that improve productivity
 Programmable safety solutions that can modify
the system behavior to best align to the
operator task performed
Focus on Cost, Performance & Ease of Development & Maintenance

The GuardLogix Logix Family Summary
A family of Programmable Safety Solutions …

Overview  Designed for a range of simple to complex control applications.
 Bring programmable flexibility to safety applications.
 Meet global safety standards.
 Reduce acquisition cost via common platform and programming tools

for both safe/standard control and visualization
Key  Improve time to troubleshoot by making diagnostic information available
Benefits via the operator HMI
 Reduce downtime by designing flexible systems that match the safety system
behavior to the task being performed
 Speed system integration via pre integration of safe and standard control tasks
Safety fully integrated with standard Logix reduces cost, speeds development
and provides an environment to improve productivity
Thank You
To learn more visit: http://www.rockwellautomation.com/solutions/safety/
Follow ROKAutomation on Facebook & Twitter.

Connect with us on LinkedIn.
www.rockwellautomation.com
Rev 5058-CO900C Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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Safety Automation

A family of programmable safety solutions

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 3

 CIP Safety on DeviceNet

Modular Safety Relays

Safety System Complexity / Functionality

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 4

 ControlLogix Integrated Safety

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 5

A family of Programmable Safety Solutions …

 Reduce acquisition cost via common platform and programming tools

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 6

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 7

Catalog 1756-L61S 1756-L62S 1756-L63S 1756-LSP

Safety I/O Total (max) Digital Safety I/O = 2,000

Integrated Motion Full ControlLogix functionality without restrictions

Scaleable Control for virtually any Control Application!

Catalog 1752-L24BBB 1752-L24BBBE

Other I/O Type 4 Pulse Test or standard 4 Pulse Test or standard

Ideal for Small-Mid-Range Machine Safety Applications!

Catalog 1753-L28BBBM 1753-L28BBBP 1753-L32BBBM-8A 1753-L32BBBM-8A

Ideal for Safety Applications Requiring Analog (BMS, ESD, …)!

 Communication via CIP Safety over DeviceNet or EtherNet/IP

 Easy migration between DeviceNet and EtherNet versions

 IP20 rated package for use in cabinet

 Programmed via RSLogix 5000 v16 or later

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 11

 IP67 rated package for use on machine

 Simplified Installation: a single M12 cable connects to

 Compatible with quick disconnect standard sensors

 Can connect dual or single channel devices

 180mm x 70mm housing

 Separate Input and Output Power via mini connector

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 12

 For use with GuardLogix®, SmartGuard™ and Guard PLC™

 Certified to Category 4, SIL 3, PLe

 Compatible with other POINT I/O products:

 Electronic over current protection of all outputs

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 13

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 14

 Devices include:  Key exchange systems  Emergency stop

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 15

Safety Architecture Benefits of Implemented Solution

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 16

Safety Architecture Benefits of Implemented Solution

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 17

Safety Architecture Benefits of Implemented Solution

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 18

Goal: Enable the rapid deployment of safety solutions that improve

Customer Application Challenges Customer Value

 Reduction of Operator Interaction with the equipment

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 20

$1.8B Rockwell Automation 9.4%

Rockwell Automation: The world leader in the $3B+ Safety Market

Product  Achieving safety goals while

 Safety consulting services to assist with the