SafeZone Scanner with a Configurable Safety Relay
Contents
1. Output CO ae LE eee ra E Stop 1 E Stop 2 440 CR30 Relay Subsystem 1 Subsystem 2 Subsystem 3 eM E a l fa ia ee E a The presence sensing SafeZone laser scanner safety function can be modeled as follows Input Logic Output Relay Laser Scanner SafeZone 440C CR30 Subsystem 1 Subsystem 2 Subsystem 3 L ey e eee a e a a E aa 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 e How frequently they are operated e Whether they are effectively monitored for faults e Whether they are properly specified and installed SISTEMA calculates the MTTFd by using B10d data provided for the contactors along with the estimated frequency of use entered during the creation of the SISTEMA project 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 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 sc2. NHP Safety Reference Guide gt Safety Function Documents 440C 6A 9 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Configure the SafeZone Laser Scanner cont 13 To verify that your programmed field is running select the Data Recorder in the Diagnostic group Pine Device Shone Type code 17 SFI A Atten Bradiey Desce denmpior EN A A E EE PE AEEA ES as taza ae hig PEE EON BDO os we Py ETID SF ee EIN e O8O 8000 k oy Corien d Bytie perii E Faciam i F akip DF irgi Re a Apg sem chagante a SF 0S0 GF Racial OF Faskd cei OF Cate Ci Tiir r Piiri tiitar Cakir j aj rbk e eb irea air aand ct The SCD software displays a real time view of the status of the warning and protective fields you configured Configure the 440C CR30 Relay The 440C CR30 relay is configured by using Connected Components Workbench software release 6 01 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 the Connected Components Workbench software 1 In Connected Components Workbench software choose Vie
3. l El O1 7 a Test Source Ac 12 Test Source 13 advanced Settings Connected Components Workbench software has assigned input terminals El_00 and El_01 on the left side of the block The software automatically assigns the next unused terminal for a newly added device The terminals can be changed to any unused input terminal but in this case leave the default Because an E Stop is an electro mechanical device the software has automatically added terminals 12 and 13 as test sources Numbers 12 and 13 refer to multipurpose terminals 12 and 13 MP_12 and MP_13 3 Toadd the Scanner monitoring block use a Light curtain block for the scanner because it also uses OSSD type outputs 4 Choose inputs El_08 and El_09 for the scanner yW E1 05 ze e z H Legh Cartan Hn e a aaee Selig Distrenancy Time emake Tripak Filter et Sarre d ak ak a NHP Safety Reference Guide gt Safety Function Documents 440C 6A 11 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Configure the Inputs cont 5 Adda Reset Reset Restart J Safety Mats 6 Change the Reset input to Plug In input P1_00 to complete the configuration of the inputs SMF 3 Ao e e Q Reset 7 Add a Feedback Monitoring inp
4. Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Verification and Validation Checklist E Stop Safety Function GENERAL MACHINERY INFORMATION Machine Name Model Number Customer Name Test Date Tester Name s Schematic Drawing Number Configurable Safety Relay Safety Wiring and Relay Configuration Verification 1 Visually inspect the safety relay circuit to verify that it is wired as documented in the schematics aa 2 Visually inspect the 440C CR30 rotary switch settings to verify that they are correct as documented ia Normal Operation Verification The safety system responds properly to all normal Start Stop E Stop and Reset commands Initiate a Start command Both contactors energize for a normal machine run condition Verify proper machine status indication and 440C CR30 relay status indication gt Initiate a Stop command Both contactors de energize for a normal machine Stop condition Verify proper machine status indication and 440C CR30 relay status indication 3 While the system is running press the E Stop button Both contactors deenergize and open for a normal safe condition Verify proper machine status indication and 440C CR30 relay status indication Repeat for all E Stop buttons 4 While the system is stopped press the E Stop button and initiate a Start command Bot
