RA TechED 2019 - SS08 - What's New and Coming Soon in Safety Automation Architectures

What's new and coming soon in
safety automation architectures

PUBLIC | TechEd | #ROKLive | Copyright ©2019 Rockwell Automation, Inc. 3
Agenda
Overview of new
GuardLogix®
controllers
New safety
component
offerings
Compact 5000™
safety I/O used
with GuardLogix®
controller
FLEX 5000™
safety I/O used
with GuardLogix®
controller
ControlLogix®
safety I/O used
with GuardLogix®
controller
Safety I/O
selection
Process safety
overview
Future safety
product releases
1 2 3 4
8765

New offerings enable compliance while providing
high-performance control and the right amount of
safety.
Integrated safety highlights
High performance
New controllers, I/O, and safety
instructions help achieve
productivity and maintain Logix
investments for the long haul
Increased valueIntegration
Integrated safety components
help differentiate our portfolio and
reduce costs with machine
builders
Next generation safety I/O is an
essential part of the high-
performance architecture, expanding
our offerings while increasing value
of our I/O platforms

These offerings help customers with productivity and
compliance, while providing high-performance control
and the right amount of safety.
Safety control priorities and
roadmap deliverables through 2020
General
Integrated and scalable safety
• SIL 2/PLd and SIL 3/PLe choices
• GuardLogix® 5580ES controller
• Compact GuardLogix® 5380S controller
Significant performance improvements
Smart machinesProcess focus
Local safety I/O
• ControlLogix® safety I/O (June)
Distributed safety I/O
• FLEX 5000™ safety I/O (April/May)
Local safety I/O
• Compact 5000™ safety I/O
Full line of Compact safety controllers
• SIL 3/PLe rated Compact GuardLogix® 5380S
controller (November)
• Total of 33 catalogs to choose from
Safety feedback direct to GuardLogix®
controller
• Distributed EtherNet/IP safety encoder module
• SIL3/PLe rated encoder on EtherNet/IP

Controller portfolio
Micro control platform
Micro800™ controller
• Low acquisition cost
• Easy connectivity
• Simple programming tools
• Ideal for standalone machines
Standard machines
Compact GuardLogix®
CompactLogix™ controller
Complex machines & process
GuardLogix® controller
ControlLogix® controller
Process safety
AADvance®/Trusted®
• Scalable redundancy for
fault tolerance
• Provides safety and
availability requirements
• Distributed processing power
• Multiple control disciplines
• Flexible and scalable
• Real-time information-enabled
• Standard, unmodified Ethernet
• One common integrated design environment
• Local and distributed I/O options

Full portfolio of chassis-based and distributed I/O
ControlLogix®
• I/O diagnostics for
detection of both
system and field-side
failures
• Electronic keying to
help prevent
replacement errors
• Wide range of
modules from high
performance to
process control
FLEX™,
FLEX 5000™
• High-performance
FLEX 5000™ I/O for
CompactLogix™ 5380
and ControlLogix®
5580 controllers
• High-channel density
on a distributed
platform
Process distributed I/O
1719 Ex,
1715 Redundant
• 1719 Ex I/O for
hazardous area
locations
• 1715 Redundant I/O
provides
high availability for
ControlLogix®
controllers
Intrinsic safety and
high availability I/O
Chassis-based I/O
Dynamix™
• Integrates machine
protection with your
standard
control system
• Dual Ethernet ports
supporting both
Linear and Device
Level Ring topologies
Condition
monitoring
ArmorBlock®
• IP67, IP67, IP69K
rated modules
• Reduces wiring
and panel space
• QuickConnect for
tool changing
application
• Analog, Digital,
specialty, machine
safety and IO-Link
options available
Compact I/O™,
Compact 5000™
• High-performance
Compact 5000™ I/O
for CompactLogix™
5380 and
ControlLogix® 5580
controllers
• High-density Compact
I/O™ for
CompactLogix™ 5370
controller
POINT I/O™
• Low-cost
platform with
lower density
inputs and
outputs
• Compact design
makes
installation easier
• Machine safety,
specialty and
IO-Link options
available
Discrete machine I/O Smart machine
distributed I/O
On-Machine™
I/O

