Home

Safety Function - Rockwell Automation

1. ips z Vestae E LI i laf lams i Tes ET M cum ms j a EE i i i i D ug E D L E L 5 Mc D EIE Fh EET Iu rr am Wand ah E u Connected Components Workbench software automatically assigns the first two available safety output terminals of the 440C CR30 relay EO 18 and EO 19 embedded safety outputs 18 and 19 respectively These outputs drive the two 100S C safety contactors The PT to the right of the terminal assignment stands for Pulse Testing a technique used to detect if the output terminal is short circuited to 24V DC or another safety output terminal Other output terminals have additional options for configuration besides Pulse Testing but for terminals 18 and 19 it is the only possible configuration Rockwell Automation Publication SAFETY AT138B EN P May 2015 15 Safety Function Light Curtain and Configurable Safety Relay 2 From the Reset Input pull down menu on the Safety Output Function SOF choose SMF3 to use the Reset we set up in the previous section Safety Output Immediate OFF 1 9 018 PT t ro19 PT Feedback Reset Type Manual Configure the Logic In this application pressing the Emergency Stop disconnects power from the motor An interruption of the light curtain also disconnects power fr
2. Output m om am um um um un mom m um 6 m mom om E Sm HB ER BROBOdGdEO HB NB NO GB OB BREE BSS SBS SF NERO NO HGB GS GEO OS GSOUM an og HBOHB HB NB REEF Pf 2 Ho Od E Stop r Channel 1 Fault i 440C CR30 i H 4 Exclusion Relay i E Stop 4 i Channel 2 i i Subsystem 1 Subsystem 2 i Subsystem 3 Subsystem 4 The Emergency Stop function is considered a complementary protective measure which is intended to be used conjunction with other safeguarding measures and protective devices that sufficiently reduce risk An Emergency Stop is not a substitute for safeguarding measures and shall be designed not to impair the effectiveness of the other protective devices or safety functions Due to the single mechanical actuator of the E Stop a Fault Exclusion must be considered In most instances the Fault Exclusion required for electromechanical devices with a single mechanical actuator such as a typical tongue interlock limits the safety function in which it is included to a maximum Performance Level of PLd however the E Stop is not the primary safeguarding device It is a complementary measure that is intended for use only in the case of unforeseeable failure or misuse of the machine The E Stops high DC high MT TFd and Category 4 structure would Fault Exclusion aside let the E Stop safety function achieve PLe It is common practice due to the E Stops complementa
3. t Download Upload 440C CR30 22BBB 3 lt Verification 10 Remote Mode Fault If an error or omission is discovered during a build a message is displayed which details the error so that it may be Output e Show output from Build n od EC Build started Project Safety Relay Build end SS a toe y Build Succeeded amm sanela vrar mage amaaan amea me corrected After you correct the error you must perform the build again Save and Download the Project Follow these steps to save and download the project 1 From the File menu choose Save as to save the project IMPORTANT Saving the project with a new name closes the workspace window 2 In the Project Organizer window double click Guardmaster_440C_CR30 to open the workspace 3 Power up the 440C CR30 safety relay 4 Connect the USB cable to the 440C CR30 relay Rockwell Automation Publication SAFETY AT138B EN P May 2015 23 Safety Function Light Curtain and Configurable Safety Relay 5 Click Download GUARDMASTER CR30 Logic JSMARDMAGTER GEO ac Guardmaster 440C CR30 Guardmaster 440C CR30 Quick Tips Device Toolbox EditLogic Build Verify 440C CR30 77BBB Verification ID Remote Mode 1 J B Fault diese a 6 In the Connection Browser expand th
4. 63 x 0 3 0 09 0 02 0 1 63 x 0 41 1 26 8 in The light curtain must not be mounted closer than 26 8 in from the guarded hazard Minimum Distance from Reflecting Surfaces The infrared light from the sender may be reflected off of shiny surfaces and be received by the system s receiver If this condition occurs it can result in an object not being detected when it enters the GuardShield sensing field All reflecting surfaces and objects for example material bins must therefore be located at a minimum distance a from the protective field of the system The minimum distance a depends on the distance D between sender and receiver Distance D meters Follow these steps to determine the minimum distance from the reflecting surfaces 1 Determine the distance D in meters between the sender and receiver 8 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay 2 Read the minimum distance a in millimeters from the graph a mm a i Hm ee d 55801 a SS LATINI p NENNEN NENNEN NENNEN NEN NE je Peer 3 5 10 15 20 minimum distance to reflecting surfaces D distance between transmitter and receiver The effective aperture angle for the GuardShield system is 2 5 at a mounting distance of gt 3 0 m 9 8 ft Calculate the minimum distance to reflecting surfaces depending on the dis
5. GuardShield 440 3 Single 317E mined nebrme runt ool televors CRID Configurable Safety Belay 1 8 Redundant EOO5 b artartars JATES 6S fulfilled 56 High The light curtain safety function can be modeled as follows Input GuardShield Light Curtain Subsystem 1 Logic 440C CR30 Relay Subsystem 2 fulfilled 100 High Output Subsystem 3 The Performance Level and Category achieved by each subsystem of the E Stop safety function as calculated by SISTEMA is shown below Safety function Wy IFA Documentation Pur PL Subsystems Ojuemy Status Tyne Lin MITFd a f Category Requirement of the category ot i SB bulion wilh redundant centast blacks ATES 65 fulfilled 99 High 108 Higit fulfilled p Nee ZB E Stop Faut Exclusi n 0 ot nefercni rebevant fulfilled L 5B CR30 Saftware Configurable Safety Relay 1 amp t fulfilled Lad SB Redundant 1005 Contactors FATES 5 fulfilled 99 High 100 High fulfilled 26 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay The E Stop safety function can be modeled as follows Input Logic
6. light curtain would need to be mounted 320 mm farther away from the hazard just because it takes 0 2 seconds longer to stop It is very important to understand the effect that stopping time has on the safety distance Rockwell Automation Publication SAFETY AT138B EN P May 2015 7 Safety Function Light Curtain and Configurable Safety Relay The Safety Distance formula from ANSI B11 19 is only slightly different and results in a very similar distance as follows Ds Kx Ts Tc Tr Tbm Dpf K the standard hand speed of 63 inches per second Ts the stop time of the machine Te the response time of the safety system Tr the response time of the presence sensing device Tbm additional time allowed for the brake monitor if any to compensate for variations in normal stopping time the distance a standard hand could possibly move through the light curtain before it is detected This is a fixed value based on the light curtain resolution For the purposes of this example we use the following values K 63 inches per second Ts 300 ms 0 3 sec for the purposes of this application technique IMPORTANT The specific machine stopping time must be measured for each application Tc 90 ms 45 ms 440C CR30 relay 45 ms K1 and K2 contactors Tr 20 ms light curtain Tr Tc 90 20 110 ms 0 11 second Tbm 0 No brake is used in this application Dpf 1 in Ds Kx Ts Tc Tr Tbm Dpf
7. 440L UM003 for instructions on resetting to the default parameters The E Stop and safety contactors are simple electromechanical devices that do not require configuration Configure the 440C CR30 Relay The 440C CR30 safety relay should be running firmware version 7 00 or later A free firmware update is available for older units The 440C CR30 relay is configured by using the free Connected Components Workbench software release 7 00 or later A detailed description of each step is beyond the scope of this document Knowledge of the Connected Components Workbench software is assumed Follow these steps to configure the Guardmaster 440C CR30 relay by using Connected Components Workbench software 1 In Connected Components Workbench software choose View and then Device Toolbox 2 In the Device Toolbox expand the Catalog section and the Safety folder 3 Double click the 440C CR30 relay to add it to the project Device Toolbox ew EH Discover 23 m amp Cata S a T Controllers E Drives B Cy Safety EC MSR57 m secu r Motor Control E E Graphic Terminals Rockwell Automation Publication SAFETY AT138B EN P May 2015 11 Safety Function Light Curtain and Configurable Safety Relay 4 In the Project Organizer double click the Guardmaster 440C CR30 safety relay Fr ci 2 I Bie Ta mae bi TA 5 Toadd the I O module called for in this circuit rig
