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Guardmaster 440C-CR30 Configurable Safety Relay User Manual

1. CR30 Hardware Details Figure 2 Hardware Details 1 2 3 4 5 6 7 Status Indicators OY Ra tf bopotodoooog aa B0000 FC ai 157 2 16 17 000 000 s 1 WS M eo EY MOOOCOO0C0CO0COCO 8 9 10 5 11 6 Description Description 1 Status indicators 10 Verification button 2 Plug in latch 11 Din Rail mounting latch 3 Plug in screw hole 12 Input status 4 40 pin high speed plug in connector 13 Power status 5 1 0 and Power terminal blocks 14 Runstatus 6 Mounting screw hole mounting foot 15 Fault status 7 Right side cover 16 Lock status 8 RS 232 non isolated serial port 17 Serial communications status 9 Type B connector USB 18 Output status Max Number of Inputs and Outputs Many of the inputs and outputs can be configured for different roles The following table shows the maximum number of terminals for a specific function Assigning a configurable terminal to one role reduces the risks of its use as another role and reduce the allowed maximum number of terminals for other functions Function Max Allowed Function Max Allowed Safety inputs normally closed up to 18 Pulse test outputs up to 6 Safety inputs normally open up to 6 OSSD safety outputs up to 10 Single wire safety input up
2. 09 Safety Input N C 10 Safety Input N C or Single Wire Safety Input N C 11 Safety Input N C or Single Wire Safety Input 24V DC A1 Power Supply 24V 15 10 COM OV A2 Power Supply 0V 12 Test Output or OSSD High Side or Safety Input N C or Safety Input N O or standard diagnostic 13 Test Output or OSSD High Side or Safety Input N C or Safety Input N O or standard diagnostic 14 Test Output or OSSD High Side or Safety Input N C or Safety Input N O or standard diagnostic 15 Test Output or OSSD High Side or Safety Input N C or Safety Input N O or standard diagnostic 16 Test Output or OSSD High Side or Safety Input N C or Safety Input N O or standard diagnostic 17 Test Output or OSSD High Side or Safety Input N C or Safety Input N O or standard diagnostic 18 OSSD High Side 19 OSSD High Side 20 OSSD High Side or Single wire Safety Output 21 OSSD High Side or Single wire Safety Output 20 Rockwell Automation Publication 440C UM001D EN P March 2015 Grounding the Configurable Safety Relay Connecting a Power Supply Power Ground and Wiring Chapter 3 must be referenced to controller ground or be floating not referenced to a potential other than ground Failure to follow this procedure can result in property damage or personal injury i WARNING All devices that are connecte
3. Figure 84 Example Schematic for Three N C without Test Pulses 24V DC 00 01 0203 04 05 06 07 08 09 10 11 CR30 IAtfa2 12 13 14 15 16 17 18 19 20 21 24V Com oes eine an Figure 85 Example Schematic for Three N C with One Test Pulse Source 24V DC 00 01 02 03 04 05 06 07 08 o9 10 11 CR30 4 A1 a2 12 13 14 15 16 17 18 19 20 21 24V Com Rockwell Automation Publication 440C UM001D EN P March 2015 73 Chapter 9 74 Safety Monitoring Functions Figure 86 Example Schematic for Three N C with Three Test Pulse Sources 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 ABC 24V Com Figure 87 Example Schematic for Three OSSD 24V DC Al A2 4 100 01 02 03 04 05 06 07 08 o9 10 11 CR30 Safeguarding Device 24V Com Rockwell Automation Publication 440C UM001D EN P March 2015 Chapter 10 Logic Levels A and B The Connected Components Workbench CCW has two levels that allow you to apply simple logic to create more sophisticated safety systems The logic levels are labeled A and B on the CCW workspace The logic functions are available in the Toolbox Figure 88 Logic Levels A and B on the CCW Workspace LA Project55 Connected Components Workbench Standard Edition Administrator File Edit View Debug Tools Communications Window Help PNW al eo o TFA Fev 2 tes BIC 477243 aj
4. Table of Contents Chapter 9 Emergency Stops miaran nione er i ea Marae e heat 45 Enabling Switeh senri ss skiss amare eons DOENE wens aes TES 46 Feedback Monitoring ssssessessesrrrrrererrrrrrr reser reser reses ra 48 Gate SWICCI ach eatin ce Scherabue aes ren ae a a ookn Sates 49 PI ORC UTA ansa she aa dt ds de SNRA Re hast A T Ee RR 51 aA BT sneer pager pre R OR Der OR Er eran ETE eae I E ERE 52 2 Sensor T Type Muting sssessereererrrrrrrrerrrrr rr re rr ra 53 2 Sensor L Type MuUting orere ederek ea skule Ae eee oles 56 A Setisor MUting aie sen sive es are TERESE ESE saan Snr 58 Muting Override s ssssssersererrrrrrerrrrerer rer rr rr ere rer era 60 M ting Lampas sania r Buses dt tees eee ae 60 RESCE cstv ga sel be E A EEEE ua hewn a ote sal RT 60 Restarts cones 25 tate alte E E ao nae heheh siren E 62 Sate ty Mat pi castor yin ore alah eat ethene aw aden 63 Sensi Gate etat cok ot vated dines hehehe de ese boy alt 64 Single Wire Safety Mniputntacdues ean seen Suocetey enue bara 65 Two Hand Control sssssrrrsesrrrsrrrrrrrrrrrrrr tear rer rr ak 66 Type IIA Two hand Control 0 3 5 esedv ive edad ee 67 Type IIIC Two Hand Controls en icectesee nh teed bedeers 67 PUteiiate DIAA AEE Suga E ean hae in Ri eee 69 Single Channel sia svenskarna sine har O a eames 69 Dual Channels ke itl Ahaha oe alice CU Gt Wate a EAE 70 Dual Channel OSSD s ssosssseeeerssrrreeeerrsrrrrrr ers ss sr resa 71 Dual Channel N C N Os sssssssssserreers
5. Chapter 10 80 Logic Levels A and B Figure 99 Logic of the Restart Function with Two Input OR Restart Input 1 Input 2 The timing diagram shows how the output of the Logic block responds to the input signals and the Restart signal Either or both inputs can be HI when the Restart signal occurs for the output to go HI If all inputs go LO the output goes LO Figure 100 OR with Restart Timing Diagram HI rl i mi M Restart 19 H H Input 1 Zi nut Lo OR i i i i 1 1 Input 2 LO OT HI i 1 i 1 i Output LO J l Rockwell Automation Publication 440C UM001D EN P March 2015 Input Connection Feedback Reset Timing Output Connections Chapter 11 Safety Outputs The safety output blocks are the fourth stage of the configuration Many of the blocks have common features Each output block has one input connection This input connection can be connected to only Logic Level B blocks The Immediate OFF ON Delay and OFF Delay blocks have a feedback parameter To use the feedback parameter a feedback input block must be declared If a feedback input block is not available the feedback parameter is set to None and can be considered to be always HI The reset parameter must be set to either automatic or manual e Ifset to automatic the output turns on when the input received from the Logic Level B block is HI e Ifthe reset is set to manual a reset input block must be
6. i WARNING Applying an inappropriate DC or any AC voltage can result in a loss specified voltage to relay inputs Input devices with mechanical contact outputs such as emergency stop buttons and safety limit switches use both a safety input terminal and a test output terminal This enables the circuit to achieve a Category 4 rating When safety devices are connected via test outputs to an input circuit on the CR30 relay the recommended wire length is 30 m 98 4 ft or less Figure 6 Input Devices with Mechanical Contacts 24 VDC 0 0000008000 Input Terminal Block a COM Input Output Terminal Block OOQO BQOO O O O Configured for Pulse Test Output 3mA Typical 24V Common Input Devices with OSSD Outputs Devices such as light curtains laser scanners and solid state interlocks having current sourcing PNP semiconductor outputs OSSD have built in test pulses or other method of detecting faults These devices are connected directly to the inputs of the CR30 relay safety and do not use a test output These devices must have a common reference with the CR30 Figure 7 Input Devices with OSSD Outputs 24V DC Receiver Transmitter OCOOC0000000 Input Terminal Block ae oe 068 ee JO ae have common restene 24V Common Rockwell Automation Publication 440C UM001D EN P March 2015 Wire Output Devices Embedded Serial Port Wiring Pow
7. 00 01 02 03 04 05 06 07 o08 o9 10 11 CR30 24V Com Rockwell Automation Publication 440C UM001D EN P March 2015 Single Wire Safety Input Safety Monitoring Functions Chapter 9 When configured for this type of input the CR30 expects a Single Wire Safety SWS input signal from a GSR relay or a safeguarding device that has an SWS output signal The GSR relay family includes the CI SI DI DIS GLP GLT EM and EMD modules Each of these modules provides the SWS signal on terminal L11 Figure 65 Single Wire Safety Function Block Toolbox a Safety Monitoring Functions Pointer Emergency Stop Enabling Switch Safety Monitoring Feedback Monitoring Gate Switch Light Curtain Muting An Single Wire Safety w Reset Restart Safety Mats Snge essay eps Two Hand Control Ho Deowmaw or Alternative Device Only terminals 10 and 11 of the CR30 can be configured to receive the SWS signal e EI 10 EI 11 embedded input terminals 10 11 The SWS signal is a long pulse followed by a short pulse which is repeated while the signal is active The SWS is active when the safety outputs of a GSR safety relay are ON When the SWS is inactive the SWS signal is OV The timing and voltage characteristics of the SWS waveform are shown in Figure 66 Figure 66 SWS Waveform Ams 0 7ms 0 5ms 1ms 24V OV Active ON Inactive OFF Figure 67 show
8. 2 On the Device Details toolbar mouse over the Secure button The tooltip message Set Change or Clear Safety Relay Password Protection is displayed GY Project157 Connected Components Workbench Standard Edition File Edit View Debug Tools Communications Window Help PNSGwW 4HB 9 8 Gla ee Project Organizer Name Project157 Guardmaster_440C_CR30 w Guardmaster 440C CR30 Guardmaster_440C_CR30 440C CR30 22BBB By Verification ID remote Progam Mode Run Fault Not Faulted 3 Click the Secure button Select Set Password 4 Provide password Confirm the password by providing it again in the Confirm field TIP Passwords must have at least eight characters to be valid Rockwell Automation Publication 440C UM001D EN P March 2015 121 Chapter 17 Security and Password 5 Click OK Once a password is created any new session that tries to connect to the safety relay has to supply the password to gain exclusive access to the target safety relay E Connected Components Workbench 9 Set password protection on the safety relay Password I Confirmation Cox IMPORTANT Ifyou have toflash the safety relay the project in the relay is lost A new project must be downloaded 6 Click OK Connected Components Workbench Keep the password carefully If lost you will have to flash the safety A relay to reset the password a Change Password Wi
9. Restart Test Source A 12 id dh Safety Mats Test Source B 13 M mn Single Wire Safety Input AA Two Hand Control Advanced Setting Alternative Device Inputs 2NC v 4 Logic Functions Boker Pulse Testing 2Sources v k Discrepancy a D AND Time S0ms zs Project Organizer x Input Filter ae 625ms v Name Project55 W Guardmaster_440C_CR30 Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 The available input selections for the Enabling Switch inputs are e EI 00 EI 11 embedded input terminals 00 11 e MP 12 MP 17 multi purpose terminals 12 17 You can modify the number and types of inputs e 2N C e 2 OSSD e INC Pulse testing can be disabled or set to 2 Sources When 2 Sources is selected the next available test sources are automatically selected You can modify the sources afterward You can use the default Discrepancy Time and Input Filter or choose to modify these settings Figure 34 Example Schematic of a Dual Channel Enabling Switch Without Test Pulses 24V DC FN 00 01 02 03 04 05 06 07 08 09 10 11 CR30 A1 a2 12 13 14 15 16 17 18 19 20 21 24V Com Figure 35 Example Schematic of a Dual Channel Enabling Switch Using Test Pulses A and B 24V DC oI oo 01 02 03 04 05 06 07 08 09 10 11 CR30 A B 24V Com Rockwell Automation Publication 440C UM001D EN P March 2015 47 Chapter 9 S
10. Specification Temperature operating e IEC 60068 2 1 Test Ad Operating Cold IEC 60068 2 2 Test Bd Operating Dry Heat IEC 60068 2 14 Test Nb Operating Thermal Shock Description 20 65 C 4 4 149 F Temperature nonoperating IEC 60068 2 1 Test Ab Unpackaged Nonoperating Cold IEC 60068 2 2 Test Bb Unpackaged Nonoperating Dry Heat IEC 60068 2 14 Test Na Unpackaged Nonoperating Thermal Shock 40 85 C 40 185 F Relative humidity operating IEC 60068 2 30 Test Db Unpackaged Damp Heat 5 85 noncondensing Relative humidity nonoperating IEC 60068 2 30 Test Db Unpackaged Damp Heat 5 95 noncondensing Vibration e IEC 60068 2 6 Test Ea Unpackaged Shock 29 10 500 Hz Shock operating EC 60068 2 27 Test Ea Unpackaged Shock 25 g DIN Rail or panel mount Shock nonoperating IEC 60068 2 27 Test Ea Unpackaged Shock 25 g DIN Rail mount 35 g panel mount Emissions e CISPR 11 Group 1 Class A Immunity ESD e EC 6100 4 2 6 kV contact discharges 8 kV air discharges Immunity radiated RF e IEC 61000 4 3 10V m with 1 kHz sine wave 80 AM from 80 2700 MHz 10V m with 200 Hz 50 Pulse 100 AM at 900 MHz 10V m with 200 Hz 50 Pulse 100 AM at 1890 MHz Immunity EFT B e EC61000 4 4 1 kV at 5 kHz on Ethernet port Immunity surge transient e IEC 61000 4 5 1 kV line earth CM
11. Thou MP13 PT z a Feedback m3 S Reset Type Manual Reset Input SMF 4 ET P sotety Mat 0 9 vee B ET Inputs 1 bs g Q ee res shad 10 2 Table 36 For SMF1 E stop Comment Value Feedback Configured Input Filter time 250 ms 10x25 ms 250 ms Safety Sensors Reaction time of sensor device Oms considered as 0 ms since mechanical device only SMF Configured Input Filter time 250 ms 10x25 ms 250 ms Reset Restart Min 2x Input Filter Time 250 ms Min 0 75 s 500ms 250 ms 0 75 s Max 3 5 Max 2 x Input Filter Time 3 s 0 5 35 3 55 Logic Internal execution time to process 100 ms input signal routing and output processing 2 SOF No On delay configured for SOF 0s Actuator Assuming a contactor with a 10 ms response time of 10 ms Total Min 1 36 s Max 4 11 s It takes a minimum of 1 36 s after a valid Reset operation of at least 250 ms to enable the outputs when the E stop is active closed contacts Rockwell Automation Publication 440C UM001D EN P March 2015 145 AppendixA Specifications 440C ENET Module Specifications 146 Table 37 For SMF2 Safety Mat Comment Value Feedback Configured Input Filter time 250 ms 10x25 ms 250 ms Safety Sensors Reaction time of sensor device Oms considered as 0 ms since mechanical device only SMF Input Filter Disabled Oms Reset Restart Min 2x Input Filter Time 250ms Min 0 75 s 500ms 250 ms 0 75 s Max 3 55
12. measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support 04H Light Curtain Mute Time Exceeded The Light Curtain was muted for longer than the maximum configured mute time Do one of the following e Verify there is no obstruction of the mute sensor or Light Curtain e Verify the application times are appropriate e Check wiring for shorts to 24V or other channels e Power cycle the safety relay Reconfigure the safety relay Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support 08H Contact bounce One channel went to the safe state and back to the active state after a reset Do one of the following e Check wiring and mechanical integrity of the field device e Power cycle the safety relay Reconfigure the safety relay Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support 10H Mute Time E
13. module Hold both buttons until the Status LED on the Cat No 2080 MEMBAK RTC module begins flashing approximately 5 seconds which indicates the restore process has begun TIP You do not have to hold the Backup button down until the flashing stops When the restore operation is complete the Status LED on the Cat No 2080 MEMBAK RTC stops flashing and the LEDs on the Guardmaster 440C safety relay begin to cycle through each of the verification digits of the application that is restored to the safety relay from the memory module Confirm the Verification ID displayed on the safety relay match the expected Verification ID of the application to be restored from the memory module Power down the Guardmaster 440C safety relay Remove the Cat No 2080 MEMBAK RTC memory module from slot lof the safety relay module bay Snap the dust cover or previous plug in module into slot 1 of the module bay Power on the Guardmaster 440C safety relay to resume normal operation Rockwell Automation Publication 440C UM001D EN P March 2015 Chapter 19 Reports The Connected Components Workbench CCW allows you to generate a report using Microsoft Word automatically The report is editable which allows you to add more information or combine the report with other documents for the safety technical file The report generator button is at the top of the logic editor Mouse over the icon that looks like a printer and click
14. x Safety Mats d Test Source A 12 ev Alternative Device Test Source B 13 Pointer Advanced Setting AND Inputs 2N C N O v OR Pulse 250 XOR Testing Input Filter oc 625ms The two hand controls can be connected to the following terminals e EI 00 EI 11 embedded input terminals 00 11 e MP 12 MP 17 multi purpose terminals 12 17 You can use the default Input Filter or choose to modify these settings When test pulses are used the CCW automatically selects another test pulse pattern for each input The two hand control can use input test pulses from following terminals e MP 12 MP 17 multi purpose terminals 12 17 Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 Type IIIA Two hand Control The Type IIIA uses only one normally open contact for each hand This configuration can be set up with or without the use of test pulses The test pulses provide short circuit fault detect between channels and between channel and 24V Figure 69 Example Wiring Connection for a Type IIIA Two hand Control without Test Pulses 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 24V Com Figure 70 Wiring Connection for a Type IIIA Two hand Control with the Test Pulses 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 A B 24V Com Type IIIC Two Hand Control The Type IIIC uses a normally open and a norma
15. 1 0 0 1 1 0 The NOT block accepts only one input The NOT inverts the input signal When the input is LO the output is HI When the input is HI the output is LO Figure 94 NOT Logic Block Logic Level A ag Deur e Rockwell Automation Publication 440C UM001D EN P March 2015 77 Chapter 10 Logic Levels A and B Table 14 NOT Logic Table for Two Inputs AND with Restart The AND with Restart accepts 2 24 inputs and requires a Restart input All inputs must be HI when the Restart button is pressed The CCW automatically recognizes the Restart function blocks and allows you to select one Once selected the Restart is no longer available for other logic blocks Figure 95 shows an example with a gate switch and a light curtain Both the gate must be closed and the light curtain clear Then the Restart input must be pressed The output of the logic block goes HI on the trailing edge of the restart signal Figure 95 Example of AND with Restart Quick Tips ao e o AND with amp Pass o Immediate OFF F018 PT if Gate Switch Restart Through ao 2 9 EEEO PT ad Feedback None v 2 z Test Source A 12 bd Restat SMF3 Reset Type Automatic Test Source B 13 bd Inputs 2 xs x Adva se an ud H Light Curtain e 03 0 9 ELO gt 9 1 Restart Figure 96 Logic of the Restart Function with Two Input AND Restart TL Inputi Input2 The timing diagram shows h
16. 10H 40H 80H 80H 168 Light Curtain Sequence Fault An illegal input pattern the pattern of sensors and light curtain being blocked and cleared was detected Do one of the following Check the sensor e Check wiring for shorts to 24V or other channels e Power cycle the safety relay Reconfigure the safety relay Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support Rockwell Automation Publication 440C UM001D EN P March 2015 Tag Definitions Appendix F Type Code Cause Recovery Method 10H FFFFH Unregistered fault Contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support 40H 01H Retrigger Fault Do one of the following Enabled input transitioned from OFF 0 to ON 1 while e Verify application logic and wiring is appropriate the output delay time was in progress e Power cycle the safety relay Reconfigure the safety relay Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com su
17. Discrepancy time of 0 disables discrepancy monitoring The time between opening or closing the channels is infinite Rockwell Automation Publication 440C UM001D EN P March 2015 139 Appendix A 140 Specifications Test Pulse Evaluation Integral test pulses are applied to the input circuit of safety sensor with electromechanical outputs The test pulse output signal becomes input signal of a safety input through the contacts of the safety sensor Sensors with electronic OSSDe output safety switching device electronic semiconductor outputs have their own test pulses and do not require a test pulse evaluation that is sourced by the logic device Note In case multiple input circuits are sourced by the same test pulse output a fault affects all inputs that are connected to this output Multi Channel Signal Evaluation and Discrepancy Monitoring Independent of the test pulse evaluation or sensor type components can be wired in a single dual channel or even three channel structure In a dual or three channel structure all channels must be active to enable the SMF Disabling at least one of the channels will demand the safety function These channels can be monitored against discrepancy The discrepancy time is the amount of time that input channels of an SMF are allowed to be in an inconsistent state before an instruction fault is generated The discrepancy time cannot be set in Single Channel Mode Sequence and Timing Faults