Integrated and scalable safety
Control differentiating value
Rockwell Automation differentiation value:
• Total cost of ownership reduced with total system
scalability from components to controllers to I/O
• High-performance control and I/O for reduced
machine size
• New safety instruction set for improved
integration with drives and motion
• Integrated safety including components
$
Reduces customer risk
Customer Value:
Increases time-to-market
Saves money in downtime
I N C R E A S E D S A F E T Y
I N T E G R A T I O N
Complete solution with machine safety capabilities

Delivering a full safety solution
Rockwell Automation® safety architecture 2019-2020
Light Curtain:
with transceiver
technology
PowerFlex® 527
AC Drive with
CIP Safety
over EtherNet/IP
Guardmaster®
440C-CR30
Configurable Relay
Easy to use and
flexible
GuardShield™
Light Curtain
with CIP Safety
over EtherNet/IP
Multi Functional
Access Box with
CIP Safety over
EtherNet/IP
Safety Automation Builder®
Software tool for
Safety System Development
SafeZone™
Scanner
CIP Safety over
EtherNet/IP
Pull with E-stop
Industry first solid
state rope pull
Multi Functional
Access Box
Integrated access
control system
440G-LZ
RFID Locking Switch
For partial body
access applications
TLS-Z
Guard Locking
Switch for full body
access
applications
Stratix® 5100:
Safety w/WIFI
Safety
Contactors.
Positively guided
contacts
MobileView™:
Tethered HMI
with E-stop
PVP7-Series:
Pre-Developed
Safety Screens
Kinetix® 5000 family of
EtherNet/IP Servo Drives
CIP Safety over EtherNet/IP
Compact
GuardLogix® 5380 controller
Studio 5000® environment
POINT Guard
I/O™
over EtherNet/IP
(PLe/SIL 3)
440G-LZ
RFID Locking
Switch for partial
body access
applications
E-stop
Self-monitoring
contact block
ArmorBlock®
Guard I/O™
over
EtherNet/IP
(PLe/SIL 3)
GuardLink®
Series
connection
of safety devices
PLe
Compact 5000™
Safety I/O
over EtherNet/IP
(PLe/SIL 3)
PowerFlex® 755
AC Drive with
CIP Safety
over EtherNet/IP

New applications in these
(and other) industries
Entertainment
Packaging
Consumer products
New capabilities in the GuardLogix® controller support
new applications
GuardLogix® controller differentiation
GuardLogix® 5570S
controller
• On-Machine™ versions
• Extreme environment versions
GuardLogix® 5580S
controller
• Enables higher performance safety
I/O (used with Bulletin 1756, 5069,
5094)
• Advance drive safety instructions
• 1 gigabit (Gb) embedded Ethernet
port enables high-speed I/O and
motion control for up to 300 nodes
• Scalable as SIL 2/PLd or SIL 3/PLe
options

High-performance CPU
• Optimized for faster safety reaction time
Scalable safety level
• SIL CL2, Up to PLd – primary controller
• SIL CL3, Up to PLe – primary controller + safety partner
1-Gb embedded EtherNet/IP port
• Integrated safety on EtherNet/IP, I/O and safety devices
IEC 61800-5-2 safety instructions
• New drive safety instructions with Kinetix® 5700 ERS4 drive
• Safe Stop 1, Safe Stop 2, Safe Operation Stop
• Safely-limited Speed, Safely-limited Position
• Safe brake control with external brake, safe direction
Increased scalability
• 1756-L81ES: 3.0 MB Std /1.5 MB Sfy; 100 Nodes
• 1756-L82ES: 5.0 MB Std / 2.5 MB Sfy; 175 Nodes
• 1756-L83ES: 10 MB Std / 5.0 MB Sfy; 250 Nodes
• 1756-L84ES: 20 MB Std / 6.0 MB Sfy 250 Nodes
Now
Available

