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Safety Function: Light Curtain with Muting (two sensor L

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1. 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 must 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 Manual publication 440L UM003 for additional information These factors also affect the safety distance calculation IMPORTANT An example 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 Rockwell Automation Publication SAFETY AT136B EN P May 2015 7 Safety Function Light Curtain with Muting Two Sensor L type
2. 2 Simulating incorrect sensor sequence is easiest to accomplish by disconnecting and reconnecting the sensor inputs from the 440C CR30 relay plug in input terminals Confirm normal operation by completing the following in sequential order within the respective synchronization times a Disconnect P2 l 00 sensor 1 b Disconnect P2 l 01 sensor 2 c Interrupt the light curtain d Reconnect P2 l 00 e Reconnect P2 l 01 f Clear the light curtain Confirm that the 440C CR30 relay OUT 0 status indicator is still ON and that the Fault Status indicator is OFF 46 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Check the system reaction to an incorrect sequence by completing the following in sequential order within the respective synchronization times a Disconnect P2 l 00 sensor 1 b Disconnect P2 l 01 sensor 2 c Interrupt the light curtain d Reconnect P2 l 01 sensor 2 Since 1 was interrupted before 2 S1 must clear before S2 As soon as 2 is reconnected cleared before S1 the 440C CR30 relay trips Confirm that the 440C CR30 relay OUT 0 status indicator turns OFF and that the red Fault status indicator starts flashing Reconnect P2 l 00 and clear the light curtain Press the reset button and confirm that the 440C CR30 relay OUT 0 status indicator is ON and that the red Fault status indicator is OFF Val
3. 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 and stop the machine within 0 5 seconds The 440C CR30 relay OUT 0 status indicator must turn OFF The red Fault status indicator 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 Cycle the E Stop The red Fault status indicator should turn OFF Press and release the Reset button The 440C CR30 relay OUT 0 status indicator 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 The 440C CR30 relay must trip immediately The 440C CR30 relay OUT 0 status indicator must turn OFF The red Fault status indicator of the 440C CR30 relay must flash Release the E Stop 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 Cycle the E Stop The red Faul
4. Using the standard 1 0 plug in for these non safety signals can reserve the limited number of safety inputs and outputs for safety rated signals 16 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 5 Click Edit Logic to open the function block editor workspace uari AOC CRS0 x Quick Tips Guardmaster 440C CR30 Guardmaster 440C CR30 Build 440C CK30 277BBB gt Verification ID Remote Mode Fault TIP Configure the Inputs Device Toolbox a Verity G aiy TE F i saoao biba If you don t see the Toolbox click View and choose Toolbox 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 i Project3 Connected Components Workbench Standard Edition Administrator File Edit View Build Debug Tools Communications Window POG MA aane ma OO O O O Oa Toolbox o 4 Xf Guardmaster440C_CR30 Logic 4 Safety Monitoring Functions pemergencySiop YJ Feedback Monitoring Gate Switch Light Curtain _ Muting Reset Restart Safety Mats Single Wire Safety Input Two Hand Control HE 2 OO8 im Alternative Device 4 Logic Functions k Pointer
5. oro SS fulfilled 94 Higi Rockwell Automation Publication SAFETY AT136B EN P May 2015 W IFA Cega Requarements of the category BS Hill fulfilled nat reievant fulfilled ASF PPL Tulfilled LS High fulfilled 37 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay The E Stop safety function can be modeled as follows Input Logic Output EERE RSE PF Pee 2 2 E E E E EEE ia tae es a E EERE BESSR EPP RES EE ES EE BEER HE HEHE ER EEF Pf 2 2 ee E Stop Channel 1 440C CR30 Relay Fault Exclusion E Stop Channel 2 Subsystem 2 Subsystem 3 Subsystem 4 Subsystem 1 PR SS SSS PES SES E BS EPS SS SS SSH S SHE SS SSS SSS SSC SSR SE SC SC SC SSCS SESS SS SS PP PPC CK PCT TPP te eh eee eo ee ee ee ee ee en ee ee oe ee oe eo ee oe oe Pea Re RRR eee es SS ee ee E E Cn ee ee ee ee ee ee oe ee ee ee ee oe oe tii i iti ni iia a a a es ee ee e a r ee o o r r e r r a a r BERR RRP RRR PRP ee The Emergency Stop function is considered a complementary protective measure which is intended to be used in 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
6. 1 AND Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Monitoring Help o gt a Ya Me i H SI wh HS Guardmaster 440C CR30 Device Toolbox Quick Tips Logic Level A 17 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 18 Connected Components Workbench software automatically assigns the next available terminals for both the inputs and the test sources Changing the terminal assignment for each function is also easy by clicking on them No terminal changes are required for this application Any necessary configuration of those I O points is also done automatically by the software In this case the default assignments are correct Safety Monitoring SMF 1 EIL 00 Y e L a Emergency Stop Eo e Test Source amp 1 Test Source B 13 Advanced Settings 2 In the Toolbox click and drag Muting to the target block below the E Stop SMF1 KA Projecti Connected Components Workbench Standaed Edition Muimi Fie Edit View Build Debug Tools Communications Window Help saes L ati Tm ms al nmaa Be amt a a mme eel m bee s BEF EV Emer i EEA TP qli ATA Toolbox 9 f Guardmaner 10C CRIO Logie uy a Safety Monitoring Functions nastier HPL OR Quick Tps Denit Tile hb Pontes w Emeperiy Hep Safety Monitoring Logic leval A Enabling Switch WO Feedback Monitoring WT IW Gate Seith EL H 9 oO Emergenc
7. FSS SS tc SPS HS SP FFs ss S E Subsystem 1 SAFE IE S ee fe ee ee ee ee ee ee ee een ne ee se se ee PFH fh CEF tigra ATES 7 fulfilled 440C CR30 Subsystem 3 O TES 65 Multiled High Logic Relay Dang fs MTT a 3 High Wy IFA 100 Highi Fufilted noe eles iea st pakou fusifiitedd 100 High w fubilled Output Subsystem 4 Calegery Piequiressents af the calegory The muting function monitors the timing and sequence of both the muting sensors and light curtains According to Annex E of ISO 13849 1 99 DC can be claimed based on Cross monitoring of input signals and intermediate results within the logic L and temporal and logical software monitor of the program flow and detection of static faults and short circuits for multiple I O Essentially the time monitoring and sequential logic of the muting function enable the system to detect faults and claim a high 99 diagnostic coverage The Performance Level and Category achieved by each subsystem of the E Stop safety function as calculated by SISTEMA is shown below Safety function Posumentation Plr PL Subsystems CE Library Gy Status Type Name lt a i 36 E Hop bulion wilh redundant contact Blacks E Bey w 55 E Stop Faut Exclusion 38 CRA Sattware Configurable Safety Relay i 36 Redundant 100 Contactors ATES 0 LE 2ATE PFA LA CCF peme DCwg M hid a Sh fulfilled 94 High a
8. For this example we use a setting of five seconds for each synchronization time by selecting a value of 100 100 x 50 ms 5000 ms 5 s SME 2 Fl 02 Sic o Mute F023 eec P200 s1 P201 es 51 99 Synch Time 0ms 2 LC Synch Time wirms Max Mute Time Time Units Seconds Time 1 8 Set the Max Mute Time Units and Time to values appropriate for your application The maximum muting time represents the maximum amount of time that the primary input device the light curtain can be muted Muting starts just after muting sensor 2 detects the load and the load must clear the light curtain before the maximum muting time elapses Set the maximum muting time as short as possible based on the requirements of the application For this example we use a setting of 20 seconds Mute ae a Tune 2 Sensor L Type 51 52 Synch Time n 650 revs 10 4 52 LC Synch Time r xo0 ms mines Max Mute Time Time Units Time 9 To set up the override function click the next to Override Settings to expand that section Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 10 Change Disabled to Enabled Ho Em0 e pP200 e P2201 e Mute Tyre 2 Sensor L Type 51 52 Synch Time c5O0nns 100 2 LC Synch Time c5O0nns Max Mute Time Time Units Seconds 100 2 Enable