18. Monitoring Functions Enabling Switch 46 You can use the default Discrepancy Time and Input Filter or choose to modify these settings Figure 31 Example Schematic of a Dual Channel E stop Without Test Pulses 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 A1 a2 12 13 14 15 16 17 18 19 20 21 24V Com Figure 32 Example Schematic of a Dual Channel E stop Using Test Pulses A and B 24V DC 100 01 02 03 04 05 06 07 08 o9 10 11 CR30 A B A1 A2 12 13 14 15 16 17 18 19 20 21 24V Com The Enabling Switch function block sets the parameters for typical enabling or hold to run devices In the CCW click and drag or double click the block to an available Safety Monitoring Function spot When mechanical operated contacts are used these contacts must be direct acting contacts Note This function block is intended to be used only in applications with a 3 position enabling switch that only allows activation of its outputs closed contacts when the operator presses and holds the switch into its middle position The switch has to be designed using a mechanical force to reset to its default off contact open position Figure 33 Enabling Switch Function Block 4 Safety Monitoring Functions a amp r Pointer E 5 _Emergency Stop a Safety Monitoring ii 3 SMF 1 00 o o H Gate Switch 1 Enabling Switch H Light Curtain E 01 ve o B Muting Reset
19. NU 2080 IQ4 l 02 103 COM COM NU NU C 24V Com 2080 0B4 The 2080 OB4 has four sourcing outputs Terminals B3 and B4 are internally connected one of these terminals must be connected to 24V DC Terminals A3 and A4 are internally connected one of these terminals must be connected to 24V Com Figure 110 2080 0B4 Schematic Showing Four Standard Output Signals 24V DC B1 B2 B3 B4 B5 B6 NU NU 24DC 24DC 0 00 0 01 L 2080 OB4 a NU NU 24DC 24DC 0 02 0 03 24V Com Rockwell Automation Publication 440C UM001D EN P March 2015 89 Chapter 12 90 Plug in Modules 2080 0W4I The 2080 OW4I has four electromechanical relays with normally open Form A contacts Figure 111 2080 OW4l Schematic Showing Four Standard Output Signals 24V DC B1 B2 B3 B4 B5 B6 CMO 0 0 CM1 O 1 CM2 0 2 Lt L4 L4 2080 OW41 CM3 O 3 NU NU NU NU Rockwell Automation Publication 440C UM001D EN P March 2015 Install a Guardmaster 440C ENET EtherNet IP Plug in Module AN Plug in Modules Chapter 12 ATTENTION Environment and Enclosure This equipment is intended for use in a Pollution Degree 2 industrial environment in overvoltage Category II applications as defined in 1EC 60664 1 at altitudes up to 2000 m 6562 ft without derating This equipment is considered Group 1 Class A industrial equipment according to IEC CISPR 11 Without appropriate precautions there may be difficulties with e
20. Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt Allen Bradley Connected Components Workbench ControlFLASH Guardmaster GuardShield Micro800 Micro830 PanelView PowerFlex Rockwell Software SafeZone SensaGuard and Zero Force Touch Buttons are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Who Should Use this Manual Purpose of this Manual Additional Resources Preface Read this preface to familiarize yourself with the rest of the manual It provides information concerning e who should use this manual e the purpose of this manual e related documentation e conventions used in this manual Use this manual if you are responsible for designing installing configuring or troubleshooting control systems that use the CR30 safety relay You should have a basic understanding of electrical circuitry and familiarity with safety related control systems If you do not obtain the proper training before using this product This manual is a reference guide for the CR30 safety relay plug in modules and accessories It describes the procedures you use to install wire and troubleshoot your relay This manual e explains how to install and wire your relay e gives an overview of the CR30 safety relay system Refer to the Online Help prov
21. Plug in 1 terminal 00 for status indication Figure 101 Immediate OFF Configuration Safety Monitoring Logic Level A Logic Level B Safety Output 81 SMF 1 OF 1 00 ve o o Pass e e Pass o e Immediate OFF ey 2018 vier gt Emergency Stop Through Through an 0 Heto PT Feedback SMF2 wv 9P Test Source A 12 v Reset Type Manual v 2 x Test Source B 13 v Reset Input SMF 3 v v Inputs 1 v 82 Rockwell Automation Publication 440C UM001D EN P March 2015 ON Delay E00 Eao E03 Safety M vee Test Source A 12 Test Source B 13 Advanced Setting MEF 2 o Feedback gt ng 7s gt Emergency Stop Safety Outputs Chapter 11 The ON Delay block turns on the output after the specified time delay expires Figure 102 shows the ON Delay output block that is connected to an E stop block through Logic Level LLB1 The feedback signal is provided by SMF2 and manual reset by SMF3 The time delay is set to 20 The output will turn on 1000 ms 20x50 ms after the reset button is released The output is connected to e Terminals 18 and 19 for dual channel safety switching of the machine hazards e Terminal 20 which is configured as a Single Wire Safety SWS output e Plug in 1 terminal 00 for status indication Figure 102 ON Delay Configuration evelA Logic Level 8 Safety Output Pass o Pass Py AN ON Delay e Eo PT Through Through Sy RE ra Feedback SMF2 ov 602
22. The other non affected outputs continue to work Examples of recoverable faults include e SMF faults e Cross loop e Simultaneity faults e Reset button fault e Muting Synchronization time exceed e Muting time exceeded e Sequence fault Faults are indicated by the fault LED If the fault LED is flashing red a recoverable fault has occurred If the Fault LED is solid red a nonrecoverable fault has occurred Figure 125 Fault LED The Fault LED is Solid red Non recoverable fault Flashing red Recoverable fault 440C CR30 Rockwell Automation Publication 440C UM001D EN P March 2015 113 Chapter 16 Troubleshooting Nonrecoverable Faults Nonrecoverable faults and failures are malfunctions of the device itself that occur during operation These faults are detected by internal monitoring measures helping to ensure the safety integrity of the device itself Nonrecoverable faults require a power cycle to allow CR30 to perform all relevant internal system tests during initialization If there are transient malfunctions CR30 will recover after power cycle If there is permanent damage or malfunction the CR30 will remain in safe state after power cycle Permanent nonrecoverable faults are typically related to random hardware faults that cause permanent damage of components Potential root cause for nonrecoverable faults e Transient EMC disturbance causing asynchrony of the two CPU e Environmental disturbances of high volta
23. Through USB connection Verify successful RSLinx Classic This appendix shows how to flash update the firmware in a Guardmaster CR30 safety relay using ControlFLASH To download the latest Guardmaster CR30 safety relay firmware revision go to http www rockwellautomation com support pcdc page and select your desired revision communications with you Guardmaster CR30 safety relay by USB using RSWho The Guardmaster CR30 uses the AB VBP x driver Aj RSLinx Classic Gateway RSWho 1 oo File Edit View Communications Station DDE OPC Security Window Help aor S amp 818 Bl x Autobrowse Browsing node 0 found EJ Workstation NAUSCHMSS1R4RL oa S amp Linx Gateways Ethernet Sss AB_ETHIP 1 Ethernet 00 15 S E AB_VBP 1 1789 A17 A Virtual Chassis RSLinx Server 440C CR30 EJ 00 Workstation RSLinx Server 115 Guardmaster CR30 440C CR30 22888 tr USE For Help press F1 NUM 08 26 14 Bram 2 Start ControlFLASH Click Start gt All Programs gt FLASH Programming Tools gt ControlFLASH 3 Select Local and click OK r Welcome to Control FLASH Welcome to Control FLASH the firmware Control Select the directory you want to use C Network Local Rockwell Automation Publication 440C UM001D EN P March 2015 153 Appendix D ControlFLASH Firmware Upgrade 4 Click Next Ed ControiFLASH Untitled Sto Control FLASH 12 00 0
24. Typically applied to specialty safety functions such as Muting or Two hand control It monitors the sequence of events to evaluate the validity of input signals to enable the SMF Integral Test Pulses of Safety Outputs Test pulses are applied to safety outputs to detect faults within the connected periphery such as short circuits to 24V of OV or cross loop faults between two output sources Integral pulses on safety outputs are also used to help ensure the safety integrity of the output itself such as ability to switch off An output fault internal or external always requires a power cycle to test if the fault is recoverable or not Note To help ensure the ability to switch off actuator devices in case of short circuits to 24V DC within the control line of one actuator it is recommended to use a pair of safety outputs controlling two redundant switching actuators Once the fault is detected a second channel is able to switch off the load Fault exclusions of potential short circuits between two conductors are also possible when following the requirements for fault exclusions according to EN ISO 13849 2 Table D 3 and D 4 among others protection for example cable conduit and separated wiring of safety signals Rockwell Automation Publication 440C UM001D EN P March 2015 Specifications Appendix A The overall monitoring time to evaluate a fault and initiate a system response after the occurrence of a recoverable fault must consider a
25. all devices in the communication coverage area Connect the Module to the EtherNet IP Network Connect the RJ45 connector of the Ethernet cable to the Ethernet port on the bottom of the plug in module as shown Figure 115 Ethernet Cable Connection O O 0000000000 H O0o00000000 r E Set the Network Address The default settings for the 440C CR30 safety relay is DHOP enabled for the Ethernet plug in You can set the network internet protocol IP address two ways e Use Dynamic Host Configuration Protocol DHCP server e Use Rockwell Automation RSLinx Classic Studio 5000 or Connected Components Workbench software Use a DHCP BOOTP Server If you do not have a large computer that can act as a boot server download our DHCP BOOTP software so you can use a personal computer as a DHCP BOOTP server To set the network address by using the Rockwell Automation DHCP BOOTP server follow these steps 1 Access the DHCP BOOTP utility at http www software rockwell com download comms rsnetworx bootp dhcp 20server 202 3 2 zip Rockwell Automation Publication 440C UM001D EN P March 2015 Plug in Modules Chapter 12 2 Download the version 2 3 1 DHCP BOOTP utility 3 Extract the zipped files to a temporary directory 4 In the temporary directory double click setup exe to install the DHCP BOOTP utility 5 Run the utility 6 Refer to the following chart which describes
26. e Do not touch connectors or pins on component boards e Do not touch circuit components inside the equipment e Use a static safe workstation if available Store the equipment in appropriate static safe packaging when not in use Installation Summary Do these steps to install the Ethernet plug in module 1 Mount the Guardmaster 440C CR30 safety relay on a DIN Rail or panel 2 Install the plug in module Rockwell Automation Publication 440C UM001D EN P March 2015 91 Chapter 12 Plug in Modules About the Module The module provides EtherNet IP connectivity for Guardmaster 440C CR30 safety relays Use Figure 112 to identify the external features of your module Figure 112 External Features Description Status indicators Plug in connector on opposite side of circuit board 2 MACID label 4 RJ45 Ethernet cable connector Software Requirements You must have one of the following versions of software Table 16 Software Versions Software Description Studio 5000 Logix Designer 20 or later You need to download the add on profile from http www rockwellautomation com support controlflah LogixProfiler asp Connected Components Workbench 8 or later You need to download the software from http www rockwellautomation com rockwellautomation support pcdc page Firmware Requirements You must have one of the following versions of firmware Table 17 Firmware Versions Modu
27. edited The editing rules follow IEC 61131 3 section 2 1 2 This feature is important because it allows you to distinguish between multiple occurrences of the same function blocks during the design wiring and troubleshooting phases The name change is initiated in one of two ways 1 Simply double click the name inside the block 2 Highlight the block and press F2 The typical editing keys Home End Backspace Delete Left Arrow Right Arrow Page Up Page Down and Mouse Click can be used to edit the name When the block is selected for editing the name appears in a light blue box and the name is highlighted in light blue background as shown in Figure 27 Figure 27 Block Name Selected for Editing Safety Monitoring GE See ELO vee Emergency_Stop 1 mo e o Test Source A 12 Test Source B 13 Follow these simple rules for naming the blocks e Names must begin with a letter upper or lower case or an underscore e Names cannot have spaces e Names can contain letters numbers and underscores no special characters e Name length can be anywhere from 1 30 characters e Letter case is not significant e Multiple leading or consecutive embedded underscores are not allowed e Trailing underscores are not allowed Rockwell Automation Publication 440C UM001D EN P March 2015 43 Chapter 8 Safety Block Renaming Naming Error Indication After tabbing off pressing enter or mousing off the
28. of a report is shown in the following two figures Figure 133 Example Report Page 1 Project 440C_CR30 This ts the body of section for project It should contain some general insoduction of the project and sa Daa Bin 3 SwopBas I C Tapet LEDs Li Type Filter Vaha 0 ty Moahereg Furctios Status SAFI 1 Safety Moakerteg Purctice Status SMF 2 2 Safety Monitorsng Punction Status SMF 3 3 Safety Monttorteg Purctios Status SMF 4 E Not Used No Used 5 Not Used Not Used e Not Used Not Used Not Used Na Used Uj Not Used Not Used 9 Not Used Not Used Ostput LEDs LED Fur Valet 0 Safety Osrpat Function Stata SOF 1 1 Safety Oarpat Fonction Staras 2 Not Used Not Used 3 Not Used Not Used 4 Not Used Not Used Now Used Nor Used Plug in Module Slot 0 ri Vendor Name Catalog ID 20801Q40B4 Fi Version Plug in Module Slot 1 f 9 Vezdor Name Allen Bradley Catalog ID MILOW Venioa 1084 Figure 134 Example Report Page 2 440C CR30 Logic Image of CRIO Logic re y eon 130 Rockwell Automation Publication 440C UM001D EN P March 2015 SIL Rating Performance Level Category Specifications Appendix A The CR30 meets the requirements of SIL CL 3 in accordance with IEC EN 61508 Table 23 SIL Rating Safety Integrity Level Claim Limit 3 PFD 1 76 10 3 whole safety function PFH 110 8 Mode of Operation High demand mode Safety Related Subsystems Type B use of
29. of the number of function blocks that are configured for the safety function 2 The maximum input filter time shall not be greater than 250 ms Table 26 shows the additional processing time of dedicated SMF Table 26 Processing Time SMF Description SMF response time Emergency Stop SMF inputs deactivated 0 ms Enabling Switch Gate Switch Light Curtain Alternative Device Muting N A Oms Light Curtain Light interrupted not muted Oms Override Deactivate Override when light Oms curtain is interrupted Safety Mats Step on Mat cross loop between 25 ms safety mat inputs Single Wire Safety Deactivated SWS signal 15 ms Two Hand Control Release of at least 1 Hand actuator Oms Rockwell Automation Publication 440C UM001D EN P March 2015 135 AppendixA Specifications Figure 136 Example Logic Level A Logic Level B Safety Output ou ESR P Dw FOP mie al ene RE ga fos f r _ aaa feedback Noe A M a oO Gi a Table 27 For SMF1 E stop Comment Value Safety Sensors Safety response time of sensor device Oms considered as 0 ms since mechanical device only SMF An E stop SMF does not require extra Oms processing time Input Filter Advanced Settings Input Filter 10 x 250 ms 25 ms 250 ms Logic Internal execution time to process 45 ms input signal routing and output processing SOF Configured Off Delay time Oms immediate OFF Actuator Assuming a contactor with a 30
30. programmable complex components Hardware Fault Tolerance HFT 1 two channel system Safe Failure Fraction 90 99 The performance Level of the safety function is dependent on the structure of all devices that comprise the safety function The CR30 is capable of being used in safety systems meeting up to Category 4 and Performance Level PLe in accordance with ISO 13849 1 Table 24 Performance Level Category Category Up to 4 Performance Level Up toe Rockwell Automation Publication 440C UM001D EN P March 2015 131 AppendixA Specifications General Environmental 132 Number of I O 22 Dimensions 90 x 100 x 80 mm 3 54 x 3 94 x 3 15 in Shipping Weight approx 0 423 kg 0 933 Ib Wire Size 0 2 2 5 mm 24 12 AWG solid copper wire or 0 2 2 5 mm 24 12 AWG stranded copper wire rated 90 C 194 F insulation max Wiring Category 2 on signal ports 2 on power ports Use this Conductor Category information for planning conductor routing See Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Insulation Stripping Length 7 mm 0 28 in Terminal Screw Torque 0 6 Nem 4 4 Ib in max Using a 2 5 mm 0 10 in flat blade screwdriver Input Circuit Type 24V DC source Output Circuit Type 24V DC source Power Supply Voltage Range 24V DC 10 15 Fuse Specification 6A Power Consumption
31. reset signal must be between 0 5 3 s long In the example below a momentary button is connected to embedded terminal _IO_EM_DI_02 e Rung 3 The push button initiates a TONOFF timer The timer is set for a 100 ms delay ON and a 1100 ms delay OFF This provides a reset signal of ls e Rung 4 The Modbus message is sent with every scan of the ladder The reset is executed because the reset value goes from 0 to 1 and back to 0 within the acceptable range of 0 5 3 s e Rung5 When the TONOFF block goes LO embedded output _IO_EM_DO_01 goes LO and moves the value of 0 into Reset Addr e Rung 6 When the TONOFF block goes HI embedded output _IO_EM_DO_01 goes HI and moves the value of 1 into Reset Addr Figure 123 Reset Ladder Diagram PE DOL 110 Rockwell Automation Publication 440C UM001D EN P March 2015 Modbus Communication Chapter 15 You should configure a second set of local variables In this example they are labeled ResetCfg ResetIrgt and ResetAddr ResetCfg must be configured as a MODBUSLOCPARA data type ResetIrgt must be configured asa MODBUSTARPARA data type ResetAddr must be configured as a MODBUSLOCADDR data type ResetIrgt Addr Enter a value of 1 which is Modbus mapping of the CR30 ResetIrgt Node Enter a value of 1 The CR30 is fixed at Node 1 ResetCfg Channel Select the serial port location Enter a 2 if the embedded serial port is used Enter a 5 to use the serial port in the fist plug in slo
32. side The muting sensors MS are mounted to form an X sensing pattern where the sensing beams cross near the center of the light curtain LC The muting sensors must be mounted asymmetrically unequal distance from the light curtain such that the material breaks one muting sensor and then the other muting sensor as it moves along the conveyor Figure 46 2 Sensor T Type Muting Arrangement Machine Muting Lamp The material can break either MS1 first or MS2 first then the other sensor and then the light curtain As the material clears the light curtain it must then clear MS2 or MS1 first and then the other sensor The muting lamp turns on shortly after the second sensor is blocked and the light curtain is muted Either of these two patterns are acceptable 1 MSIV MS2V LCV LCM MS24 MS1 M 2 MS2V MSIV LCV LCT MS1 M MS2 With proper arrangement of the sensors the conveyor can move in the forward or reverse direction while also maintaining safeguarding integrity Rockwell Automation Publication 440C UM001D EN P March 2015 53 Chapter 9 Safety Monitoring Functions 54 In the example below the OSSD outputs of the light curtain are connected to terminals 00 and 01 The two muting sensors are connected to terminals 02 and 03 The momentary normally open override switch is connected between terminals 12 to 04 to take advantage of pulse testing Contactors K1 and K2 which provide power to the conveyor