Right size your control!
Improved scalability and
competitive positioning
with 33 catalog numbers
New capabilities in the Compact GuardLogix® controller
support new applications
Compact GuardLogix® controller differentiation
Compact GuardLogix® 5370S
controller
• Our current offering for SIL 3, PLe,
Cat.4 version
• On-Machine™ version
• Fully compatible with Compact I/O™
(Bulletin 1769)
Compact GuardLogix® 5380S
controller
• Enables higher performance safety I/O
(Used with Bulletin 5069, 5094)
• Advance drive safety instructions
• Dual NIC support for linear and
Device Level Ring topologies,
• Scalable as SIL 2/PLd or SIL 3/PLe
(AFC November 2019)

Compact GuardLogix® 5380 controller | SIL 3
High-performance CPU
• Optimized for faster safety reaction time
Scalable safety level
• SIL CL3, Up to PLe
Dual 1-Gb embedded EtherNet/IP ports
• Configurable dual IP or DLR
• Integrated safety on EtherNet/IP
Compact 5000™ local safety I/O - increased scalability
• 5069-L306ERMS3: 600 KB Std / 300 KB Sfy; 2 axes; 16 nodes
• 5069-L310ERMS3: 1 MB Std / 0.5 MB Sfy; 4 axes; 24 nodes
• 5069-L320ERMS3: 2 MB Std / 1 MB Sfy; 8 axes; 40 nodes
Excellent solution for OEMs with Integrated Motion
Available Late 2019

Properly engineered and
validated systems can provide:
Advanced drive safety functions
Offer users a certified
building block solution
for a modern safety
system
• Improved asset utilization like
reduced floor space
• Improved machine cycle times
• Increased system yield
• Improved operator ergonomics
• Reduced repetitive stress injuries
• Pre-certified safety functions reduce
the amount of engineering and
testing required
Support routine machine functions safely with the latest drives, servos and controllers
I N C R E A S E D S A F E T Y
I N T E G R A T I O N
Example of SAFE SPEED LIMIT

Advanced drive safety instructions for Kinetix® 5700 drive
New capabilities in
Compact GuardLogix® 5380S and GuardLogix® 5580ES controllers
SFX SS1 SS2 SOS SLS SLP SDI SBC
IEC-61800-5-2 › Adjustable speed electrical power
drive systems – safety requirements - functional
• New drive safety instructions (8 total)
 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 & 5580 family of controllers

These offerings help customers with productivity and
compliance, while providing high-performance
control and a migration path forward.
Safety I/O priorities and roadmap
deliverables through 2020
General
Faster system performance
• Compact 5000 safety I/O
• ControlLogix® CIP safety I/O
(Bulletin 1756)
Smart device/sensor integration
and increased diagnostics
• IO-Link and GuardLink®
Smart machinesProcess focus
Process safety (including BPCS)
• 1715 – Stable offering gaining SIL 2
adoption, extends compliance
Lifecycle/modernization strategies
• FLEX 5000™ I/O Release
• Safety Release 1 (April/May 2019)
• Safety Release 2 (Late 2020)
Reduced footprint, local safety I/O
• Compact 5000™ safety I/O
Integration and simplification
• Single channel safety up to SIL 3/PLe
• GuardLink® and CIP safety networked
components

