1. A M E M B E R O F T H E K E N D A L L G R O U P

2. Functional Safety – Overview
Requirements
Standards
Safety Life Cycle
Product Solutions
Industrial Safety
Safe Off/Speed
Safety Integration
Application Examples
Safety Wiring Diagrams
Safety Function Documents
RASWIN

3. OSHA Occupational Safety and Health Administration
In the United States, one of the main drivers of industrial safety is the Occupational
Safety and Health Administration (OSHA). OSHA was established in 1971 by an
Act of the U.S. Congress.
Article 5 of the Act sets the basic requirements. Each employer shall furnish to
each of his employees employment and a place of employment which are free from
recognized hazards that are causing or are likely to cause death or serious physical harm to his employees; and shall comply with occupational safety and health
standards promulgated under this Act.
OSHA 1910
ANSI
NFPA

4. Global Standards ISO (International Organization for Standardization)
ISO generates standards for designing, manufacturing and using machinery more
efficiently, safer and cleaner.
For more information, visit the ISO website:
IEC (International Electrotechnical Commission)
The IEC prepares and publishes international standards for electrical, electronic
and related technologies.
For more information, visit the IEC website:
EN Harmonized European Standards
Their use is voluntary but designing and manufacturing equipment to them is the most direct way of demonstrating compliance with the EHSRs of the Machinery Directive.

5. Categories

6. US Standards ANSI/RIA TR15.306 Method ISO 13849 Method
Both US and International standards require a systematic approach for safety system development which starts with a risk assessment!
So which method is right for you?
ANSI/RIA TR Method
ISO Method S1 S2 F2 F1 a b P1 P2 e c d OR
Either is OK as long as you are following a risk assessment and risk reduction method!

7. SAFEBOOK 5

8. Standards (EN) ISO 13849-1 and IEC/EN 62061
Both standards produce similar results but use different methods.
(EN) ISO – PLr – Less complex manufacturing machinery
IEC/EN – SIL – Typically more complex machine safety systems

9. Safety Standards
1. (EN) ISO “Safety of machinery – General principals for design – Risk assessment and risk reduction”
2. (EN) ISO “Safety of machinery - Safety related parts of control
systems”
3. IEC/EN “Functional safety of safety related electrical, electronic and
programmable electronic control systems”
4. IEC/EN “Safety of machinery - Functional safety of safety related
electrical, electronic and programmable electronic control systems”
5. IEC “Functional safety - Safety instrumented systems for the process
industry sector”

10. Safety Standards

11. Standard Types A B C Don’t forget about OSHA 1910 standard. B1 B2
General principles
for design & Risk
Assessment
EN12100 B
Safety Distances
EN13857 B1
Guards design &
EN 14120
construction
EN & 2
Safety Control
Systems
General Safety
Aspects B2
Special
Protective
Devices
Emergency Stop
EN 13850
equipment
Presses and Shears mechanical/
EN 692/693
hydraulic C
Injection Moulding Machines
EN 201
Printing and Paper
EN 1010
Machines
Special safety features for individual machine groups
Automated production
EN 1921
systems
Don’t forget about OSHA 1910 standard.

12. Safety Life Cycle Follow the Safety Life Cycle!
5. Operate, Maintain and Improve
1. Assessment
4. Installation and Validation
2. Functional Safety
System Requirements
3. Design and Verification
Identifies Task & Hazards Pairs
Circuit & Component Selection
Safety System Design
Design Verification
Guarding design
Outlines functional requirements of the safety system
Final site assembly
Commissioning
Validation
Final Assessment Validation
Detailed operational specification
Required maintenance schedule
Preventive maintenance schedule

13. Traditional Safety Single or dual channel No Annunciation
Safety Relays Are Confusing
Accidental estop, cable pull or door vibration

14. Traditional Solutions

15. Take it to another level

16. Take it to another level

17. Take it to another level

18. Top Level - Components

19. Top Level - Components - GuardLink

20. Top Level – Components

21. Top Level - Components 32 nodes
2 Channel Safety Relay for a total of 64 nodes
35uS response time
Taps – 5 & 8 pin, EM and SS

22. CIP Safety
Available Now!
Available Someday…

24. Smart safety solutions

25. Hardwired Safety SIL3/Ple (20-750-S)
SensaGuard
Non-Contact
Interlocks
GuardLogix
Controller
Guardmaster
Safety Relay
Stratix Switch
Hardwired solution with the S offers safety via hardwired connections. This setup does require additional wiring and hardware.