8. Application Technique Allen Bradley Safety Function Light Curtain and Configurable Safety Relay Products Guardmaster 440C CR30 Configurable Safety Relay 440L GuardShield Light Curtain 100S C Safety Contactors 800F E Stop Button 800F Reset Button Safety Rating CAT 4 PLe to ISO 13849 1 2008 Topic Page Important User Information 2 General Safety Information 3 Introduction 3 Safety Function Realization Risk Assessment 3 Light Curtain and Configurable Safety Relay Safety Function 4 Safety Function Requirements 4 Functional Safety Description 4 Bill of Material 5 Setup and Wiring 5 Configuration 11 Calculation of the Performance Level 25 Verification and Validation Plan 28 Verification of the Configuration 33 Additional Resources 36 USEN Rockwell Allen Bradley Rockwell Software Automation Safety Function Light Curtain and Configurable Safety Relay Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained pers
9. D ON Remove the jumper Neither the light curtain nor the 440C CR30 relay responds Press and release the Reset button Nothing changes Cyde power to the light curtain Approximately five seconds after power is restored to the light curtain its outputs turn ON 3 Press and release the Reset button The 440C CR30 relay s OUT 0 status indicator LED should turn ON Validation of Safe Response to Abnormal Operation The safety system responds properly to all foreseeable faults with corresponding diagnostics 29 30 1 440C CR30 Relay K1 and K2 Contactor Tests While the machine is running break the connection between terminal EO 18 of the 440C CR30 relay and the coil of 100S C contactor K1 The machine must stop 2 Restore the connection Use the standard control system to restart the machine 3 While the machine is running short the 440C CR30 relay terminal _18 which is connected to the A1 terminal of the K1 coil to 24V After approximately 18 seconds the 440C CR30 relay must trip The machine stops The red 440C CR30 relay Fault status indicator LED is ON 4 Remove the jumper Press and release the Reset button The 440C CR30 relay must not respond 5 Cycle power to the 440C CR30 relay Press and release the Reset button The 440C CR30 relay s OUT 0 status indicator LED should turn ON Use the standard control system to start the machine While the machine is running short the 440C CR30 relay terminal EO 18 whi
10. R30 relay s OUT 0 status indicator LED should turn ON Validation of Safe Response to Abnormal Operation The safety system responds properly to all foreseeable faults with corresponding diagnostics GuardShield Light Curtain 440C CR30 Relay Tests Keep the light curtain clear Remove the light curtain OSSD 1 wire from terminal El 02 of the 440C CR30 relay The 440C CR30 relay must trip immediately The red Changes Modifications Fault status indicator LED of the 440C CR30 relay must flash Reconnect the wire to El_ 02 The 440C CR30 relay must not respond Press and release the Reset button The 440C CR30 relay must not respond Interrupt and the clear the light curtain The red Fault status indicator LED should turn OFF Press and release the Reset button The 440C CR30 relay s OUT 0 status indicator LED should turn ON 2 3 4 5 Use the standard control system to start the machine Confirm that the motor starts and the machine begins to operate This step is optional in the following GuardShield validation tests Jump OSSD 1 to 24V Interrupt and the clear the light curtain When the light curtain turns its OSSDs OFF the short circuit to 24V is detected and it does not turn its outputs back ON The 440C CR30 relay trips The light curtain indicates the fault on its status indicator LEDs red LED flashing orange LED ON 7 Remove the jumper Neither the light curtain nor the 440C CR30 relay responds Pres
11. al publication 440L UM003 for additional information These factors also affect the safety distance calculation IMPORTANT Anexample calculation is shown in this document but you must perform a final calculation for your specific application based on the safety system specification as well as the machine stopping time 6 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay Safety Distance Calculation A safety light curtain provides no physical barrier between a person and the hazardous motion The safety light curtain must be installed at a sufficient distance from the hazardous motion to make sure that someone putting a hand through the light curtain cannot reach the hazard before it has stopped This distance is referred to as the Safety Distance The Safety Distance S or Ds required varies from installation to installation and therefore must be calculated for each specific application This application technique provides example calculations based on the formulae from both the international standard ISO 13855 and the US standard ANSI B11 19 The Safety Distance formula for vertically installed safety light curtains from ISO 13855 S KxT C S the minimum distance in millimeters mm K a parameter in millimeters per second mm s derived from data on approach speeds of the body or parts of the body T the overall stopping performance in second s based o
12. atus indicator LEDs are green The Run status indicator can be flashing green to indicate a non verified project Press and release the Reset Button Confirm that the 440C CR30 relay output status indicator LED indicator OUT 0 is ON status of SOF 1 Confirm that the motor does not start Use the standard control system to start the machine Confirm that the motor starts and the machine begins to operate Rockwell Automation Publication SAFETY AT138B EN P May 2015 29 Safety Function Light Curtain and Configurable Safety Relay Use the standard control system to stop the machine The machine must stop in its normal configured manner The safety system must not respond Use the standard control system to start the machine again Confirm that the motor starts and the machine begins to operate Press the E Stop button The safety system must trip The machine must stop in less than 0 4 seconds the maximum stopping time The 440C CR30 relay s status 10 1 1 indicator LED OUT 0 must be OFF Press and release the Reset button The 440C CR30 relay must not respond Release the E Stop button The machine must not start The 440C CR30 relay must not respond The OUT 0 status indicator LED must remain OFF Press and release the Reset button The 440C CR30 relay s OUT 0 status indicator LED turns ON The machine must not start Use the standard control system to start the machine Confirm that the motor starts and the
13. bug Tools Communications Window Help iQ Hx o ec 8 3 89 1 Toolbox l1 Xl Guardmaster 440C CR30 Logic x P eR MCN Quick Tips Device Toolbox 4 Safety Monitoring Functions Jd mm E Ed P m aa 8E IS 3p xm E n Safety Monitoring Logic Level A Feedback Monitoring Gate Switch Light Curtain Muting Reset Restart Safety Mats Single Wire Safety Input Two Hand Control HE OO 8 t5 gg ti Alternative Device 4 Logic Functions k Pointer AND Rockwell Automation Publication SAFETY AT138B EN P May 2015 13 Safety Function Light Curtain and Configurable Safety Relay Connected Components Workbench software automatically assigns the next available terminals for both the inputs and the test sources Any necessary configuration of those I O points is also done automatically by the software In this case the default assignments are correct and no terminal changes are required for this application Safety Monitoring SME 1 EI 00 Y o Emergency Stop 9 e Test Source 12 Test Source B 13 Advanced Settings 2 In the Toolbox click and drag Light Curtain to the target block below the E Stop SMF 1 e e Light_Curtain_1 H0 9 e Advanced Settings 3 To add a Reset safety monitoring function click and drag a Reset from the Toolbox to the target block below the Light Curtain SMF 2 Tooter FE Gosedmac