Discrete manufacturing
Machine safety offerings

This NEW safety light curtain
uses a unique transceiver
technology that allows it to be
used as a transmitter or receiver
simply by the plug-in used.
• 450E
• Reduces customer inventory
• IP69K enclosures for harsh
environments
• Software configuration via
Connected Components
Workbench™ software
• CIP Safety over EtherNet/IP
NEW Safety Components: Distinguishing features at-a-glance
Next generation safety laser
scanner that features high def
distance measurement scanning
technology that improves the
accuracy of the scan data and
increases the immunity of the
scanner to dust, smoke, and
optical interferences.
• CIP Safety over EtherNet/IP
• Double the number of
simultaneously monitored fields
NEW enhancement to the
440C Guardmaster®
configurable safety relay
family with a higher number
of local I/O and expansion
capabilities.
• 440C-CR50ER
• Embedded GuardLink®
reduces the wiring
effort/mistakes
• Increased diagnostics
reduces down time and lost
production
GuardShield™
NEW safety component offerings improve control system integration and simplification
SafeZone™ 3 Safety Encoder Guardmaster®
NEW SIL 3/PLe CIP safety rated
encoder allows velocity and
position feedback directly into the
safety task of GuardLogix®
controllers.
• Only SIL 3/PLe CIP Safety encoder
on market
• Configurable via AOP in Studio 5000®
application
• Reduces wiring and implementation
costs

GuardLink® Overview
 SMART: Provides access to diagnostic data when safety
function is in a safe state
 SIMPLE: No configuration required and devices use
standard 5-wire cables with M12 connectors
 SAFE: Daisy chain up to 32 devices with no loss of safety
rating (up to PLe)
Solution - Diagnostics are critical for identifying the location and reason for
the demand on the safety system as well as guiding operators through a
quick recovery
Problem - Series connection of devices typically reduces the granularity of
the diagnostics, leading to unnecessary machine downtime; not so with
GuardLink®

• Compact 5000™ I/O (Bulletin 5069)
• Optimized footprint fits the tightest
panels
• Highest performance platform
• Broadest price range
• Local or distributed usage
New safety I/O: Distinguishing features at-a-glance
• FLEX 5000™ I/O (Bulletin 5094)
• Fixed field wiring termination
• Hold last state feature
• Operating temperature -40 °C…+70 °C
(-40 °F...+158 °F)
• Fiber and copper media
• Mount horizontal or vertical
• Distributed usage only
• Future - safety analog
• ControlLogix® I/O (Bulletin 1756)
• Leverages rack-based portfolio
values
• Hold last state feature
• Local or distributed usage
Machine focus Integrated Architecture® focusProcess focus
Enabling customer compliance with a secure, common user experience and scalable safety ratings

Compact 5000™ I/O discrete safety input
Catalog 5069-IB8S
• 8 Channel Safety 24V DC digital input module
• Single channel: PLd
• Dual channel: PLe
• Diagnostic capability
• Short circuit, muting lamp error, over & critical
temperature, field power off, internal fault,
overload detection with test output.
Now
Available
Local and distributed I/O for Compact GuardLogix® controller
Distributed I/O for GuardLogix® 5580 controller

Compact 5000™ I/O discrete safety output
Catalog 5069-OBV8S
• 8 Channel Safety 24V DC digital output module
• Configurable safety output module (sourcing/bipolar)
• Ratings sourcing mode:
• Single channel: SIL 3, up to and including PLe
• Dual channel: SIL 3, up to and including PLe
• Ratings Bipolar mode: SIL 3, up to and including PLe
• Diagnostic capability:
• Short circuit, no load (open wire), overload, over
and critical temperature, field power off, dual
channel fault (only sourcing mode)
Now
Available
Local and distributed I/O for Compact GuardLogix® 5380 controller
Distributed I/O for GuardLogix® 5580 controller

FLEX 5000™ I/O
Rugged, flexible design and ease of maintenance
• Modular design supports Removal and Insertion Under Power (RIUP) and
online addition of modules
• Consistent I/O wiring allows direct termination of 2-, 3-, and 4-wire devices in
addition to consistent power wiring across terminal bases with jumpers
• Mount up to 16 I/O modules in either a horizontal or vertical mounting without
derating, interconnect cable available for bank expansion
• Standard operating temperatures from -40…+70 °C (-40...+158 °F), XT
variant available for all catalogs for conformal coating and G3 compliance
Flexible network media and topologies
• 1-Gb embedded switch technology for Device Level Ring, Linear,
Star, and Parallel Redundant Protocol (PRP) topologies
• Dual Ethernet ports available as 2 copper or 2 fiber SFP ports,
compatible with any Stratix® SFP transceiver
Integrated control and safety
• Channel-level control and configuration with enhanced diagnostics.
• Ability to mix safety and standard I/O for simplified safety implementation.
• Safety integrity level SIL 3, PLe, Cat. 4 single channel
• Supports high, low and continuous demand in fail-safe applications.
• Improved safety reaction time
Distributed I/O for ControlLogix® 5580 controller, GuardLogix® 5580 controller
Distributed I/O for CompactLogix™ 5380 controller, Compact GuardLogix® 5380 controller
Now
Available