9. can continue running Release the override key switch Run a normal sized load out of the machine area on the conveyor and into the muting area at a normal operating speed Use the standard control system to stop the load while it is interrupting the light curtain After 20 seconds the maximum muting time or 5 seconds the 1 S2 and S2 LC Synch Times if a muting sensor is not blocked by the load the muting lamp must start flashing at 1 Hz to indicate the timing fault The 440C CR30 relay OUT 0 status indicator must turn OFF 28 Use the key to actuate the override key switch After three seconds the muting lamp starts flashing faster 3 Hz to indicate the override function Press the Reset button and then use the standard control system to start the conveyor The conveyor should start While the load is still interrupting the light curtain release the override switch The 440C CR30 relay must trip The 440C CR30 relay OUT 0 status indicator must turn off The conveyor must stop The flashing of the muting lamp slows down back to 1 Hz indicating there is no override but the muting function is still faulted To clear the light curtain use the key to actuate the override key switch After three seconds the muting lamp starts flashing faster 3 Hz to indicate the override function Press the Reset button and then use the standard control system to start the conveyor The conveyor should start Release the override after the load has cleared
10. has cleared the light curtain Use the standard control system to stop the conveyor Rockwell Automation Publication SAFETY AT136B EN P May 2015 41 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 34 Confirm muting sensor synchronization times Run a normal sized load out of the machine area on the conveyor and into the muting area at a normal operating speed Use the standard control system to stop the load just after it interrupts muting sensor 1 but before it interrupts muting sensor 2 After five seconds the maximum S1 S2 Synch Time as configured on the 440C CR30 relay the muting lamp must start flashing at 1 Hz to indicate the timing fault Because the light curtain is clear the 440C CR30 relay OUT 0 status indicator remains ON Use the standard control system to start the conveyor until the load interrupts the light curtain At this point the 440 CR30 relay must trip and the hazardous motion must stop a Use the override key to clear the load from the muting area as documented in step a 33 Run a normal sized load out of the machine area on the conveyor and into the muting area at a normal operating speed Use the standard control system to stop the load just after it interrupts muting sensor 2 but before it interrupts the light curtain After five seconds the maximum 1 S2 Synch Time as configured on the 440C CR30 relay the muting lamp must start flashing at 1 Hz to indicate the t
11. 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 example shows example calculations based on the formula from both the international standard ISO 13855 and ANSI B11 19 The Safety Distance S formula from ISO 13855 S KxT C S 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 seconds based on the machine stopping time plus the safety system total reaction time C the intrusion distance in mm For the purposes of this example we use the following values K 1600 mm per second T 610 ms 500 ms Machine Stopping Time 20 ms light curtain 45 ms 440C CR30 relay 45 ms K1 and K2 contactors IMPORTANT The specific machine stopping time must be measured for each application C 128 mm 8 x d 14 but not less than 0 where d is the resolution of the light curtain d 30 mm S 1600 mm s x 0 61 s 8 x 30 14 976 mm 128 mm 1104 mm The light curtain must not be mounted closer than 1104 mm approx 43 5 in from the haz
12. your application SMF 2 LLA Z El 02 r ic a bad Pass e Through H 03 E ic Mute Hod E ov Fl 05 rE ov sg ue 2 Sensor L Type 51 52 Synch Time palms 2 LC Synch Time Ors 100 Max Mute Time Time Unrts Seconds Time 20 Overnde Settings Override Enabled Max Override 4 Time 255 z Inputs 2 N C Pulse Testing 2 Sources Test Source A 12 ha Test Source B 13 ha Advanced Settings Light Curtain Discrepancy ee Time 500s Mute Sensors Input Filter oe 25s Light Curtain Input Filter oe 25s Override Input Filter 25 rns 13 Click the arrow at the bottom of the Muting SMF to minimize the block Advanced Settings Light Curtain Discrepancy Time 60 rns Mute Sensors Input Filter Oc Sires Light Curtain Input Filter Oc Sires Override Input Filter 25 rns 22 Rockwell Automation Publication SAFETY AT136B EN P May 2015 The minimized SMF block looks like this EL 02 E03 P2_00 P2_01 EI 04 EL 05 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay SMF 2 14 To adda Reset safety monitoring function click and drag a Reset from the Toolbox to the target block below SMF2 It appears a few rows below the muting block because the muting block is consuming three of the available SMF blocks Toolbox IX 4 Safety Monitoring Functions b Pointer Emergency Stop Enabling
13. Application Technique Allen Bradley Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Products Guardmaster 440C CR30 Configurable Safety Relay 440L GuardShield Light Curtain 42EF RightSight Photoelectric Sensors 100S C Safety Contactors 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 with Muting two sensor L type Safety Function 4 Safety Function Requirements 4 Functional Safety Description 5 Bill of Material 6 Setup and Wiring 6 Configuration 14 Calculation of the Performance Level 36 Verification and Validation Plan 39 Verification of the Configuration 47 Additional Resources 50 USE NE THINK SOME Rockwell Allen Bradley Rockwell Software Automation Safety Function Light Curtain with Muting Two Sensor L type 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 disa
14. CR30 4 Download Upload N Verity 440C CR30 22BBB gt Verification ID Remote Mode Fault Output Show output from Build P gls x l Build started Project Safety Relay SS Build end r ep a nnes Build Succeeded ee n a nuer a er e 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 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 s 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 AT136B EN P May 2015 33 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 5 Click Download GUARDMASTER CR30 Logic SURO MST ER EE om Guardmaster 440C CR30 Guardmaster_440C_CR30 Quick Tips Device Toolbox Lad Build Verify 440C CR30 22BBB 2 Verification ID Remote Mode E oe J 8 E t Fault fff yd he EEE Aal er 6 In the Connection Browser expand the AB_VBP 1 Virtual Chassis and select the Guard
15. R30 relay to terminal El_05 After approximately five seconds the 440C CR30 relay must trip The red Fault status indicator of the 11 12 13 14 15 6 1 17 8 1 19 0 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 because the E Stop and Override share Test Pulses on MP12 and MP13 Cycle the Override key switch and hold it on Press and release the Reset button The 440C CR30 relay OUT 0 status indicator should turn ON Clear the load or substitute from the muting sensors and light curtain The outputs of those devices turn ON 42 3 4 44 45 46 Press and release the Reset button The 440C CR30 relay OUT 0 status indicator 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 OSSD1 wire to terminal El_02 of the 440C CR30 relay The 440C CR30 relay must trip immediately The red Fault Status indicator of the 440C CR30 relay must flash 2 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 Changes Modifications Interrupt and the clear the light curtain T
16. RS0 Lo uardmaster 4400 CR30 Guardmaster_440C CR Guardmaster_440C_CR30 2 Click LED Configuration on the lower left Rockwell Automation Publication SAFETY AT136B EN P May 2015 31 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 3 Configure the Type Filter and Value for each LED as shown in Table 1 G uard master 440C CR30 Logic Guar imaste Guardmaster 440C CR30 Guardmaster_440C CR30 _440C_CR30 gt BOTT as Device Toolbox 4 t Download Upload Edit Logic Build Verify 440C CR30 22BBB 3 Verification ID Remote Mode Fault a Safety Relay Safety Relay LED Configuration eee reat Input LEDs LED Configuration LED Type Filter i o nina statu Modbus Mapping J es j Plug In Modules TCA YC Empty of Not Use cused 2080 IQ40B64 Terminal Status aK Safety Mon Table 1 Status Indicator Settings 32 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 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 Guardmaster 440C_CR30 Logic Guardmaster440C_CR30 x gamta aif Device Toolbox Guardmaster 440C CR30 Guardmaster 440C
