The latest Programmable Automation Controller (PAC) from
Rockwell Automation has been introduced to bring the
benefits of scalable integrated safety and motion options to
a wider range of machines

Factories are under pressure to produce
their goods faster, more efficiently and
at a lower total cost. They must also
operate in a safe and sustainable manner.

Rockwell believes lean and safe go hand-inhand.

Its two new controllers provide
machine builders and manufacturers with
integrated safety, motion, discrete and drive
control capabilities in a single controller for
medium size applications.

The Allen-Bradley L43S and L45S
Compact GuardLogix programmable
automation controllers (PACs) extend
capabilities previously available only in the
larger Allen-Bradley ControlLogix platform.

These include diagnostics and information
capabilities that help reduce nuisance
shutdowns and prolonged restarts, as well as
a single programming environment for
enhanced design and development
productivity.

New opportunities
As part of the Rockwell Automation
Integrated Architecture system, the Compact
GuardLogix controllers use the same
configuration, networking and visualisation
environment as the company’s larger-scale
systems. This helps provide machine builders
and end users with cost-effective integration
of a machine or safety application into the
plantwide control system.

“The introduction of the Compact
GuardLogix PACs opens a new door for
many manufacturers with medium size
applications who previously did not have the
means to implement an integrated
architecture solution with embedded safety
functionality,” said Ken Deken, vice president
of portfolio management.

Single control engine
“The scalability of the Integrated
Architecture system means manufacturers
and machine builders can design their
applications to include standard and safety
control using a single control engine and a
single development environment, regardless
of the application size.”
The Compact GuardLogix PACs can
control up to eight axes of integrated motion
over the SERCOS communication network
and when used in combination with the Allen-
Bradley Kinetix 6200 servo drive, machine
builders have access to the drives embedded
safety functions which include safe speed
control, safe direction and safe torque off.

The controllers also support the use of
the Allen-Bradley CompactBlock Guard I/O
modules and Allen-Bradley POINT Guard
I/O modules on EtherNet/IP, enabling fast
system configuration and improved sharing
of information. Featuring a 1oo2 safety
architecture, the Compact GuardLogix
controllers are rated up to Safety Integrity
Level 3 (SIL 3) and Performance Level e (PL
e) – the highest level of machine safety.

When used with the latest version of
Rockwell Software RSLogix 5000
programming software (version 18), the
Compact GuardLogix controllers can
leverage high-integrity add-on instructions
(AOIs) for faster commissioning.

AOIs encapsulate code for common
routines into pre-validated modules that can
be easily reused, helping to save time and
lower the risk of coding errors.

Manufacturers in the highly regulated life
sciences, and food and beverage industries
also can use the RSLogix 5000 software
available with the Compact GuardLogix
PACs to manage revision control, fulfil
regulatory requirements, and help protect
intellectual property.

Benefits
The benefits claimed for a combined stand
and safety controller solutions include:
Reduced risk – accommodates tasks and
processes and does not require workers to
‘work around’ the system
Reduced time and costs to design,
program, install and start-up
Improved efficiency – Improved operator
diagnostics and opportunities for
alternatives to lock-out-tag-out for routine
tasks (where applicable)
Reduced maintenance
Reduced wiring
Reduced space requirements
Accommodates future process or safety
changes
Ken Deken continues: “Machine builders,
integrators and end users are designing
contemporary solutions with an eye toward
improving safety, achieving higher levels of
performance, and realising better integration
of a machine with the rest of the
manufacturing operation.

“Through our scalable control platform
and advanced configuration environment,
manufacturers, suppliers and integrators
have more opportunity than before to
achieve this goal.”