5. Subtvilems Documentation Pu PL PL PRR Lh CEF iioie Drg fal ATF Category Requitements of ihe categ fey Library G Sialus Type Name W gt E Prevence Serrit SaleZone 4431 5 re 4005 E T opel nelever nol ein ul pete J Pied E new x ZA Sofware Contiqueable Satety Belay a4el Ce so 16S ed Garmas a 4 tamileg s7 58 100 Contactors e SOREL SS fulfilled High 2500 High 4 Fuso idee d Cae Ui Dei F The Performance Level and Category achieved by each subsystem of the emergency stop safety function as calculated by SISTEMA is shown below Safety function w IFA Dasumentation pu pL Sunne MITFa fa Category Requirements ol the categ Pi PFH Mh COF arare icma Fe 2 uibrary G Stas Type Mams ros SE Estap F AEA AS puie 2 High LOD High 3 Puttar i Her J a So Seltware Conliguradle Safely Relay 4400 CR z LES me raii ef reiewur wi reterani 4 Pulisi ow 56 1005 Contactor z Q05E10 G5 puhiedj Faji 00 Bigh 4 fuit ed NHP Safety Reference Guide gt Safety Function Documents 440C 6A 17 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Calculation of the Performance Level cont The E Stop safety function can be modeled as follows Input Logic
6. Verify LARCELATTER TED Ling Guardmaster 440C cRI0 ARAA AR E 4 Answer all the questions and check each box if completed et you beberle ae ed Bed ba Coe bo peels eek gules Haren een veered Ghat ee cherie al ieee of Re pesos ed et ae Spee Haren ween eee Ghat ee choc paa af Re Gulp eed Be ee re See Hier pees calcelnbed the pba p pph capper brip lor each pole chee Bi GO Poet Bek ot ere cles i the Ste Slee bee het pechuately PP PP La wale Gene cole becca bo th pabati p poanian yiga ren yo Cerrone el ippa Poel ees ee ss Eh ee tl IMPORTANT All of the boxes must be marked in order to Generate the Verification ID 5 Click Generate 6 Click Yes to proceed with the verification Concerted Lurgra Feo beech e Pei perg ri i eel eee er rir rey bo Peper Fuge Phat ceed ee Bet Sete eri 7 Click Yes to change to Run mode 8 Record the Safety Verification ID in the machine s documentation TA Comed Compose Workbench This process is the feedback to the 440C CR30 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 verification actions generate a different verification ID The Safety Verification ID is displayed in Connected Components Workbench software only when you are connected to the 440C CR30 rela
7. 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 Verification and 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 functional 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 NHP Safety Reference Guide gt Safety Function Documents 440C 6A 19 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Verification and Validation Checklist GENERAL MACHINERY INFORMATION Machine Name Model Number Machine Serial Number Customer Name Test Date Tester Name s Schematic Drawing Number Configurable Safety Relay Safety Wiring and Relay Configuration Verific
8. meter RS232 programming cable with USB connector Cat No 442L SFZNMZ 442L CSFZNMZ 10 442L ACUSB 2 Guardmaster 440C CR30 software configured safety relay PLe SIL 3 22 safety 1 0 embedded serial port 440CCR30 22BBB USB programming port 2 plug in slots 24V DC 800F 1 hole enclosure E Stop station plastic PG twist to release 60 mm non illuminated 1 N O 2N C Modular Control System MCS 100S C safety contactor 9 A 24V DC with electrical coil bifurcated 2 contact Setup and Wiring For detailed information on installing and wiring refer to the publications listed in the Additional Resources on the back cover 100S CO9EJ23BC System Overview INFORMATION A multizone scanner configured as a singlezone scanner was used in this safety function The Guardmaster 440C CR30 software configurable safety relay monitors the input from the SafeZone laser scanner control and the E Stop The laser scanner control provides two PNP outputs that are de energized when an object interrupts the field of view When an intrusion in the SafeZone sensing area is detected a pair of 100S C safety contactors K1 and K2 are deenergized The contactors are controlled by the 440C CR30 relay These are wired in a redundant configuration and are tested on startup for faults These de energized contactors remove power to the motor and the motor coasts to a stop Stop Category 0 When the laser scanner control returns to
9. standard gray because it is not a safety I O module That is not a problem in this application because the standard I O module is not used to connect safety signals Inputs such as Feedback and Reset button are not considered strict safety signals By using the standard I O module for these non safety signals you can reserve the limited number of safety inputs and outputs for true safety signals 5 Click Edit Logic to open the Connected Components Workbench Workspace 6 From the View pull down menu choose Toolbox lt Solely Monitoring Fences Guardmaster 440C CR30 R Pointer a Emergency Stop Guardmaster _440C CR30 Enabling Switch BR Feedback Monitoring IHI Gate Switch H Light Cuttain 3 Muting 440C CR30 22BBB rex Verification I O feurt Remote En Safety Mats Mode na Single Wire Safety Input Fault 2 Two Hand Control Alternative Device a Loge Functions TTN NNN NNN k Pointer Configure the Inputs Follow these steps to configure the inputs 1 Select Emergency Stop Toolbox O Guadmaster dtt ORS0 Logic x DSTI GE soe meee d Salety Momtoine Fumcoorm Ua Cm ri k Porter Emergency Stop Enabling Saath Feriak Montane babe Switch Light Curtain Muting Safety Whenitoring Paenare M E EEEE a Fettmi 2 Drag Emergency Stop to the green rectangle under Safety Monitoring and release it safety Monitoring EI 00 zE 6 Emigency Ei faca