17. Reset E Stop Light Curtain and Muting Sensor inputs Confirm that no one is in the guarded area Confirm that the motor is stopped Confirm that the E Stop is released Confirm that the light curtain and muting sensors are clear Apply power to the safety system Confirm that the E Stop and light curtain status input indicators of the 440C CR30 relay are ON Confirm that the Power status and Run status indicators are green Run 3 4 5 can be flashing green to indicate a non verified project Confirm that the Muting Sensor input indicators of the 2080 Plug in are ON Press and release the Reset button Confirm that the 440C CR30 relay OUT 0 status indicator is ON status of SOF 1 es Confirm that the motor does not start on powerup Use the standard control system to start the machine Confirm that the motor starts and that the machine begins to operate 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 that the machine begins to operate a Press the E Stop button The safety system must trip The machine must stop in less than 0 61 seconds the maximum stopping time The 440C CR30 relay OUT 0 status indicator must be OFF Press and release the Reset button The 440C CR30 relay OUT 0 status indicator turns ON The machine must not
18. Switch a Feedback Monitoring Gate Switch Light Curtain Muting H FI Restart Jh Safety Mat mr Single Wire Saffi Input ai Two Hand Contro Alternative Device 4 Logic Functions Pointer AND OR XOR NAND NOR NOT AND with Restart OR with Restart safety Output Function Blocks VOYYOUUU0 F wr 4 Pointer Immediate OFF OWN Delay OFF Delay Jog WDE d L F Muting Lamp Rockwell Automation Publication SAFETY AT136B EN P May 2015 P2_00 P2 01 El 04 E 05 ki ki ki k Bs Bs Tov Sov Sat OGIE Mute Reset E Guardmaster 440C_ CR Guardr Advanced Settings 23 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 15 On the Reset block SMF 5 click the input terminal EI_02 and choose Plug in 2 Inputs P2_02 The reset can come from a standard plug in input or even via the serial port through a Modbus message SMF 5 Reset Configure the Outputs Follow these steps to add 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 block iio o p ajf ee re de a LET birea ieg i ii am ak ij L 71 a i kerr low B to He l zE a oe d p Ho i li Fi i Bo g i amp LE ng eel mi L i Tima cane if P A gt ithe a lapa henn amp ieee iif u
19. Y AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Electrical Schematic 24V DC Class 2 DC COM 440C CR30 22BB8 AT AJ E Stop 440C CR30 as mas ze T a a aeee Override fae Q i cade 440L P4KL1 28070 Transmitter Receiver 42EF P2JBB F4 2 gJ i i Plug in 1 0 Slot 2 Inputs 4 1 02 Rockwell Automation Publication SAFETY AT136B EN P May 2015 13 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 24V DC Class 2 DC COM 440C CR30 27BB6 LI L2 L3 JAI Aa ___ tt jia tn necins 440 CR30 External Switched Stop Start Circuit vutputs 1005 C23EJ23BC 2 et age in in J m m e ee i 2080 1040B4 Muting Lamp P100 Plug in 1 0 Slot 2 Outputs ISO 13849 2 requires transient suppression across the load as a Basic Safety Principal The EJ electronic coil provides suitable suppression Configuration The 42EF RightSight muting sensors do not require configuration The light curtain uses the standard default configuration If it is possible that the configuration DIP switches have been changed refer to the GuardShield Type 4 and GuardShield Remote Teach User Manual publication 440L UM003 for instructions on how to reset them to the default parameters Verify that the 440C CR30 safety relay is running firmware revision 7 00 or later A f
20. _02 Embedded Input 02 through EI_05 for the Light Curtain and Muting Sensors For this application the muting sensors are wired into the plug in module so we need to change the input terminals 5 On the input terminal selection table click Plug in 2 Inputs 2080 IQ4OB4 terminal 00 to select that input for the muting sensor 1 S1 SMF 2 E02 1c o 03 v amp c Mute 2 Sensor L Type ich Time 1 z mch Time 1 m mamate Time Time Units Seconds Time 1 Override Settings Advanced Settings 6 On the Muting block SMF 2 click the fourth input terminal S2 and assign Plug in 2 Inputs terminal 01 With the changes the Muting block looks like this EI 02 r c Ea B T Mute EI 03 r c 2 LC Synch Time x5O0rns ly Max Mute Time Time Units Seconds Time 1 Override Settings Advanced Settings ka Rockwell Automation Publication SAFETY AT136B EN P May 2015 19 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 20 7 Set the S1 S2 Synch Time and S2 LC Synch Time to values appropriate for your application The synchronization times represent the maximum amount of time between the changes of state of the two devices The value for your application is dependent upon how fast the load is moving through the muting area and the distance between the sensing devices The maximum setting is 10 seconds The value is set in 50 ms increments
21. allation instructions and precautions to conform to applicable safety standards E Hive you venfied that the electrical specifications of the sensor and inputs are compatible E fave you verified that the electrical specifications of the outputs and the actuators are compatible E fave you calculated the system s safety response time for each safety chain E he system response time in proper relation to the process tolerance time lve probability PFD PFH PLx values been calculated according to the system s configuration E 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 48 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 5 Click Generate 6 Click 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 Verity After about ten seconds a pop up window will appear 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 H
22. and Configurable Safety Relay The timing diagram below shows the correct sequence of operation beginning in the OFF state At A the reset button is pushed for longer than 0 25 s and released within 3 0 s As long as the safety inputs are ON when the reset is pressed the safety outputs turn ON after the reset is released To initiate muting the light curtain must be clear At B the material is detected by sensor 1 S1 and then at C by sensor 2 S2 The light curtain function is muted and the muting lamp turns ON after sensor 2 is interrupted The light curtain must be interrupted at D The material must be large enough to be detected by both sensors and the light curtain at the same time As the material continues down the conveyor sensor 1 must clear E then sensor 2 F and then the light curtain G at which point the muting function ends and the muting lamp turns OFF For muting an N C style configuration is typically used for the muting sensor it is normally ON and then turns its output OFF when the target is detected Because we are using polarized retroreflective sensors we use the L O Light Operate PNP output of the sensor for this application example Figure 3 Timing Diagram for Normal Muting Operation 1 Sensor 1 S1 0 1 Sensor 2 2 0 1 Light Curtain LC 0 1 Reset 0 1 Muting Active 0 1 Output 0 1 Muting Lamp 0 30 ms lt t1 lt S1 S2 Synch Tim
23. ardous motion being guarded against The Safety Distance Ds 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 in 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 Dpf 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 Rockwell Automation Publication SAFETY AT136B EN P May 2015 11 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay For the purposes of this example we use the following values K 63 in per second Ts 500 ms 0 5 second for the purposes of this application example IMPORTANT The specific machine stopping time must be measured for each application Te 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 78 7 mm 3 1 in Ds 63 x 0 5 0 11 3 1 41 5 in The light curtain must not be mounted closer than 41 5 in from the guarded hazard 12 Rockwell Automation Publication SAFET
24. ardous motion to stop A mute dependent override capability is provided to clear objects stuck in the monitored area for example if the conveyor stops while the load is blocking the light curtain and the S2 LC synchronization time expires The override function is engaged by using a key actuated momentary selector switch and is time limited In summary when the un muted light curtain is interrupted for example by a person s hand the contactors de energize removing rotational power from the motor When the light curtain is clear and the appropriate reset button is pressed the contactors are energized When properly muted the light curtain s field of view can be interrupted without de energizing the safety contactors Whenever the light curtain is muted the muting lamp is energized Rockwell Automation Publication SAFETY AT136B EN P May 2015 5 Safety Function Light Curtain with Muting Two Sensor L type 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 22AWG 5 meter 16 4 feet 1 889D F8AB 5 DC Micro M12 female straight 8 pin PVC cable yellow unshielded 24AWG 5 meter 16 4 feet 1 42EF P2JBB F4 PHOTOSWITCH photoelectric sensor Righ
25. ave you venfied that the electrical specifications of the sensor and inputs are compatible Have you venfed 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 PLx 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 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 Verify 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 relay The Safety Verification ID can be displayed on the IN and OUT input and output status indicators 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 AT136B EN P May 2015 49 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Additional Resources These documents contain more information about related product