33. the configuration file of your CR30 project to the CR30 safety relay The download process automatically performs a file transfer verification to help ensure that the project configuration and configuration in the CR30 is valid and equal Successful file transfer verification allows you to change the CR30 operation mode to Run and execute the safety function IMPORTANT Transfer file verification only checks inconsistency of the configuration in the project and the relay such as connection errors and corrupted files After file transfer the configured safety function itself is still not verified The responsible personnel must check whether the configured safety function meets the safety requirements according to the risk assessment and fulfills all applicable standard and regulations 11 Click the Download icon to build and download the configuration to the CR30 KA E Stop Gate Switch with Pane View C600 Connected Components Edition ERS id aaao sla JIS si Eb a Aes ERRI aTa jo S 44 YR I s Application Language Toolbox Q X Guardmaster 440C CR30 Logic Guardn trey Montering funcions L Guardmaster_440C_CR30 Emergency Stop Guardmaster 440C CR30 Enabling Switch Feedback Monitoring Gate Switch Light Curtain Muting Reset Restart Safety Mats Single Wire Safety Input Two Hand Control HE 2s heect rtaw or Alternative Device al o gic Functions Pointer JF 12 Expand the navigation tre
34. the device and select Upload EDS file from device ST TS amp File Edit View Communications Station DDE OPC Security Window Help S amp 218 amp liz X E E Workstation NAUSCHMBSIRARI Sds Linx Gateways Ethemet amp AB_ETHIP 1 Ethernet E AB_VBP 1 1789 A17 A Virtual Chassis EJ 00 Workstation RSLinx Server 15 Unrecognized Device 440 Remove Driver Diagnostics Configure Driver Upload EDS file from device Security Device Properties 06 26 14 1118 4 2 Click Yes S User Account Control a Program name RSEdsUI Verified publisher Rockwell Automation File origin Hard drive on this computer S Show ti Change when these notifications appear Rockwell Automation Publication 440C UM001D EN P March 2015 157 Appendix D ControlFLASH Firmware Upgrade 3 Click Next Welcome to Rockwell _ Automation s EDS Wizard The EDS Wizard alows youto upload EDS file s stored in a device To continue cick Next Graphec Image You can change the graphic image that is associated wth a device Product Types Change icon TP vendor pectic Type W cexcnenter cro 158 Rockwell Automation Publication 440C UM001D EN P March 2015 ControlFLASH Firmware Upgrade Appendix D 6 Clic k Next Final Task Summary This is a review of the task you wart to complete You have successtuly completed the EDS Wizard Rockwell Automation Publicati
35. to 2 Non pulsed standard outputs up to 6 Single wire safety output up to2 Rockwell Automation Publication 440C UM001D EN P March 2015 Software Overview Chapter 1 The CR30 is software configurable using the Rockwell Automation Connected Components Workbench CCW Connected Components Workbench is a set of collaborative tools that supports the CR30 safety relays CCW is based on Rockwell Automation and Microsoft Visual Studio technology The CCW is used to configure the CR30 program the Micro800 controllers and configure many PowerFlex drives and PanelView graphic display terminals Obtain Connected Components Workbench The Connected Components Workbench is free and can be downloaded from http compatibility rockwellautomation com Pages MultiProductDownload aspx Keyword Free amp crumb 112 To help you configure your relay through the Connected Components Workbench software you can refer to the Connected Components Workbench Online Help provided with the software USB Connection The CR30 has a USB interface for connection to a personal computer for configuration Use a standard USB A Male to B Male cable for connecting to the relay Serial Port Connection The embedded serial port is used to transfer control and status to other Allen Bradley products The CR30 only supports RS 232 protocol The connection is not isolated The RS 232 signals are referenced to the relay power ground Rockwell Au
36. 0 ISWS 7 Time Delay x epiw 50ms AE Reset Type Manual v bd Reset Input SMF 3 v Rockwell Automation Publication 440C UM001D EN P March 2015 83 Chapter 11 Safety Outputs OFF Delay The OFF Delay block turns off the output after the specified time delay expires The retriggerable parameter can be set to enabled or disabled e When enabled the input to the OFF Delay block can go HI again during the timing cycle and the output remains HI e When disabled the timing cycle runs to completion regardless of changes to the input Figure 103 shows the OFF Delay output block that is connected to a gate switch block through Logic Level LLB1 The feedback signal is provided by SMF2 and manual reset by SMF3 The time delay is set to 30 The output will turn off 1500 ms 30x50 ms after the gate is opened The output is connected to e Terminals 18 and 19 for dual channel safety switching of the machine hazards e Terminal 20 which is configured as a Single Wire Safety SWS output e Terminal 00 of Plug in 2 for status reporting Figure 103 OFF Delay Configuration Safety Monitoring Logic Level A ogic Level B Safety Output 10 vee o Pas o o Pass amp oF Dely of eet i HBG ia Gate Switch Through Through eD fol e o t019 PT Feedback SMF2 Seow SWS Test Source A 12 Jm aay Pe ep20 Test Source B 13 Retriggerable Enabled 9 Reset Type Manual Advanced Setting Reset Input SMF 3
37. 0 ms synchronization time between MS1 and MS2 and a 1000 ms synchronization time between MS2 and the light curtain Note The synchronization time also depends on the input filter time settings for the muting sensor inputs Synchronization time total 2 x Input Filter Time Synch Time Table 6 Muting and Synchronization Times for 2L Muting Muting Time Units Available Values Synchronization Time Available Values Seconds 1 59 MS1 to MS2 50 10 000 ms in 50 ms increments Minutes 1 59 MS2 to LC Hours 12 223 Days 1 10 Rockwell Automation Publication 440C UM001D EN P March 2015 57 Chapter 9 58 Safety Monitoring Functions 4 Sensor Muting The sensors and light curtain form the shape of an upside down T when viewed from the side Two muting sensors MS are mounted on either side of the light curtain LC Figure 52 4 Sensor Muting MS2 MS1 foo Loo a aaan Machine rr aa o0 OO Muting Lamp The material can travel in either direction breaking MS1 first and MS4 last or breaking MS4 first and MS1 last The muting lamp turns on and the light curtain is muted after the second sensor is blocked The object must be large enough to break all four sensors In the example below the OSSD outputs of the light curtain are connected to terminals 00 and 01 The four muting sensors are connected to terminals 02 to 05 The momentary normally open override switch
38. 1 Welcome to Control FLASH the firmware update tool Control FLASH needs the following information from you before t can 1 begn updating a device BITRE 1 The Cetalog Number of the target device 2 The Network Configuration parameters 7 foptenal I The Network Path to the target device PZ 4 The Firmware Revision for this update 5 Select the catalog number of the Guardmaster CR30 safety relay 440C CR30 22BBB that you are updating and click Next E ControlFLASH Untitled o gt a ControlFLASH 12 00 01 Enter the catalog number of the target device s40C CR30 22B88 Control 154 Rockwell Automation Publication 440C UM001D EN P March 2015 ControlFLASH Firmware Upgrade Appendix D 6 Expand the AB_VBP 1 1789 A17 A Virtual Chassis by clicking the 7 Select the safety relay in the browse window and click OK If the device comes up unrecognized the EDS file has not been loaded aa Browsing node 0 found E E Workstation NAUSCHMSSIRRL E m Gss Linx Gateways Ethernet amp AB_ETHIP 1 Ethernet 00 15 S E AB_VBP 1 1789 A17 A Virtual Chassis RSLimx Server 440C CR30 EJ 00 Workstation RSLinx Server rt amp Ae USB 8 Verify the revision and click Next to continue Eh ControlFLASH 440C CR30 22888 le o ControlFLASH 12 00 01 Catalog Number 440C CR30 228B8 Serial Number FFFFFFFF Current Revision 7 006 Control Rockwell Au
39. 11 e MP_12 MP_17 multi purpose terminals 12 17 You can use the default Input Filter or choose to modify this setting When test pulses are used the CCW automatically selects the test pulse pattern The single channel N C can use input test pulses from following terminals e MP_12 MP_17 multi purpose terminals 12 17 Rockwell Automation Publication 440C UM001D EN P March 2015 69 Chapter 9 70 Safety Monitoring Functions Figure 75 Example Schematic for Single Channel N C without Test Pulse 24V DC 00 01 02 03 04 05 06 07 08 o9 10 11 CR30 24V Com Figure 76 Example Schematic for Single Channel N C with Test Pulse 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 A a1 A2 12 13 14 15 1617 18 19 20 21 24V Com Figure 77 Example Schematic for Single Channel OSSD 24V DC 100 01 02 03 04 05 06 07 08 o9 10 11 CR30 24V Com Dual Channel Dual channel safety monitoring functions require two independent circuit connections to the CR30 Dual channel inputs are used for medium and high risk applications You can modify the number and types of inputs e 2NC e 2 OSSD e 1N C 1 N O The available input selections for the dual channel OSSD and two N C inputs are e EI 00 EI 11 embedded input terminals 00 11 e MP_12 MP_17 multi purpose terminals 12 17 The available input selections for the N O contac
40. 161 Appendix E EtherNet IP 1 0 Assemblies Output Assemblies The following are output assemblies available over EtherNet IP for the Guardmaster 440C CR30 safety relay Table 42 440C CR30 Output Assemblies Instance Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Decimal hex 150 96h 0 PNB 07 PNB 06 PNB 05 PNB 04 PNB 03 PNB 02 PNB 01 PNB 00 1 PNB 15 PNB 14 PNB 13 PNB 12 PNB 11 PNB 10 PNB 09 PNB 08 2 3 Reserved Where PNB Produced Network Bit writes to the Communications Inputs selections in the 440C CR30 editor SMF 3 Reset 1 162 Rockwell Automation Publication 440C UM001D EN P March 2015 Tag Definitions Table 43 440C CR30 Input Tags Appendix F Name Data Type Tag Definition RunMode BOOL Run Mode Indicates the operating mode of the safety relay 0 Idle Program Mode 1 Run Mode ConnectionFaulted BOOL Connection Faulted Indicates the state of the communication connection between the safety relay and the controller 0 Connection 1 Connection faulted MajorFault BOOL Major Fault Status Indicates whether the safety relay is major non recoverable faulted 0 No Fault 1 Fault MinorFault BOOL Minor Fault Status Indicates whether the safety relay is minor recoverable faulted 0 No Fault 1 Fault VerificationID INT Verification ID Indicates the unique verification ID of the safety relay when the configurati
41. 18 Using the Memory Module Overview Guardmaster 440C safety relays support the Cat No 2080 MEMBAK RTC memory modules for the following purposes e Project backup and restore e Firmware and project backup and restore the Cat No 2080 MEMBAK RTC memory module when used with a ATTENTION Removal and Insertion Under Power RIUP is not supported on Guardmaster 440C safety relay ATTENTION The Cat No 2080 MEMBAK RTC module can only be installed in Slot 1 the leftmost plug in slot on the Guardmaster 440C safety relay IMPORTANT Do not remove the Cat No 2080 MEMBAK RTC or power down while operations such as backup and restore are ongoing to prevent data loss A blinking status indicator on the memory module indicates that these operations are ongoing IMPORTANT Backup can only occur when the safety relay is in the Safety Verified state To learn about safety verification see Verification on page 30 IMPORTANT Using the Cat No 2080 MEMBAK RTC with the CR30 is only supported with firmware revision 7 or later Project Backup and Restore Project backup and restore on Guardmaster 440C safety relays are supported through the Cat No 2080 MEMBAK RTC memory module Both backup and restore can be initiated through the Connected Components Workbench CCW software and using buttons physically present on the Guardmaster 440C safety relay and the Cat No 2080 MEMBAK RTC module A backup of both the Guardmaster 440C s
42. 4 382 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 440C UM001D EN P March 2015 Supersedes Publication 440C UM001C EN P November 2014 Copyright 2015 Rockwell Automation Inc All rights reserved Printed in the U S A
43. 40C CR30 The behavior of the IN and OUT LEDs depends on whether the configuration is verified e Verified the IN and OUT LEDs continuously cycle through the verification number e Not Verified the IN 0 and the OUT 1 2 3 and 4 are solid green The backup cannot take place since the configuration is not verified Rockwell Automation Publication 440C UM001D EN P March 2015 10 Using the Memory Module Chapter 18 Using a small flathead screwdriver press the Backup button on the Cat No 2080 MEMBAK RTC memory module Hold the button until the Status LED on the Cat No 2080 MEMBAK RTC module begins flashing indicating the backup process has begun When the backup operation is complete the Status LED on the Cat No 2080 MEMBAK RTC stops flashing TIP If the Status LED does not blink and turns on after 15 seconds the program is not verified and backup cannot take place Confirm the Verification ID displayed on the safety relay match the expected Verification ID of the application to be backed up Power down the Guardmaster 440C safety relay Remove the Cat No 2080 MEMBAK RTC memory module from slot 1 of the safety relay module bay Snap the dustcover or previous plug in module into slot 1 of the module bay Power on the Guardmaster 440C safety relay to resume normal operation Restore Project You can restore a Guardmaster 440C safety relay project from a Cat No 2080 MEMBAK RTC memory modu
44. 440C ENET plug in by non Logix automation controllers that support EtherNet IP explicit messaging This example shows the configuration of an explicit message to read data from the Guardmaster 440C CR30 safety relay 1 Set up the MSG instruction to read the data assembly from the Guardmaster EtherNet IP network interface by configuring the following fields Channel 1 Integral this is the Ethernet port Communication Command CIP Generic Data Table Address Receive N7 0 choose an address that supports 28 bytes Size in Bytes Receive 28 Extended Routing Info File RIX RIX11 0 Service Read Assembly Class 04 Instance 100 64h Attribute 03 MSG MG20 0 1 Elements This Controller Channet Communication Command Data Table Address Receive Size in Bytes Receive Send Target Device Message Timeout 5 Control Bits Ignore if timed out TO 0 Break Connection BK 0 Awaiting Execution EW 0 Enor ER 0 Message done DN 0 Message Transmitting ST 0 Message Enabled EN 0 Local Remote MultHop Extended Routing Info File RIX m Service Read Assembly Service Code hex E Class hex 4 deck Instance hex deck Attribute hex 3 deck B Error Code Hex 0 Error Description No ertors Rockwell Automation Publication 440C UM001D EN P March 2015 Automation Controller Communicat
45. 5 1275 seconds in 5 second increments Muting Lamp The muting lamp shows four states e OFF light curtain is not muted e ON light curtain is muted e 1 Hz blink rate muting sequence fault e 3 Hz blink rate muting is overridden the Override input is on The muting lamp is not monitored If the lamp burns out the muting function continues to work properly The reset block is used in safety functions that require a manual intervention to turn on the safety system Figure 55 Reset Function Block 4 Safety Monitoring Functions Pointer Emergency Stop Safety Monitoring Enabling Switch Feedback Monitoring az gt Gate Switch awo Sp Qo Light Curtain Advenced Setting Safety Mats Input Filter oc 625s an Single Wire Safety Input tet Two Hand Control E Alternative Device a Logic Functions h Pointer D AND Name Project70 DI Gvrsmaster 440C CR30 To prevent inadvertent actuation of the reset block the reset requires a leading edge and trailing edge within a specific time frame The pulse width must be between 250 3000 ms If the pulse width is too short or too long the reset function will not be executed Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 Figure 56 Reset Timing 24V DC 3000 ms 24V Com The reset block is a Safety Monitoring Function in the CCW For a valid Reset operation according to the req
46. 5 28 W 1 0 Rating Input 24V DC 4 mA Output 24V DC Class 2 0 5 A per point Enclosure Type Rating IP20 Power has to be supplied by a power supply that complies with IEC EN 60204 and IEC EN 61558 1 Such a power supply meets the electrical safety requirements and maintain the minimum power of 18V DC during 20 ms even in the event of voltage dips Temperature Operating 5 55 C 23 131 F Relative Humidity 90 Vibration 10 55 Hz 0 35 mm Shock 10g 16 ms Pollution Level 2 Rockwell Automation Publication 440C UM001D EN P March 2015 Specifications Appendix A Inputs Number of Inputs Up to 18 embedded 12 dedicated inputs 6 configurable as Inputs Operating Voltage Range 20 4 26 V DC Off state Voltage max 5V DC Off state Current max 2 91 mA independent of supply On state Voltage max 26 4V DC On state Voltage min 11 0V DC On state Current min 3 14 mA at 20 4V DC On state Current nominal 3 2 mA at 24V DC On state Current max 3 25 mA at 26 4V DC Off Pulse Accepted for OSSD Min 0 ps Setting without Declaring Max 700 ps the Input as OFF Reverse Voltage Protection No Input Capacitance 10 nF Galvanic Isolation 1 0 from No Logic Outputs Number of Outputs Up to 10 Output Signals Standard OSSD and Single Wire Safety Continuous Output Current 0 5 A Terminals 12 19 0 3 A Terminals 20 21 Ag
47. 9 20 21 24V Com Figure 42 Example Schematic of a Dual Channel Safety Gate Switch Using OSSD Outputs 24V DC 05 or a2 05 oa OS os 7 os sa or CR30 A1 A2 12 13 14 15 16 17 18 19 20 21 24V Com Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 Light Curtain The Light Curtain function block sets the parameters for light curtains that have dual OSSD outputs In the CCW click and drag or double click the block to an available Safety Monitoring Function spot This block can be used for other devices like laser scanners with OSSD outputs Figure 43 Light Curtain Function Block Toolbox as Guardmaster 440C CR30 Logic x Meee C_CH 4 Safety Monitoring Functions O lt rh Pointer Emergency Stop Safety Monitoring I Enabling Switch RB Feedback Monitoring E raser HH GeteSwitch uo a E tioht curtain EL light Curtain Ty ao e e BH Mating Reset Restart Safety Mats Single Wire Safety Input Discrepancy za Two Hand Control Time bSOms Input Filter oc Alternative Device 4 Logic Functions Advanced Settings 25s Pointer AND Project Organizer Name Project55 Ww Guardmaster_440C_CR30 The available input selections for the Light Curtain inputs are e EI 00 EI 11 embedded input terminals 00 11 e MP_12 MP_17 multi purpose terminals 12 17 You can use the default D
48. Cause Muting Sequence Fault An illegal input pattern the pattern of sensors being blocked and cleared for the mute sensors was detected Recovery Method Do one of the following Check the sensor Check wiring e Power cycle the safety relay Reconfigure the safety relay Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support 44H Combination of faults detected See all of the following fault codes e 04H 40H 50H Combination of faults detected See all of the following fault codes 10H 40H 54H Combination of faults detected See all of the following fault codes gt 4H 10H 40H 90H Combination of faults detected See all of the following fault codes 10H 80H 94H Combination of faults detected See all of the following fault codes 4H 10H 80H 120H Combination of faults detected See all of the following fault codes 40H 80H 124H Combination of faults detected See all of the following fault codes 4H 40H 80H 130H Combination of faults detected See all of the following fault codes 10H 40H 80H 134H Combination of faults detected See all of the following fault codes 4H
49. Data SMF21 Data SMF20Data SMF19Data SMF18Data SMF 17 Data 17 LLA 8 Data LLA 7 Data LLA 6 Data LLA 5 Data LLA 4 Data LLA 3 Data LLA 2 Data LLA 1 Data 18 LLA 16 Data LLA15Data ILLA 14 Data LLA13Data LLA12Data LLA11Data ILLA 10 Data ILLA 9 Data 19 LLB 8 Data LLB 7 Data LLB 6 Data LLB 5 Data LLB 4 Data LLB 3 Data LLB 2 Data LLB 1 Data 20 LLB 16 Data LLB15Data LLB14Data LLB13Data LLB12Data LLB11Data LLB10Data LLB9 Data 21 SOF8 Data SOF7Data SOF6Data SOF5Data SOF4Data SOF3Data SOF2Data SOF 1Data 22 SOF 16 Data SOF15Data SOF14Data SOF13Data SOF12Data SOF11Data SOF10Data SOF9Data 23 SOF 8 Reset SOF7Reset SOF6Reset SOF5 Reset SOF4Reset SOF3Reset SOF2Reset SOF 1 Reset Required Required Required Required Required Required Required Required 24 SOF 16 Reset SOF 15 Reset SOF 14Reset SOF 13 Reset SOF12Reset SOF11 Reset SOF 10 Reset SOF 9 Reset Required Required Required Required Required Required Required Required 25 Reserved 26 Reserved 27 Reserved Where e Pt Value of the 1 0 point SMF Safety Monitoring Function SMF block status in the 440C CR30 editor e LLA Logic Level A LLA Function block status in the 440C CR30 editor LLB Logic Level B LLB Function block status in the 440C CR30 editor SOF Safety Output Function SOF block status in the 440C CR30 editor XY See Appendix F page 163 for details on Faults Rockwell Automation Publication 440C UM001D EN P March 2015
