Selection Criteria

Selection Criteria

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Selection Tips

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Is This a Multizone Application?

In order to comply with safety standards and remain productive, machine builders have begun building functional safety features into machines using what has been termed the “Zone Concept.” The Zone Concept increases both safety and productivity by allowing a portion of the production line to slow or stop while the rest of the line remains active. The safety hazard, whether a minor malfunction of line equipment or an obstruction, can be removed or corrected without taking the entire line down, eliminating lengthy production shut downs and worker downtime. When the hazard is cleared, the line can quickly return to normal operation. Single function and/or expandable relays systems are suited only for single-zone control, while multizone control for 2…3 zones is best served through a configurable system such as MSR300 relays or a SmartGuard packaged controller. Any applications involving control of more than three zones (and therefore more complex logic) is better suited for a programmable safety controller—SmartGuard, GuardPLC or GuardLogix.

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Diverse Inputs—Number and Type

For single- and multizone applications (£ 3 zones), the number and type of inputs (e.g. interlock switches, safety mats, light curtains) will dictate the use of either safety relays (MSR100, MSR200 and MSR300) or a small packaged safety controller such as SmartGuard. For 1…2 inputs, dedicated standalone relays (MSR100) are a simple and cost effective solution, but for applications involving a high number of input devices, the hard wiring associated with individual relays can be restrictive. Therefore, in applications requiring a moderate input device count (20 or less), an expandable relay system with modular design and plug-in connections (MSR200, MSR300) is an ideal solution. In any case with safety relays, the types of input devices used will dictate the relay modules that must be selected; thus relay selection for a wide range of input devices can be complex. Applications requiring greater than 20 diverse inputs and a degree of complex logic lend themselves to the SmartGuard Controller in combination with Distributed I/O. Larger installations—those with a high number and wide variety of input device types—are best served with a safety PLC system as their programmable nature allows safety applications to be solved in software rather than hard-wiring large, cascaded relay systems.

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Is Standard Control Using a Logix Controller?

A safety control system can be a dedicated (safety only) system or integrated, where standard and safety control are combined to maximize the re-use of components and tools.

GuardLogix brings together the benefits of a Logix platform—common programming environment, common networks, and common control engine—with integrated safety control in an easy-to-use environment while providing Safety Integrity Level (SIL) 3 control. By partnering with the ControlLogix processor, GuardLogix users can benefit from common programming software, controller and I/O to help reduce development time and application cost.

GuardPLC and SmartGuard are the recommended platforms for applications requiring safety to be physically separated from standard control.

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Do You Need Communications?

On-board communications allow the relay to deliver output and error status over an RS232/RS485 or fieldbus network (such as DeviceNet) to an HMI or other device. While the MSR200 series of modular safety relays does offer communications compatibility, it is not the most economical solution—MSR300 configurable safety relays are the best choice for applications requiring communications. Programmable safety controllers offer network connectivity and a high level of diagnostics, with SmartGuard and GuardPLC having DeviceNet and Ethernet capabilities, respectively.

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Do You Need Muting?

Sometimes the process requires that the machine stop when personnel enters the area, yet remains running when automatically-fed material enters or exits—this is a situation where a muting function is necessary. Muting requires the combination of a light curtain, two or four muting sensors and a control unit to process the signals and determine if and when to activate the muting function. Muting sensors are mounted in front of and behind the light curtain and only a specific sequence of sensor outputs will initiate the muting function. For example, when the two sensors in front of the light curtain change state within a predetermined timeframe, the light curtain is “muted” and will not send a stop signal to the machine as the material enters. The MSR300 modular safety monitoring relay offering includes a module specifically designed to control the muting function in applications that do not require a specific sequence or timing requirement. If sequence and timing is required, then the MSR22LM may be better suited for your application.

Technology Overview

MSR100 Single Function Safety Relays

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Features/Benefits

A simple and cost-effective solution for a wide variety of applications, MSR100 single function safety relays support a wide variety of input devices and output configurations. Ideal for relatively small safety applications and single zone control, MSR100 relays are designed in a compact package with removable terminal for ease of installation and maintenance. These relays are also available in electromechanical versions, or solid-state models for applications involving high cycle rates.