26. blication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 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 Override and hold it on After three seconds the muting lamp flashes faster 3 Hz Press and release the Reset button The 440C CR30 relay OUT 0 status indicator should turn ON Short the Override input wire at terminal El_ 04 of the 440C CR30 relay to 24V DC After approximately five seconds the 440C CR30 relay must trip 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 because the E Stop and Override share Test Pulses on MP12 and MP13 Cycle the Override key switch and hold it on Press and release the Reset button The 440C CR30 relay OUT 0 status indicator should turn ON Short the Override input wire at terminal El_ 04 of the 440C CR30 relay to DC Com OV DC The 440C CR30 relay must trip immediately The red Fault status indicator of the 440C CR30 relay turns ON not flashing Remove the jumper The 440C CR30 relay must not respond Press and release the Reset button The 440C CR30 relay must not respond 2 Cycle power to the 440C CR30 relay 21 to 40 Repeat steps 1 through 20 using MP_13 for MP_12 and El_05 for El_ 04 Short terminal El_04 of the 440C C
27. 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 Stop s 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 Stop s complementary 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 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 MTT Fd 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 contactor
28. d Connected Components Workbench software adds two override OV inputs to the Muting block SMF2 and assigns the next two available terminals as well as Test Source outputs which are shared with the E Stop block SMF1 The default terminal settings are correct for this application 11 Set the Max Override Time to a value appropriate for your application The maximum override time represents the maximum amount of time that the override function can enable the safety outputs It should correspond to the amount of time that it would take the load to clear the light curtain in the case of a muting fault Set the maximum muting time as short as possible based on the requirements of the application Keep in mind that a second override can be easily engaged by releasing the override switch and then actuating it again A second reset is also required for a second override For this example application we set the time to 20 seconds by selecting a value of 4 4 x 5 seconds 20 seconds The other default Override Settings can remain unchanged Override Settings Override Enabled Inputs 2 N C T Pulse Testing 2 Sources Test Source A 1 Test Source Bs 13 Rockwell Automation Publication SAFETY AT136B EN P May 2015 21 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 12 When complete the Muting block SMF2 looks like this with minor changes for the specific time values of
29. e configurable up to 10 s 30 ms lt t2 lt S2 LC Synch Time configurable up to 10 s t3 lt Max Mute Time configurable 8 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay If the sequence of the changes of state of the muting sensors and light curtain is incorrect or the timing limits are exceeded the muting function faults If the light curtain is interrupted while the muting function is faulted the system de energizes the redundant pair of 100S contactors causing the hazardous motion to stop The most common type of muting fault occurs when the conveyor stops while the material is in the muting area and either the synchronization time or the maximum muting time elapses If the light curtain is subsequently interrupted the conveyor stops This operation makes it difficult to clear the material out of the light curtain detection area and resume normal operation Safety standards recommend keeping the configured maximum muting time as short as possible for normal operation so it is not appropriate to lengthen the maximum muting time just to avoid this timing fault Therefore it is more appropriate to design the standard control system so that the conveyor is unlikely to have a standard stop during muting A mute dependent override capability is provided to clear objects stuck in the monitored area The override function is engaged by
30. ection of the E Stop SMF which is the blue dot on the right of the block The dot turns light gray indicating that it is selected 3 Click the first input connection blue dot of the AND block to connect it to the E Stop block A connection line appears and both connection dots turn dark gray Also a Pass Through block automatically appears in the Logic Level A column Safety Monitoring Logic Level A Logic Level B SMF 1 LLB1 Emergency Stop 1 AND EI 01 r 0 Test Source A 12 x Inputs r Test Source B 13 Ww Advanced Settings ka 26 Rockwell Automation Publication SAFETY AT136B EN P May 2015 The logic looks like this E1 00 EI 01 re 6 Emergency Stop E Safety Monitoring SMF 1 Test Source A 12 Test Source B 13 Advanced Settings F Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Logic Level A Logic Level B kai Pass a Through 4 Click the blue dot on the right of the Mute SMF2 block which is the output connection of the Muting SMF Pass Through block LLA 2 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 LLA 2 Pass Through block A connection line appears and both dots turn dark gray Emergency Stop EI 01 EI 02 EI 03 P200 P2 01 EI 04 El 05 E k O k E E Test Source A 12 T
31. en material and persons the system monitors for a certain sequence of events within specific time limitations Under normal operation if an object interrupts the light curtain the system de energizes the final control devices in this case a redundant pair of 100S C contactors thus removing electrical power from the motor which causes the hazardous motion to stop Stopped is considered to be the safe state If the E Stop is pressed at any point in time the safety outputs turn off and hazardous motion coasts to a stop Stop Category 0 The muting and override functions do not affect the E Stop function 6 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay The arrangement of the muting sensors and the light curtain is shown in these illustrations from above and from the side According to IEC TS 62046 the muting sensors should be placed high enough so that they can detect the load on the conveyor but not the pallet or unit being used to transport loads If that is not achievable you must use other methods so that personnel cannot enter the zone and climb on to the pallet See the IEC TS62046 standard for more information Figure 1 System Layout from Above Machine 3 Material Muting Lamp Figure 2 System Layout from the Side Material Cc cS S YO l Machine S1 52 O Ol a E OOOODOOGOOGOOOSG
32. en actuates the override key switch at E Three seconds after the override is engaged the override function turns ON at F The muting lamp which was previously flashing at 1 Hz to indicate the fault begins flashing at 3 Hz to indicate the override Because we are utilizing a manual monitored reset we must push the reset button to turn ON the safety outputs G Once the safety outputs are ON the conveyor can move forward to clear the material out of the detection area In this application we have configured the maximum override time to be 20 seconds If the light curtain was still interrupted after the time elapsed or after the override switch was released the safety outputs would turn OFF It is possible to initiate a second override sequence by releasing the override switch turning it OFF and then turning it back ON but this requires a reset Figure 4 Timing Diagram for Override Function Sensor 1 S1 Sensor 2 S2 _ Light Curtain LC Reset Override Output Muting Lamp MH O Iftl gt S2 LC Synch Time muting function faults t2 2 LC Synch Time t3 3 seconds fixed t4 lt Max Override Time 10 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Safety Distance Calculation A safety light curtain provides no physical barrier between a person and the hazardous motion The safety