14. ce gt gt IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARC FLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt 2 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay General Safety Information Contact Rockwell Automation to find out more about our safety risk assessment services IMPORTANT This application example is for advanced users and assumes that you are trained and experienced in safety system requirements assessment can require additional circuitry to reduce the risk to a tolerable level Safety circuits must take into consideration safety 1 ATTENTION Perform a risk assessment to make sure all task and hazard combinations have been id
15. ch is connected to the 1 terminal of the K1 coil to DC COM The 440C CR30 relay must 7 trip The machine stops The red 440C CR30 relay Fault status indicator LED is ON Remove the jumper Press and release the Reset button The 440C CR30 relay must not respond Cycle power to the 440C CR30 relay 10 Press and release the Reset button The 440C CR30 relay s OUT 0 status indicator LED should turn ON 11to 20 Repeat steps 1 through 10 using EO 19 for EO 18 and K2 for K1 Verification of the Configuration You must confirm the verification of the 440C CR30 safety relay configuration for each individual application by using the Verify command in the configuration software If the configuration is not verified the 440C CR30 safety relay will fault after 24 hours of operation N ATTENTION The verification process should be documented in the safety system s technical file Rockwell Automation Publication SAFETY AT138B EN P May 2015 3 UJ Safety Function Light Curtain and Configurable Safety Relay Follow these steps to confirm the verification of the configuration 1 Make sure the 440C CR30 relay is powered up and connected to your workstation via the USB cable 2 Confirm that the upper right hand corner of the Connected Components Workbench Project tab shows that the 440C CR30 relay is connected If it is not click Connect to Device to establish the software connection Guard master 440C_CR30 2 BITS a T De
16. ch safety function To Realization and PL Evaluation Rockwell Automation Publication SAFETY AT138B EN P May 2015 3 Safety Function Light Curtain and Configurable Safety Relay Light Curtain and Configurable Safety Relay Safety Function This application technique includes two safety functions 1 Safety related stop of hazardous motion initiated by a light curtain 2 Emergency stop of hazardous motion initiated by an E Stop button Safety Function Requirements Interrupting the light curtain or pressing the Emergency Stop button stops and prevents hazardous motion by removal of power to the motor The motor then coasts to a stop Stop Category 0 When the safety system is reset hazardous motion and power to the motor do not resume until a secondary action occurs for example pressing the start button Faults at the light curtain wiring terminals or safety controller are detected before the next safety demand The safe distance from the location of the light curtain to the hazard must be established such that the hazardous motion stops before you can reach the hazard The safety function in this example is capable of connecting and interrupting power to motors rated up to 9 A 600V AC Position the reset button outside of the hazardous area where it is possible to view the entire hazardous area ATTENTION If it is not possible to view the entire hazardous area additional safety rated presence sensing devices must be used to
17. ck Yes to proceed with the verification Connected Components Workbench Performing a Safety Verify will change the safety relay to Program mode Proceed with the Safety Verify After about ten seconds a pop up window appears to confirm that the Verify process was successful 7 Click Yes to change to Run mode 8 Record the Safety Verification ID in the machine s documentation Connected Components Workbench Have you followed installation instructions and precautions to conform to applicable safety standards Have you venfied that the electrical specifications of the sensor and inputs are compatible Have you verified that the electrical specifications of the outputs and the actuators are compatible Have you calculated the system s safety response time for each safety chain Is the system response time in proper relation to the process tolerance time Have probability PFD PFH PILx values been calculated according to the system s configuration Have you performed all appropriate functional verification tests on the system This process is the feedback to the 440C C R30 relay that the system verification and functional tests have been completed The unique verification ID can be used to check if changes have been made to a configuration file Any change to the configuration removes the Safety Verification ID Subsequent Verify actions generate a different verification ID The Safety Verification ID is displayed in Connecte
18. contactors after 12 7 years assuming the actual frequency of operation matched the original estimate It would also be good practice to advise the user of the impact of the number of operations of the electro mechanical device which in turn is driven by how frequently the safety devices are actuated for example by interrupting the light curtain TIP Use of an output control device with its own electronic safety monitoring such as a Variable Frequency Drive with a modern Safe Torque off implementation eliminates the need for calculation of lifetime based on number of operations as that type of device has a defined lifetime that is not dependent on the number of cycles The DCavg 99 for the contactors is selected from the Output Device table of ISO 13849 1 Annex E Direct Monitoring The DCavg 99 for the E stop is selected from the Input Device table of ISO 13849 1 Annex E Cross Monitoring with detection of static faults and short circuits The CCF value is generated by using the scoring process outlined in Annex F of ISO 13849 1 The complete CCF scoring process must be performed when actually implementing an application A minimum score of 65 must be achieved The Emergency Stop function is a complementary protective measure which is intended to be used in conjunction with other safeguarding measures and protective devices to sufficiently reduce risk The emergency stop function shall be designed not to impair the effectiveness of t
19. ct it to the E Stop block Dairia Meni rj Lom Lowel A xil t ILE fm Tes M 14 7 Inputs a Tet 11 T Setbinga A connection line appears and both connection dots turn dark gray The logic looks like this 5alety r ky Li 2 tw o Renee 1 od l1 Ho E 6 12 inputs Test Source 15 t Advanced benng 4 Click the blue dot on the right side of the Light Curtain SMF2 block which is the output connection The dot turns light gray indicating that it is selected 5 Click the second input connection blue dot of the AND block to connect it to the Light Curtain SMF 2 A connection line appears and both dots turn dark gray im Loge Lewel A LA 1 Er o0 1 roi r 4 gt Test A 12 Inputs a E Li Li Sette hl 2 EL 02 a Light Curzain 1 rE m Seres Rockwell Automation Publication SAFETY AT138B EN P May 2015 17 Safety Function Light Curtain and Configurable Safety Relay 6 Click the output connection the blue dot on the right of the AND logic block to select it Logic Level A LLA 1 9 amp Inputs 2 bd The dot turns light gray 7 Click the input connection the blue dot on the left of the Immediate OFF Sa