50. Figure 131 Report Icon at Top of Logic Editor File Edit View Debug Tools Communications Window Help ige aalo o Qly JSk gt akt PANS si HS ATR aS ele sl a4yay si Application Language Project Organizer Name Project 176 Dj Gvrsmaser ssoc cR0 fl Mouse over ard Generate Report PTEE TT mn ama groves pe P Test Source A 12 Inputs 2 Test Source B 13 Advanced Settings Inputs Pulse Testing Discrepancy Time 50ms Input Filter 625ms The report generator takes a snapshot of the logic editor as viewed by the operator If the editor is actively monitoring the configuration the report generator captures the colors reflected the block status You can expand or collapse the blocks as desired to show or hide the advanced setting of each block Figure 132 Report Output Settings TA Connected Components Workbench gt Output type Orientation Image options Microsoft Word Portrait None POF Landscape Scale Split Header Footer options No Header or footer Header Footer Output file CAUsers srdukich Documents SafetyRelay_CR30 docx __ Browse oc Cancel Rockwell Automation Publication 440C UM001D EN P March 2015 129 Chapter 19 Reports Select the desired output type orientation image options header footer options and output file location and name Ifa report with the same name already exits the user is prompted to overwrite it An example
51. Max 2 x Input Filter Time 3 s 0 5 3s 3 5s Logic Internal execution time to process 45 ms input signal routing and output processing 2 SOF No On delay configured for SOF 0s Actuator Assuming a contactor with a 10 ms response time of 10 ms Total Min 1 055 s Max 3 3 s It takes a minimum of 1055 s after a valid Reset operation of at least 250 ms to enable the outputs when the E stop is active closed contacts The following are specifications for the Guardmaster 440C ENET Ethernet plug in module Table 38 Technical Specifications Specification Module location Description Slot 1 module bay only Backplane current mA at 24V DC 42 mA Isolation voltage 50V DC Reinforced Insulation Type Ethernet to system Type tested at 1500V AC for 60 s Power consumption max 1W Thermal dissipation 3 41 BTU hr 65 C Wire size Ethernet connections RJ45 connector according to IEC 60603 7 2 or 4 pair Category 5e minimum cable according to TIA 568 B 1 or Category 5 cable according to ISO IEC 24702 Wiring category 1 on communication port Enclosure type rating None open style 1 Use this Conductor Category information for planning conductor routing Refer to Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Rockwell Automation Publication 440C UM001D EN P March 2015 Specifications Appendix A Table 39 Environmental Specifications
52. Muting Safety Monitoring Function turns off The FAULT indicator and Mute continue to flash Use the muting override command to temporarily turn on the output of the Safety Monitoring Function and clear the material from the light curtain and muting sensors The fault condition is cleared Rockwell Automation Publication 440C UM001D EN P March 2015 55 Chapter 9 56 Safety Monitoring Functions 2 Sensor L Type Muting The sensors and light curtain form the shape of the letter L when viewed from the side The muting sensors MS are mounted on one side of the light curtain LC Figure 49 2 Sensor L Type Muting Arrangement LC es om EDLER a raed a SE 8 The material must first break MS1 then MS2 and then the light curtain As the material progresses the material must clear MS1 and then MS2 The muting lamp turns on and the light curtain is muted after MS2 is blocked The conveyor can only move one direction Muting Lamp IMPORTANT The2 L muting arrangement must only be used for material exiting the hazard area It must not be used for material entering the hazard area In the example below the OSSD outputs of the light curtain are connected to terminals 00 and 01 The two muting sensors are connected to terminals 02 and 03 The momentary normally open override switch is connected between terminals 12 to 04 to take advantage of pulse testing Contactor K1 and K2 which provide power to the conveyo
53. Overnde Setting gt Override Enabled m mere Max Override 0 roject Organizer Time 055 Name ProjectSS Inputs 2NC ia Guardmaster_440C_CR30 Pulse Testing 2Sources Test Source 12 v Test SourceB 13 hg Advanced Settings Light Curtain Discrepancy Time xS0ms Mute Sensors Input Filter Fe 625ms Light Curtain Input Filter s 625ms Override Input oc Filter 25ms The light curtain LC signals can use the following terminals e EI 00 EI 11 embedded input terminals 00 11 e MP_12 MP_17 multi purpose terminals 12 17 The muting S1 S4 and override OV signals can use the following terminals e EI 00 EI 11 embedded input terminals 00 11 e MP 12 MP 17 multi purpose terminals 12 17 e P1 00 P1 03 plug in 1 terminals 00 03 e P2 00 P2 03 plug in 2 terminals 00 03 Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 You can use the default Discrepancy Time and Input Filters or choose to modify these settings The CR30 safety relay has three distinct types of muting where the sequence and timing of signals that are monitored by the CR30 allows objects to pass through the light curtain without shutting down the machine process The three types are e 2 sensor T Type e 2 sensor L Type e 4 sensor 2 Sensor T Type Muting The sensors and light curtain form the shape of an upside down T when viewed from the
54. Pulse A and another signal is assigned to Test Pulse B or C then a short circuit from one input to the other is detected by the CR30 and the CR30 de energizes the outputs of those safety functions using the two inputs In this example you cannot select terminal 12 as one test pulse source and terminal 15 as the second test pulse source as both of these produce the A pulse The CCW automatically prevents the user from selecting two of the same pulses when dual channel inputs and two test sources are selected Internally the CR30 provides dual channel capability to turn off its safety outputs Conceptually think of this as a main output transistor feeding individual output transistors The CR30 repeats a test process where it tests the main transistor twice and then sequentially tests each individual output twice After successful completion of the tests the CR30 repeats the test sequence IMPORTANT Safety systems requiring a Category 4 structure per 1S013849 1 and SIL 3 rating per IEC61508 must use pulse testing for the dual channel outputs Pulse testing for Category 3 2 and 1 structures and SIL 2 and 1 ratings is recommended Figure 20 Output Pulse Testing 24V DC 00 01 02 03 04 05 06 07 o8 09 10 11 ar amp Main Transistor ESE eee ee 24V Com When the main transistor is tested a 50 us test pulse appears simultaneously on all outputs The main transistor is tested again 125 ms later F
55. Standard Edition Administrator PQ Gid sos 4 General There are no usable controls in this group Drag an item onto this text to add it to the toolbox Project Organizer Name Project36 Guardmaster 440C CR30 File Edit View Debug Tools HRC at ub So fo Communications Window Help Guardmaster_440C_CR30 Guardmaster_440C_CR30 4 STR le Download Upload Edt Bgic Build voty 440C CR30 228BB a Verification ID 4 Safety Relay Serial Port USB Port LED Configuration Faults Modbus Mapping f vad Controllers a oie ase amp MSRS7 DM s40c crao 22888 ia metbacentrel 5 v ll Graphic Terminals The Workspace By expanding the Toolbox on the left blocks can be added to the Workspace and safety functions can be created Figure 10 Workspace The workspace is split into a grid of four columns Safety Monitoring the inputs Logic Level A Logic Level B and Safety Output BA Project3 Connected Components Workbench Standard Edition Administrator So Fae Eat View Debug Teck Com Window Help iD ASO Oa Bivavuse ay 44 Safety Mendtonng Functions Logic Functions Safety Output Function Blocks 4 General There are no vasble controls in this group Drag an item onto this test te add it to the teclbox The Workspace 26 Rockwell Automation Publication 440C UM001D EN P March 2015 10 Configuring the CR30 Chapter 4 Click and drag the Ga
56. Standard a File Edit View Buld Debug Tools Communications Window Help DSa aajo o aal i Application Language English United States 1033 Pointer Momentary Push Button Latched Push Button Maintained Push Button Multistate Push Button Ete r z EDERE Ls gt Osh gt Os ke Oe Oe oe Oe T Forward One Screen LETS St I Back One Sereen gt Numeric Increment Decrement O Key W Numeric Entry W String Entry List Selector G Sereen Selector Display h Pointer m Numeric Display 4 Safety Relay Safety Relay LED Configuration me String Display roger 2 Input LEDs E Linear Scale LED Configuration LED Type Fiter Value PV Circular Scale Faults Th Mukistate Indicator r logo Mod Mapping a pake Project Empty Name Moo 8B30 CR30 4 DE cunts soc cro f E YEE User Defined Function Blocks CE dataTypes Be Pv ctpptcation First select one of four Filter Types for each LED 1 Not Used 2 Terminal Status 3 Safety Monitoring Function Status 4 Safety Output Function Status Then select the instance for each Filter Type Monitoring a function is advantageous when the input and output logic blocks have multiple inputs or outputs A single LED can provide status information about multiple inputs or outputs when it provides the status of an input or output block 102 Rockwell Automation Publication 440C UM001D EN P March 2015 Controller Status LEDs In the previous ex
57. Table of Contents Chapter 15 Modbus Mapping sssesserserrersererrerrrrererer reser reser be 105 Example Architectures epen keane SRS ASS Sen SAR anaes 107 Reading CR30 Status sssesserrerserrrrerrrrerere rr rr ere rer rr na 109 Sending Reset to GRIO heroien ana EEEE EE ss 110 Chapter 16 Recoverable Faults 0 cece cece cece ence rer rer rer rer rss 113 SE A E R EE OE AE E ean an winner E E ethers 113 Nonrecoverable Faults ssssssssrsrerrrrrrrr rr rr rr or res ror ra 114 Troubleshooting with the GOW s ssossrerererererrrrer reser esas 114 Troubleshooting with Modbus iss jit sis comtwia bind nies Sibetewtaronpcea 116 Example Fault Analysis Crossfault 02 02 eee eeeees 117 Chapter 17 Exclusive Access ccc cece eee ad anda ccc NN Tee el E NR aN e 119 Password Protection ssseserrrrsrerrerrrr rs rr rr rer rr resa 119 Compatibility srira ONT Ne den SNR eee SA ARD 120 Work with a Locked Safety Relay ssessessersrerserrrrrer sera ra 120 Upload from a Password Protected Safety Relay 120 Connect to a Password Protected Safety Relay s s 120 Download to a Password Protected Safety Relay 120 Configure Password sime Trn eeina sne Ihe RE E aa 121 Set Safety Relay Password 2 052 3 el oneal ied ie Siecle 121 Change Passwotdisc cpactawusss cases se nes ran advan 122 Cleat Password cus 3s cS cts bese eee aoa ted tone th eek 123 Lost Password 00 cece c
58. User Manual Original Language Allen Bradley Guardmaster 440C CR30 Configurable Safety Relay Catalog Number 440C CR30 22BBB Allen Bradley Rockwell Software Automation Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for 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 r
59. ablished If no connections are configured no action is required If connections are configured check connection originator for connection error code Green The port has an IP address and CIP connections Class 1 or Class 3 are established No action is required Red Duplicate IP The device has detected that its IP address is being used by another device in the network Change the devices IP address Flashing red green The port is performing its power up self test No action is required Rockwell Automation Publication 440C UM001D EN P March 2015 95 Chapter 12 Plug in Modules Indicator Status Description LNK Off The port is not connected to a powered Ethernet device Therefore the safety relay cannot communicate over an Ethernet network Verify that all Ethernet cables are connected Verify that Ethernet switch is powered Flashing green The port is communicating on Ethernet No action required The port is performing its power up self test No action required Green The port is connected to a powered Ethernet device Therefore the safety relay can communicate over an Ethernet network No action required Ch apter Summa ry In this chapter you learned how to install and wire your Guardmaster 440C ENET Ethernet plug in module 96 Rockwell Automation Publication 440C UM001D EN P March 2015 Chapter 13 Automation Controller Communications Introduction This chapter describes and gives examples
60. afety Monitoring Function minor fault 40H Safety Output Function minor fault MinorFaultInstance SINT Minor Fault Instance Indicates the instance of the function block that is faulted Valid values 01 24 MinorFaultCode INT Minor Fault Code Indicates the specific minor fault code for the corresponding minor fault type and instance See Table 46 for additional details SMFxx 1 BOOL Data Off On status for Safety Monitoring Function echoed back from the safety relay This is used to verify proper communication only No field side verification is done 0 Off 1 0n LLAxx BOOL Data Off On status for Logic Level A Function echoed back from the safety relay This is used to verify proper communication only No field side verification is done 0 Off 1 0n LLBxx BOOL Data Off On status for Logic Level A Function echoed back from the safety relay This is used to verify proper communication only No field side verification is done 0 Off 1 0n SOF xx BOOL Data Off On status for Safety Output Function echoed back from the safety relay This is used to verify proper communication only No field side verification is done 0 Off 1 0n SOFxxResetRequired BOOL Safety Output Function Reset Required Indicates whether a safety output function is awaiting a reset command before initiating its output 0 No reset required 1 Reset required 1 xx corresponds to 01 16 for bits 00 15 of the integer Ta
61. afety Monitoring Functions Feedback Monitoring 48 The Feedback function block is used in safety systems to monitor the status of output devices like safety contactors When the output device is off a HI signal is fed back to the input of the CR30 to indicate that the device is indeed off When the output device is energized the feedback signal goes LO If the output device remained energized the feedback signal remains LO and the CR30 will not energize the output The feedback contacts can be positive guided mechanically linked or mirrored contacts The CR30 accepts 1 2 3 or 4 inputs into each feedback block All inputs must be HI for the output of the block to go HI In the CCW click and drag or double click the block to an available Safety Monitoring Function spot Figure 36 Feedback Monitoring Function Block Toolbox B X f Guardmaster 440C CR30 Logic x PRTC 4 Safety Monitoring Functions Pointer Emergency Stop Safety Monitoring SMF 1 z H0 7e E Feedback Light Curtain Muting Reset Inputs 1 Restart Advanced Setting Safety Mats Single Wire Safety Input Input Filter z 3 4 25ms ov HE 3 heettaw or Two Hand Control Alternative Device sd a Logic Functions hk Pointer D AND Name Project70 fiat Guardmaster_440C_CR30 The available input selections for the Feedback Monitoring are e EI 00 EI 11 embedded input terminals 00 11 e MP 12 MP 17 multi pu
62. afety relay firmware and project can only occur through the CCW software Rockwell Automation Publication 440C UM001D EN P March 2015 125 Chapter 18 126 Using the Memory Module Backup and restore can only occur when the Cat No 2080 MEMBAK RTC module is present in plug in Slot 1 the leftmost slot of the Guardmaster 440C safety relay On safety relay power up the safety relay enters a fault state where the application logic is not executing Backup and restore commands can be issued in this fault state The Cat No 2080 MEMBAK RTC memory module stores the safety relay password if present in encrypted format When the password is mismatched the contents of the Cat No 2080 MEMBAK RTC memory module is not restored on the safety relay Back up Project You can back up a Guardmaster 440C safety relay project to a Cat No 2080 MEMBAK RTC memory module using the button on the memory module 1 Power down the Guardmaster 440C safety relay 2 Remove the dustcover or plug in module that is currently located in slot 1 the leftmost slot of the safety relay module bay 3 Snap the Cat No 2080 MEMBAK RTC module into slot 1 of the module bay 4 Power on the Guardmaster 440C safety relay The safety relay detects the presence of the Cat No 2080 MEMBAK RTC memory module and enters a fault state The LEDs are as follows PWR solid green RUN off not executing FAULT solid red LOCK solid green COM off 4
63. ample LEDs Chapter 14 a Input LED 1 is monitoring a terminal status In this case it is monitoring terminal 01 When the signal to terminal 1 is HI the LED is on When the signal to terminal 1 is LO the LED is off If this were a single channel input then the LED provides all information that we need to know about the input Input LED 2 is monitoring safety monitoring function 1 If the LED is on then we know that all inputs are satisfied for whatever function for example dual channel input muting or two hand control is being monitored Output LED 3 is monitoring the status of a Safety Output Function In this case SOF 1 is being monitored If SOF 1 is driving four outputs two safety one diagnostic and one Modbus we expect all four outputs to be HI when LED 3 is on The CR30 has five module status LEDs that are described in Table 19 Table 19 Status LEDs LED Color Indicates POWER Off No input power or power error condition Green Power on RUN Off Program mode Green Run mode Flashing Green 2 Hz Application is running but not verified FAULT Off No fault detected Red Flashing 2 Hz Application fault detected recoverable Red Controller hardware faulted non recoverable LOCK Off Not used COM Off No communications Green Communications by serial port or USB Rockwell Automation Publication 440C UM001D EN P March 2015 103 Chapter 14 LEDs Notes 104 Rockwel
64. and to other hazards are connected to terminals 18 and 19 The muting lamp is connected to terminal 13 this terminal should be configured with no pulse testing Filament lamps will not be affected by pulse testing but LED lamps may appear to flicker if pulse testing is enabled Figure 47 Example Schematic for 2 Sensor T Type Muting 24V DC Light Curtain 1 Override Contactors for Conveyor Power Omansie BIR For simplicity the power and ground connections of the light curtain and muting sensors are not shown The light curtain and muting sensors must have the same reference 24V Com as the CR30 for proper operation 24V Com For proper operation the muting sensors are on normally closed when not muting and the light curtain OSSD outputs are also on the light curtain is clear Figure 48 Muting Time for 2 Sensor T Type Muting Start of Next Cycle Light Curtain Muted Muting sensor Muting sensor Muting lamp Muting Time SA Synchronization Time Jo ee For proper operation MS1 and MS2 must be activated deactivated within the synchronization time and the light curtain must be clear before the muting time expires Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 The minimum synchronization time is dependent on the connection of the muting sensors and is summarized in Table 4 When connected to the embedded term
65. ard with Integrated Latch Guardlocking Interlocks TLS ZR 440G LZ Short circuits are detected by the safeguarding device and the safeguarding device turns off its safety outputs Devices with OSSD outputs are capable of operating in high risk applications Rockwell Automation Publication 440C UM001D EN P March 2015 71 Safety Monitoring Functions Figure 80 Example Schematic for Two OSSD 24V DC Safeguarding Device 00 01 02 03 04 05 06 07 08 09 10 11 CR30 24V Com Dual Channel N C N 0 The N C N O configuration applies the diversity concepts where one contact is open and the other contact is closed The contact while in an open state cannot be welded closed The CR30 turns off its safety outputs when either channel changes state Both channels must change state for proper performance Figure 81 Example Schematic for N C N 0 without Test Pulse 24V DC 00 01 02 03 04 05 06 07 08 o9 10 11 CR30 24V Com Figure 82 Example Schematic for N C N 0 with One Test Pulse 24V DC 100 01 02 03 04 05 o6 07 08 o9 10 11 CR30 A1 A2 12 13 14 15 16 17 18 19 20 21 24V Com Figure 83 Example Schematic for N C N 0 with Two Test Pulses 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 ch 24V Com If a short circuit occurs on terminal 12 to 24V the CR30 turns off its safety outputs within 35 ms Remove t
66. are HI the output of the block is HI If all inputs go LO the output of the block goes LO The OR block is often used with enabling devices Figure 90 OR Logic Block Logic Level A LAL i Doe Inputs 2 hd Table 10 OR Logic Table for Two Inputs Input 1 Input 2 Output 0 0 0 0 1 1 1 0 1 1 1 1 The XOR block accepts 2 24 inputs The output of the XOR block is HI when any input is HI The output is LO when multiple inputs are HI or ifall inputs are LO Figure 91 XOR Logic Block ogic Level D xor 9 inputs 2 Table 11 XOR Logic Table for Two Inputs Input 1 Input 2 Output 0 0 0 0 1 1 1 0 1 1 1 0 Rockwell Automation Publication 440C UM001D EN P March 2015 NAND NOR NOT Logic Levels AandB Chapter 10 The NAND block accepts 2 24 inputs The NAND performs the opposite of an AND block The output of the NAND block is LO when all inputs are HI When any input is LO the output is HI Figure 92 NAND Logic Block Logic Level A FETT D gt nano e Table 12 NAND Logic Table for Two Inputs Input 1 Input 2 Output 0 0 1 0 1 1 1 0 1 1 1 0 The NOR block performs the opposite of the OR block When any input is HI the output is LO When all inputs are LO the output is HI Figure 93 NOR Logic Block Logic Level A D NOR 9 Inputs 2 Table 13 NOR Logic Table for Two Inputs Input 1 Input 2 Output 0 0 1 0 1 0