33. ensor L type and Configurable Safety Relay 2 Click the Feedback input terminal EI_06 and change it to Plug in 2 Inputs 03 SMF 6 Wm Feedback TIP To independently monitor each of the redundant contactors you can connect each to its own input and change the number of inputs on the SMF to 2 This is not necessary for safety but could simplify troubleshooting in the event of an output device failure 3 To associate this Feedback SMF with the Safety Output Function on the Immediate OFF SOF click the pull down menu next to Feedback and change it from None to SMF 6 which is the Feedback Monitoring block Safety Output SOF 1 wi Immediate OFF e F018 PT Feedback Reset Type Reset Input k 30 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay The complete logic configuration looks like this is e oO ak alle pi J gt pe a oL i ij zE iE EDIF bg F a LEE td Lu i oe a Fri Tire Liars Tiri bie Priel Pom i Lo oa g E Eha a Pr Peru ES Must Lera l i Dg E a ii E a d Lul Configure the Status Indicators The status indicators on the 440C CR30 relay can easily be configured per your preference to show more information than typical status indicators 1 Click the Guardmaster_440C_CR30 Project tab on the Workspace Guardmaster 4400 C
34. entire hazardous area additional safety rated presence sensing devices must be used to detect persons in that area for example by using a laser scanner or safety mat inside the cell Position the override switch outside of the cell in a location where it is not possible for someone to reach the hazards inside the zone through the light curtain while operating the switch The switch must be positioned so that an E Stop button is within reach For practical purposes position it near the reset button 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 and two RightSight muting sensors are 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 contacts the hazardous motion coasts to a stop Stop Category 0 The 440C CR30 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 clearing the light curtain once all safety input signals are correct no faults are detected and the reset push butto
35. est Source B 13 Advanced Settings w Lc ic O51 52 Sov ov Safety Monitoring Fa SMF 1 SMF 2 Mute Rockwell Automation Publication SAFETY AT136B EN P May 2015 Logic Level A Logic Level B LLB 1 Through PEN Inputs 2 r LLA 2 bad Pass Through 27 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 6 Click the output connection the blue dot on the right of the AND logic block to select it The dot turns light gray Logic Level B LLB 1 Dao Inputs 2 v or 7 Click the input connection the blue dot on the left of the Immediate OFF Safety Output Function block SOF1 to connect it to the AND block A connection line appears and both connection dots turn dark gray Safety Output SOF 1 ies Immediate OFF Feedback None Reset Type Manual Reset Input SMF 5 The resulting logic looks like this Logic Lewel B Safety Output SOF 1 fO18 PT E gt AND a ET Immediate OFF e i E019 i PT Feedback None i 7 Inputs 2 Reset Type Manual z Reset Input SMF5 iat 28 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 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 drivin
36. g that device is OFF 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 an N O contact is closed the linked N C contact is mechanically held open A 24V DC signal that is 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 input P2_03 the 440C CR30 relay knows that the main motor contacts the N O channels are open and therefore no power is reaching the motor which is considered a safe state That portion of the wiring schematic is shown below Plug in 1 0 Slot 2 Inputs 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 SMIF 3 P2_00 ie a Advanced Settings ag aT Connected Components Workbench software automatically assigns the next available terminal In this application the feedback monitoring circuit is wired into plug in input 03 so we need to change the terminal assignment Rockwell Automation Publication SAFETY AT136B EN P May 2015 29 Safety Function Light Curtain with Muting Two S
37. gle 317E Pile E Bad wi 4h CRO Software Configurable Safety Relay 1 8 ryt of migra fof nehewer Fueled yr 28 Redundant 100S Cartarctars 24TF SR BS fulfilled 2 High 100 High fitiiledd The light curtain safety function can be modeled as follows Input ee Ge en Output lt lt e e eee ee ee ee po lt Se eee eee ee ee eS fF Pee ee eee ee ee ee Se i L i E i E E E E E il i E i GuardShield 440C CR30 a E Light Curtain Relay Subsystem 1 Subsystem 2 Subsystem 3 Pe E E a E a EEE E E EE SPSS E E E SESE STS STS SS E T T T T E T E T E T E TJ T T T E T E T E T E T E E EEEE oe oe oe en ee ee ee ee ee ee ee es ee ee 36 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay The Performance Level and Category achieved by each subsystem of the muting safety function as calculated by SISTEMA is shown below Safety function Bowumenitation Per PL Subsystems i Library St lus Tp Hame a 368 Muling Sensors 1E ee yi 46 Light Curtairc Guardshield 4400 Type 4 Single il 38 ORO tottware Configurable Safety Relay if 5E Redundant 1005 Contachors The muting safety function can be modeled as follows Input PRR RSFSR PF REE 2 2 Sa SSS SSP SP SPS SS SE Ss SF SC SP PPP PS SS SS GuardShield Light Curtain Subsystem 2 E oe m m tn eo CP SSC FC
38. he red Fault status indicator should turn OFF 4 Press and release the Reset button The 440C CR30 relay OUT 0 status indicator should turn ON 5 Use the standard control system to start the machine Confirm that the motor starts and that the machine begins to operate This step is optional in the following GuardShield validation tests Rockwell Automation Publication SAFETY AT136B EN P May 2015 4 wn Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Jump OSSD 1 to 24V Interrupt and the clear the light curtain When the light curtain turns off its OSSDs 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 indicators red status indicator flashing orange status indicator ON 7 Remove the jumper Neither the light curtain nor the 440C CR30 relay respond Press and release the Reset button Nothing changes Cycle power to the light curtain Approximately five seconds after power is restored the light curtain outputs turn ON Press and release the Reset button The 440C CR30 relay OUT 0 status indicator should turn ON 10 Jump OSSD 1 to DC COM The light curtain detects the fault immediately and turns OFF its OSSDs The light curtain indicates the fault on its status indicators red status indicator flashing orange status indicator ON The 440C CR30 relay trips pp 11 Remove
39. i fi i Bean Hp EF zp r ae ull C3 A marb a chee aed re e L d Ii E iu l Eii m E Fa Tree E i k mti sh my D 3 a rE a 1 ms Lk eB sf g F E rE E i I 7 aa aia Es f icy Connected Components Workbench software automatically assigns the Mute SMF as SMF 2 and the output terminal as MP 14 4 Click the output terminal MP_14 and change it to Plug in 2 Outputs P2_00 SOF 2 Mute_Lamp_1 Mute SME SME 2 Rockwell Automation Publication SAFETY AT136B EN P May 2015 25 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Configure the Safety Logic In this application pushing the Emergency Stop disconnects power from the motor An interruption of the light curtain when it is not muted should also disconnect power from the motor Using an AND function configures the outputs of the 440C CR30 relay to turn ON when the E Stop is closed that is when the N C E Stop button is released and clear and the light curtain is clear or muted 1 In the Toolbox under the Logic Functions click and drag an AND logic block onto the first Logic Level B target block Deme Tmi Exi incipoossaw nri 7 E E i T k li 2 lepur i F MeL Prr SES nii ha E y E ini E Tht Baa Ti oe Aue E Fu m RLE bair AAT io nE u Le fr Ce BETI LE E El ri IE ri ai a ry hipa chen Mach ies 7 E E i ic i areata Coe 2 Click the output conn
40. idation of Safe Response to Abnormal Operation The safety system responds properly to all foreseeable faults with corresponding diagnostics 440 CR30 Relay K1 and K2 Tests While the machine is running break the connection between terminal EO_18 of the 440C CR30 relay and the S1 coil of K1 The machine must stop 2 Restore the connection Use the standard control system to restart the machine ee 3 While the machine is running short 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 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 OUT 0 status indicator should turn ON Use the standard control system to start the machine While the machine is running short the A1 terminal of the K1 coil to DC COM The 440C CR30 relay must trip The machine stops The red 440C CR30 relay Fault status 7 indicator 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 OUT 0 status indicator should turn ON 11 to 20 Repeat steps 1 through 10 using El_ 19 for El_ 18 and K2 for K1 Verification of the Configuration You must co