10. 440C SAFETY FUNCTION DOCUMENTS SafeZone Scanner with a Configurable Safety Relay NHP SAFETY REFERENCE GUIDE Authorised Distributor AB uny Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Table of Contents Important User Information 3 Introduction te 3 Safety Function Realization Risk Assessment 5 Area Scanner Single Zone Safety Function 5 Safety Function Requirements 5 Functional Safety Description 5 Configuration ie 7 Calculation of the Performance Level 7 Verification and Validation Plan 19 Verification of the Configuration 22 Additional Resources 23 i Authorised Distributor v NHP Safety Reference Guide gt Safety Function Documents 440C 6A 2 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Introduction This safety function application technique explains how to wire and configure a Guardmaster 440C CR30 configurable safety relay to monitor both an E Stop and a SafeZone laser scanner If an object intrudes into the SafeZone laser scanner sensing field if the E Stop is actu
11. Bee aa ait wa Project 1 Flea Serial communication AK 512 6 To configure the scanner right click the scanner and choose Open device window wa Project 1 l ata Seral communication AK 512 Ki io EE pen device window Access rights e Configuration draft b Safezone Safezone Create development dump Restart device Delete device The device window opens This window provides the Arc drawing tool which lets you configure the protective and warning fields for your facility plaia itt anes Pe tn caas aa d a 7 Qe FHS the i i 7 ey NHP Safety Reference Guide gt Safety Function Documents 440C 6A 8 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Configure the SafeZone Laser Scanner cont 7 To configure the protective and warning field use the Arc drawing tool Th sa Sem 8 D NTE Sie Eear umre Tamina ire ere be ae meae m eter br msr ge mra e el nar ir A tyne pa Rasam e pats oes hia eit joan I geile egua tikgan AR Ew Mai of e J bimi paa m p Da P a E m la y i a yf Derme r gt ee E i 8 When you finish configuring the protective and warning field click Transfer to transfer the information to the scan
12. aser Scanner While the system is running remove the channel 1 wire from the input El_08 Both contactors de energize Verify proper machine status indication and 440C CR30 relay status indication Repeat for channel 2 gt While the system is running short channel 1 terminal El_ 08 of the 440C CR30 relay to 24V DC Both contactors de energize Verify proper machine status indication and 440CCR30 relay status indication Repeat for channel 2 While the system is running short channel 1 terminal El_ 08 of the 440C CR30 relay to OV DC Both contactors de energize Verify proper machine status indication and 440CCR30 relay status indication Repeat for channel 2 While the system is running short channels 1 and 2 terminal El_08 and 09 of the 440C CR30 relay Both contactors are de energized Verify proper machinestatus indication and 440C CR30 relay status indication Validation of Safe Response to Abnormal Operation The safety system responds properly to all foreseeable faults with corresponding diagnostics Safety Contactor Output Tests While the system is running remove the contactor feedback from the safety relay All contactors remain energized Initiate a Stop command followed by a Reset command The relay does not restart or reset Verify proper machine status indication and 440CCR30 relay status indication NHP Safety Reference Guide gt Safety Function Documents 440C 6A 20 Safety Function Documents 440C Safety Related
13. ated or if a fault is detected in the monitoring circuit the 440C CR30 relay de energizes the final control devices in this case a pair of 100S C safety contactors The safety scanner can be used in either vertical or horizontal applications to detect the intrusion of personnel or objects into the sensing field You configure the safety scanner s warning and safety fields by using the Safety Configuration and Diagnostics SCD software supplied with each scanner 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 personnel 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 illus
