SAFETY-AT024A-EN-P, GuardLogix Pneumatic Safety Control … · 2016-06-07 · 3 General Safety...
Transcript of SAFETY-AT024A-EN-P, GuardLogix Pneumatic Safety Control … · 2016-06-07 · 3 General Safety...
Safety Application Example
GuardLogix Pneumatic Safety Control
Networked Example Safety Rating: Category 4 per EN954-1, Designated Architecture Category 4 per ISO 13849-1:2006
TUIntroduction UT ..............................................................................................1 TUImportant User Information UT.....................................................................2 TUGeneral Safety Information UT .....................................................................3 TUDescriptionUT ...............................................................................................3 TUSetup and WiringUT .....................................................................................4 TUConfigurationUT ...........................................................................................4 TUProgrammingUT............................................................................................6 TUPerformance Data UT ....................................................................................7 TUAdditional Resources UT ..............................................................................7
TIntroductionT The purpose of this application example is to show how to wire,
configure and program a GuardLogix safety controller with a DM2
Crossflow SERPAR Double Valve from Ross Controls. A Guard I/O
module monitors the state of the pneumatic valve, which has two valve
elements independently controlled by two solenoid pilots.
Features and Benefits
• Category 4 air dump / release application may be integrated with
other safety applications using GuardLogix controllers and
Guard I/O modules
• Pneumatic valve lockout if asynchronous movement of valve
elements occurs during actuation or de-actuation
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Important User Information Solid state equipment has operational characteristics differing from those
of electromechanical equipment. Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls (publication
HTUSGI-1.1 UTH available from your local Rockwell Automation sales office or
online at HTUhttp://literature.rockwellautomation.comUTH) describes some
important differences between solid state equipment and hard-wired
electromechanical devices. Because of this difference, and also because
of the wide variety of uses for solid state equipment, all persons
responsible for applying this equipment must satisfy themselves that
each intended application of this equipment is acceptable.
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.
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.
Identifies information that is critical for successful application and understanding of the product.
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.
Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.
Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.
Publication SAFETY-AT024A-EN-P – May 2009
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General Safety Information
This application example is for advanced users and assumes that you are trained and experienced in safety system requirements.
A risk assessment should be performed to make sure all task and hazard combinations have been identified and addressed. The risk assessment may require additional circuitry to reduce the risk to a tolerable level. Safety circuits must take into consideration safety distance calculations which are not part of the scope of this document.
Contact Rockwell Automation to find out more about our safety risk
assessment services.
TDescriptionT Many machine designers use both electricity and pressurized air as
energy sources for machine movement. These energy sources can
produce hazards to the machine operator and other users of the machine,
and must be appropriately controlled.
This application note provides an example of how to integrate electrical
safety into pneumatic safety. The three main devices in this application
example are the GuardLogix safety controller, the CompactBlock Guard
I/O module, and the DM2 Crossflow pneumatic safety valve
manufactured by Ross Controls.
Safety Function
This example contains a safety device (like an emergency stop
pushbutton) that is monitored by the Guard I/O module and GuardLogix
safety controller. The GuardLogix and safety I/O module controls a
redundant and self-monitored pneumatic valve.
Example Bill of Material
This application example uses these components.
Catalog Number Description Quantity
1756-L62S GuardLogix safety controller 1
1756-LSP GuardLogix safety partner controller 1
1756-A4 4 slot chassis 1
1756-PA73 ControlLogix power supply 1
1756-ENBT/A Ethernet module 1
1791ES-IB8XOBV4 CompactBlock safety I/O module with 8 safety inputs 4 safety bipolar outputs
1
DM2CNA42A21 DM2 Crossflow SERPAR Double Valve, ½ in. valve port size
1
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Setup and Wiring
For detailed information on installing and wiring, refer to the product
manuals listed in the Additional Resources on page X7X.
TConfigurationT Follow these steps to add the 1791ES-IB8XOBV4 safety module to your
GuardLogix project:
1. Open your RSLogix 5000 project.
2. Add the 1791ES-IB8XOBV4 module to your I/O Configuration:
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3. Configure the 1791ES-IB8XOBV4 module as shown.
Input Configuration Tab
Test Output Tab
Output Configuration Tab
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TProgrammingT Program your safety application code within the safety task of your
RSLogix 5000 project.
Create application code as shown.
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TPerformance DataT The typical sequence of operation is described below.
1. The operator determines that the system is not operating properly.
2. The operator presses the E-stop button.
Output pressure goes to zero.
3. The operator releases the E-stop.
Output pressure is at zero.
4. The operator presses Circuit Reset.
Output pressure goes to 35 psi.
5. An open-wire fault is detected on the channel 1 valve.
Pressure goes to zero and air is directed to the exhaust.
If the channel 2 valve is opened so that both valves are now open and
the circuit is reset, the air stops going through the exhaust and the
output pressure remains at zero. If valve 1 then closes, the air goes
back through the exhaust. The valve must be reopened and the circuit
reset to stop losing air. Both valves must close simultaneously for the
output pressure to go to 35 psi.
To properly correct the fault, follow these steps.
a. Open the other valve.
b. Press circuit reset to clear the fault.
c. Press circuit reset again to close both valves simultaneously
(within 120ms).
TAdditional ResourcesT For more information about the products used in this example, refer to
these resources.
Resource Description
GuardLogix Controllers Users Manual, publication HTU1756-UM020UTH
Provides detailed information on installing, configuring and operating a GuardLogix controller
GuardLogix Controller Systems Safety Reference Manual, publication HTU1756-RM093UTH
Provides information on the safety concept and safety requirements for using GuardLogix controllers in safety applications
HTUwww.rosscontrols.comUTH
Ross Controls website containing more information on DM2 pneumatic safety valves.
Safety Accelerator Toolkit for GuardLogix Systems Quick Start, publication HTUIASIMP-QS005UTH
Provides step-by-step directions for using the diagrams and sample code included in the Safety Accelerator Toolkit
You can view or download publications at
HTUhttp://literature.rockwellautomation.comUTH. To order paper copies of
technical documentation, contact your local Rockwell Automation
distributor or sales representative.
Publication SAFETY-AT024A-EN-P – May 2009
Rockwell Automation, Allen-Bradley, GuardLogix, CompactBlock Guard I/O, RSLogix 5000 are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication SAFETY-AT024A-EN-P – May 2009 Copyright © 2009 Rockwell Automation, Inc. All rights reserved. Printed in U.SA