Copyright 2011 Rockwell Automation, Inc. All rights reserved. Next Generation Guardmaster Safety Relay Platform Overview

Transcription

1 Next Generation Guardmaster Safety Relay Platform Overview

2 RA Safety Relays MSR Minotaur Safety Relay MSR6 Rockwell Automation s first electromechanical safety relay series MSR100 2nd generation of electromechanical relays MSR30 Rockwell Automation s first solid state safety relay family MSR200 modular safety relay series MSR300 modular configurable relay series Next Gen Guardmaster Safety Relay Compact family of Logic Configured Compatible Relays (Fewer part numbers can replace a broader range of legacy products) 1990s MSR6 MSR100 MSR30 MSR200 MSR300 Guardmaster Safety Relays

3 The next generation & Two 2-Ch. Inputs Logic Consolidates functionality Supports broad range of safety sensor types A single unit monitors two dual channel safety devices & Rotary Switch Configuration Flexibility of a software configurable safety relay Single rotary switch for logic & reset configuration &/OR logic can be used for zoning Logic and zoning & Configurable versatile devices cover more applications with fewer part numbers

4 Next Generation Safety Relays Concept & Innovations SWS Universal Input A single catalog number to support all types of safety components e-stops switches mats light curtains 6 part numbers will cover a majority of safety applications with consistent wiring. Dual Input Dual Channel Modules Twice the functionality of a single input dual channel relay in a 22.5mm housing. Reduced wiring for commissioning and multiple inputs can have logic configured simply in a single relay. Single-Wire Safety Connection (Single Chanel Safety Input) TÜV approved concept of one-wire connection to expand and cascade safety functions to SIL3 Simplifies wiring Increases number of I/O on terminal Maintains PLe, SIL3 rating Single Rotary Switch TÜV approved concept to eliminate double switches. Unique validation method. Expedite configuration Single device can address a broader range of reset modes, time delays, etc. Scalable platform to address single- and multi-zone applications for a variety of standard and special functional requirements

5 Universal Inputs S11 (CH1) S21 (CH2) Cross fault Safety Inputs IN1 IN2 S12 S22 S32 S42 A1 A2 S11 S21 PWR CH1 CH2 Test Out Universal Input All sensor types go to same terminals Automatic cross-loop monitoring no configuration by switch setting or hardwired-jumper required Supports both single-channel and two dual-channel safety inputs Two dual-channel inputs on DI models configured by logic switch All Faults including Cross-Loop are detected by test outputs S11 and S21 Cable Pull Switches E-Stops Light Curtains Laser Scanners Contact Interlocks Hinge Switches Non Contact Interlocks Grip Switches Safety Mats

6 Single wire safety connection & Logic IN OUT Feedback/ Reset L12 L11 Y32 S34 L11 dynamic test pattern +4 A single wire safety connection is used to expand and cascade multiple relays while maintaining a PLe / SIL3 rating A dynamic signal with specific test patterns is transmitted through a single wire which is the only signal the input will recognize. (Any other signal will be a fault) Terminal L11 sends the Logic signal (output) Terminal L12 receives the Logic signal (input) Single Wire Safety input (L12) can be configured with safety inputs of device using AND/OR logic Safety functions can be cascaded through multiple zones Expansion modules are easily added to a base relay while leaving all safety outputs of base module available for use & Logic/ Zoning Expansion

7 Logic Single Wire Safety Logic Feedback/ Reset IN Safety Inputs IN1 IN2 S12 S22 S32 S42 OUT L12 L11 Y32 S34 Logical Functional Block The relationship between the two safety inputs & the Single Wire Safety (SWS) Input (L12) can be configured with AND/OR logic Hence 4 logic combinations are available 1. L12 OR (IN1 OR IN2) 2. L12 OR (IN1 AND IN2) 3. L12 AND (IN1 OR IN2) 4. L12 AND (IN1 AND IN2) Safety outputs and single wire safety (SWS) output (L11) become active after valid reset (S34) A HIGH signal on IN1, IN2 and a valid SWS signal on L12 is considered to be true in this logic. So if an input is to be ignored or muted, OR logic should be used.

8 Configuration Selectable functions 4 Logic conditions for safety inputs and the Single Wire Safety input (L12) Reset modes automatic/manual and manual monitored reset Timing configuration (EMD) Time needs to be configured before operation. Easy to configure: 1. Set Device to 0 2. Power Up device. Relay is now in configuration mode 3. Turn rotary switch to desired logic & reset value (see table). Power LED will glow green and Input 1 LED will provide feedback of position. 4. Cycle power to lock in configuration. 5. Relay maintains setting until configuration process is repeated. Single input devices only need reset mode configured Dual input devices configure logic between inputs and reset mode. Time delay expansion modules configure output type and time delay.