20. ctional test includes normal operating conditions in addition to potential fault injection of failure modes A checklist is typically used to document the validation of the safety control system Prior to validating the system confirm that the Guardmaster 440C CR30 configurable safety relay has been wired and configured in accordance with the installation instructions Verification and Validation Checklist General Machinery Information Machine Name Model Number Machine Serial Number Customer Name Test Date Tester Name Schematic Drawing Number Input Devices 800FP MT44 E Stop 800FP F611 Reset 440L P4JLO640YD Light Curtain Configurable Safety Relay 440C CR30 22BBB Safety Contactor 100S C09EJ23C x2 Safety Wiring and Relay Configuration Verification 1 Confirm that all components specifications are suitable for the application Refer to Basic Safety Principles and Well tried Safety Principles from ISO 13849 2 2 Visually inspect the safety relay circuit to confirm that it is wired as documented in the schematics 3 Confirm that the configuration in the 440C CR30 relay is the correct intended configuration Normal Operation Verification The safety system responds properly to all normal Start Stop Reset E stop and Light Curtain inputs NL I Confirm that the E Stop and light curtain input indicator LEDs of the 440C CR30 relay are ON Confirm that the Power status and Run st
21. d Components Workbench software only when you are connected to the 440C CR30 relay The Safety Verification ID can be displayed on the IN and OUT status indicator LEDs of the 440C CR30 safety relay at any time by pushing and holding the MEM ID button below the USB receptacle Rockwell Automation Publication SAFETY AT138B EN P May 2015 35 Safety Function Light Curtain and Configurable Safety Relay Additional Resources These documents contain additional information concerning related products from Rockwell Automation Resource Guardmaster 440C CR30 Software Configurable Safety Relay Quick Start Guide publication 440C 05001 Guardmaster 440C CR30 Configurable Safety Relay User Manual publication 440C UM001 GuardShield Type 4 and GuardShield Remote Teach User Manual publication 440L UM003 Safety Contactors with DC Coil Installation Instructions publication 100S IN006 Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Safety Products Catalog publication 5117 001 Website http www rockwellautomation com rockwellautomation catalogs overview page Product Certifications website available from the Product Certifications link on http www ab com Description Provides information on how to configure a Guardmaster 440C CR30 configurable safety relay to communicate with a PanelView Component terminal via Modbus communication protocol Provides detailed information on how to install configure
22. de the E Stop The red Fault status indicator LED should turn OFF Press and release the Reset button The 440C CR30 relay s OUT 0 status indicator LED should turn ON N 13 14 15 Rockwell Automation Publication SAFETY AT138B EN P May 2015 31 Safety Function Light Curtain and Configurable Safety Relay Short the E Stop input wire at terminal El 00 of the 440C CR30 relay to DC Com OV DC The 440C CR30 relay must trip immediately The red Fault status indicator LED of the 440C CR30 relay turns ON not flashing 16 17 Remove the jumper The 440C CR30 relay must not respond Press and release the Reset button The 440C CR30 relay must not respond 9 18 Cyde power to the 440C CR30 relay After the initial self checking the red Fault status indicator LED should be OFF 1 Press and release the Reset button The 440C CR30 relay s OUT 0 status indicator LED should turn ON 20 to 40 Repeat steps 1 through 19 using MP 13 for MP_12 and El_01 for El_00 a D 41 Short terminal El 00 of the 440C CR30 relay to terminal El 01 After approximately five seconds the 440C CR30 relay must trip The red Fault status indicator LED of the 440C CR30 relay must flash Remove the jumper The 440C CR30 relay must not respond Press and release the Reset button The 440C CR30 relay must not respond Cycle the E Stop The red Fault status indicator LED should turn OFF 42 43 4 4 Press and release the Reset button The 440C C
23. detect persons in that area for example by using a laser scanner or safety mat inside the cell The safety functions in this application technique each meet or exceed the requirements for Category 3 Performance Level d CAT 3 PLd per ISO 13849 1 and control reliable operation per ANSI B11 19 Functional Safety Description Hazardous motion is stopped or prevented by interrupting the field of view of the light curtain The 440L light curtain is connected to the 440C CR30 configurable safety relay The safety outputs of the 440C CR30 relay control the power to the 100S C contactor coils Whenever the 440C CR30 relay de energizes the safety contactors the hazardous motion coasts to a stop Stop Category 0 The safety relay monitors the status of the 100S C output contactors via mechanically linked auxiliary contacts and does not reset unless both sets of main motor contacts are open After the load clears the light curtain all safety input signals are correct no faults are detected and the reset push button is pressed for 0 25 to 3 0 seconds and released the 440C CR30 relay turns its safety outputs ON providing power to the contactor coils The E Stop is connected to the 440C CR30 relay which uses pulse checking to monitor the E Stop for actuation and faults Whenever the E Stop is actuated pressed the 440C CR30 relay turns OFF its safety outputs and the hazardous motion is stopped After the E Stop button is released all safety input
24. e _ 1 Virtual Chassis and select the Guardmaster 440C CR30 22BBB Aubobrowse Refresh Workstation NAUSCHMS991BW1 faa Linx Gateways Ethernet x2 AB ETHIP 1 Ethernet AB VBP 1 1789 A17 A Virtual Chassis M im m 00 Workstation RSLinx Server USB 7 Click OK 8 Click Yes to change from Run to Program mode Connected Components Workbench Safety relay is in Run made Do you want to change to program mode Connected Components Workbench Download Complete Do you want to change the safety relay back to Run mode 24 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay 10 Click Edit Logic to see the online diagnostics persi ges Lise aleng 1 P 7 Ersan Seg te AB de 7 u Bre OFF 1 ar T B Fiba lant carm i pp Tin eee B 71 v0 ptm 4 LE Ele if dS wd E X gi anm Green indicates that a block is True or that an input or output terminal is ON Flashing green indicates that a Safety Output Function is ready to be Reset The complete safety system must be installed and powered up to fully use the online diagnostics mode The online diagnostics mode of the 440C CR30 relay can be very helpful during the verification process 11 Review the information in Calculation of the Performance Lev
25. edback monitoring signals can be connected to safety rated inputs if so desired This example uses the 2080 plug in I O module to show the capability of the 440C CR30 safety relay The light curtain monitors its internal circuitry and its OSSD outputs for faults When the light curtain detects a fault in the internal circuitry the light curtain responds by turning its OSSD outputs OFF A fault on the OSSD outputs is detected either immediately or upon the next safety demand The light curtain turns its OSSD outputs OFF when it detects an output fault such as a short circuit to another signal or between the two OSSD channels Most internal and wiring faults of the light curtain require you to cycle power after removing the cause of the fault to internally clear the fault and enable the light curtain to turn its outputs ON The 440C CR30 safety relay sends test pulse signals from multi purpose terminals 12 and 13 through the contacts of the E Stop which are connected back to the safety inputs on the safety relay Pressing the E Stop interrupts this circuit The safety relay responds by turning its safety outputs OFF which de energize the coils of the 100S C contactors This causes the main motor contacts to open removing power from the motor and causing it to coast to a stop Stop Category 0 The 440C CR30 safety relay monitors the E Stop circuit for faults Loose wires shorts to 24V shorts to ground contacts failed closed and cross faults are de