14. ation 1 Visually inspect the 440C CR30 circuit to verify that it is wired as documented in the schematics a 2 Visually inspect the SafeZone laser scanner to verify that it is wired as documented an Normal Operation Verification The 440C CR30 configurable safety relay responds properly to all normal Start Stop Reset and E Stop commands i Initiate a Start command Both contactors energize for a normal machine run condition Verify proper machine status indication and 440C CR30 relay status indication 2 Initiate a Stop command Both contactors de energize for a normal machine Stop condition Verify proper machine status indication and 440C CR30 relay status indication 3 While the system is running interrupt the SafeZone laser scanner Both contactors are de energized and open for a normal safe condition Verify proper machine status indication and 440C CR30 relay status indication if configured 4 While the system is stopped interrupt the SafeZone laser scanner and initiate a Start command Both contactors remain de energized and open for a normal safe condition Verify proper machine status indication and 440C CR30 relay status indication 5 Initiate a Reset command Both contactors remain de energized Verify proper machine status indication and 440C CR30 relay status o indication Validation of Safe Response to Abnormal Operation The safety system responds properly to all foreseeable faults with corresponding diagnostics SafeZone L
15. ation industrial system Safety Products Catalog publication 117 CA001 website http www rockwellautomation com rockwellautomation catalogs overview page Product Certifications website available from the Provides declarations of conformity certificates and Product Certifications link on http www ab com other certification details Provides information about Rockwell Automation safety products You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative NHP Safety Reference Guide gt Safety Function Documents 440C 6A 23 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 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 DUOO02 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 rockw
16. d 1 The Scanner inputs are displayed on LED 2 and 3 LED 4 and 5 display the status of the Reset and Feedback monitoring blocks 5 Configure the remaining Input LED status indicators as shown 6 Configure the Output LED status indicators as shown Output LEDs LED Type Fi Filter Cc m K1 Coil K2 Coil E Stop SOF 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 2 Click Build Buaniniaaies 440c cR30 Guardmaster_440C_CR3I0 Hanigan A a a a G A Build Succeeded message confirms that the configuration is valid tpt nee ie cha Balt LP og fhe ied cad wild startes Free Safrty Aelay foin Prgj ETETE Belid Su c68e0 eons If an error or omission is discovered during a build a message is displayed that details the error so that it can be corrected After you correct the error you need to perform the build again NHP Safety Reference Guide gt Safety Function Documents 440C 6A 14 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Save and Download the Project 6 Inthe Connection Brow
17. ellautomation com rockwellautomation about us sustainability ethics product environmental compliance page NHP Safety Reference Guide gt Safety Function Documents 440C 6A 24 Safety Function Document Disclaimer The information contained in this and any related publications is intended as a guide only Every care has been taken to ensure that the information given is accurate at time of publication Neither NHP nor any of the manufacturers portrayed in this and any related publications accept responsibility for any errors or omissions contained therein nor any misapplications resulting from such errors or omissions Risk assessments should be conducted by authorized persons The purchaser and installer are responsible for ensuring the safety system s incorporating these products complies with all current regulations and applicable standards Products are subject to change without notice and may differ from any illustration s provided All products offered for sale are subject to NHP standard Conditions of Sale a copy of which is available on application NHP Safety Reference Guide gt Safety Function Documents 440C 6A 25