67. ave been Reserved At least one circuit shorted to 24V or Hand Control in an inconsistent state for longer another input circuit than 500 ms Safety Mat Reserved Discrepancy Fault Input channels One channel went to the safe state At least one circuit shorted to 24V or inconsistent greater than the and back to the active state while the another input circuit configured discrepancy time other channel remained active or One channel went to the safe state upon power up 3 Channel Reserved Reserved One channel went to the safe state At least one circuit shorted to 24V upon power up Reset Reserved Reserved Reserved Atransition of the reset input from ON 1 to OFF 0 did not occur within 3 000ms Override Reserved Reserved Reserved At least one circuit shorted to 24V or another input circuit Restart Reserved Reserved Reserved A transition of the restart input from ON 1 to OFF 0 did not occur within 3 000ms Mute Reserved Muting sensor sequence fault The Light Curtain was muted for Too much time elapsed between longer than the configured maximum Sensors being blocked mute time Lack of Muting Too much time elapsed between Muting sensor sequence fault The Light Curtain was muted for Too much time elapsed between L Type Sensor2 and Light Curtain2 being longer than the configured maximum Sensor1 and Sensor2 being blocked blocked Example Fault Analysis Crossfault mute time Create a crossfault from In
68. be used with one AND or OR logic block Figure 58 Restart Function Block 4 Safety Monitoring Functions hk Pointer Emergency Stop Enabling Switch Feedback Monitoring Gate Switch Light Curtain Advanced Settings Input Filter Safety Mat s 25ms Single Wire Safety Input Two Hand Control HE3 pe Alternative Device The Restart Function requires a leading edge and trailing edge within a specific time frame The pulse width must be between 250 3000 ms If the pulse width is too short or too long the Restart function will not be executed Figure 59 Restart Timing 24V DC 3000 ms 24V Com The available input selections for the Restart are e EI 00 EI 11 embedded input terminals 00 11 e MP_12 MP_17 multi purpose terminals 12 17 e P1_00 P1_03 plug in 1 terminals 00 03 e P2_00 P2_03 plug in 2 terminals 00 03 e SP_00 SP_15 Modbus inputs 00 15 For a valid Restart operation according to the requirements specified in the approved safety concept you must use the default Restart timing and leave the input filter setting 0 The filter setting is enabled in CCW versions smaller than Rev 7 A filter time setting greater than 0 extends the Reset Timing by 2 x Filter Time Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 Safety Mat Figure 60 Wiring Connection for a Restart Signal to Termi
69. ble 44 440C CR30 Output Tags Name LogicDefinedDataxx 1 1 xx corresponds to 00 15 Data Type Tag Definition Logic Defined Data These 16 bits write to the Communications Inputs in the 440C CR30 safety relay editor 164 Rockwell Automation Publication 440C UM001D EN P March 2015 Table 45 Major Faults Tag Definitions Appendix F Type Code Cause Recovery Method 01H 01 RAM test failure Do one of the following 7 e Power cycle the safety relay 02 ROM test failure Reconfigure the safety relay 03 Stack overflow or underflow Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken 04 Watchdog expired If the fault persists contact your local Rockwell Automation 05 M technical support representative For contact information see Emory error http rockwellautomation com support 06 Register failure 07 Flow control switch default 08 EEPROM fault 11 Host detected incorrect safety firmware version Do one of the following d di fety fi C e Power cycle the safety relay 12 Host detected incorrect safety firmware CRC A Update the firmware in the safety relay 13 Host detected incorrect safety firmware CRC B e Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken 15 Host software error If the fault persists contact your local Rockwell Automation technical s
70. block the CCW evaluates the integrity of the name If valid the name appears in black letters If invalid the CCW shows a naming error in two ways 1 A red box around the name 2 An error message in the build results Figure 28 Red Box Indicates Naming Error Safety Monitoring SMF 1 a0 e o Splitter Estop p 1 01 vee TestSourceA 12 13 Test Source B This example block has two errors 1 The name starts with a period 2 The name contains a space Figure 29 Build Error List Esrar Liat er ma O 2Erors DO Wamings Li 0 Messages Description bd 1 Safety Monitoring Function 1 Emergency Stop Name Incorrect bd 2 Safety Output Function 1 Immediate OFF Name Incorrect After clicking the Build button the Error List shows the name errors In the example above SMF1 and SOF1 have naming errors When a naming error occurs the project cannot be built and downloaded to the CR30 Then naming errors must be corrected However the project can be saved and reopened with the naming errors Rockwell Automation Publication 440C UM001D EN P March 2015 Emergency Stop Chapter 9 Safety Monitoring Functions Many types of safeguarding and safety devices and safety related signals can be connected as inputs to the CR30 The Connected Components Workbench CCW facilitates the selection and connection of the device Each block is assigned the next available settings for input t
71. conds the LED will revert to show the status of the inputs and outputs as configured in the CCW Rockwell Automation Publication 440C UM001D EN P March 2015 33 Chapter 4 Configuring the CR30 Multiple Block Connections Multiple blocks can be connected between e Safety Monitoring Functions and Logic Level A 34 ELO E03 ELOS a05 e Logic Level A and Logic Level B and e Logic Level B and Safety outputs This is done by clicking the desired input and output connection points The CCW automatically determines whether the connection can be made Figure 16 Multiple Block Connections SMF Z LLAS us3 o P ass H Light Curtain D AND Through yee e Inputs HE SMF 4 LLB 4 gt Ka JEN Light Curtain i O Tarih D XOR yee e Rockwell Automation Publication 440C UM001D EN P March 2015 SOF 3 eo ay Immediate OFF e e MP 13 Feedback None Reset Type Manual Reset Input SOF 4 e MP7 e ON Delay oN Feedback None hd Time Delay 2 bSOms 9 Reset Type Manual Reset Input SOFS iia Immediate OFF Feedback None v Reset Type Manual Reset Input MP 12 Om AE MP1s MP16 pT PT Md PT bod PT ud pT PT M Normally Open Input Pulse Testing Chapter 5 Pulse Testing The CR30 performs three types of pulse testing functions e N O inputs e N C inputs e Outputs When a safety input is configured for normally op
72. connected to e Terminal 14 a multi purpose terminal with no pulse testing No PT e Plug in 1 terminal 00 for more status indication e The muting lamp should be connected to terminals without pulse testing Pulse testing does not affect filament lamps but LED lamps can appear to flicker if pulse testing is enabled Figure 105 Muting Lamp Configuration 3 Mute Lamp e OMPI NoPT ero gt Mute SMF smi v bd v Rockwell Automation Publication 440C UM001D EN P March 2015 85 Chapter 11 Safety Outputs Notes 86 Rockwell Automation Publication 440C UM001D EN P March 2015 Plug in Modules Chapter 12 The CR30 accepts up to two plug in I O modules Table 15 shows which modules are available for the firmware that is installed in the CR30 Table 15 Plug in Modules for the CR30 Module Description Firmware Release 2080 1040B4 4 sinking inputs 4 sourcing outputs 6 and later 2080 104 4 sinking inputs 7 and later 2080 084 4 sourcing outputs 7 and later 2080 0W4I 4 electro mechanical relay outputs 7 and later AN ATTENTION The input and output signals of these modules are not safety rated They must only be used for standard control functions Insert Module into Controller Follow the instructions to insert and secure the plug in module to the controller Figure 106 Plug in Module Rockwell Automation Publication 440C UM001D EN P March 2015 controller as shown Snap the mo
73. d to the RS 232 communication port This product is intended to be mounted to a grounded mounting surface such as a metal panel See the Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 for more information Power for the relay is provided by an external 24V DC power supply source To comply with the CE Low Voltage Directive LVD the I O must be powered by a DC source compliant with Safety Extra Low Voltage SELV or Protected Extra Low Voltage PELV To comply with UL restrictions I O must be powered by DC sources whose secondary circuits are isolated from the primary circuit by double insulation or reinforced insulation The DC power supply must satisfy the requirements for Class 2 The following Rockwell Automation power supplies are SELV and PELV compliant and they meet the isolation and output hold off time requirements of the CR30 relay e 2080 PS120 240VAC e 1606 XLP30E e 1606 XLP50E e 1606 XLP50EZ e 1606 XLP72E e 1606 XLP95E e 1606 XLDNET4 e 1606 XLSDNET4 Figure 5 Power Supply pa r Input Terminal Blo oy r Input Output Terminal Block f oo snar 24V DC 24V Common Rockwell Automation Publication 440C UM001D EN P March 2015 21 Chapter3 Power Ground and Wiring Wire Input Devices 22 Input Devices with Mechanical Contacts of safety function product damage or serious injury Properly apply only the
74. ddition to labeling use colored insulation to identify wiring based on signal characteristics For example you can use blue for DC wiring and red for AC wiring Disabling pulse testing on safety related terminals including dedicated safety outputs and test pulse source evaluating input signals requires protection for example cable conduit and separated wiring of safety signals to exclude potential cross loop faults IMPORTANT Fault exclusions for conductors and wiring must follow the requirements according to EN ISO 13849 2 Table D 3 and D 4 A fault exclusion can reduce the overall safety rating of the related safety function to a maximum of PL per EN ISO 13849 1 Rockwell Automation Publication 440C UM001D EN P March 2015 19 Chapter3 Power Ground and Wiring Wire Size Table 1 Wiring Requirements Wire Size Min Type Max Copper Stranded 0 326 mm 1 31 mm2 Rated 90 C 194 F 22 AWG 16 AWG insulation min Terminal Assignments Some terminals are designed to have one specific function Some terminals can perform multiple functions these terminals must be configured in the application software Table 2 Terminal Assignments Terminal Function 00 Safety Input N C 01 Safety Input N C 02 Safety Input N C 03 Safety Input N C 04 Safety Input N C 05 Safety Input 06 Safety Input N C 07 Safety Input N C 08 Safety Input N C
75. declared Before the reset button is pressed the input that is received from the Logic Level B block must be HI Then the output turns on if the reset button must be pressed and held for at least 0 25 s and released within 3 s Timing is used in the ON Delay OFF Delay and Jog functions The timing can be set between 50 300 000 ms 5 minutes in 50 ms increments The output of the block can be connected to one or more of the following wiring terminals e 12 17 Multi Purpose MP e 18 21 Embedded Output EO e 00 03 plug in 1 module not safety rated e 00 03 plug in 2 module not safety rated The multi purpose outputs can be configured to operate with pulse test PT or without test pulses No PT The embedded terminals always operate with test pulses Terminals 20 and 21 can be configured as Single Wire Safety SWS output WARNING The plug in outputs must only be used for nonsafety rated purposes Rockwell Automation Publication 440C UM001D EN P March 2015 81 Chapter 11 Safety Outputs Immediate OFF The Immediate OFF block is used to turn off output terminals immediately upon a demand that is placed on a safety function Figure 101 shows the Immediate OFF output block that is connected to an E stop block through Logic Level LLB1 The feedback signal is provided by SMF 2 and manual reset by SMF3 The output is connected to e Terminals 18 and 19 for dual channel safety switching of the machine hazards e
76. dule into the module bay Using a screwdriver tighten the 10 12 mm 0 39 0 47 in M3 Position the plug in module with the terminal block facing the front of the self tapping screw to 0 2 Nem 1 48 lbein torque 87 Chapter 12 88 Plug in Modules 2080 1Q40B4 The 2080 1Q40 B4 has four sinking inputs and four sourcing outputs The COM connection B3 is internally connected to A3 This COM connection is for the inputs without it the inputs do not turn on Terminal B4 must be connected to the 24V supply to provide power to the outputs terminals O 00 0 03 Figure 107 2080 1040B4 Schematic Showing Four Standard Input Signals me 1 a HA H HY H B1 B2 B3 B4 b5 B6 l 00 101 COM 24DC 0 00 0 01 2080 IQ40B4 l 02 1 03 COM 24DC 0 02 0 03 24V Com Figure 108 2080 1040B4 Schematic Showing Four Standard Output Signals 24V DC B1 B2 B3 B4 B5 B6 100 101 COM 24DC 0 00 0 01 2080 IQ40B4 l 02 1 03 COM 24DC 0 02 0 03 24V Com Rockwell Automation Publication 440C UM001D EN P March 2015 Plug in Modules Chapter 12 2080 104 The 2080 1Q4 has four sinking inputs The four COM connections A3 A4 B3 and B4 are internally connected At least one COM connection must be connected to 24V Com without it the inputs do not turn on Figure 109 2080 104 Schematic Showing Four Standard Input Signals Ne oa HY H FA H B1 B2 B3 B4 B5 B6 00 1 01 COMCOM NU
77. e 13 Select the CR30 14 Click OK AB_VBP 1 1789 A17 A Virtual Chassis EJ 00 Workstation RSLinx Server a 15 Micro830 Micro830 116 Guardmaster CR30 440C n30 2288B gt Rockwell Automation Publication 440C UM001D EN P March 2015 Configuring the CR30 Chapter 4 15 File transfer successful or failed a File transfer successful Click Yes to change the relay to Run mode For unverified configuration this allows the CR30 to operate for a maximum duration of 24 hours to perform relevant tests to validate the safety function Click No to maintain the relay in Program mode and continue with the verification process Components Workbench Download success las S b File transfer failed If the transfer file verification failed the following message occurs Click OK and repeat steps 11 15 Connected Components Workbench x Dowrioad taled tion CRC Downloaded Configural ABCD 1234 COWS GRET Uploaded Configuravon ABCD 1234 COWS LAME 15b bot Validation and Verification To complete the safety system requirements the configuration of the CR30 must be validated and verified At the first download any configuration is in an unverified state This means that you have not confirmed that the configuration and installation meets all specified operational and environmental requirements of the machine to which CR30 is to be fitted determine whether the specifications of this devic
78. e are suitable for all foreseeable operational and environmental characteristics of the machine to which itis to be fitted At regular intervals during the life of the machine check whether the characteristics foreseen remain valid f ATTENTION Before installation a risk assessment must be performed to Validation You must perform appropriate testing to validate the configured safety function of the CR30 Entering Run mode after first download enables operation of a maximum duration of 24 hours to execute relevant tests of the safety function The CR30 displays the execution of an unverified configuration by a flashing Run LED After 24 hours the CR30 stops operation and the power to the CR30 must be cycled to restore the operation for another 24 hours Rockwell Automation Publication 440C UM001D EN P March 2015 29 Chapter4 Configuring the CR30 Verification After validation you can assign a unique verification ID to the current configuration in Connected Components workbench Any change to a verified configuration invalidates the verification ID and requires a new validation and verification process To complete the validation and verification you finally have to acknowledge that the safety configuration and installation meets the operational and environmental specification of the machine Relevant documentation e Details of the authorized and responsible personnel e Revision of the firmware of the CR30 e Version of the Con
79. ece eee RR rd ARK eoe HAAN RA 124 Chapter 18 QV ELVA Woe SR sons hate dictate EES FR ISA MN LA RAN SNES SEEE ONT 125 Project Backup and Restore sssessesrersrrrerererrrrr reser rer rss 125 B ck up Project ss sens sion end dk Swed vara 126 Restore Project is sa vs bs tain eis GNA dad ua ee ats 127 Chapter 19 Reports ac an e e E Be ores eel weve eae ee we eae ee 129 Rockwell Automation Publication 440C UM001D EN P March 2015 9 Table of Contents Specifications Regulatory Approvals Configuration Reference Document ControlFLASH Firmware Upgrade EtherNet IP 1 0 Assemblies Tag Definitions Appendix A STI RAGING brer ith hl adel eh owner id aed aaah Bytes ett RE 131 Performance Level Category s sssssserseserrererrerere rr rr rr rr ra 131 Generalisasi a ria ea Maa NNE FRA fe GR MAR ERA SA PINGA 132 Environmental sedeer i r neen ee stance NS NE RR Te a r 132 INpuls shed er bland Nr Re eagle eee E rel ns fa ERAN bb Er gr 133 MT PU ES atest en i a a ei E BASE SAN E A ASA de dete dad E AR RNA 133 Reaction TIMES agerar nba Saleen bd odlarna ara eri re ears SARA areas 133 RECOVERY Times oa aan E nacke de Bea rls le ad eal el eh ae 134 Response TiTiCS 2 anis snar enes ner teed oes awlnedoee dude bee teak eased es 134 System Response Time Calculation 0 2 eee scene eee ees 134 Response Time Demand of the Safety Function 135 Monitoring Time Occurrence of Recoverable Faults and Failures 137 Te
80. ed control system of a machine The CR30 must be configured using a personal computer PC running the Allen Bradley Connected Components Workbench CCW The CR30 accommodates up to 24 safety monitoring functions Examples of safety monitoring functions are single channel input dual channel input two hand control reset and feedback It is based on the Micro800 platform The housing is red to signify it as a safety device and to distinguish it from the grey colored standard controllers Figure 1 CR30 Relay 00 01 02 03 04 05 06 07 08 09 10 11 VEGF FF 8A Allen Bradley Allen Bradley WD 8 8 8 8 8 8 BA 227 tOCCOM 49 43 14 15 16 17 18 19 2021 Sara The CR30 has 22 embedded safety rated inputs and outputs and accepts up to two plug in modules each of which has four standard inputs and four standard outputs The CR30 can be configured to accept two single wire safety inputs and to provide two single wire safety outputs This feature allows the CR30 to be an integral part of an extensive machine safeguarding system Rockwell Automation Publication 440C UM001D EN P March 2015 11 Overview Chapter 1 12
81. en N O operation the CR30 periodically checks the status of the input The purpose of the test pulse is to detect short circuits in the wiring to 24V DC OV and between two channels This test is independent of the Input Test Pulses Six terminals 12 17 can be configured for normally open operation When a terminal is configured for N O operation the CR30 tests the status of each terminal by generating a test pulse as shown in Figure 17 The normally open input pulse testing cannot be configured to be on or off If the terminal is configured to be N O the pulse testing is performed by the CR30 Figure 17 N 0 Terminal Test Pulse 24V OV Pe l 0 640pus When multiple terminals are configured for normally open operation the CR30 tests each one at 500 ms intervals This test sequence is repeated every 6 4 seconds In Figure 18 on page 36 terminals 12 14 15 and 17 are configured for N O operation and are tested Terminals 13 and 16 are configured for normally closed N C operation therefore the test pulse does not occur on these two terminals Rockwell Automation Publication 440C UM001D EN P March 2015 35 Chapter 5 Pulse Testing Normally Closed Input Pulse Testing 36 Figure 18 Test Sequence oo ee O O 8 HI i i i Terminal 12 Lo Terminal 13 Terminal 14 Terminal 15 Terminal 16 Terminal 17 gt T intervals Terminals 12 17 can be configured to generate test pul
82. er Ground and Wiring Chapter 3 Use Surge Suppressors Because of the potentially high current surges that occur when switching inductive load devices such as motor starters and solenoids the use of some type of surge suppression to help protect and extend the operating life of the relays output is required By adding a suppression device directly across the coil of an inductive device you prolong the life of the outputs You also reduce the effects of voltage transients and electrical noise from radiating into adjacent systems The following diagram shows an output with a suppression device We recommend that you locate the suppression device as close as possible to the load device Since the outputs are 24V DC we recommend 1N4001 50V reverse voltage to 1N4007 1000V reverse voltage diodes for surge suppression for the OSSD safety outputs as shown in Figure 8 Connect the diode as close as possible to the load coil Figure 8 Surge Suppressors 24V DC ape nv Input Output Terminal Block 660660000000 Diode Surge Suppressor 24V Common Example suppressors include e 100 FSD250 for Bulletin 100S Contactors e 1492 LD4DF terminal block with built in 1N4007 diode The embedded serial port is a non isolated RS 232 serial port that is targeted to be used for short distances lt 3 m to devices such as HMIs for example PanelView Pin 2 and the shield are both internally connected to the 24V Common A2