26. el on page 25 and Verification and Validation Plan on page 28 before proceeding with Verification of the Configuration on page 33 Calculation of the Performance Level When properly implemented the light curtain and E Stop safety functions can achieve a safety rating of Category 4 Performance Level e CAT 4 PLe according to ISO 13849 1 2008 as calculated by using the SISTEMA software PL calculation tool The Performance Level required PLr from the risk assessment for each of the safety functions in this application is PLd or better Additionally each safety function must achieve a CAT 3 rating or better in order to be considered Control Reliable per ANSI B11 19 Project gt Hew Status Name Type Pir je Edit Documentation y SF Light Curtain Safety related stop function initiated by safeguard d v SF E Stop Emergency stop function Rockwell Automation Publication SAFETY AT138B EN P May 2015 25 Safety Function Light Curtain and Configurable Safety Relay The Performance Level and Category achieved by each subsystem of the light curtain safety function as calculated by SISTEMA is shown below Safety function Documentation Pir 1 Subsystems Status Type Quem w 58 w 46 j 5B 2 Hame CCFaicore Desg Mi KITTFd a Legh Curlain
27. entified and addressed The risk distance calculations which are not part of the scope of this document Introduction Light curtains are used to detect attempted access to a hazardous area In normal operation ifa light curtain detects an object such as the operator s hand it causes the safety system to stop any hazardous motion in the hazardous area This safety function application technique explains how to wire and configure a Point of Operation Control POC GuardShield light curtain and an E Stop function The system is based on a Guardmaster 440C CR30 software configurable safety relay Safety Function Realization Risk Assessment The required performance level is the result of a risk assessment and refers to the amount of the risk reduction to be carried out by the safety related parts of the control system Part of the risk reduction process is to determine the safety functions of the machine In this application the performance level required PLr by the risk assessment is Category 3 Performance Level d CAT 3 PLd for each safety function A safety system that achieves CAT 3 PLd or higher can be considered control reliable Each safety product has its own rating and can be combined to create a safety function that meets or exceeds the PLr From Risk Assessment ISO 12100 1 Identification of safety functions 2 Specification of characteristics of each function v 3 Determination of required PL PLr for ea
28. essed for 0 25 to 3 0 seconds and released the 440C CR30 relay turns its safety outputs ON providing power to the contactor coils Position the reset button where it is possible for the operator to view the entire hazardous area If a person is in the hazardous area the reset button should not be pressed If it is not possible to view the entire accessible hazardous area when operating the reset button use supplemental safeguarding such as a safety mat or a laser scanner to monitor the hazardous area Another option is to use mechanical implementations that make it impossible to be in the hazardous area without interrupting the light curtain Rockwell Automation Publication SAFETY AT138B EN P May 2015 5 Safety Function Light Curtain and Configurable Safety Relay The reset button and contactor feedback monitoring circuits connect to the 2080 plug in I O module This module is not safety rated It is acceptable to use standard inputs for the reset and feedback because they are not safety rated signals They are simple 24V signals The 440C CR30 safety relay limits the use of standard I O to functionality that does not require safety rated signals By comparison the E Stop and light curtain signals must not be connected to the standard I O plug in module These signals must be connected to safety rated inputs Both the configuration software and the firmware prevent you from using standard inputs for signals that must be safety rated Reset and fe
29. fety Output Function block SOF1 to connect it to the AND block Safety Output SOF1 5 iki Immediate OFF 1 ej 8 19 E T Feedback None Reset Type Manual Reset Input A connection line appears and both connection dots turn dark gray Also a Pass Through block automatically appears in the Logic Level B column The resulting logic looks like this Logic Level A Logic Level B Safety Output LLA 1 LLB 1 SOF 1 1 AND Pass Through Immediate OFF 1 FO18 PT z t roi19 PT Feedback None Inputs 2 a Reset Type Manual Reset Input SMF 3 Configure the Feedback Monitoring Feedback is the act of monitoring the output device to confirm that it is OFF when the 440C CR30 relay output driving that device is Safety rated output devices such as safety contactors use mechanically linked contacts so that an external device can monitor their status Mechanical linkage means that all of the contacts are mechanically linked so that when a N O contact is closed the linked N C contact is mechanically held open A 24V DC signal sent through the N C contact only gets to the 440C CR30 relay input if the N C contact is closed Therefore if the 440C CR30 relay detects 24V DC on inputs P2_01 and P2 02 the 440C CR30 relay knows that the main motor contacts the N O channels are 18 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safet
30. he light curtain Push the Reset button Confirm that the 440C CR30 relay turns its safety outputs ON Use the test rod to confirm that the OSSD outputs of the light curtain are OFF when the test rod is anywhere within the light curtain s protective field by observing the 1 2 3 4 5 status of the output indicator LEDs on the light curtain and 440C CR30 relay IN 2 and 3 LED indicators Ww 0 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay Pass the test rod through the protective field as shown in the attached illustration Confirm that the light curtain output LEDs and 440C CR30 relay input LEDs remain OFF throughout the procedure Transmitter Receiver Validation of Safe Response to Abnormal Operation The safety system responds properly to all foreseeable faults with corresponding diagnostics E stop 440C CR30 Relay Tests While the machine is running remove the E Stop input wire at terminal El 00 of the 440C CR30 relay The 440C CR30 relay must trip immediately stopping the machine within 0 4 seconds The 440C CR30 relay s OUT 0 status indicator LED must turn OFF The red Fault status indicator LED of the 440C CR30 relay must flash Reconnect the wire to El_ 00 The 440C CR30 relay must not respond Press and release the Reset button The 440C CR30 relay must not respond Cyde the E Stop The red Fault status indicator LED should
31. he other protective devices or safety functions For emergency stop devices in accordance with IEC 60947 5 5 a fault exclusion for mechanical aspects is allowed up to PLe if the maximum number of operations is considered However the actual number of operations NOP is used for the purposes of the MTTFd calculation in this document Verification and Validation Plan Verification and validation play important roles in the avoidance of faults throughout the safety system design and development process ISO 13849 2 sets the requirements for verification and validation The standard calls for a documented plan to confirm that all of the safety functional requirements have been met Verification is an analysis of the resulting safety control system The Performance Level PL of the safety control system is calculated to confirm that the system meets the required Performance Level PLr specified The SISTEMA software is typically used to perform the calculations and assist with satisfying the requirements of ISO 13849 1 28 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay Validation is a functional test of the safety control system to demonstrate that the system meets the specified requirements of the safety function The safety control system is tested to confirm that all of the safety related outputs respond appropriately to their corresponding safety related inputs The fun