18. h contactors remain de energized and open for a normal safe condition Verify proper machine status indication and 440C CR30 relay status indication Repeat for all E Stop buttons 5 Initiate a Reset command Both contactors remain de energized Verify proper machine status indication and 440C CR30 relay status a indication Validation of Safe Response to Abnormal Operation The safety system responds properly to all foreseeable faults with corresponding diagnostics E Stop Input Tests While the system is running remove the channel 1 El_ 00 wire from the 440CCR30 relay input Both contactors de energize Verify proper machine status indication and 440CCR30 relay status indication Repeat for channel 2 gt While the system is running short channel 1 terminal El_00 to 24V DC Both contactors de energize Verify proper machine status indication and 440CCR30 relay status indication Repeat for channel 2 3 While the system is running short channel 1 terminal El_00 to OV DC Both contactors de energize Verify proper machine status indication and 440CCR30 relay status indication Repeat for channel 2 4 While the system is running short channel 1 and 2 El_00 to El_01 Both contactors de energize Verify proper machine status indication and 440CCR30 relay status indication Validation of Safe Response to Abnormal Operation The safety system responds properly to all foreseeable faults with corresponding diagnostics Safety Contactor Outpu
19. hat 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 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 Level on page 24 and Verification and Validation Plan on page 26 before proceeding with Verification of the Configuration on page 29 NHP Safety Reference Guide gt Safety Function Documents 440C 6A 16 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Calculation of the Performance Level When properly implemented these safety functions can achieve a safety rating of Category 3 Performance Level d CAT 3 PLd according to ISO 13849 1 2008 as calculated by using the SISTEMA software PL calculation tool Project WI IFA Safety functions Type PLr PL Status Type Mame Safe stop initiated by presence in the protective area of the single zone 4 d d e y SF l Edit ili y SF Emergency stop initiated by actuation of an emergency push button The Performance Level and Category achieved by each subsystem of the SafeZone laser scanner safety function as calculated by SISTEMA is shown below wy IFA Safety function
20. ical 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 gt gt Contact NHP to find out more about our safety risk assessment services 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 ATTENTION Perform a risk assessment to make sure all task and hazard combinations have been identified and addressed The risk distance calculations which are not part of the scope of this document NHP Safe
21. ion Documents 440C 6A 12 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Configure the Logic The logic ties the inputs to the outputs making the outputs respond to the inputs in the manner required Add an AND function to the Logic Level A Click the blue dot on the E Stop input block and notice that the dot turns gray Click the blue dot on the LLA1 block to connect the blocks Connect the output of the Light Curtain block SMF 2 to LLA1 Connect the output of the LLA1 block to the input of the Immediate OFF block SOF 1 The software automatically adds the Pass Through blocks because no additional Logic Functions are being used a e YS The completed logic looks like this hahrty tWerregrteng bipi brr A agen irer fates Chet i Te Lie k j mi ma as n b Buy as fer Ll ED x FT retary Moe ATi a i if r a Lil on 13 aT 1a Of Pa 7 k Peediact Wall 4 Tet eee A LD age J Are tpr Wims Ti amp LE a r eu Inge T j NHP Safety Reference Guide gt Safety Function Documents 440C 6A 13 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contacto
22. n initiated by actuation of an E Stop button Safety Function Requirements Interrupting the configured sensing zone of the laser scanner stops and prevents hazardous motion by removing power to the motor The motor coasts to a stop Stop Category 0 When the scanner is reset hazardous motion and power to the motor do not resume until a secondary action occurs the Start button is depressed A fault at the laser scanner is detected before the next safety demand The safe distance from the location of the laser scanner to the hazard must be established per ISO 13855 2010 such that hazardous motion must be stopped before the user can reach the hazard Pressing the E Stop button stops hazardous motion by removing power to the motor Releasing the E Stop does not restart hazardous motion Once the Reset button is pressed and all faults are cleared the system is enabled to accept a separate Start command The safety functions in this application technique each meet 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 sensing field of the SafeZone laser scanner The laser scanner and the E Stop are connected to the Guardmaster 440C CR30 software configurable safety relay The 440C CR30 relay provides two solid state safety outputs that control power to the 100S C contac