FLEX 5000™ I/O
Integrated control and safety for the process industry
Safety digital 16 input
Catalog 5094-IB16S
• SIL 3, PLe, Cat. 4 single channel
• 6 ms safety reaction time*
• 8 test output: pre-assigned
• Test output rating: 0.2 A
• Overload detection with test output
Safety digital 16 output
Catalog 5094-OB16S
• SIL 3, PLe, Cat. 4 single channel
• 4.5 ms safety reaction time*
• Output rating: 0.5 A
• 1.5 A surge current for 150 ms*
• Safety mode, safety pulse mode
*Conditions apply
See FLEX 5000™ modules technical data (5094-TD001) for more details.
Now Available
Safety relay
Catalog 5094-OW4IS
coming soon

ControlLogix® Safety I/O
Available
July 2019
Certifications available at release
ControlLogix® I/O, Bulletin 1756, with CIP Safety technology
• New - Chassis-based, local I/O
• Can also be used as distributed I/O via bridging/routing
• New - Enhanced reaction time (compared to POINT Guard I/O™)
Safety rated:
• Up to SIL 3, PLe – TÜV certified modules
• Digital Input Modules: IB16S – 16 channels (each SIL 3 rated)
• Sinking input type
• Digital Output Modules: OBV8S – 8 channels (each SIL 3 rated)
• New - One module covers both Sourcing and Bipolar type outputs
• 8 sourcing outputs or 8 bipolar outputs per module, user configurable
• New - Hold last state feature, maintain output on communications loss
Flexible
• Any ControlLogix® Safety I/O module can be used in combination with all other
standard ControlLogix® I/O modules
• Use with Compact GuardLogix® 5380 or GuardLogix® 5580 (version 32+) controllers
Compliance markings include
• TÜV, UL, IECEx, ATEX, CE, Marine, FM and so on.
Highest density I/O platform,
Positioned for ControlLogix® I/O users to satisfy fail to safe machinery and
shutdown applications

Safety controllers and I/O: Distinguishing features at-a-glance
Universal feedback
• Bulletin 1791ES
• Safe speed, direction and position monitoring
• Rather than stop, machine can remain active
while safely monitored
• Supports two channel Digital AqB, SIN/COS, and
SSI feedback
• DLR Network
Compact GuardLogix® I/O
• Bulletin 5069
• SIL 3 catalog numbers
• High-performance CPU
• Configurable dual IP or DLR
• Advanced drive safety instructions
• Local or remote Compact 5000™ safety I/O
• FLEX 5000™ remote safety I/O
Scalable safety levels, high performance for faster reaction times and increased safety integration

Machine focus - Selection of safety I/O
Platform figures of merit
Typical considerations when choosing an I/O system…
As used with L8 Series CIP safety controllers
Distinguishing Feature Compact 5000™ I/O
Bulletin 5069
POINT I/O™
Bulletin 1734
FLEX 5000™ I/O
Bulletin 5094
ControlLogix® I/O
Bulletin 1756
Max SIL/PL rating SIL 3/PLe SIL 3/PLe SIL 3/PLe SIL 3/PLe
Fixed field wiring terminals No Yes Yes No
I/O module types available DI, DO AI, DI, DO DI, DO, relay
AI+AO in future
DI, DO
Channel isolation None None Yes in analog None
Demand rate Low & High Low & High Low & High Low & High
Special note L8 series only L7 or L8
supported
L8 series only L8 series only
Key features distinguish each platform, along with price per point and preference