32. ht click the right hand plug in slot of the relay and choose 2080 IOAOBA egoseot eoe e 2 Le 2080 104 2080 OB4 TIP The 1 0 module is shown in standard gray because it is not a safety 1 0 module That is permissible in this application because it is not used to connect safety rated signals Inputs such as Reset buttons and Feedback are not safety rated signals By using the standard 1 0 plug in module for these non safety signals you can reserve the limited number of safety inputs and outputs for safety rated signals 12 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay 6 Click Edit Logic to open the function block editor workspace C Guardmaster 440C CR30 Guardmaster 440C CR30 x Device Toolbox Quick Tips i Verify Download Upload Build 440C CR30 22BBB Verification ID Remote Irogral 07 Ate treater Mode T B Fault di wil aep fs ik If you don t see the Toolbox click View and choose Toolbox Configure the Inputs Follow these steps to configure the input safety monitoring functions 1 Click and drag an Emergency Stop Safety Monitoring function SMF from the Toolbox to the upper left hand Safety Monitoring target block in the logic editor Project3 Connected Components Workbench Standard Edition Administrator File Edit View Build De
33. ht curtain the light curtain turns its two OSSD outputs OFF These signals are connected to the safety input terminals of the 440C CR30 safety relay When the light curtains OSSD outputs turn OFF the safety relay responds by turning OFF its own redundant safety outputs This action removes the 24V signal from the coils of the two safety contactors whose main motor contacts then open thus removing power from the motor This action causes the motor to coast to a stop Stop Category 0 Stopped is the safe state The 100S C safety contactors are the final control devices 24V signal is passed through mechanically linked normally closed N C auxiliary contacts of the 100S C contactors to inputs on the 440C CR30 safety relay enabling the relay to monitor the status of the main contacts This 24V feedback monitoring signal is only present at the safety relay s inputs if the main contacts are open meaning that the contactors are in a safe state If one of the main motor contacts is welded shut the auxiliary N C contacts are held open by the mechanical linkage and the 24V feedback signal does not reach the inputs of the safety relay The safety relay does NOT reset under this condition The failed contactor would have to be replaced After the load clears the light curtain the light curtains OSSD outputs turn ON When the safety relay detects these signals and the feedback monitoring signal when no faults are detected and the reset push button is pr
34. l Automation Publication SAFETY AT138B EN P May 2015 21 Safety Function Light Curtain and Configurable Safety Relay 3 Configure the Type Filter and Value for each LED status indicator as shown in Table 1 Guardmaster440C_CR30 gt lt Seme Quick Tips Device Toolbox Guardmaster 440C CR30 Guardmaster_440C_CR30 n t Download Upload Secure Edit Logic Build Verify 440C CR30 22BBB 5 Verification 10 SE Remote Mode Fault 4 Safety Relay Safety Relay LED Configuration Input LEDs LED Configuration Fic minal Status Terminal 00 Modbus Mapping a mmm Backup Restore gt 4 Plug In Modules af Not Used NotUsed 7 Empty Terminal Status h 2080 IQ4 OB4 3 Safety Monitoring Function Status Safety Output Function Status Not Used IN Used Table 1 Status Indicator Settings Confirm the Validity of the Build Follow these steps to confirm the validity of the logic by using the Build feature in Connected Components Workbench software 1 Click Guardmaster_440C_CR30 in the bar above the Workspace 22 Rockwell Automation Publication SAFETY AT138B EN P May 2015 2 Click Build Safety Function Light Curtain and Configurable Safety Relay Guard ma ster_440 cc R30 Lo gic Guardmaster 440C CR30 Guardmaster 440C CR30 Guardmaster 440C x Device Toolbox
35. lautomation com rockwellautomation about us sustainability ethics product environmental compliance page Allen Bradley Connected Components Workbench Guardmaster GuardShield LISTEN THINK SOLVE Rockwell Automation and Rockwell Software are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y Istanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication SAFETY AT138B EN P May 2015 Supersedes Publication SAFETY AT138A EN P February 2015 Copyright 2015 Rockwell Automation Inc All rights reserved Printed in the U S A
36. machine begins to operate Use a test rod included with the light curtain to interrupt the light curtain protective field The safety system must trip The machine must stop in less than 0 41 seconds N 13 14 15 16 7 1 system response time plus maximum stopping time The 440C CR30 relay s OUT 0 status indicator LED must turn OFF While interrupting the light curtain with the test rod press and release the Reset button The 440C CR30 relay must not respond Clear the light curtain The machine must not start The 440C CR30 relay must not respond the OUT 0 status indicator LED must remain OFF Press and release the Reset button The OUT 0 status indicator LED must turn ON The machine must not start Use the standard control system to start the machine again Confirm that the motor starts and the machine begins to operate Normal Light Curtain Verification 18 19 20 1 2 Changes Modifications Confirm that access to the hazardous machine parts is only possible via passage through the protective field of the GuardShield light curtain Confirm that the distance from the light curtain to any hazard in the cell is greater than the calculated safety distance of the application Confirm that the optic front covers of both the light curtain transmitter and receiver are neither scratched nor dirty Disconnect 24V power from the light curtain and confirm that the 440C CR30 relay trips Reconnect 24V power to t
37. n be actuated for no more than 1 333 333 cycles It would then need Rockwell Automation Publication SAFETY AT138B EN P May 2015 27 Safety Function Light Curtain and Configurable Safety Relay to be replaced To convert this into a time period we divide by the number of operations For example if we expect that the light curtain will be interrupted every ten minutes that is 6 times per hour in an application that will operate 24 hours per day 365 days per year the total number of operations annual cycles of the 100S C contactors would be 52 560 cycles per year Number of Operations nop 6 operations hour x 24 hours day x 365 days year 52 560 cycles per year T10d B10d nop 1 333 333 52 560 25 4 years This means that the operation time of these components is limited to 25 4 years Since 25 4 years are longer than the typical estimated system lifetime of 20 years this number of operations is acceptable However if operation was more frequent there would be a challenge As an example here are the same calculations if we expected the light curtain to be interrupted every five minutes instead of every ten minutes with 24 7 365 operation Number of Operations nop 12 operations hour x 24 hours day x 365 days year 105 120 cycles per year T10d B10d nop 1 333 333 105 120 12 7 years Because 12 7 years are less than the typical system lifetime of 20 years the user of the machine must be instructed to replace the 100S C
38. n the machine stopping time plus the safety system total reaction time C the intrusion distance in millimeters mm For the purposes of this example we use the following values K 2000 mm per second or when S gt 500 mm K 1600 mm per second when using the latter a minimum S of 500 mm must be used T 410 ms 300 ms machine stopping time 20 ms light curtain 45 ms 440C CR30 relay 45 ms and K2 contactors IMPORTANT The specific machine stopping time must be measured for each application C 0 mm 8 x 4 14 but not less than 0 where d is the resolution of the light curtain d 14 mm S Kx T C 2000 mm s x 0 41 s 0 mm 820 mm Since 820 mm gt 500 mm we repeat the calculation using K 1600 mm s S KxT C 1600 mm s x 0 41 s 0 mm 656 mm IMPORTANT If the calculation of S results in a value less than 500 mm when using K 1600 mm s a safety distance of 500 mm must be used The light curtain must not be mounted closer than 656 mm approx 26 in from the hazardous motion being guarded against IMPORTANT For Point of Operation Control Light Curtain applications the machine stopping time is critical the machine must be capable of stopping in a very short period of time In the example we use a machine stopping time of 300 ms The machine must stop within 300 ms every time to be able to use this number By comparison if the stopping time was 500 ms the safety distance would be 976 mm The