83. erable reaction times for a safety function Table 33 Safety Function Reaction Times Description Where to find Value Feedback Feedback Input Filter time From SMF configuration advanced settings Safety Sensors Reaction time of sensor Sensor operating manual device SMF Configured Input Filter From SMF configuration time advanced settings Reset Restart Reset Restart Pulse Time Reset Pulse max 3s 3s 2 x Input Filter 2 x Filter Time Input Filter Time from SMF configuration Logic Internal execution timeto From technical 100 ms process input signal specification routing and output processing SOF Configured On Delay time From SOF configuration Actuator Safety switching device Actuator Operating manual controlling the load Total 1 If input filter time settings are not disabled the recommended setting is 0 Values greater 0 must be considered for the reaction time 2 The internal execution time is static and independent of the number of function blocks that are configured for the safety function 3 The maximum input filter time must not be greater than 250 ms Figure 138 Example 1 Pass o o o A o D AND Through o toi O iici e f018 PT gt m gt Feedback Inputs 2 a Reset Type 143 Appendix A 144 Specifications Table 34 For SMF1 E stop Comment Value Feedback Disabled for SOF Oms Safety Sensor
84. erified the ID is 0000 Press and release the Verification button The IN 0 LED is green The OUT 1 2 3 and 4 LEDs are green After five seconds the LEDS will revert to show the status of the inputs and outputs as configured in the CCW Figure 11 Verification ID is 0000 Not Verified All Values are 0 Verification Digits 1 2 3 and 4 440C CR30 If the CR30 configuration has been verified pressing the Verification button will cycle the LEDs through each verification digit In the following example the Verification ID is 7916 Press and release the verification button once Figure 12 First Verification Digit Value is 7 L Verification Digit 1 440C CR30 Rockwell Automation Publication 440C UM001D EN P March 2015 Configuring the CR30 Chapter 4 Press the Verification button within five seconds Figure 13 Second Verification Digit Value is 9 gt E PWR EI RUN SE FAULT mi Lock EE COM Verification Digit 2 012 OUT 345 440C CR30 Press the Verification button within five seconds Figure 14 Third Verification Digit Value is 1 Verification Digit 3 012 OUT 3465 440C CR30 Press the Verification button within five seconds Figure 15 Fourth Verification Digit Allen Bradley SR R ter 01234 51789 E PWR E RUN EE FAULT MM LOCK EE COM 012 OUT 3 5 440C CR30 Value is 6 Verification Digit 4 After five se
85. erminals test sources number of inputs pulse testing discrepancy time and input filter The Emergency Stop function block sets the parameters for typical emergency stop push buttons In the CCW click and drag or double click the block to an available Safety Monitoring Function spot When mechanical operated contacts are used these contacts must be direct acting contacts Figure 30 Emergency Stop Function Block Guardmaster 440C CR 4 Safety Monitoring Functions hk Pointer Enabling Switch Feedback Monitoring Gate Switch Light Curtain Muting Reset Restart Test Source A 12 Safety Mats Single Wire Safety Input Test Source B 13 Two Hand Control P Advanced Settings HE 3 heevrtaw Alternative Device a Logic Functions Inputs 2NC X hk Pointer Pulse Testing 2 Sources v Discrepancy T 0 ae Time x50ms 26 Input Filter Project Organizer 625ms Name ProjectSs a Guardmaster_440C_CR30 The available input selections for the Emergency Stop inputs are e EI 00 EI 11 embedded input terminals 00 11 e MP_12 MP_17 multi purpose terminals 12 17 You can modify the number and types of inputs e 2NC e 2 OSSD e INC Pulse testing can be disabled or set to 2 Sources When 2 Sources is selected the next available test sources are automatically selected You can modify the sources afterward Rockwell Automation Publication 440C UM001D EN P March 2015 45 Chapter 9 Safety
86. espect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the 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
87. et safety relay through the Connected Components Workbench software 1 On the Device Details toolbar click the Secure button Select Clear Password E Project157 Connected Components Workbench Standard Edition File Edit View Debug Tools Communications Window Help Ngasaan GLA JSE o Language Project Organizer X Guardmaster 440C CR30 Logic 3 Guardmaster_440C_CR Guardmaster_440C_CR30 Name Project157 w Guardmaster 440C_CR30 440C CR30 22BBB Verification ID Remote Mode Fault Not Faulted The Clear Password dialog appears TA Connected Components Workbench 9 Clear password protection from the safety relay Password eeececooes OK cance Help 2 Enter Password 3 Click OK to clear the password The safety relay will require no password on any new session Rockwell Automation Publication 440C UM001D EN P March 2015 123 Chapter 17 Security and Password Lost Password If the safety relay is secured with a password and the password has been lost then it becomes impossible to access the safety relay using the Connected Components Workbench software To recover use ControlFLASH to refresh the safety relay firmware which also clears the safety relay memory and clears the password ATTENTION The project in the safety relay is lost but a new project can be downloaded 124 Rockwell Automation Publication 440C UM001D EN P March 2015 Chapter
88. fety relay security has two components Exclusive access that prevents simultaneous configuration of the safety relay by two users e Password protection that secures the intellectual property that is contained within the safety relay and prevents unauthorized access Exclusive access is enforced on the Guardmaster 440C safety relay regardless of whether the safety relay is password protected or not This means that only one Connected Components Workbench CCW session is authorized at one time and only an authorized client has exclusive access to the safety relay application This helps ensure that only one software session has exclusive access to the Guardmaster 440C application specific configuration Exclusive access is enforced on Guardmaster 440C firmware version 7 and later When a CCW user connects to a Guardmaster 440C safety relay the software is given exclusive access to that safety relay By setting a password on the safety relay you effectively restrict access to the configuration software connections to the safety relay to software sessions that can supply the correct password Essentially CCW operations such as upload download and connect are prevented if the safety relay is secured with a password and the correct password is not provided Guardmaster 440C safety relays with firmware version 7 and later are shipped with no password A password can be set through the CCW software version 7 or later The safety relay pas
89. function When the safety function is demanded during the monitoring time after the occurrence of a recoverable fault the system will respond within the safety response time according to the response time considerations of this safety function See System Response Time Calculation on page 134 Note Monitoring measures that are provided by CR30 to the periphery define the diagnostic coverage of the application and thus the safety rating Internal monitoring measures related to a fail safe design of CR30 are only related to the safety integrity of the CR30 itself see nonrecoverable faults Examples of recoverable faults include e Cross loop and shorts to 24V and COM faults e Input discrepancy e Muting Synchronization times exceed e Muting time exceeded e Muting sequence fault e Two hand discrepancy fault e Reset Restart timing fault Rockwell Automation Publication 440C UM001D EN P March 2015 137 The evaluation method of the input or output signal depends on the configuration of the SMF and SOF in CCW and the wiring of the sensor Table 29 shows typical evaluation functions and required settings to be enabled Table 29 Evaluation Method Evaluation Method Multi channel signal evaluation Configuration Inputs 2 N C 2 OSSD 3 N C or 3 OSSD Pulse Testing 2 Sources v Discrepancy 2 Time 650m z Input Filter Is 625ms Applicable for SMF Emergency Stop Enabling Switch Gate Switch Light C
90. g Info File RIX RI11 0 a Service wre Assembly _ E ceo hes Eror Code Hex 0 Cass he dec E Saco Instance hex 96 deck 150_ Attibute hex 3 dec 2 Entot Description No enors Rockwell Automation Publication 440C UM001D EN P March 2015 99 Chapter 13 100 Automation Controller Communications 2 Setthe Ethernet network address of the Guardmaster 440C ENET plug in module as the target of the message instruction MSG Rung 20 MGO0 Arr General MultiHop Send Data Receive Data Ins Add Hop Del Remove Hop EtheiNet IP Device str Appendix E page 161 describes the individual members of the data returned from the message instruction Rockwell Automation Publication 440C UM001D EN P March 2015 LEDs Chapter 14 The CR30 has 21 LEDs on the upper left front of the module These 21 LEDs fall into three categories e Input status e Module status e Output status Figure 116 LEDs Input Module gt f ao O a s k PWR RUN FAUL E ao gt a 440C CR30 Rockwell Automation Publication 440C UM001D EN P March 2015 101 Chapter 14 LEDs Input and Output LEDs To access and configure the LEDs in the CCW 1 In the Project Organizer double click Guardmaster_440C CR30 2 Click LED Configuration 3 Configure the filter type and value for input and output LEDs 1 Micro 830 CR30 Connected Components Workbench
91. ge or high current spikes that cause internal damage of components e Power supply interruptions that are detected by internal voltage level monitor e Transient overload conditions of safety outputs that trigger short circuit and overload protection or the output for example high inrush currents Troubleshooting with the When connected to the CR30 through the USB port the CCW Logic Editor ccW monitors and displays the status of each terminal and block e Green shows an ON HI state e Red shows a Fault state output is LO e Grey blocks are OFF LO state Figure 126 Monitor Status with Logic Editor Grey indicates OFF Green indicates ON p id w Restart e mm Mouse over the red block and the CCW displays an error message for 5 seconds Move the mouse away and then back over the block to show the message again Red indicates a Fault 114 Rockwell Automation Publication 440C UM001D EN P March 2015 Troubleshooting Chapter 16 Figure 127 Mouse Over to Show Error Message in Yellow Box Tre The type of fault is also shown in the top panel of the Project tab Figure 128 e For a recoverable fault the Device Details view only indicates Fault Recoverable For further details navigate to the Logic Editor view and mouse over the red marked function block A user is allowed to change the operation mode to Program Mode e For a nonrecoverable fault the Device Detail
92. gregate Current of Outputs 3A per Device Max Surge Output Current 1A Surge Output Current 5 ms Duration Residual Voltage Drop from 0 2V DC Power Supply max Max Load Capacitance 200 nF 20 mA load 100 nF 10 mA load 22 nF without load Off state Leakage Current lt 0 1mA max Short Circuit Detection Yes Short Circuit Protection Yes Galvanic Isolation 1 0 from No Logic Pulse Test Duration S700 ps Pulse Test Period lt 13000 ms less than 15 s Reaction Times Safety Input z p Automatic reset lt 100 ms Single Wire Safety Input Manual monitored reset lt 500 ms Safety Mats Rockwell Automation Publication 440C UM001D EN P March 2015 133 AppendixA Specifications Recovery Times Response Times System Response Time Calculation 134 To trigger Inputs again Response time as demand reaction time 100 ms Safety Input 45 ms Input Filter time Single Wire Safety Input lt 45 ms Safety Mats lt 70 ms Single Wire Safety Output lt 60 ms The safety response time is the time that is required to establish the safe state of the safety output function considering the demand of the safety monitoring function and or occurrence of faults and failures in the safety chain The overall response time of the safety function considers the whole safety chain including the safety input device logic device and actuator The safety response time is used to calculate the safety distance distance between a safe
93. guarding device and the hazardous area The following paths have to be considered Figure 135 System Response Time Input Logic Actuator E g Interlock E g CR30 E g Contactor switch Embedded Input CPU Logic Embedded routing Output Rockwell Automation Publication 440C UM001D EN P March 2015 Specifications Response Time Demand of the Safety Function Appendix A The safety response time of CR30 is the screw to screw response time to turn off a safety output at demand of the safety function by the safety input device The safety response has to be calculated for each safety monitoring function Table 25 shows the possible safety chain with all considerable response times Table 25 Safety Chain Response Times Description Where to find Value Safety Sensors Safety response time of sensor device Sensor operating manual SMF Specific Processing time of safety Below table of specific SMF processing monitoring function configured in CCW times Input Filter Configured Input Filter time From SMF configuration advanced settings Logic Internal execution time to process input From technical specification 45 ms signal routing and output processing SOF Configured Off Delay time From SOF configuration Actuator Safety switching device controlling the Actuator operating manual load Total 1 The internal execution time is static and independent
94. h hand buttons must be released to start a 8 Both hand buttons must be released to start a new cycle new cycle 68 Rockwell Automation Publication 440C UM001D EN P March 2015 Alternate Device Safety Monitoring Functions Chapter 9 The Alternate Device provides the flexibility to create other types of input monitoring blocks Use this block for the following types of input functions e Single channel OSSD e Single channel N C e Dual channel OSSD e Dual channel 2 N C e Dual channel 1 N C 1 N O e Three channel N C e Three channel OSSD Figure 74 Alternate Device Function Block Toolbox lt Guardmaster 440C C Pointer Emergency Stop Safety Monitoring vee oe y Safety Device 9 ELO1 v o Enabling Switch JA Feedback Monitoring Hl Gate Switch El Light Curtain B Mating 4 Q Oo nn as PEY Reset Restart Test Source A 12 Test Source B 13 bd Safety Mats Single Wire Safety Input Two Hand Control Advanced Setting eriadan Inputs 2NC gt Pointer Pulse Testing 2 Sources Discrepancy a AND Time 650ms 27 OR Input Filter E 625ms s XOR NAND NOR Single Channel Single channel safety monitoring functions require only one connection to an input terminal The single channel input must only be used in low risk safety systems The available input terminals are e EI 00 EI 11 embedded input terminals 00
95. he fault and cycle the contacts to clear the fault Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 If a short circuit occurs on terminal 12 to ground the CR30 turns off its safety outputs within 3 3 seconds Remove the fault and cycle the contacts to clear the fault If a short circuit occurs from terminal 12 to terminal 13 the CR30 turns off its safety outputs within 35 ms Remove the fault and cycle the contacts to clear the fault Three Channel The CR30 can accept three channels into one safety monitoring function All three inputs must be HI to satisfy the input If any one of the inputs goes LO the output of safety monitoring function goes LO and turns off its associated output devices The three N C inputs can be operated without input test pulses with one input test pulse with only two input test pulses or with three input test pulses The available input selections for the three channel inputs are e EI 00 EI 11 embedded input terminals 00 11 e MP 12 MP 17 multi purpose terminals 12 17 Pulse testing can be set to 1 Source 2 Sources 3 Sources or Disabled When 1 2 or 3 Sources is selected the next available test sources are automatically assigned by the CCW You can modify the sources afterward You can use the default Discrepancy Time and Input Filter or choose to modify these settings The three terminals do not necessarily have to be consecutive
96. hould configure local variables In this example they are labeled LocalCfg TargetCfg and LocalAddr e LocalCfg must be configured as a MODBUSLOCPARA data type TargetCfg must be configured as a MODBUSTARPARA data type LocalAddr must be configured asa MODBUSLOCADDR data type e TargetCfg Addr Select the first value from the Modbus Mapping table for the CR30 In this case the initial value is set to 000273 leading zeros must be included which is mapped to terminal 00 of the CR30 e TargetCfg Node Enter a value of 1 The CR30 is fixed at Node 1 e LocalCfg Channel Select the serial port location Enter a 2 if the embedded serial port is used Enter a 5 to use the serial port in the fist plug in slot e LocatCfg TriggerType Enter a 0 to have the block execute only once Each time the push button that is connected to terminal _IO_EM DI 00 is pressed message is sent once e LocalCfg Cmd Enter a 1 to instruct the block to read a coil which is mapped to the CR30 e LocalCfg ElementCnt Enter a 5 read the status if 5 inputs starting at 000273 and ending at 000277 Rockwell Automation Publication 440C UM001D EN P March 2015 109 Chapter 15 Modbus Communication e LocalAddr The results are placed in Local Addr There is no need to make changes Figure 122 Read Local Variables Sending Reset to CR30 The Reset function must use a separate Modbus message block Another constraint that must be considered is
97. ided with Connected Components Workbench software for more information on configuring your CR30 safety relay These documents contain additional information concerning related products from Rockwell Automation Resource Description 2711C UM001_ EN P PanelView Component HMI Terminal User Manual 440C 0S001_ EN P Guardmaster 440C CR30 Software Configurable Safety Relay Quick Start Guide Industrial Automation Wiring and Grounding Guidelines Provides general guidelines for installing a Rockwell publication 1770 4 1 Automation industrial system Product Certifications website http www ab com Provides declarations of conformity certificates and other certification details Allen Bradley Industrial Automation Glossary AG 7 1 A glossary of industrial automation terms and abbreviations 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 You can download the latest version of Connected Components Workbench for your CR30 at http compatibility rockwellautomation com Pages MultiProductDownload aspx Keyword Free amp crumb 112 Rockwell Automation Publication 440C UM001D EN P March 2015 3 Preface Definitions Publication AG 7 1 contains a glossary of terms and abbreviations used by Rockwell Automation to describe industrial au
98. igure 21 Main Transistor Test gt 50s i 24V gt Terminal 12 o H 24V 4 i Terminal 13 ov 24V Terminal 20 ov l l 24V Terminal 21 ov Rockwell Automation Publication 440C UM001D EN P March 2015 37 Chapter 5 38 Pulse Testing Then a sequence occurs in which each output is individually tested twice The test pulse is 50 us wide The test pulses occur every 250 ms and switch to the next output configured with testing Figure 22 Test Pulse Sequence Terminal 12 Terminal 13 Terminal 20 Terminal 21 24V ov 24V ov 24V ov 24V ov e tan a r CEE EE Rockwell Automation Publication 440C UM001D EN P March 2015 Chapter 6 Input Filter Input filtering gives the CR30 the ability to filter out noise and in some cases inadvertent operation Sometimes an operator presses a push button and immediately realizes that they pressed the wrong button and immediately releases the button In muting applications an object moving down a conveyor might stop just at the point where the muting sensor is deactivated and then back off enough that the muting sensor is reactivated When an input filter time t1 is specified an input channel is allowed to go to the LO state while the other channel is in the HI state for that length of time without the output of the instruction going to the LO state However the output goes to the LO state when both input channels are in the LO state s