23. ner The Transfer dialog box appears de hs pea Seve be mien ihe neers eo fF 9 Click Yes A Progress dialog box appears and displays warning notices for the parameters you set for the scanner Saluton BA Saa Taden zady reiri Coretule check fhe iori aber ody zj D iora Faad feki os 1 i A iia Pemirg iek dala OP ie Fading ora Gace OD iira Fingdeey orir ten So Ch SateZere Tinlad fail pet 1 10 Review the warning notices make any necessary adjustments to the confirmation and when you are satisfied with the results click Continue A configuration window appears i o a gara TETEET E BD iay Conwell est Rockwell Configuration amp Diagnostic Sothcace Contiguration protocol Safezone from 8 25 2014 17 15 ial jpe ee s Fe san miar min ran Paper San TEF ieee ee ae eke rane et Sof 11 Review the configuration details and if you are satisfied that the configuration meets your requirements click Release A second Progress dialog box appears and displays information about the transfer progress apna Atvamaheerieed ber Hee diver Cotignd de patere Goritered he dete Beto wun Aeontong Dee Toke Li bees i aap Wa aira ar chorea Ser ar bes giera e pria iai i EE b amni xj Cem 12 Once the transfer is complete click Continue The Progress dialog box closes and the application returns you to the main window of the SCD software
24. ore of 65 must be achieved The Emergency Stop function is a complementary protective measure which is intended to be used with other safeguarding measures and protective devices to sufficiently reduce risk The emergency stop function shall be designed not to impair the effectiveness of the 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 PLd 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 NHP Safety Reference Guide gt Safety Function Documents 440C 6A 18 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 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
25. rs Safety Rating CAT 3 PLd to ISO 13849 1 2008 Configure the Status Indicators The 440C CR30 relay lets you configure ten input status indicators and six output status indicators These status indicators can be very helpful while testing the system during installation and commissioning They are also useful for monitoring the system in operation To configure LED status indicators to show the status of the E Stop Terminals 00 and 01 and SafeZone laser scanner follow these steps 1 Click Guardmaster_440C_CR30 U Projecti Conna File Edit View Debug Tools PENITE iade Heip i Lare a ab r T a aa w L J R Pa i Appian Laren tE as TT 2 aih ty ee TAT Ee a Sofety Monitonng Funcions p minder Emergency Step Enathng Svith Feedback Monitornng EI e Gate Saith B Emam P a a Sal ny Wien coring Light Curtain Hol Sith w E felutimg 2 Select LED configuration 4400 CR30 27E BB 5 Verification I Remote ie A A en Oe a F Safety Relay Serial Port Safety Relay LED Configuration Enact LEDs LED Type Fite Value Modbus Mappang E Pheg in Mioduhen 2080 1Qeae Empty 3 Choose Terminal Status as the Type Filter for LED 0 Safety Felry LED Configuration irapa LEDs LED Type eer Valu 4 Select Terminal 00 as the Value for LED 0 f E E N 2 Temna EE Safety Monkoring Function Sah In this example the E Stop inputs on are displayed on LED 0 an
26. ser expand the AB_VBP 1 Virtual Follow these steps to save and download the project Chassis and select the Guardmaster 440C CR30 22BBB 1 From the File menu choose Save as to save the project INFORMATION Saving the project with a new name closes the workspace windows pty Lira Galamay Ehernat SS h TFL bere 2 Inthe Project Organizer window double click C Fst Guardmaster_440C_CR30 to open the workspace O aiL 3 Power up the 440C CR30 safety relay Connect the USB cable to the 440C CR30 relay 5 Click Download 7 Click OK 8 Click Yes to change from Run to Program mode BS eS Guardmaster 440C CR3I0 Guardmaster 440 CRI0 Connected Components Workbench Salleh peta wh en Pon meit tioc Die pes ward Ge cherie ty aea iiia p Veera Rimae es He a kide 9 When the download is complete click Yes to change from Program to Run mode Dometal Components Workbench Leerrided Compi fn wo wa AS chenge Hha iter rely bach ce Puan recede NHP Safety Reference Guide gt Safety Function Documents 440C 6A 15 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Save and Download the Project cont 10 Click Edit Logic to see the online diagnostics depen Green indicates t