39. om the motor Using an AND function configures the outputs of the 440C CR30 relay to turn ON allowing the system to run when the E Stop is closed that is when the N C E Stop button is released and clear and the light curtain is also clear 1 In the Toolbox under the Logic Functions click and drag an AND logic block onto the first Logic Level A target block oolbox 1l X Guardmaster 440 Logic gt lt Device Toolbox 4 Safety Monitoring Functions b J a Pointer Emergency Stop Safety Monitoring Logic Level A Enabling Switch Feedback Monitoring Gate Switch a o Emergency Stop 1 amp Light Curtain EL 01 6 Muting Reset Restart Test Source A g Safety Mats Test B 13 SensaGuard Single Wire Safety Input Advanced Settings Two Hand Control HESZ QGO U mu Alternative Device r 4 Logic Functions lh Pointer e El Light_Curtain 1 OR EI 03 ve XOR NAND NOR NOT Advanced Settings 5 AND with Restart gt OR with Restart OY uu 2 Click the output connection of the E Stop SMF 1 which is the blue dot on the right of the block The dot turns light gray indicating that it is selected 16 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay 3 Click the first input connection blue dot of the AND block to conne
40. onnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired 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 WARNING 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 ATTENTION 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 consequen
41. operate and troubleshoot a Guardmaster 440C CR30 configurable safety relay Provides information on how to properly mount configure install commission operate and maintain the GuardShield safety light curtain Provides instructions on how to install 100S C safety contactors Provides general guidelines on how to install a Rockwell Automation industrial system Provides information about Rockwell Automation safety products Provides declarations of conformity certificates and other certification details You can view or download publications at http www rockwellautomation com literature order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative 36 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay Notes Rockwell Automation Publication SAFETY AT138B EN P May 2015 37 Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature For more information on Safety Function Capabilities visit http marketing rockwellautomation com safety en safety functions Rockwell Automation maintains current product environmental information on its website at http www rockwel
42. ry function and the high reliability demonstrated in extensive use to allow the E Stop to be used in systems requiring PLe A Fault Exclusion subsystem has been included in the SISTEMA project to document this consideration Because these are electro mechanical devices the safety contactor data includes the following e Mean Time to Failure dangerous MTTFd e Diagnostic Coverage DCavg e Common Cause Failure CCF Electro mechanical devices functional safety evaluations include the following How frequently they are operated e Whether they are effectively monitored for faults e Whether they are properly specified and installed SISTEMA calculates the MT TFd by using B10d data provided for the contactors along with the estimated frequency of use entered during the creation of the SISTEMA project The B10d data affects not only the MT TFd but also the expected lifetime of the electro mechanical safety device B10d is defined as the number of cycles until 1096 of the components fail dangerously and is determined through extensive testing by the manufacturer of the component According to Annex C 4 2 of ISO 13849 1 the operating time of a device must not exceed the T 10d the mean time it takes for 1096 of the components in the system to have a dangerous failure following the equation T10d B10d number of operations For the 100S C contactors used in this application the B10d is 1 333 333 cycles For a safety application this device ca
43. s and release the Reset button Nothing changes Cycle power to the light curtain Approximately five seconds after power is restored to the light curtain its outputs turn ON Press and release the Reset button The 440C CR30 relay OUT 0 status indicator LED should turn ON Jump OSSD 1 to DC The light curtain detects the fault immediately and turns OFF its OSSDs The light curtain indicates the fault on its status indicator LEDs red LED 10 flashing orange LED ON The 440C CR30 relay trips 11 Remove the jumper Neither the light curtain nor the 440C CR30 relay responds Press and release the Reset button Nothing changes 2 Cycle power to the light curtain Approximately five seconds after power is restored to the light curtain its outputs turn ON 2 Rockwell Automation Publication SAFETY AT138B EN P May 2015 1 UJ Safety Function Light Curtain and Configurable Safety Relay 13 Press and release the Reset button The 440C CR30 relay s OUT 0 status indicator LED should turn ON 14 to 27 Repeat steps 1 through 13 using El_03 for El_02 and OSSD 2 for OSSD 1 28 Jump OSSD 1 to OSSD 2 terminal El_02 to terminal El 03 Interrupt and then clear the light curtain When the light curtain attempts to turn its OSSDs ON the short circuit between the channels is detected and it turns its outputs OFF The 440C CR30 relay trips The light curtain indicates the fault on its status indicator LEDs red LED flashing orange LE
44. signals are correct no faults are detected and the reset push button is pressed for 0 25 to 3 0 seconds and released the 440C CR30 relay turns its safety outputs ON providing power to the contactor coils 4 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay Bill of Material This application uses these products 440C CR30 22BBB Guardmaster 440C CR30 software configured safety relay PLe SIL 3 22 safety 1 0 embedded serial port USB 1 programming port 2 plug in slots 24V DC 889D F4AC 5 DC Micro M12 female straight 4 pin PVC cable yellow unshielded 22 AWG 5 meter 16 4 feet 1 889D F8AB 5 DC Micro M12 female straight 8 Pin PVC cable black unshielded 24 AWG 5 meter 16 4 feet 1 800FP MT44PX02S 800F non Illuminated mushroom operators twist to release 40 mm round plastic type 4 4X 13 IP66 red plastic latch 1 mount 0 N O contacts 2 N C contacts self monitoring standard pack 800FP F611PX10 800F push button plastic flush blue R plastic latch mount 1 N 0 contacts 0 N C contacts standard standard pack 1 1005 9 23 MCS 1005 safety contactor 9 A 24V DC with electronic coil 2 Setup and Wiring For detailed information on installing and wiring refer to the publications listed in the Additional Resources on the back cover System Overview When an object such as the operator s hand interrupts the lig
45. tance between the transmitter and the receiver using an aperture angle of 2 5 or take the appropriate value from the following table Distance between transmitter Minimum distance to reflecting and receiver m ft surface mm in 0 2 3 0 0 65 9 8 135 5 31 4 0 13 1 175 6 88 5 0 16 4 220 8 66 6 0 19 6 265 10 43 7 0 22 9 310 12 2 10 0 32 8 440 17 32 16 0 52 4 700 27 55 Rockwell Automation Publication SAFETY AT138B EN P 2015 9 Safety Function Light Curtain and Configurable Safety Relay Electrical Schematic 24V DC Class 2 800Fx MTx 440L Transmitter Receiver Brown Brown Pink Gray Green Blue Blue Reset OQ 800Fx F6x K1 440C CR30 22BBB A1 A2 440C CR30 2080 IQ4OB4 l 00 Plug in 1 0 Slot 2 100S CxxEJx 2 r DC COM L1 L2 L3 S SK KF External Switched i Stop Start Circuit S0 13849 2 requires transient suppression across the load as a Basic Safety Principal The EJ electronic coil provides suitable suppression 10 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay Configuration Configure the Input and Output Devices The light curtain uses the standard default configuration If the configuration DIP switches may have been changed refer to the GuardShield Type 4 and GuardShield Remote Teach User Manual publication