41. iming fault Because the light curtain is clear the 440C CR30 relay OUT 0 status indicator remains ON Use the standard control system to start the conveyor The conveyor runs until the load interrupts the light curtain At this point the 440C CR30 relay must trip and the hazardous motion must stop a Use the override key to clear the load from the muting area as documented in step a 33 Run a normal sized load out of the machine area on the conveyor and into the muting area at a normal operating speed Use the standard control system to stop the load just after it clears muting sensor 1 muting sensor 2 and the light curtain remain interrupted After five seconds the maximum 1 S2 Synch Time as configured on the 440C CR30 relay the 440C CR30 relay must trip The muting lamp must start flashing at 1 Hz to indicate the timing fault a Use the override key to clear the load from the muting area as documented in step a 33 Run a normal sized load out of the machine area on the conveyor at a normal Operating speed into the muting area but this time use the standard control system to stop the load just after it clears muting sensor 2 the light curtain remains interrupted After five seconds the maximum 2 LC Synch Time as configured on the 440C CR30 relay the 440C CR30 relay must trip The muting lamp must start flashing at 1 Hz to indicate the timing fault E TT 33 Normal Light Curtain Verification 1 Confirm that access to the ha
42. indicator turns ON Immediately remove the override input wire at terminal El_ 04 of the 440C CR30 relay The 440C CR30 relay must trip immediately and stop the machine within 0 5 seconds The 440C CR30 relay OUT 0 status indicator must turn OFF The red Fault status indicator of the 440C CR30 relay must flash 4 Reconnect the wire to El_ 04 The 440C CR30 relay must not respond After three seconds press and release the Reset button The 440C CR30 relay must not respond 5 Cycle the Override and hold it on After three seconds the muting lamp flashes faster 3 Hz The red Fault status indicator continues flashing due to the muting fault which is independent of the override fault Press and release the Reset button The 440C CR30 relay OUT 0 status indicator should turn ON Use the standard control system to start the machine Confirm that the motor starts and that the machine begins to operate This step is optional in the following Override validation tests While the motor is running jump the Override input wire at terminal MP_12 to terminal El_ 04 of the 440C CR30 relay The 440 CR30 relay should not respond Release the Override The 440C CR30 relay must trip immediately The 440C CR30 relay OUT 0 status indicator must turn OFF The red Fault status indicator of the 440C CR30 relay must flash 10 Actuate the Override Press and release the Reset button The 440C CR30 relay must not respond 44 Rockwell Automation Pu
43. l T a ILE F i i a le i D 1 E mM mi Wikin j Y ey i W E KOI HE i i i AE E i i i T l mi Boor lore a bay Darpa i peer E J E T kears F i W IE Pris 1 E eer Fr 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 24 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 2 From the Reset Input pull down menu choose SMF5 to use the Reset you configured in the previous section Safety Output 3 In the Toolbox under Safety Output Function Blocks click and drag Muting Lamp to the next Safety Output Function target block amp pemg Lage i Do inning bs B lerk E Ei a ie Hz E o bai le ni E my kemige TFI oo Fa bal J uprise IE E Eici F i Wey za f i heir E lma F a Tam hama amp LJ Erch qe lma ety bets tier j
44. l Automation safety products Provides declarations of conformity certificates and other certification details Provides details on how to model safety functions in the SISTEMA tool 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 50 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Notes Rockwell Automation Publication SAFETY AT136B EN P May 2015 51 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 rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page Allen Bradley Connected Components Workbench Guardmaster GuardShield LISTEN THINK SOLVE PanelView PHOTOSWITCH RightSight Rockwell Automation and Rockwell Software are trademarks of Rockwell Au
45. lay OUT 0 status indicator should turn ON 20 to 40 Repeat steps 1 through 19 using MP_13 for MP_12 and El_01 for El_00 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 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 should turn OFF 42 43 4 4 Press and release the Reset button The 440C CR30 relay OUT 0 status indicator should turn ON Override Switch 440C CR30 Relay Tests Interrupt the light curtain and at least one muting sensor use either the normal load or a substitute such as a piece of cardboard The light curtain and at least one muting sensor must remain interrupted throughout this section The 440C CR30 relay faults either immediately or after the maximum muting time expires depending on the sequence of the sensor interruption At that time the red Fault Status indicator of the 440C CR30 relay flashes and the muting lamp flashes at 1 Hz IMPORTANT Throughout this section every actuation of the override must be followed by waiting for three seconds for the override function to initiate Actuate the override key After three seconds the muting lamp flashes faster 3 Hz Press the reset button The 440C CR30 relay OUT 0 status
46. master 440C CR30 22BBB Connection Browser Aubobrowse Refresh E Workstation NAUSCHMS991BW1 faa Linx Gateways Ethernet AB ETHIP 1 Ethernet AB VBP 1 1789 A17 A Virtual Chassis ee m 00 Workstation RSLinx Server H USB 7 Click OK 8 Click Yes to change from Run to Program mode Connected Components Workbench Safety relay is in Run mode Do you want to change to program mode Connected Components Workbench Download success 26 Downloaded Configuration CRC DFG3 Uploaded Configuration CRC DFG3 Do you want to change the safety relay back to Run mode 34 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 10 Click Edit Logic to see the online diagnostics DEY Samet rear er re een da m fe irat T By ef 1 a 7 etg ip a i o F imam or aep 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 utilize 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 Level on page 36 and Verification and Validation Plan on page 39 before proceeding with Verificati
47. n is pressed for 0 25 to 3 0 seconds and released the 440C CR30 relay turns ON its safety outputs 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 releasing the E Stop button once 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 ON its safety outputs providing power to the contactor coils If an object of the specified size passes through the muting sensors in the proper sequence within the configured time interval then the light curtain function is muted in the 440C CR30 relay The object is allowed to continue passing through the light curtain without motion being stopped Whenever the light curtain is muted the muting lamp is energized Muting is terminated as soon as the object leaves the detection area of the light curtain Two sensor L type muting can only be used at exit points If the sequence of the change of state of the muting sensors and light curtain is incorrect or the timing limits are exceeded the muting function faults If the light curtain is interrupted while the muting function is faulted the system de energizes the redundant pair of 100S C contactors causing the haz
48. nfirm the verification of the 440C CR30 configuration for each individual application by using the Verify command in the configuration software If the 440C CR30 configuration 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 gt Rockwell Automation Publication SAFETY AT136B EN P May 2015 4 Safety Function Light Curtain with Muting Two Sensor L type 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 x pema Device Toolbox Guardmaster 440C_CR30 Logic Guardmaster 440C CR30 E Connected Jw Guardmaster_ 440C CR30 4 t lad Download Upload Edit Logic Build Verify 3 Click Verify GUARDMASTER CR30 Logic GUARDMASTER CR30 x Quick Tips Device Toolbox Guardmaster 440C CR30 Guardmaster_440C_CR30 t F Download Upload Edit Logic Build 440C CR30 77BBB j Verification ID Remote Mode Fault 4 Answer all the questions and check each box if completed Connected Components Workbench E fave you followed inst
49. nsideration 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 Introduction Light curtains are used to detect attempted access to a hazardous area In normal operation if a light curtain detects an object it causes the safety system to stop any hazardous motion in the hazardous area In some applications it is desirable for product to pass through the light curtain without stopping motion in the hazardous area This can be done through the use of muting Two sensor L type muting is used to let product pass through a light curtain without interrupting the normal Run mode of the machinery Two sensor L type muting can be used only at exit points of the hazardous area Other types of muting can be used for entry points This safety function application example explains how to wire and configure a Two sensor L type single direction muting system with override and an additional E Stop function The system is based on a Guardmaster 440C CR30 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 ap