26. Networked Safety SIL3/Ple (20-750-S3)
PointGuard I/O
GuardLogix
Controller
SensaGuard
Non-Contact
Interlocks
Stratix Switch
Eliminate field wiring and safety relays
Networked Safety offers STO via EtherNet/IP. Here you see the reduction in hardware and wiring which helps reduce labor and hardware costs. Less panel space required. The S3 card also offers the hardwired solution and allows for future expansion or standardization on one option card.

27. 20-750-S4 Integrated Safety Functions Option Module
A typical system may include a Guardlogix controller, safety Point I/O™ and perhaps you have the light curtain, push buttons and some other safety devices, to allow Safe Torque Off, safe limited speed and other safety functions to be programmed all in one single application.
Note: You still need a Universal Feedback option ( UFB1) or a Dual Encoder option ( DENC1) to connect the encoders to obtain the safe motion feedback.

28. Non-Integrated Safety System:
External Components: Safety Relays, Hardwire, Safety Contactors, Encoders (dual), 2 channel wiring, etc. Monitoring is performed on the drive, limited flexibility and limited customizability.

29. Integrated Safety with Safety Functions for drives and motion:
Less hardware, smaller control cabinet, quicker installation and commissioning as a result of certified safety instructions, higher flexibility by using the safety task because multiple functions can run simultaneously.

30. NEW Compliance to the IEC › Adjustable speed electrical powAer drive systems – Safety requirements - Functional
New Drive Safety Instructions (8)
SFX (Safe Feedback Scaling)
SS1 (Safe Stop 1)
SS2 (Safe Stop 2)
SOS (Safe Operating Stop)
SLS (Safely-limited Speed)
SLP (Safely-limited Position)
SDI (Safe Direction)
SBC (Safe Brake Control w/ external brake)
Available in the Logix 5380 & Family of Controllers

31. Removes power, that can cause rotation or motion
Removes power, that can cause rotation or motion. The drive will not provide energy to the motor which can generate torque or force

32. Initiates and monitors the motor deceleration rate within set limits to stop the motor and initiate the STO function when the motor speed is below a specified limit

33. Provides a safe output signal to control an external brake
Provides a safe output signal to control an external brake. The SBC function is coordinated with the STO function

34. Initiates and monitors the motor deceleration rate within set limits to stop the motor and initiates the safe operating stop function when the motor speed is below a specified limit

35. Initiates and monitors the motor deceleration rate within set limits to stop the motor and initiates the safe operating stop function when the motor speed is below a specified limit

36. The SLS function prevents the motor from exceeding the specified speed limit.

37. The SDI function prevents the motor shaft from moving in the unintended direction.

38. The SLP function prevents the motor shaft from exceeding the specified position limit(s).

39. Compact GuardLogix® 5380 Controller+ =
Compact
GuardLogix® 5380
Greatness of CompactLogix™ 5380
Integrated with safety

40. Compact GuardLogix® 5380 Controller
Integrated Architecture
Single Controller for Standard and Safety Control
No Extra Time For Data Integration
Better diagnostics, Easy data sharing up to HMI
Single Software for Standard and Safety Control
Same look and feel; speeds up application building
Design Flexibility saves time
Single Controller for Standard and Safety Control
No special network or gateways for I/O
Ability to mix and match with standard I/O
Capable and flexible
Certified Safety instructions (More than 100)
Also facilitates to create your own (Add-On Instruction

41. Compact GuardLogix® Controllers
Integrated Motion on EtherNet/IP™ up to 16 2 axis /ms
Integrated safety up to SIL 3, PLe CAT 4 versions
Minimizes hardware in the control cabinet with placement directly on the machine
Helps protect against dust and water with IP67-rated wash down protection
Conformal coated versions
Multiple disciplines
Flexible and scalable
One common
design environment
Compact GuardLogix® 5380
Integrated Motion on EtherNet/IP™ up to axis/ms
1 gigabit (Gb) embedded Ethernet port enables high-speed I/O and motion control for up to 180 nodes
Integrated safety up to SIL 2, PLd CAT 3 versions
Conformal coated versions
Enhanced security features

42. Compact GuardLogix® 5380 Controller
What’s NEW
SCALABLE
HIGH PERFORMANCE
INCREASED SAFETY INTEGRATION
Scalable Safety Level
SIL CL2, Up to PLd – 1oo1
SIL CL3, Up to PLe – 1oo2 (Future)
Multi-core CPU
Optimized for faster safety reaction time
Networked Safety Functions with drives and Motion
By using safety instructions in the safety task