46. tected When a fault is detected the safety relay responds by turning its safety outputs OFF taking the system to a safe state The 440C CR30 safety relay checks itself for internal faults and turns its outputs off if any are detected No single fault results in the safety system failing to perform its safety function A single fault is detected before or upon the next demand on the safety system The system cannot be reset until the fault is corrected When a light curtain is used additional mechanical protective devices must be installed so that hazardous machine elements cannot be reached by personnel or material without first passing through the protective field of the light curtain For example the entire rest of the hazardous cell should be surrounded by expanded metal fencing of sufficient height and or interlocked gates including the area above and beneath the protective area of the light curtain if it would otherwise be possible for a person to access the hazard through these spaces Refer to the relevant standards and the GuardShield Type 4 and GuardShield Remote Teach User Manual publication 440L UM003 for additional information on how to position the light curtain The selection of light curtain model protective height resolution and other specifications is dependent on the results of the risk assessment for the specific application Refer to the relevant standards and the GuardShield Type 4 and GuardShield Remote Teach User Manu
47. ter CRI Logic a Palety Monitoring Furcctionr k Pane o Emeegency 1 Enable Saleh Bb feedback E Gate faih H Light Curban Sei Sale ul BA Tao Flos zo Ahiri Des a Logic Functions lh Pone D AND D os D HAND Le HOF HOT D AMD wath Peces gt GE wath Fenat al Sate Fonction Rieks B cia OFF ON Bey x OFF Dali NE 8 Mutina Lamo Monitore uno a o Emergency 5topl in rE Tet 17 lei L 2 02 E H Light Curtaim 1 i TO o 4 On the Reset SMF 3 click the input terminal EI 04 and select Plug in 2 Inputs P2 00 14 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay Note that the reset come from a standard plug in input or even from the serial port via a Modbus message SMF 3 Configure the Outputs Follow these steps to configure the Safety Output Function SOF 1 In the Toolbox under Safety Output Function Blocks click and drag Immediate OFF to the first Safety Output function target on the logic editor 0 amp Oe s ay a T rx L 5 E TP P s rea E ama om on um oo ate 1 F we us Bos ri
48. turn OFF Press and release the Reset button The 440C CR30 relay s OUT 0 status indicator LED should turn ON Use the standard control system to start the machine Confirm that the motor starts and the machine begins to operate This step is optional in the following E Stop and GuardShield validation tests 2 3 4 5 While the motor is running jump the E Stop input wire at terminal MP_12 to terminal El 00 of the 440C CR30 relay The 440C CR30 relay should not respond Press the E Stop button The 440C CR30 relay must trip immediately The 440C CR30 relay s OUT 0 status indicator LED must turn OFF The red Fault status indicator LED of the 440C CR30 relay must flash Release the E Stop button Press and release the Reset button The 440C CR30 relay must not respond Remove the jumper The 440C CR30 relay must not respond Press and release the Reset button The 440C CR30 relay must not respond Cyde the E Stop The red Fault status indicator LED should turn OFF Press and release the Reset button The 440C CR30 relay s OUT 0 status indicator LED should turn ON Short the E Stop input wire at terminal El 00 of the 440C CR30 relay to 24V DC After approximately five seconds the 440C CR30 relay must trip The red Fault status 10 11 indicator LED of the 440C CR30 relay must flash Remove the jumper The 440C CR30 relay must not respond Press and release the Reset button The 440C CR30 relay must not respond Cy
49. urable Safety Relay 2 In the Feedback function block change the number of inputs from 1 to 2 by selecting 2 from the pull down menu The software adds an additional input and automatically assigns the next available terminal SMF 4 E04 e Feedback 1 Inputs EE H p PME Settindk A 3 Click the first input terminal currently assigned EI_04 and change it to Plug In 2 Inputs 01 4 Click the second input terminal EI_05 and change it to Plug In 2 Inputs 02 SMF 4 P2 01 d Feedback 1 5 To associate this Feedback SMF with the Safety Output Function on the Immediate OFF SOF 1 click the pull down menu next to Feedback and change it from None to SMF 4 which is the Feedback Monitoring block Safety Output SOF 1 ik Immediate OFF 1 e 9EO18 PT e 19 PT Feedback Reset Type Reset Input 20 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay The complete logic configuration looks like this Configure the Status Indicators The LEDs on the 440C CR30 relay can easily be configured per your preference to show more information than typical status LEDs To configure the LED status indicators follow these steps 1 Click the Guardmaster_440C_CR30 Project tab on the Workspace Quick Ti m Device To alb Guardmaster 440C CR30 2 Click LED Configuration on the lower left Rockwel
50. vice Toolbox Guardmaster 440C_CR30 Logic Guardmaster 440C CR30 2 Connected Guardmaster 440C CR30 5 7 d lad Download Upload Edit Logic Build Verify 3 Click Verify GUARDMASTER CR30 Logic GUARDMASTER Quick Tips Device Toolbox Guardmaster 440C CR30 Guardmaster 440C CR30 t F Download Upload Edit Logic Build 440C CR30 77BBB Verification ID Remote Fault 4 Answer all the questions and check each box if completed Connected Components Workbench fave you followed installation instructions and precautions to conform to applicable safety standards EX HBve you verified that the electrical specifications of the sensor and inputs are compatible fave you verified that the electrical specifications of the outputs and the actuators are compatible EX fave you calculated the system s safety response time for each safety chain EX he system response time in proper relation to the process tolerance time probability PFD PFH PLx values been calculated according to the system s configuration EX e you performed all appropriate functional verification tests on the system Safety Verification ID IMPORTANT Allofthe boxes must be marked in order to generate the Verification ID 34 Rockwell Automation Publication SAFETY AT138B EN P May 2015 Safety Function Light Curtain and Configurable Safety Relay 5 Click Generate 6 Cli
51. y Function Light Curtain and Configurable Safety Relay open and therefore no power is reaching the motor which is considered a safe state That portion of the wiring schematic is shown below 24V DC Plug in 1 0 Slot 2 External Switched i Stop Start Circuit For the 440C CR30 relay Feedback Monitoring is configured as a Safety Monitoring Function SMF that is subsequently associated with a Safety Output Function SOF 1 In the Toolbox under Safety Monitoring Functions click and drag Feedback Monitoring to the target block underneath the Reset block Toolbox Guardmaster 440 CR30 Logic gt lt Device 4 Safety Monitoring Functions b Pointer o Emergency Stop 1 Enabling Switch Gate Switch Light Curtain EX Muting Reset Festart i Safety Mats SensaGuard nn Single Wire Safety Input Z4 Two Hand Control Feedback 1 Alternative Device Advanced Settings wt SMF 4 4 Logic Functions b Pointer AND Inputs 1 Advanced Settings XOR c Connected Components Workbench software automatically assigns the next available terminal In this application the feedback monitoring circuit is wired into plug in inputs 01 and 02 so you must change the configuration of this SMF and the terminal assignments Rockwell Automation Publication SAFETY AT138B EN P May 2015 19 Safety Function Light Curtain and Config

Safety Function - Rockwell Automation

Contents

Download Pdf Manuals

Related Search

Related Contents