99. ime between the Muting Sensors and between Muting Sensor can be set individually The longest synchronization must be considered Table 31 Response time of the Safety Chain at Occurrence of Recoverable Faults without a Demand of the Safety Function Description Where to find Value SMF Fault processing Above table according to configured input evaluation of the SMF Logic Internal execution time to From technical 45 ms fix process input signal specification routing and output processing SOF Fault processing time and From SOF configuration configured time delay Actuator Safety switching device controlling the load Actuator Operating manual Total 1 The internal execution time is static and independent of the number of function blocks that are configured for the safety function Rockwell Automation Publication 440C UM001D EN P March 2015 141 AppendixA Specifications Figure 137 Example 6 00 0 o o o 018 PT L o EmergencyStop 9 D AND o E a o ep Immediate OFF o anm e o toi PT Feedback None I z Test Source A 12 Inputs 2 Reset Type Automatic Test Source B 13 bd S es Inputs Pulse Testing Discrepancy Time Oms x Input Filter 25mns E102 vee A Safety Mat 9 1 03 ee Test Source A 14 Test Source B 15 v Table 32 Consideration for Recoverable Faults of E stop Safety Function Description Value SMF Cross loop fault 3
100. imultaneously The input filter operates on both the leading edge and trailing edge of the input signals If specified the filter time must be included in the response time calculation Figure 23 Input Filtering 1 Channel A 0 Channel B 0 Output P 0 Input filtering can set in 25 ms increments from 0 1000 ms The default value is 0 ms Rockwell Automation Publication 440C UM001D EN P March 2015 39 40 Chapter 6 Input Filter The input filtering is set in the Advanced Settings of each safety monitoring block Figure 24 shows that the Enabling Switch function with the input filter is set to 4 4 x 25 100 ms Figure 24 Enabling Switch Safety Monitoring EL00 vee _ Enabling Switch fio e o Test Source A 12 v Test Source B 13 Advanced Setting Inputs 2NC G Pulse Testing 2 Sources v Discrepancy Time 6S0ms 25 Input Filter 124 25ms Rockwell Automation Publication 440C UM001D EN P March 2015 Chapter 7 Discrepancy Time Safety Monitoring functions using dual inputs have a feature that allows the CR30 to test for the timing of the operation of both channels In most cases the outputs of dual channel safeguarding devices change state within a few milliseconds of each other In some cases the second channel can change state much later than the first In these later cases you want to allow that is make sure that both channels return to their safety state withi
101. inals 00 11 you must maintain at least SOms delay for reliable operation When the muting sensors are connected to a plug in module the synchronization delay must be at least 150ms Table 4 Minimum Synchronization Times Muting Sensor Connection Minimum Synchronization Time Connected to embedded terminals 00 17 50 ms Connected to Plug in module terminals Px_00 Px_03 150 ms Note The synchronization time also depends on the input filter time settings for the muting sensor inputs Synchronization time total 2 x Input Filter Time Synch Time Table 5 shows the muting and synchronization times that are selectable in the CCW These times are linked For example if you select a 10 s muting time then the synchronization time between MS1 and MS2 is 3 s To use a synchronization time of 6 s you must select a 60 s muting time Table 5 Muting and Synchronization Timing Selections Ws s omn YDS 20s 35 1800 s 30 min 180 s 3 min 30s 35 3600 s 1 hr 180 s 3 min 60 s 1 min 6s 28 800 s 8 hr 180 s 3 min 300 s 5 min 305 Infinite Infinite If the synchronization time is exceeded the FAULT indicator and muting output will flash On the CCW the Muting Safety Monitoring Function turns red and the Mute Lamp flashes green If the material is backed away from the sensors the fault is cleared and the muting lamp turns off If the material proceeds to break the light curtain the output of the
102. inals 12 and 13 Rockwell Automation Publication 440C UM001D EN P March 2015 63 Chapter 9 Safety Monitoring Functions SensaGuard 64 Figure 62 Example Schematic for a Safety Mat 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 A B A1 a2 12 13 14 15 16 17 18 19 20 21 Safety Mat 24V Com The SensaGuard function block sets the parameters for interlocks having dual OSSD outputs In the CCW click and drag or double click the block to an available Safety Monitoring Function spot This block can be used for other devices with OSSD outputs Figure 63 SensaGuard Function Block x E ster 30 Logic x GRIEIIEEE R Emergency Stop Enabling Switch Safety Monitoring BB Feedback Monitoring Hl Gate Switch ae H Light Cunain Pf nd H SensaGuard 2 o G Muting fo e o Reset O Restart i Safety Mats ma Single Wire Safety Inp Discrepancy 22 Standard Signal SA gt Aa Two Hand Control 625ms va Alternative Device 4 Logic Functions Rh Pointer D AND D OR The available input selections for the SensaGuard inputs are e EI 00 EI 11 embedded input terminals 00 11 e MP_12 MP_17 multi purpose terminals 12 17 You can use the default Discrepancy Time See Discrepancy Time on page 41 and Input Filter See Input Filter on page 39 or choose to modify these settings Figure 64 Example Schematic of a SensaGuard Interlock 24V DC Pink OSSD2
103. ions Chapter 13 2 Set the Ethernet network address of the Guardmaster 440C ENET plug in module as the target of the message instruction MSG Rung 2 0 MG10 0 General MutiHop Send Data Receive Data Ins Add Hop Del Remove Hop Appendix E page 161 describes the individual members of the data returned from the message instruction This example shows the configuration of an explicit message to write data to the Guardmaster 440C CR30 safety relay 1 Set up the MSG instruction to read the data assembly from the Guardmaster EtherNet IP network interface by configuring the following fields Channel 1 Integral this is the Ethernet port Communication Command CIP Generic Data Table Address Send N7 0 choose an address that supports 4 bytes Size in Bytes Send 4 Extended Routing Info File RIX RIX11 0 Service Write Assembly Class 04 Instance 150 96h Attribute 03 ra MSG MG20 0 1 Elements General MutiHop Send Data Receive Data This Controller Control Bis Chavet irea io nau 110 T Commurscaton Command Bresk reece ERD Data Table Address Receive Send Awaiting Execution EW 0 Size in Bytes Receive N A Send 4 Enor ER E no r Target Device Message done DN 0 Message Timeout d Message Transm ting ST 0 Message Enabled EN 0 Local Remote Local MutiHop Yes Extended Routin
104. is categorized as Data Communications Equipment DCE The PanelView HMI s are Data Terminal Equipment DTE This is important when point to point wiring connections are made When DTE communicates with DCE the connections are pin x to pin x When DTE communicates with other DTE a cross over is required for example TxD must be connected to RxD The state of the CR30 upon power up depends on its state when power was turned off The Run LED indicates the state of the CR30 1 Program Mode RUN LED off The CR30 is in program mode upon power up 2 Run Mode with Program Not Verified RUN LED flashing The CR30 returns to Run mode Run mode without verification is good for only 24 hours on continuous running 3 Run Mode with Program Verified RUN LED solid green The CR30 returns to Run mode with no limitation on the run duration Rockwell Automation Publication 440C UM001D EN P March 2015 Chapter 4 Configuring the CR30 This manual assumes that the Connected Components Workbench has been loaded and describes basic operations Use the online help for configuring the safety functions ATTENTION Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be conducted by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner that is not specified by the manufacturer the protection that is provided by
105. is connected between terminals 12 to 06 to take advantage of pulse testing Contactor K1 and K2 which provide power to the conveyor and other hazards if necessary are connected to terminals 18 and 19 The muting lamp is connected to terminal 13 this terminal should be configured with no pulse testing Filament lamps will not be affected by pulse testing but LED lamps may appear to flicker if pulse testing is enabled Figure 53 Example Schematic for 4 Sensor Muting 24V DC Light Curtain 00 01 02 03 04 05 06 07 o8 09 10 11 CR30 A TA Contactors for Conveyor Power Muting Lamp 24V Com For simplicity the power and ground connections of the light curtain and muting sensors are not shown The light curtain and muting sensors must have the same reference 24V Com as the CR30 for proper operation Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 For proper operation the muting sensors are on normally closed when not muting and the light curtain OSSD outputs are also on the light curtain is clear Figure 54 Muting Time for 4 Sensor Muting Muting sensor 1 4 Muting sensor 2 3 Muting sensor 3 2 Muting sensor 4 1 Muting lamp nn nn yn EJE E ojo Oo MIA mM mMm ATA A A 30ms lt t t lt muting time 30ms lt t t lt synchronization gt lt gt t lt synchronization time time Table 7
106. iscrepancy Time and Input Filter or choose to modify these settings Figure 44 Example Schematic of a Light Curtain 24V DC Receiver Transmitter 00 01 02 03 04 05 06 07 08 09 10 11 CR30 a1 a2 12 13 14 15 16 17 18 19 20 21 24V Com Rockwell Automation Publication 440C UM001D EN P March 2015 51 Chapter 9 Safety Monitoring Functions Muting 52 Muting is the temporary automatic suspension of the protective function of a safeguarding device like a light curtain The muting function allows the transport of material through a light curtain without stopping a conveyor To distinguish between material and persons a certain sequence of events and timings are used Muting sensors are mounted in a certain pattern and the material must pass by the sensors and light curtain within specified time limits If the muting sensor sequence is incorrect or the timing parameters are violated the conveyor is turned off An override signal moves the material through the light curtain after a violation Figure 45 Muting Function Block 4 Safety Monitoring Functions h Pointer os Emergency Stop I Enabling Switch JA Feedback Monitoring IE Gate Switch H Light Curtain i Mating 0 Safety Mats mn Single Wire Safety Input 22 The Hand Control Alternative Device H 4 Logic Functions hk Pointer oes 2 Sensor T Type v X y Mute Time 10s pN Sensor Synch Time D sk 3s D D
107. l Automation Publication 440C UM001D EN P March 2015 Modbus Mapping Chapter 15 Modbus Communication The CR30 uses Modbus RTU communications to transfer status information and control signals to Micro800 controllers and human machine interfaces like the Allen Bradley PanelView The Modbus configuration of the CR30 is fixed to Modbus RTU slave at address 1 For more information on PanelView refer to the following documents e User Manual 2711C UMO001_ EN P e Quick Start Guide 440C QS001_ EN P The CR30 Modbus addresses are mapped to parameters shown in Table 20 The addresses in the range of 1 512 can be accessed as coils The fault log can be accessed by holding register reads each address contains 16 bits of data Table 20 Modbus Addresses Modbus Address Parameter 000001 000016 Modbus serial input data 000025 000028 Input Data for Plug in 1 Terminals l 00 1 03 000033 000036 Output Data for Plug in 1 Terminals 0 00 0 03 000265 Processor HW fault 000266 Safety Input HW fault 000267 Safety Output HW fault 000268 Power supply fault Main transistor fault 000269 Communication fault 000270 Configuration fault wrong revision invalid configuration 000271 Time out Clock monitoring 000272 Plug in fault 000273 000294 State of Embedded Terminals 00 21 000297 000300 Input of Plug in 2 Terminals l 00 1 03 000301 000304 Ou
108. l latch downwards until it is in the unlatched position For environments with greater vibration and shock concerns use the panel mounting method instead of DIN Rail mounting Rockwell Automation Publication 440C UM001D EN P March 2015 15 Chapter2 Installation Panel Mounting Figure 4 Panel Mounting mm in 86 3 39 O OOOOOOO0O0OO0O0O0Q BEEBE ba EJ OE 000 2 W S EN A SV IH L 2 16 Tel TOOOOO000G000 i eel CE lA YW Z The preferred mounting method is to use four M4 8 screws per module Hole spacing tolerance 0 4 mm 0 016 in Follow these steps to install your relay using mounting screws 1 Place the relay against the panel where you are mounting it Make sure that the relay is spaced properly 2 Mark drilling holes through the mounting screw holes and mounting feet then remove the relay 3 Drill the holes at the markings then replace the relay and mount it Leave the protective debris strip in place until you are fi
109. lautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure 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 Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul 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 41
110. le 440C CR30 22BBB Description 8 001 or later You need to download the firmware from http www rockwellautomation com rockwellautomation support pcdc page 92 Rockwell Automation Publication 440C UM001D EN P March 2015 Plug in Modules Chapter 12 Install the Module To install the module follow this procedure ATTENTION A N e Do not insert or remove the plug in module while power is applied otherwise permanent damage to equipment may occur e This plug in module is not compatible with Micro800 controllers 1 Position the plug in module as shown Figure 113 Plug in Module Positioning 2 Snap the module into slot 1 of the module bay 3 Using a screwdriver tighten the 10 12 mm 0 39 0 4 in M3 self tapping screw to torque specifications Wire the Ethernet Connector Use an RJ45 connector to connect to the EtherNet IP network Wire the connector as shown Figure 114 Connector Wiring BNC Je g 6 RD fe 4 c 1 r J RDH Pere D gt TTD naa For detailed EtherNet IP connection information see the EtherNet IP Media Planning and Installation Manual available from the Open DeviceNet Vendor Association ODVA at http www odva org Rockwell Automation Publication 440C UM001D EN P March 2015 93 Chapter 12 94 Plug in Modules Grounding Considerations The grounding and bonding must be of equal potential between
111. le using the buttons on the memory module and safety relay 1 2 Power down the Guardmaster 440C safety relay Remove the dustcover or plug in module that is currently located in slot 1 the leftmost slot of the safety relay module bay Snap the Cat No 2080 MEMBAK RTC module into slot 1 of the module bay Power on the Guardmaster 440C safety relay The safety relay detects the presence of the Cat No 2080 MEMBAK RTC memory module and enters a fault state The Fault LED is solid Red and the application logic is not executed The LEDs are as follows PWR solid green RUN off not executing FAULT solid red LOCK solid green COM off 012 our 345 440C CR30 Rockwell Automation Publication 440C UM001D EN P March 2015 127 Chapter 18 128 Using the Memory Module 10 11 The behavior of the IN and OUT LEDs depends on whether the configuration is verified e Verified the IN and OUT LEDs continuously cycle through the verification number of the configuration currently running in the CR30 e Not Verified the IN 0 and the OUT 1 2 3 and 4 are solid green The restore can take place since the configuration being downloaded is verified Press and hold the MEM ID button that is located on the Guardmaster 440C safety relay just below the USB port While holding the MEM ID button using a small flathead screwdriver press the Backup button on the Cat No 2080 MEMBAK RTC memory
112. lectrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support Rockwell Automation Publication 440C UM001D EN P March 2015 165 Appendix F Tag Definitions Type Code Cause Recovery Method 08H 01 Over under voltage detected or pulse test failure of main Do one of the following internal transistor Validate the electrical installation and appropriate supply 02 Pul fault of vol itoring mal 3 voltage is provided ulse test fault of voltage monitoring main transistor Power cycle the safety relay 03 Under voltage reset Reconfigure the safety relay x If the fault persists contact your local Rockwell Automation 10H 01 Compare UART data during operation technical support representative For contact information see http rockwellautomation com support 02 Communication timeout between safety processors Do one of the following H d daa e Power cycle the safety relay y Patas etected satety processors are e Reattempt download of the safety relay configuration P Validate the electrical installation and appropriate 18 Host processor detected safety processors lost measures to reduce noise and suppress surges are taken communication If the fault persists contact you
113. lectromagnetic compatibility in residential and other environments due to conducted and radiated disturbances This equipment is supplied as open type equipment It must be mounted within an enclosure that is suitably designed for those specific environmental conditions that will be present and appropriately designed to prevent personal injury resulting from accessibility to live parts The enclosure must have suitable flame retardant properties to prevent or minimize the spread of flame complying with a flame spread rating of 5VA V2 V1 VO or equivalent if nonmetallic The interior of the enclosure must be accessible only by the use of a tool Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications In addition to this publication see e Industrial Automation Wiring and Grounding Guidelines for additional installation requirements Allen Bradley publication 1770 4 1 e NEMA 250 and IEC 60529 as applicable for explanations of the degrees of protection provided by different types of enclosures ATTENTION Prevent Electrostatic Discharge This equipment is sensitive to electrostatic discharge which can cause internal damage and affect normal operation Follow these guidelines when you handle this equipment e Touch a grounded object to discharge potential static e Wear an approved grounding wrist strap
114. leg 4 Chapter 1 Intended USE denen ener eo EEEE op TE meee mnens ee 11 Hardware Features niens rederiet a ari ome ded Taoa ee kes 11 CRIO Hardware Details ss ass hamster dar ek A 12 Max Number of Inputs and Utputs sserseeserserrsersa 12 Software ier n br be sea eerie ead AR HAr EE Eh 13 Obtain Connected Components Workbench 5 13 USB COUNCCHON 4 oss uiing Sti tao BS and ARA RA Ra BARR eae tee 13 Serial Port Connecti n sig cted namaste i se e a E 13 Chapter 2 Mounting Dimensions sic susadan dn as crea cnta Sols SAN SRS Dine dats he 15 DIN Rail Mounting c cs00n50 sate vee eckagenekens vee rese rr oe 15 Panel Mounting aiken A teers beth oes ee Dee ek oh aia 16 Enclosure Considerations s sseeseesrrrerrserrerrrrrerr rer rr sa 17 Preventing Excessive Heat ss smed sdedsrneress beses died delens 17 Chapter3 Wiring Requirements and Recommendation sssresererrerera 19 WV TCS LZ E Srn e a ad hahah e doers ates alata E E Alle 20 Terminal Assignments sssssersersrersrrrererrrrrrr reser rese ra 20 Grounding the Configurable Safety Relay sssseseserrererrrora 21 Connecting a Power Supply siacs cespcasy cine neue swiss Gas de Riese be 21 Wire Input Devices ss gcocdeyegsangewedatas ope periti rieme ete ne 22 Input Devices with Mechanical Contacts sseesersrt 22 Input Devices with OSSD Outputs sseesssrrssrrserrrrra 22 Wire Our put Devices iis renne on theses aoa end dreads 23 Use Surge SUPP
115. lication 440C UM001D EN P March 2015 Example Architectures Modbus Communication Chapter 15 Some examples of how the CR30 is used with Modbus are shown in Figure 118 In the example below a PanelView C600 is connected to the serial port of the CR30 The C600 is configured over its Ethernet port The C600 can read status information from the CR30 and can send reset and restart signals to the CR30 Figure 118 Modbus RTU Communication PanelView C600 To Ethernet DHCP enabled Network PanelView C600 2711C T6T Modbus Master Ethernet Port 10 100Base T RS 232 Serial Port 9 pin D shell Ethernet Cables 1761 CBL PM02 Cable CR30 440C CR30 22BBB Modbus Slave 8 pin Mini DIN RS232 In this example a Micro830 is connected to the CR30 by the 8 pin DIN serial port connections The Micro830 can read use status information from the CR30 and can send reset and restart signals to the CR30 Figure 119 Modbus RTU Communication Micro830 ON AN oh 5 12200080900000000 Micro830 2080 LC30 24QBB Modbus Master io cae E E Y 1761 CBL HM02 lt 8 Pin mini DIN to 8 Pin mini DIN CR30 440C CR30 22BBB Modbus Slave Standard Cable USB A Male to B Male In the example below a PanelView C600 is connector the serial port of the Micro830 and the Micro830 is connected to the CR30 through a SERIALISOL plug in module The Micro830 can