43. Compact GuardLogix® 5380 Controller
High Performance CPU
Optimized for faster safety reaction time
Scalable Safety Level
SIL CL2, Up to PLd – 1oo1
SIL CL3, Up to PLe – 1oo2 (Future release)
1-Gb Embedded Ethernet/IP Port
Integrated Safety on EtherNet/IP, I/O and Safety Devices
IEC Safety Instructions
New Drive Safety Instructions with Kinetix® 5700 ERS4 drive
Safe feedback scaling, Safe Stop 1, Safe Stop 2, Safe Operation 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 MB
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 controller

44. Scalable Safety Level
SCALABLE
First in scalable Safety Performance Levels (PLs)
and Safety Integrity Levels (SILs) for machine safety
The risk assessment is the key to defining the safety requirements
Right Sizing” can create compliant designs
Optimized for cost and performance
Help achieve the safety, cost and timing targets for each project
Just the right amount of safety for your unique application
Up to PLd (Cat. 3)
SIL CL2
1oo1 Architecture
Up to PLe (Cat. 4)
SIL CL3
1oo2 Architecture
Industry-wide, Sistema is used to calculate the performance level, based on the design of the system.
I believe that many people think choosing the highest safety level means that a risk assessment is unnecessary, but they don’t always understand how difficult and expensive it is to achieve SIL3 or PLe. There are also many restrictions associated with SIL3 and PLe, like no fault exclusion, that make the choice of components, and how those components are interconnected into a system, more difficult and confusing.
Talk about the increased complexity, increased cost, increased commissioning time, etc associated with using a higher safety level than is required

45. TOTAL # OF CONTROLLER ETHERNET/IP NODES*
Compact GuardLogix® 5380
Performance & Features
COMPARISONS
SPECIFICATIONS
5370S
5380S
Overall performance 1x
5x-20x
Safety Memory
0.5 – 1.5 MB MB
Axis per controller 16 32
Axis per ms (50% CPU loading) 2
Number of I/O (Class 0&1) connections
512*
Number of message (Class 3) connections
Drive Safety Instructions No
Yes
Integrated safety SIL CL3, Up to PLe
Integrated safety SIL CL2, Up to PLd
Embedded Ethernet port
10/100Mb
100/1000Mb
Ethernet I/O (Class 0/1) Packets/Sec
10,000
128,000
1734 PointGuard I/O, 1732 ArmorBlock Guard I/O
Networked STO for Drives (CIP Mode/IO Mode)
Networked STO for Kinetix (CIP Mode)
Logix Designer
V28+
V31
* Connection ≠ Node : 1 or more 1756-ENxT modules required for EtherNet/IP connections 1 Data size = 32-bits / 1-DINT
CATALOG NUMBER
STANDARD MEMORY SIZE
SAFETY MEMORY SIZE
TOTAL # OF CONTROLLER ETHERNET/IP NODES*
5069-L306ERMS2
0.6 MB
0.3MB 16
5069-L310ERMS2
1 MB
0.5MB 24
5069-L320ERMS2(K)**
2 MB
1MB 40
5069-L330ERMS2(K)**
3 MB
1.5MB 60
5069-L340ERMS2
4 MB
2MB 90
5069-L350ERMS2(K)**
5 MB
2.5MB
120
5069-L380ERMS2
8 MB
4MB
150
5069-L3100ERMS2
10 MB
5MB
180
5069-L306ERS2
5069-L310ERS2
5069-L320ERS2(K)**
5069-L330ERS2(K)**
5069-L340ERS2
5069-L350ERS2(K)**
5069-L380ERS2
5069-L3100ERS2
Simplified to nodes
No need to count connections in L8 controllers, enough capacity and connections behind the scenes to support the # of devices for each controller.
All high speed I/O and Motion out the front port – NOT across the backplane
**Catalog with K added can be conformal coated

46. Safety-AT and WD Examples
Safety-Wiring Diagrams - GSR
Safety Function Documents – GSR and PLC

47. RASWIN

48. RASWIN

49. RASWIN

50. RASWIN

51. RASWIN

52. Resources Guardmaster Safety Relay Wiring Examples
Safety Function Documents
Machinery SafeBook 5
Process SafeBook 1
Safety Automation Builder
RASWIN
Sistema

53. Services Safety Services Website
For more information on Rockwell Services, contact your account manager or Phil Reece, who is our Kendall Services specialist at