50. on of the Configuration on page 47 Rockwell Automation Publication SAFETY AT136B EN P May 2015 35 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Calculation of the Performance Level When properly implemented the light curtain muting and E Stop safety function 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 Documentation Safety functions fa Mew G Status Type Mame Type PLr PL are y SF Light Curtain Safety related stop function initiated by safeguard d e MEREEN y SF Muting of Light Curtain Muting function d e I Delete y SF E Stop Emergency stop function d The Performance Level and Category achieved by each subsystem of the light curtain safety function as calculated by SISTEMA is shown below Safety function Ww IFA Gocumentation l Pir PL sub airte E Library St lus Tyo Hame PFH fh CEF tigra Desg Pi MTTFd fal f Calegery WRequiressents of the category TEEN ey al 8 Light uiia Guedshield 440 Tripe d Sin
51. plication 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 Rockwell Automation Publication SAFETY AT136B EN P May 2015 3 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 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 Light Curtain with Muting two sensor L type Safety Function This application technique includes three safety functions 1 Safety related stop of hazardous motion initiated by a light curtain 2 Two sensor L type muting of a light curtain 3 Emergency stop of hazardous motion initiated by an E Stop button Safety Function Requirements Interrupting the light curtain 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 does not resume until a secondary action occurs for example pressing the start button The light curtain is muted to let automatically fed material e
52. ree firmware update is available for older units The 440C CR30 relay is configured by using Connected Components Workbench software version 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 14 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Configure the 440C CR30 Relay 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 Inthe Device Toolbox expand the Catalog section expand the Safety folder and then double click the 440C CR30 relay to add it to the project xoqjoo aainag F Rockwell Automation Publication SAFETY AT136B EN P May 2015 15 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 4 Toadd the I O module called for in this circuit right click the right hand plug in slot of the relay and choose 2080 IQ40OB4 2080 104 g Be i AT fj 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
53. s from Rockwell Automation Resource GuardShield Type 4 and GuardShield Remote Teach User Manual publication 440L UM003 Guardmaster 440C CR30 Software Configurable Safety Relay Quick Start Guide publication 440C QS001 Guardmaster 440C CR30 Configurable Safety Relay User Manual publication 440C UM001 Safety Contactors with DC Coil Installation Instructions publication 100S IN006 Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Safety Products Catalog publication 117 CA001 website http www rockwellautomation com rockwellautomation catalogs overview page Product Certifications website available from the Product Certifications link on http www ab com The SISTEMA Cookbook 4 available at http www dquv de ifa Praxishilfen Software SISTEMA SISTEMA Kochb C3 BCcher index 2 jsp Description Provides guidelines on how to install configure operate and maintain a GuardShield light curtain 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 operate and troubleshoot a Guardmaster 440C CR30 configurable safety relay 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 Rockwel
54. s 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 38 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 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 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 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
55. ssembly 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 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 A
56. start 0 1 2 3 4 5 Use the standard control system to start the machine Confirm that the motor starts and that the machine begins to operate 8 9 0 1 2 Release the E Stop button The machine must not start The 440C CR30 relay must not respond The 440C CR30 relay OUT 0 status indicator must remain OFF 7 1 1 1 1 1 1 1 1 1 17 Use a test rod to interrupt the light curtain protective field The safety system must trip The machine must stop in less than 0 61 seconds system response time plus maximum stopping time The 440C CR30 relay OUT 0 status indicator must turn OFF While interrupting the light curtain with the protective 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 440C CR30 relay OUT 0 status indicator must remain OFF Press and release the Reset button The 440C CR30 relay OUT 0 status indicator must turn ON The machine must not start Use the standard control system to start the machine again Confirm that the motor starts and that the machine begins to operate 2 Run a normal sized load out of the machine area on the conveyor and into the muting area at a normal operating speed Interrupt sensor 1 then sensor 2 and then the light curtain Just after the load interrupts sensor 2 the 885E stack light muting lamp must turn ON indicating that the light curtain is muted The load mus
57. t 2 2 continue through the muting area without tripping the safety system The 440C CR30 relay OUT 0 status indicator must remain ON Press and release the Reset button The 440C CR30 relay must not respond a Eoo 0 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Run a normal sized load out of the machine area on the conveyor and into the muting area at a normal operating speed Use the standard control system to stop the load while it is interrupting both muting sensors and the light curtain After 20 seconds the maximum muting time the muting lamp must start flashing at 1 Hz to indicate the timing fault The 440C CR30 relay OUT 0 status indicator must turn OFF 24 Use the standard control system to attempt to start the conveyor The conveyor must i E not start Use the key to actuate the override key switch After three seconds the muting lamp starts flashing faster 3 Hz to indicate the override function Press the Reset button and then use the standard control system to start the conveyor The conveyor should start moving the load out of the light curtain field Continue actuating the override key switch After 20 seconds the maximum configured override time the muting lamp must stop flashing turn OFF indicating that the override is no longer active As long as the light curtain is clear the conveyor
58. t status indicator should turn OFF Press and release the Reset button The 440C CR30 relay OUT 0 status indicator 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 12 indicator 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 13 4 1 Cycle the E Stop Cycle the Override key switch because the E Stop and Override share Test Pulses on MP12 and MP13 The red Fault status indicator should turn OFF 15 Press and release the Reset button The 440C CR30 relay OUT 0 status indicator should turn ON Ww Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 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 19 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 of 18 Cycle power to the 440C CR30 relay After the initial self checking the red Fault Status indicator should be OFF Press and release the Reset button The 440C CR30 re
59. tSight polarized retroreflective red DC light operate both sink NPN and 2 source PNP 4 pin DC Micro QD on 152 mm 6in pigtail 889D F4AC 5 DC Micro M12 female straight 4 pin PVC yellow unshielded 5 m 2 60 2649 60 2649 swivel tilt mounting bracket 2 92 124 92 124 reflector 2 855EP G24Y5 Control tower stack light pre assembled 10 cm pole mount with cap gray housing 24V AC DC full voltage amber 1 Steady status indicator 800FP MT44PX02S 800F non illuminated mushroom operators twist to release 40 mm round plastic Type 4 4X 13 IP66 red plastic 1 latch mount 0 N 0 contact s 2 N C contact s self monitoring standard pack 800FP F611PX10 800F push button plastic flush blue R plastic latch mount 1 N 0 contact s 0 N C contact s standard standard 1 pack 800FP KR21PX20 800F 2 position key selector switch plastic spring return from right left key removal key code 3825 standard 2 N 0 1 contact block s standard pack 100S C09EJ23C MCS 100S C safety contactor 9A 24V DC with electric 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 Muting is the temporary automatic suspension of the protective function of a safeguarding device like a light curtain Muting lets materials travel through the light curtain without stopping the hazardous motion To distinguish betwe