27. supplied with each scanner SCD software revision 3 0 0 is used in this application technique NHP Safety Reference Guide gt Safety Function Documents 440C 6A 7 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Configure the SafeZone Laser Scanner Follow these steps to configure the SafeZone laser scanner 1 Connect the scanner s USB cable to the PC and verify that the correct Com port is set on the PC TIP This example uses the Com2 port 2 Start the SCD software SOD ScD Safety Configuration amp Diagnostic Software Allen Bradley fd 300 CP ges Mee Rackeal 007 00 3 Togo online locate your project and expand Serial communication 4 Right click Com2 and choose Connect ff Test rwr Rockwell Automation SCD Project Edit View Extras Window Help ee ig M oe ee Project 1 Elsa Serial communication RE 512 eal COM ee COM dd device i Identify Comet o WTS GOH eG Greate diagnostics dump v Gonnection active The Configuration software searches for and connects to the scanner 5 Click Continue When the connection is made the scanner name appears in Blue T Test rwr Rockwell Automation SCD Project Edit View Extras Window Help
28. t Tests followed by a Reset command The relay does not restart or reset Verify proper machinestatus indication and 440CCR30 relay status indication While the system is running remove the contactor feedback from the safety relay All contactors remain energized Initiate a Stop command _ NHP Safety Reference Guide gt Safety Function Documents 440C 6A 21 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Verification of the Configuration The system must verify the configuration of each individual application by using the Verify command If the 440C CR30 configurable safety relay is not verified it will fault after 24 hours of operation ATTENTION The verification process should be documented in the safety system s technical file Follow these steps to download and verify 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 the relay is not connected click Connect to Device to establish the software connection Pemba BS EE Stas hy Tag Drea Peele Cuardmaster 44 00 CRID ee Mika Bad Tet 3 Click
29. the non interrupted state the contactors in the output do not energize until the system is reset by a momentary push button The 440C CR30 relay also monitors the E Stop circuit for faults Open circuit faults shorts to 24V DC shorts to GND output faults and cross channel faults are detected When a fault is detected or when the E Stop is actuated the 440CCR30 relay responds by de energizing the 100S C contactor coils removing power to the motor The motor coasts to a stop Stop Category 0 Two N C contacts one from each of the safety contactors are connected as part of the reset circuit The outputs of the 440C CR30 relay can only be energized if both safety contactors are in a proper de energized state The system is to be designed such that no single fault results in the safety system failing to perform its safety function A single fault is detected before the next demand on the safety system The system cannot be reset until the fault is corrected NHP Safety Reference Guide gt Safety Function Documents 440C 6A 6 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Electrical Schematic 24V DC Configuration Configure the SafeZone laser scanner by using the Safety Configuration and Diagnostics SCD software
30. tor coils Whenever the 440C CR30 relay disables its outputs hazardous motion is stopped When all safety input signals are correct no faults are detected and the Reset button is pressed the 440C CR30 is enabled to accept a separate Start command The E Stop is connected to the 440C CR30 relay inputs El_00 and El_01 which uses pulse checking to monitor the EStop for actuation and faults Whenever the E Stop is actuated the 440C CR30 relay disables its safety outputs and hazardous motion is stopped When all safety input signals are correct no faults are detected and the Reset button is pressed for 0 25 3 0 seconds then released the 440C CR30 relay re energizes its safety outputs EO_18 and EO_19 providing power to the contactor coils In summary when the laser scanner is blocked or the E Stop is actuated the contactors drop out When the laser scanner is unblocked the E Stop is released and the reset button is pressed the contactors are energized NHP Safety Reference Guide gt Safety Function Documents 440C 6A 5 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Bill of Material This application uses these products Description SafeZone multizone scan head and 1 0 module 10M prewired 13 conductor memory module 2