9 Reset and Feedback & & t A1 (24V DC) Automatic reset: Unit is active once LOGIC is true Manual reset: Unit is active once the LOGIC is true and then the reset circuit is closed. Manual Monitored Reset: Unit is active once: LOGIC is valid and then the reset circuit is closed and opened again. Reset button must be pressed at least for 250ms but no longer than 3s & +4 X32 of the last Expansion Configurable for manual monitored and automatic/manual reset In compliance with EN ISO plus time pulse monitoring for future requirements Actuator feedback N/C contacts monitored in series with Reset Base Units (DI, DIS, SI, CI) Feedback/Reset sourced by a static 24V DC signal Allows individual zone reset Expansion Modules Aux. Output of Expansion units X32 recommended to source Feedback/Reset Loop

10 Diagnostics and Aux. Output DI, DIS, SI (Y32) CI Expansion EM, EMD (X32) LED Description Color PWR/Fault Device Status, flashing codes for fault states Unit Status Y Active and healthy Off Open Inactive and healthy 24VDC Closed Faulty 24VDC Closed Unit Status Active and healthy Inactive and healthy Faulty X32 Off 24VDC Off Green / Red IN1 Status Input 1 Green IN2 Status Input 2 Green Logic IN Status single wire safety input Green Out 1 Status output 1 Green or PLC or PLC Meaningful LED diagnostics Up to 6 LEDs indicate device status During configuration one LED for each rotary switch shows its position to validate the setting The PWR/Fault LED allows rapid troubleshooting with blinking fault codes Next Generation Platform: diagnostics consistent across full line Aux. Output Y32, 41-42: Complies with parallel N/C connection (like MSR127) Ideal for diagnostics through indicator lamp or PLC connection X32: Complies with serial N/C connection (like MSR132) Ideal to source feedback and reset circuit. Prevents Reset in case of expansion unit faults

11 New Housing Previous Generation New Generation Dimensions [mm] W x D x H 22.5 x x x x No impact to wiring profile Larger faceplate provides more real-estate for LEDs and rotary switches Larger housing supports a broader range of applications

12 Cabinet wiring simplified Control Input + - PWR L N Control output Safety Inputs Safety Outputs and feedback back front front Safety Inputs IN1 IN2 S12 S22 A1 A2 PWR L12 L11 S32 S42 S11 S21 Test Out Single Wire Safe Logic Feedback/ IN OUT Reset Y32 S34 Grouping terminals eliminates top to bottom wiring All inputs on top Power on top Output and feedback on bottom Single wire safety connections on bottom Simplifies installation by keeping device s wires in single cable tray back OUT1 OUT2 Safety Outputs

13 Diverse Inputs Application Example: Light Curtain & E-stop Simple system where breaking a light curtain beam or hitting an e-stop stops a machine E-Stop Light Curtain Universal input allows various types of safety devices to be connected to the relay Dual input relay can handle 2 dual-channel devices, simplifying wiring and commissioning Rotary switch on front of device configures reset mode and logic between two devices ( AND logic shown) 100S Safety Contactor Legacy Solution and Logic set with rotary switch and Logic Next Gen. Solution The new generation relay s ability to communicate with a broad range of safety devices reduces hardware and simplifies wiring needed to configure systems.

14 Logic Link Application Example: Form/Fill/Seal machine Single Zone with safe operation mode selection to mute the guard and allow operator access & Logic E-Stop1 Guard 1 O1 O2 O3 O4 OR Logic set with rotary switch Service or Maintenance mode is selected by key switch In service mode the key switch overrides the guard and operator gains access to the area OR Function A global E-Stop stops operation in all modes AND connection O1 O2 O3 or Logic O4 Zone 1 Legacy Solution PLd (SIL2) 100S Safety Contactor AND Logic via single wire connection and rotary switch Next Gen. Solution PLe (SIL3) Configured logic and single wire connection reduce wiring and components needed for logic applications.