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MSR200 Modular Safety Relays

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Features/Benefits

Using plug-and-play digital I/O expansion modules, the MSR200 expandable modular relay system supports up to 22 diverse inputs (mats, light curtains, switches, etc.) to allow safety control of larger, more complex manufacturing equipment with a single relay system. The MSR200 family’s microprocessor-based design offers enhanced diagnostic and communication functionality over multiple protocols. It also allows the relay to deliver output and error status over a fieldbus network to an HMI. Simple plug-in connectivity between modules provides simple system expansion with reduced wiring. Offering SIL3, delayed output support and an optional dedicated display module, the MSR200 system provides substantial cabinet space savings over dedicated single-function relays.

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MSR300 Configurable Safety Relays

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Features/Benefits

The MSR300 family of expandable modular safety relays handles larger, more complicated safety systems by allowing connection of multiple input modules to a single base unit. It offers a logic configuration with multiple inputs and the control of multiple independent outputs. The system supports up to 20 diverse inputs and can control up to 3 zones, performing simple function block logic configurations through rotary switch settings as opposed to software configuration. Modules can be mixed and matched to work with various input device types, reducing the need for multiple single-purpose relays, simplifying setup, wiring, maintenance and saving valuable panel space. The MSR300’s diagnostic capabilities over multiple protocols provide input, output and error status. Offering SIL3, two-hand control support and monitoring through HMI, the MSR300 is easily customized and expanded thanks to plug-in connections that reduce wiring for the addition of inputs and outputs.

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Technology Overview (continued)

SmartGuard™

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Features/Benefits

The SmartGuard 600 controller is designed for SIL3 applications that require some complex logic. It is a “packaged safety controller” that includes the CPU, 16 Safety Inputs and 8 Safety Outputs and an embedded DeviceNet communications port. Using the DeviceNet communications port, the SmartGuard 600 controller can control additional safety I/O modules including the 1791DS CompactBlock Guard I/O and 1732DS ArmorBlock Guard I/O, as well as 1734 POINT Guard I/O modules via a 1734-PDN module. In addition, the SmartGuard controller can also communicate with standard PLCs and HMIs on DeviceNet or EtherNet/IP networks. SmartGuard 600 systems are programmed using RSNetworx software.

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Guard I/O™

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Features/Benefits

Guard I/O is the name for Rockwell Automation’s family of Safety I/O modules that communicate on EtherNet/IP and DeviceNet. Guard I/O modules on DeviceNet are available in both IP 20 (cabinet mount) and IP 67 (on-machine) form-factors. Guard I/O modules on EtherNet/IP are available in IP 20 form factors. Guard I/O modules are block I/O modules that include the communications adaptor and either 8 or 16 points of safety I/O in a single package.

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GuardPLC™

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Features/Benefits

GuardPLC refers to a family of SIL3 safety controllers that are programmed with the RSLogix Guard software package. Like the SmartGuard 600, the GuardPLC 1600 and GuardPLC 1800 Safety PLCs are “packaged safety controllers” with a CPU, safety I/O and embedded communication networks. In the case of the GuardPLC 1600 and 1800 the embedded communication network is Ethernet for communication to GuardPLC Safety I/O modules as well as EtherNet/IP for communications to standard controllers and HMIs. The GuardPLC 1600 includes 20 safety inputs and 8 safety outputs. The GuardPLC 1800 includes 24 safety inputs, 8 safety outputs, 8 analog safety inputs and 2 safety rated high speed counters.

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GuardLogix®

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Features/Benefits

The GuardLogix system is a SIL3 ControlLogix controller that in addition to running all standard control functions like sequential, motion, etc., also has the ability to run a Safety Task and control safety DIO. This enables both safety and standard applications to run simultaneously in a single application project. This significantly reduces integration, spares and training and improves the flow of data to HMI and information systems. A GuardLogix is placed in a standard ControlLogix chassis and communicates to Safety I/O via a standard EtherNet/IP or DeviceNet communication module. It is programmed with RSLogix 5000, just like a ControlLogix processor.

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