31. trative 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 NHP Safety Reference Guide gt Safety Function Documents 440C 6A 3 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Important User Information cont 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 consequence gt gt IMPORTANT Identifies information that is crit
32. ty Reference Guide gt Safety Function Documents 440C 6A 4 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 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 3 Determination of required PL PLr for each safety function To Realization and PL Evaluation HH Area Scanner Single Zone Safety Function This application technique includes two safety functions 1 Safety related stop function initiated by presence in the protective area of the safety scanner 2 Safety related stop functio
33. ut Feedback Morstonng Hl Gate Switch H slight Curtain The software assigns it to the next available input terminal which in this case is El_02 8 Change the number of inputs to 2 and use the Input pull down menu to select plug in inputs P1_01 and P1_02 instead Shil l z L Fergha a LF E Inputs Z Acwancod Settings ot Configure the Outputs Follow these steps to configure the safety and diagnostic outputs 1 Select and drag the Immediate OFF safety output function block to the top position in the Safety Output column of the Workspace 4 Safety Output Function Blocks ko Podniter BE immediate OFF ie OM Dieta Safety Cuiput ia the immediate OFF EQ 1H PT me E19 PT z Fein ice Nore Reset Type Manual Keset Input The software automatically assigns two outputs to the next available safety outputs which in this case are EO_18 and EO_19 and leaves one blank unassigned output One two or three outputs may be configured Because we are using EO_18 and EO_19 as our outputs no I O changes are required 2 Change the Feedback input to SMF 4 Cafety Output Feedback Reset Type Rese input 3 Change the Reset Input to SMF 3 Safety Outpui SF a viele immediate OFF e SEO m _ e Fo BT Feedbacte CME ii Reset Type Manual Heset Input 4 Configuration of the safety outputs is complete NHP Safety Reference Guide gt Safety Funct
34. w and then Device Toolbox TB Project2 Connected Comme File Eda view Debug Tools Communications Window Help if Tyce hy Project Organier Cil Akp j l TEBE Ete 7 Device Toolbar Cihan GF Appleton 3e Toolbes Ctrte Alte X Breck Ors Enver List Ctrls Ane Hame Pro D Dupa Ciria Aea g Choose a W Quick Tips Cole Alte wang Cy A Cress Reference Brose Cole We Corie Decani Dveri Teslbars b JM Full Screen Shifts AB Enter ft Properties Windes Fat 2 fi Hama Hern lei 2 Select 440C CR30 22BBB ee maai rte ia uin Rover ec ine bees tora aju ETT 3 Inthe Project Organizer double click the Guardmaster_440C_CR30 relay l i 1 i leeds l f a 1 Sarre Tot i _ ti La Coe Lill Tari a tan thor em Er pr F E doe Bisse Ma ee Hn a err ikim Haike Law i Smeg E diy SAS Speed Prajm Peas gx NHP Safety Reference Guide gt Safety Function Documents 440C 6A 10 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Configure the 440C CR30 Relay cont 4 To add the plug in I O module called for in the schematic right click the left plug in module space and choose the 2080 IQ40B4 module eT ot F 7 8 ke PP ee h e h TIP The I O module is shown in
35. y NHP Safety Reference Guide gt Safety Function Documents 440C 6A 22 Safety Function Documents 440C Safety Related Stop Initiated by a SafeZone Scanner Products Guardmaster 440C CR30 Configurable Safety Relay 442L SafeZone Laser Scanner 100S C Safety Contactors Safety Rating CAT 3 PLd to ISO 13849 1 2008 Additional Resources These documents contain additional information concerning related products from Rockwell Automation Resource Description Provides information on how to mount install commission operate and maintain the SafeZone laser scanner SafeZone Singlezone and Multizone Safety Laser Scanner User Manual publication 442LUM003 Provides information on how to configure a Guardmaster 440CCR30 Software Configurable Safety Guardmaster 440CCR30 configurable safety relay to Relay Quick Start Guide publication 440C QS001 communicate with a PanelView Component terminal via Modbus communication protocol Provides detailed information on how to install configure operate and troubleshoot a Guardmaster 440 CR30 configurable safety relay Guardmaster 440GCR30 Configurable Safety Relay User Manual publication 440C UM00 Safety Contactors with DC Coil Installation Instructions Provides instructions on how to install 100S C safety publication 100S IN006 contactors Industrial Automation Wiring and Grounding Provides general guidelines on how to install a Guidelines publication 1770 4 1 Rockwell Autom
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