15 Global e-stop Application Example: Printing Machine Global E-Stop through multiple zones The SI relay controls the global e-stop which distributes its signal over the single-wire safety output which is wired to all zones in parallel, maintaining PL e, SIL3 Multiple devices dedicated to one zone through dual input relays. Each DI relay is dedicated to a zone which is supporting multiple devices through AND/OR configuration (here single wire input is AND with safety inputs which are also AND ) Single wire safety connection wired in parallel provides fast integration of a global e-stop to multiple zones

16 Benefits of New Guardmaster Safety Relays Distribution of global safety applications in % 43% 1 or 2 Relays 3 or more Consolidating two legacy relays to one New Generation Guardmaster Relay will yield: Select one safety relay that can replace the need for two devices and save on associated purchase costs and inventory management. Zones: 1 Logic: Safe-Off Inputs: 1-2 Zones: 2-4 Logic: AND/OR Inputs: 2-10 Reduce the footprint on your DIN rail by consolidating two safety relay functions into a single housing. e.g. Form filling e.g. Carton packaging Significant wiring reduction through the ability to connect two safety input devices to one safety relay, thus removing the need for complex relay-to-relay wiring. Connection between relays can also be achieved via simple single wire safety connection. & & & Additional Value: Reduce inventory with fewer part numbers addressing a broader range of applications Universal input can communicate with a broader range of safety input devices Rotary switch allows reset modes and logic to be configured Cleaner cabinet appearance with relay terminal layout consistent with PLC positioning Product modification is simplified as new line maintains consistent design & terminal location

17 Next Generation Guardmaster Relay Phase 1 3 Basic Units 6 SKUs 1 low-cost Single Input Dual Ch. (SI) 2 Dual Input Dual Ch.(DI) 1 solid state (DIS), 1 Relay Output (DI) 1 Legacy Compatible Unit Terminal layout similar to legacy MSR products (CI) 2 Expansion Modules Instantaneous Relay Output (EM) Multi Timing Delayed Relay Output (EMD) Six basic relay devices Consolidate catalog numbers Provide the best safety logic solution on the market Relay Type Dual Input Dual Ch. Single Input Dual Ch. Expansion Module Unit Name Part # DIS (Dual Input SS out) DI (Dual Input) SI (Single Input) CI (Compatible w/ MSR Input) EM (Expansion Module) EMD (Expansion Module Delay) 440R-D22S2 440R-D22R2 440R-S12R2 440R-S13R2 440R-EM4R2 440R-EM4R2D

18 Single Input Dual Channel Devices MSR127 CI SI Single Input Dual Channel (SI) Most basic unit of core family Same terminal layout as DI (but only has one set of safety inputs) One dual channel input Single Wire Safety Output Configurable for reset 24V DC supply voltage 2 N/O safety outputs and 1 PNP aux. Output Compatible Input Dual Channel (CI) For MSR conversions when customer does not want to deal with moving terminals Layout does not align with rest of family consistent housings Compatible to MSR127 One dual channel input Configurable for Reset 24V DC supply voltage Single wire link output only configurable as aux. PNP output 3 N/O safety outputs, 1 N/C aux.

19 Dual Input Dual Channel Devices DI DIS DI 2 safety inputs Configurable for Reset and logic 24V DC supply voltage Full single wire cascading capability 2 N/O safety outputs, 1 PNP aux. DIS 2 safety inputs Configurable for Reset and logic 24V DC supply voltage Full single wire cascading capability 4 PNP safety outputs (most applications use one pair or the other), 1 PNP aux. 14, 24 up to 1.5A 34, 44 up to 500mA - special filters on output to prevent false trips in applications with high capacitive loads (eg. Drives)

20 Expansion Modules EM EMD EM 24V DC supply voltage Full single wire cascading capability 4 N/O safety outputs, 1 PNP aux. EMD 24V DC supply voltage Full single wire cascading capability Timer functions (TM, EMD): delay-on energization, delay-on de-energization, jogging (single pulse for teach-in) Selectable time delays Time x Factor = s 4 N/O delayed safety outputs, 1 PNP aux.

21 Guardmaster Safety Relay Phase 1 Product Overview Description Dual Input Single Input Expander Compatibility Input # Models DI DIS SI EM EMD CI Description Dual Input Relay Output Dual Input Solid State Output Single Input Expansion Module Expansion Module Time Delay Terminal Layout consistent with legacy products Catalog Number 440R-D22R2 440R-D22S2 440R-S12R2 440R-EM4R2 440R-EM4R2D 440R-S13R2 Width [mm] 22.5 Safety Outputs 2 N.O. 2 S.S. 2 N.O. 4 N.O. 3 N.O. Auxiliary Outputs 1 PNP 1 N.C. MSR Replacement New Concept E 132ED 127 Additional MSRs Replaced 127, 131, 142, , 142, 144 Terminal Layout PLC Layout Compatible to MSR (top to bottom) DI module replaces two MSR127 Pricing for the new relay is based off the legacy MSR line which it is intended to replace (though the MSR products have no immediate obsolescence plan).

22 Thank You!