60. the jumper Neither the light curtain nor the 440C CR30 relay respond Press and release the Reset button Nothing changes 12 Cycle power to the light curtain Approximately five seconds after power is restored the light curtain outputs turn ON Pf 1 Press and release the Reset button The 440C CR30 relay OUT 0 status indicator 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 the clear the light curtain When the light curtain attempts to turn its OSSDs back 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 indicators red Status indicator flashing orange status indicator ON 29 Remove the jumper Neither the light curtain nor the 440C CR30 relay respond Press and release the Reset button Nothing changes 30 Cycle power to the light curtain Approximately five seconds after power is restored the light curtain outputs turn ON 31 Press and release the Reset button The 440C CR30 relay OUT 0 status indicator should turn ON Validation of Safe Response to Abnormal Operation The safety system responds properly to all foreseeable faults with corresponding diagnostics Muting Function Tests 1 Confirm that the safety system is reset and that the 440C CR30 relay OUT 0 status indicator is ON
61. the light curtain Use the standard control system to stop the conveyor Confirm that the E Stop still stops the machine even during the override function Run a normal sized load out of the machine area on the conveyor and into the muting area at a normal operating speed Use the standard control system to stop the load while it is interrupting the light curtain After 20 seconds the maximum muting time the muting lamp must start flashing at 1 Hz to indicate the timing fault The 440C CR30 relay OUT 0 status indicator must turn OFF Use the key to actuate the override key switch After three seconds the muting lamp starts flashing faster 3 Hz to indicate the override function Press the Reset button and then use the standard control system to start the conveyor The conveyor should start While actuating the override switch push the E Stop button The 440C CR30 relay must trip immediately The 440C CR30 relay OUT 0 status indicator must turn OFF The conveyor must stop 32 Release the E Stop The machine must not start The 440C CR30 relay must not respond The 440C CR30 relay OUT 0 status indicator must remain OFF To clear the light curtain use the key to actuate the override key switch After three seconds the muting lamp starts flashing faster 3 Hz to indicate the override function Press the Reset button and then use the standard control system to start the conveyor The conveyor should start Release the override after the load
62. 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 Verification and Validation Checklist General Machinery Information Machine Name Model Number Machine Serial Number Customer Name Tester Name s Schematic Drawing Number Input Devices 800FP MT44 E Stop 800FP F611 Reset 800FP KR21 Override Switch 440L P4KL1280YD Light Curtain 42EF P2JBB F4 x2 Photoelectric Sensors 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 of the 440C CR30 relay is the correct intended configuration Rockwell Automation Publication SAFETY AT136B EN P May 2015 39 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Normal Operation Verification The safety system properly responds to all normal Start Stop
63. tomation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Rockwell Otomasyon Ticaret A 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 AT136B EN P May 2015 Supersedes Publication SAFETY AT136A EN P January 015 Copyright 2015 Rockwell Automation Inc All rights reserved Printed in the U S A
64. ttentions help you identify a hazard avoid a hazard and recognize the consequence 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 gt gt 2 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type 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 co
65. using a momentary selector switch and is time limited In this application example we use a key operated switch to discourage the use of the override for anything other than its intended purpose Rockwell Automation Publication SAFETY AT136B EN P May 2015 9 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay The following timing diagram shows the override sequence in the context of an S2 LC Synchronization Time fault beginning in the OFF state At A we push and release the reset As long as the safety inputs are ON when the reset is pressed the safety outputs turn ON after the reset is released The material is detected by muting sensor 1 and then at B by sensor 2 at which point the light curtain function is muted and the muting lamp turns ON At this point in time the standard control system stops the conveyor and the load does not interrupt the light curtain within the configured 2 LC Synchronization Time causing the muting function to fault at C The muting lamp begins flashing at 1 Hz Because the light curtain is still clear the safety outputs are still ON The standard control system starts the conveyor The load blocks the light curtain at D Because the muting function is faulted blocking the light curtain causes the safety outputs to turn OFF causing the hazardous motion including the conveyor to stop The operator views the hazardous area to confirm there are no people inside and th
66. xit the hazardous area through the light curtain To initiate the muting function per IEC TS 62046 multiple sensors are configured to detect the material before it interrupts the light curtain Faults at the light curtain muting sensors 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 the user 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 According to the IEC TS 62046 technical specification you can only use a muting function when it is required by the process being performed on the machine You must make sure that a person cannot remain undetected in the hazardous zone when muting is terminated Muting can be used to allow access by materials only when safety is maintained by other means for example when the presence of a loaded pallet on a conveyor prevents access to the hazardous zone by personnel Refer to IEC TS 62046 for additional considerations when applying muting 4 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 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
67. y Stop r im e Oo Test Source ac 12 ki O Safety Mati Test Source e 13 mm Single Wire Safety Input Ai Two Hand Centred Advanced Sabrni E Alienate Device Leget Furini k Punter D ano P NAND l i gt N a 2 D AND wath Hestar Th COR wath Rett a Safety Output Function Dorks ne 2 Senior T Type b Pointer bla Aybute Time is t Wo immediate OFF sk W ON Delwy re nee Tee GO OFF Delay lsg Charie etini B Miutinglamp a General Auhvanced Setia There are oo usable cordrols in thr arene Drees en dem ante Pha The Muting block SMF2 consists of the primary input device the light curtain the muting function consisting of two sensor inputs and the override function The override function is optional in this block but we will configure one later The Muting block consumes three SMF blocks although it is consolidated to one block visually for simplification It also consumes one Logic Level A block which is represented as a Pass Through block 3 In the Muting block SMF2 change the Mute Type to 2 Sensor L Type by choosing it from the pull down menu Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay 4 On the Muting block SMF 2 click the third input terminal EI_04 connected to S1 to view the selection table Connected Components Workbench software automatically assigns the next available terminals EI
68. zardous 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 cover is not scratched or dirty Disconnect 24V power from the light curtain and confirm that the 440C CR30 relay trips Reconnect 24V power to the light curtain Push the reset button Confirm that the 440C CR30 relay turns its safety outputs ON Use the test rod included with the light curtain in the original packaging 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 status of the output status indicators on the light curtain and the IN 2 and 3 status indicators on the 440C CR30 relay 2 Rockwell Automation Publication SAFETY AT136B EN P May 2015 Safety Function Light Curtain with Muting Two Sensor L type and Configurable Safety Relay Pass the test rod through the protective field as shown in the illustration Confirm that the light curtain output status indicators and 440C CR30 relay input status indicators 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

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