I/O support summary
Feature Compact
GuardLogix® 5380
controller
GuardLogix® 5580
controller
ControlLogix® I/O (Bulletin 1756)  (ALL)
FLEX™ I/O (Bulletin 1794)  
FLEX 5000™ I/O (Bulletin 5094)  
1719 Ex I/O (Bulletin 1719)  
Dynamix™ System (Bulletin 1444)  
Compact I/O™ (Bulletin 1769)  
Compact 5000™ I/O (Bulletin 5069)  
POINT I/O™ (Bulletin 1734)  
ArmorBlock® I/O (Bulletin 1732)  
Compact GuardLogix® 5370
controller
GuardLogix® 5570
controller
All Except
Safety
 
 
 

 
 

Process safety

ControlLogix® I/O and 1715 Redundant I/O
• Stable platform with “active” product lifecycle
• Fault Tolerant/Fail-safe, SIL 2 rated by TÜV
• Distributed I/O on EtherNet/IP
• Leverages ControlLogix® 5570 controller and ControlLogix® I/O
family
• Safety Add-On instructions
• Integrated control and safety
• Supports up-to-date Logix releases (includes V31.050)
• Supports fail-safe and fault tolerant configurations
• Application markings
• DNV Marine, IECEx, ATEX, CE, UL Demko, TÜV
Key attributes
• DNV-GL marking for marine applications June 2019
• IEC61508 edition 2 compliance target October 2019
New for 2019

What’s NEW in AADvance® solution
• Ability to reset faults
remotely on any
processor slice
• Updated CIP Stack
(Produce/Consume
with Status)
• Offering new
development
environment based on
VS Shell
• Faster, more intuitive,
enhanced capabilities
• Peer-to-peer
between AADvance®
and Trusted®
• Ability to prioritize
Ethernet traffic
• Certified IEC61508 ed.2 –
SIL 2 to SIL 3
• Improved documentation
generation
• Enhanced ladder and
function block editors
• Drawing
capabilities/graphics
• Import/export variables
now include bindings
• Connections between
controllers
System release R1.40
Improved diagnostics Additional
functionality/certifications
Faster
communications rate

What’s NEW in Trusted® system
• Form factor – no change,
function, form and fit
compatible with series A.
• Certification – no change
existing certification will be
maintained for series B
• Software – existing
Trusted® toolset can be
used to program series B
• Applications now
execute 2-3x faster
• Improved durability of
plastics in more
humid/corrosive
environments
• Conformal coating is
standard
• Principle driver in RoHS
compliance
• Being adopted primarily in
Europe, but also in many
other industrial countries in
some form or another.
Complete hardware refresh
Investment in longevity More rugged design Improved performance

Process focus - Selection of safety I/O
Platform figures of merit
Used with L7
controller
As used with L8 Series CIP safety controllers
Distinguishing Feature 1715 Redundant I/O
Bulletin 1715
POINT I/O™
Bulletin 1734
FLEX 5000™ I/O
Bulletin 5094
ControlLogix® I/O
Bulletin 1756
Max SIL rating 2 3 3 3
Fault tolerant IO-Duplex Yes Yes No No
Fixed field wiring terminals Yes Yes Yes No
I/O module types available AI, AO, DI, DO AI, DI, DO DI, DO, relay
AI+AO in future
DI, DO
Safety implementation Application SIL 2 CIP Safety CIP Safety CIP Safety
Channel isolation 50 V None Yes in Analog None
Demand rate Low ONLY Low & High Low & High Low & High
Special note L7 series only L7 or L8 supported L8 series only L8 series only
Typical considerations when choosing an I/O system…
Key features distinguish each platform, along with price per point and preference

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RA TechED 2019 - SS08 - What's New and Coming Soon in Safety Automation Architectures