116. ll a Guardmaster 440C ENET EtherNet IP Plug in Module 91 Installation Summary sseseeresrrerrerrrrerrrrrrrr rer rer resa 91 About the Module sssssrresrrrrrrrrrrrrr rss rr reses sa 92 Software Requirements 92 Firmware Requirements 92 Install the Module ssssseseeesrrereeeerrrrrrr ers rss rs 93 Wire the Ethernet Connector sssersrersrrerrrrrer rer ee 93 Grounding Considerations sssesererererrrrerrrrrrr rr rr oe 94 Connect the Module to the EtherNet IP Network 94 Set the Network Address sssserreeerrrrrrrrrrrrrrrr rs 94 Use a DHCP BOOTP Server 94 Use RSLinx Classic Studio 5000 or Connected Components Work bench Software 95 Status TN dICAT LS 25 52 2050 dvs Ri eo eee os EEE 95 Chapter Summary eee nan a SANN E NR RNE era a ASEA 96 Chapter 13 PRR UCtIOL 4 sss tous sce E os eataranio sen ood oda eee aoe 97 Ethernet Messaging lt n c0cs uc taystie esse ip EE EER Odens pawns 97 Vi Messaging enen Midi tA bok al oh UNE Mate a ERE 97 Logix Configuration sssessrerserererrrrrrrr reser reser ere rea 98 Explicit ACSC AG IES ss nace gebtn cterag edanan e biaa 98 Chapter 14 Input and Output LEDS s s ssssso sssrssssstssrssnsursr reta skr ra 102 Controller Status LEDS sssssereseeserrrsrerrr cece eee rss ror rea 103 Rockwell Automation Publication 440C UM001D EN P March 2015 Modbus Communication Troubleshooting Security and Password Using the Memory Module Reports
117. lly closed contact for each hand Figure 71 Example Wiring Connection for a Type IIIC Two hand Control without Test Pulses 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 24V Com When test pulses are used the CR30 will detect a short from Channel 1 to Channel 2 after 3 7 seconds and turn the output OFF To clear the fault release both buttons Rockwell Automation Publication 440C UM001D EN P March 2015 67 Chapter 9 Safety Monitoring Functions Figure 72 Wiring Connection for a Type IIIC Two hand Control with Test Pulses 24V DC 00 01 02 03 04 05 o6 07 o8 oo 10 11 CR30 A B 24V Com The timing diagram for the two hand control is shown in Figure 73 The Type IIIA uses only the N O contact of the button The Type IIIC uses both the N C and the N O contacts Figure 73 Two hand Control Timing Diagram 0 8 8 eo 8 8 0 HI i Hand 1 N C Lo Ls FF Le J rand no A e i i LO Hand 2 N C HI l l H LO i i Hand 2 N O Me HI wacom ga Lt gt L must be less than 500ms J Description Description 1 Hand 1 button is pressed 5 Hand 2 button is pressed 2 Hand 2 button must be pressed within 500 ms 6 Hand 1 button must be pressed within 500 ms for the output logic to turn ON for the output logic to turn ON 3 Releasing either hand button causes the logic 7 Releasing either hand button causes the logic output to turn off output to turn off 4 Bot
118. lt of accessibility to live parts The enclosure must have suitable flame retardant properties to prevent or minimize the spread of flame complying with a flame spread rating of SVA V2 V1 VO or equivalent if non metallic The interior of the enclosure must be accessible only by the use of a tool Subsequent sections of this publication contain more information regarding specific enclosure type ratings that are required to comply with certain product safety certifications For more information see Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 for more installation requirements e NEMA Standard 250 and IEC 60529 as applicable for explanations of the degrees of protection that is provided by different types of enclosure For most applications normal convective cooling keeps the controller within the specified operating range Verify that the specified temperature range is maintained Proper spacing of components within an enclosure is usually sufficient for heat dissipation In some applications other equipment inside or outside the enclosure produce a substantial amount of heat In this case place blower fans inside the enclosure to help with air circulation and to reduce hot spots near the controller More cooling provisions are necessary when high ambient temperatures are encountered Do not bring in unfiltered outside air Place the controller in an enclosure to help protect it from a corro
119. lug In Modules 2080 1Q4084 Empty J Have you performed all appropriate functional verification tests on the system Safety Verification ID Firmware revision 30 Rockwell Automation Publication 440C UM001D EN P March 2015 Configuring the CR30 Chapter 4 21 Click Yes to change the safety relay back to Run mode f Connected Components Workbench dss a am Safety Verify complete Do you want to change the safety relay back to Run mode 21 22 The CCW generates a Safety Verification ID Click OK to continue TA Connected Components Workbench Safety Verification ID 7916 ne 23 Confirm the Verification ID in the CCW The ID is stored in the CR30 During power up the CR30 uses this number during its self testing to help ensure its internal processors are functioning properly When the configuration is uploaded from the CR30 the CCW shows the Verification ID The ID is not stored with the CCW project file Guardmaster 440C CR30 Guardmaster 440C CR30 Rockwell Automation Publication 440C UM001D EN P March 2015 31 Chapter 4 32 Configuring the CR30 Viewing the Verification ID without CCW During machine lifecycle it is required to check whether the system requirements are still valid The LEDs can be used to view the verification ID without the use of the CCW and compare the documented verification ID of the technical file of the machine If the CR30 configuration has not been v
120. ment must be updated anytime changes to the configuration have been made validated and verified Any new configuration or changes to an existing configuration require a validation and verification before putting it into service An unverified application will stop operating after 24 hr after power up With your signature you confirm that e you have conducted validation and verification of the safety configuration identified the above mentioned details AND e the configuration and installation meets all specified operational and environmental requirements of the machine to which CR30 is to be fitted AND e you have read and understood the Important User Information Read the documents that are listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be conducted by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner that is not specified by the manufacturer the protection that is provided by the equipment can be impaired In no event will Rockwell Automation Inc be respon
121. ms response time of 30 ms Total 325 ms A demand of the E stop will force a safe state after 325 ms 136 Rockwell Automation Publication 440C UM001D EN P March 2015 Specifications Appendix A Table 28 For SMF2 Safety Mat Comment Value Safety Sensors Safety response time of sensor device Oms considered as 0 ms since mechanical device only SMF Safety mat processing time 25 ms Input Filter Advanced Settings Input Filter 0 ms Oms Logic Internal execution time to process 45 ms input signal routing and output processing SOF Configured Off Delay time Oms immediate OFF Actuator Same contactor is controlled by the 30 ms safety mat SMF as by the E stop Total 100 ms A demand of the Safety Mat will force a safe state after 100 ms Monitoring Time Occurrence of Recoverable Faults and Failures Recoverable faults as defined earlier Chapter 16 Troubleshooting are faults and failures within the connected periphery of the CR30 The ability to detect faults depends on the wiring the type of sensor and the signal evaluation function that is applied to the circuit The monitoring time is the amount of time to evaluate the fault or failure after detection and to initiate appropriate system response Recoverable faults can be recovered by removing the fault and cycling the appropriate input circuit The detection of a recoverable fault does not lead to the loss of the safety
122. n a specified time relative to each other For example the safety state of dual N C input is when both inputs are in the closed state Channel A can close before Channel B or Channel B can close before Channel A The CR30 allows you to specify a discrepancy time in 50 ms increments from 0 3 seconds Figure 25 Discrepancy Time 1 Channel A 0 1 Channel B 0 t t 1 HEN Output P TTT A A TT T t lt Discrepancy Time The discrepancy is set in the Advanced Settings of each safety monitoring block The following example shows the Gate Switch function with the discrepancy time set to 2 2 x 50 100 ms When the discrepancy setting is set to zero the CR30 does not test for discrepancy The duration between the operation of channel one and channel two is infinite The default value 100 ms Figure 26 Setting Discrepancy Time ia Gate Switch gt Test Source A 12 v Test Source B 13 M J Inputs 2NC ov Pulse Testing 2Sources Discrepancy 24 Time b50ms 21 Input Filter 25ms oc Rockwell Automation Publication 440C UM001D EN P March 2015 4 Chapter7 Discrepancy Time Notes 42 Rockwell Automation Publication 440C UM001D EN P March 2015 General Chapter 8 Safety Block Renaming With Release 7 of the Connected Components Workbench CCW and Release 7 of the CR30 firmware the names of both the safety monitoring functions and safety output functions can be
123. n the safety relay header 4 Select the target safety relay in the Connection Browser 5 When requested provide the safety relay password Download to a Password Protected Safety Relay 1 Launch the CCW software project with your Guardmaster 440C safety relay configuration 2 Double click the Guardmaster 440C safety relay in the Project Organizer to open the Safety Relay workspace 3 Select Download from the pull down menu in the safety relay header 4 Select the target safety relay in the Connection Browser 5 When requested provide the safety relay password 120 Rockwell Automation Publication 440C UM001D EN P March 2015 Configure Password Security and Password Chapter 17 Set change and clear the password on a target safety relay through the Connected Components Workbench software IMPORTANT The following instructions are supported on Connected Components Workbench version 7 and Guardmaster 440C safety relays with firmware revision 7 Set Safety Relay Password In the following instructions e The Connected Components Workbench software is connected to the Guardmaster 440C safety relay e The relay is loaded with a viable configuration e The configuration does not necessarily have to be verified e The CR30 can be in either program or run mode 1 On the Connected Components Workbench software open the project for the target safety relay by double clicking the safety relay in the Project Organizer
124. nal 02 with Inputs on Terminals 00 and 01 24V DC 100 01 02 03 04 05 06 07 08 o9 10 11 CR30 A1 A2 12 13 14 15 16 17 18 19 20 21 24V Com Four wire safety mats can be connected to the CR30 The four wires create two channels Stepping on the safety mat creates a short circuit between channel 1 and 2 To detect the short circuit input pulse testing is used The mats must be connected to the input test pulses Figure 61 Safety Mat Function Block Guardmaster_440C_CR Pointer Emergency Stop Enabling Switch Feedback Monitoring Gate Switch Light Curtain Safety Monitoring 0 oe o T E ao e o in Muting Test Source A 12 Test Source B 13 AA Two Hand Control Alternative Device Advanced Settings Discrepancy a 4 Logic Functions Time bS0ms as Pointer Input Filter a AND 625ms OR XOR YUOr The safety mat can be connected to the following terminals e EI 00 EI 11 embedded input terminals 00 11 e MP_12 MP_17 multi purpose terminals 12 17 You can use the default Discrepancy Time and Input Filter or choose to modify these settings For input test pulses terminals 12 17 are available The CCW automatically selects another test pulse pattern for each input An example schematic shows a safety mat that is connected to terminals 0 and 1 The mat uses test pulses that are generated at term
125. nals Reaction Time Describes the time between the true states of one input to the ON state of the output Recovery Time Describes the time required for the input to be in the LO state before returning to the HI state Response Time Describes the time between the trigger of one input to the OFF state of the output Safety Function This describes the complete sensing of the action e g open a safety gate to execution the final output device e g turning off a pair of contactors Safety Monitoring Function SMF This is the input block on the Connected Components Workbench for the CR30 Safety Output Function SOF This is the output block on the Connected Components Workbench for the CR30 Single Wire Safety SWS This is a unique safety rated signal sent over one wire to indicate a safety status The SWS can be used in Category 4 Performance Level e per ISO 13849 1 and Safety Integrity Level SIL 3 per IEC 62061 and IEC 61508 Rockwell Automation Publication 440C UM001D EN P March 2015 Preface Overview Installation Power Ground and Wiring Table of Contents Important User Information sserererserrsrrrrrrrrrrrserrrr rr rra 2 Who Should Use this Manual sssseesersrrsrrrerrrrrerrrr rer ers 3 Purpose of this Manual sseseesererrrrrsrrrrrrer rer rr rr rer r ra 3 Additional ResOUrCES s s sssbswrenwee blo ade eos E E rg Ad 3 Definitions a ana e e ed Abed ahold COUR A Aaa MR elk
126. nected Components workbench e Identification of the configured safety function and project IMPORTANT The verification process must be documented in the safety system technical file Use the Configuration Reference Document on page 151 or the verification report feature in CCW release 7 or higher 16 The CCW must be connected to the CR30 during verification 17 The CR30 must be in Program mode 18 Click the Verify button the Safety Verification window appears 19 Answer all questions and check each box if completed 20 Click Generate ATTENTION The verification process should be documented in the safety system technical file Suardmaster 440C_CR30 Log Guardmaster_440C_CR30 M Guardmaster 440C CR30 440C CR30 2288B Verification ID Remote Mode Program bi J Have you followed installation instructions and precautions to conform to applicable safety standards Fault Not Faulted J Have you verified that the electrical specifications of the sensor and inputs are compatible J Have you verified that the electrical specifications of the outputs and the actuators are compatble Have you calculated the system s safety response time for each safety chain 4 Safety Relay pitt Port J is the system response tme in proper relation to the process tolerance time USB Port LED Configuration V Have probability PFD PFH PLx values been calculated according to the system s configuration Faults Modbus Mapping 4 P
127. nished wiring the relay and any other devices 16 Rockwell Automation Publication 440C UM001D EN P March 2015 Installation Chapter 2 Enclosure Considerations Preventing Excessive Heat Most applications require installation in an industrial enclosure to reduce the effects of electrical interference and environmental exposure Pollution Degree 2 is an environment where normally only non conductive pollution occurs except that occasionally temporary conductivity that is caused by condensation can be expected Overvoltage Category II is the load level section of the electrical distribution system At this level transient voltages are controlled and do not exceed the impulse voltage capability of the product insulation This equipment is intended for use in a Pollution Degree 2 industrial environment in overvoltage Category II applications as defined in IEC 60664 1 at altitudes up to 2000 m 6562 ft without derating This equipment is considered Group 1 Class A industrial equipment according to IEC CISPR 11 Without appropriate precautions there could be difficulties with electromagnetic compatibility in residential and other environments due to conducted and radiated disturbances This equipment is supplied as open type equipment It must be mounted within an enclosure that is suitably designed for those specific environmental conditions that are present It must also be appropriately designed to prevent personal injury as a resu
128. nsor L Type v S1 S2 Synch Time bSOms 2 LC Synch Time 50ms Max Mute Time Time Units Seconds Time ans Specifications Appendix A Applicable for SMF Muting Muting time Max Mute Time 1s 10 days Maximum amount of time during which the instruction lets the protective function of the light curtain be disabled before generating a fault Mute Kasse 2 Sensor L Type v S1 S2 Synch Time 1 650ms 2 LC Synch Time bSOms Max Mute Time Time Units ls Time ES SMF Muting Input pulse monitoring Input Pulse of 250 ms 3 s Monitors the operation of a valid reset or restart actuation SMF Reset Restart Retrigger Time Delay If retrigger function is disabled once the Time Delay has begun timing it cannot be reset When SOF input signal transitions from the Safe state back to the Active state when timing has started the time will completely lapse but the SOF indicates a fault oe amp OFF Delay e Feedback None Time Delay 0SOm X Retriggerable Disabled Reset Type Manual Reset Input v SOF Off Delay Integral test pulses 1 For Alternative SMF only Integral test pulses are enabled for safety outputs controlled by an SOF When using the multi purpose terminals 13 17 as outputs the integral test pulses can be disabled MP12 gt NoPT empi gt PT v SOF Immediate OFF OFF Delay ON Delay Jog 2 A
129. ny specific fault processing times depending on the I O evaluation method and configured input filter times Table 30 shows the response time for specific recoverable faults if the safety function is not demanded and the required settings of SMF and SOF to enable the proper fault evaluation method Table 30 Processing Time of Recoverable Faults and Required Settings Recoverable Fault Detection Enabled by Processing Time Cross loop fault Inputs 2 N C 35 Pulse Testing 2 Sources Short circuit fault Inputs I N C or 2 N C 35 Pulse Testing 1 Source 2 Sources Inputs 2 N C 2 OSSD Discrepancy Time gt 0 3s Default 0 25 3 s 0s Input discrepancy fault Discrepancy time Input Filter time Reset restart timing fault Configured time delay 2 Max Synch Time 8 Non retriggerable timer fault Retriggerable Disabled Synch Time 0 05 10 s Muting Synchronization time exceeded Muting Sensors Input Filter 0 3 s 2x Input Filter Time Muting time exceeded Max Mute Time 1 s 10 days Configured Max Mute Time Muting sequence fault Muting Type 2 Sensor T Type 2 Input Filter Time Sensor L Type 4 Sensor 1 AReset Restart Timing Fault can only occur when safety outputs are OFF so there is no impact on the safety response time 2 The maximum of the configured delay must be considered The remaining time at occurrence of fault will lapse 3 The synchronization t
130. o a a SS vi Application Language At Two Hand Control Alternative Device a Logic Functions lt _ Rh Pointer AND Safety Output se o o Seos PT gt an o Emergency Stop TY OR Ne ie Immediate OFF an e o So PT O NAND D NOR gt NOT O AND with Restart I D OR with Restart a Safety Output Function Blocks he Pointer OR Immedine OFF ON Delsy O OFF Delay f 49 Test Source A 12 Inputs 2 Test Source amp 13 x anana Workspace MF 9 aoe Emergency stop e ao 0 9 Name Projects DI cuerdenaster 140 _cro0 Test Source 12 Test Source B 13 Advanced Setting Pass Through When a logic level is not used the CCW automatically creates a Pass Through AND block The AND block accepts 2 24 inputs When all inputs are HI the output of the block is HI If any of the inputs is LO the output of the block is LO The AND block is often used when multiple E stops must be released and multiple safety gates must be closed for the safety system to be energized Figure 89 AND Logic Block Logic Level A A K D mo 9 Rockwell Automation Publication 440C UM001D EN P March 2015 75 Chapter 10 OR XOR 76 Logic Levels A and B Table 9 AND Logic Table for Two Inputs Input 1 Input 2 Output 0 0 0 0 1 0 1 0 0 1 1 1 The OR block accepts 2 24 inputs If any of the inputs
131. of how each type of EtherNet IP messaging I O messaging and Explicit messaging is used Ethernet Messaging The Guardmaster 440C ENET plug in module supports two types of EtherNet IP messaging e I O Messaging Used for deterministic EtherNet IP communications with ControlLogix CompactLogix SoftLogix and EtherNet IP scanners Its primary use is to read and write I O data for control purposes e Logic Explicit Messaging Used for non deterministic communications in which data is not critical for control Logic explicit messages have a lower priority compared to I O messages and are used to read and write non critical data 1 0 Messaging Studio 5000 Logix Designer software is used to configure I O messaging between an automation controller and a Guardmaster 440C ENET plug in module on an EtherNet IP network Rockwell Automation Publication 440C UM001D EN P March 2015 97 Chapter 13 Automation Controller Communications Explicit Messaging 98 Logix Configuration An Add on Profile is available for the Guardmaster EtherNet IP network interface and can be used with Studio 5000 Logix Designer version 20 and higher The profile can be downloaded from http support rockwellautomation com controlflash LogixProfiler asp Follow the procedures outlined in the online help that accompanies the Add on profile to configure the I O messaging connection Data can be accessed from the Guardmaster 440C CR30 safety relay with
132. on 440C UM001D EN P March 2015 159 Appendix D ControlFLASH Firmware Upgrade Notes 160 Rockwell Automation Publication 440C UM001D EN P March 2015 Input Assemblies Instance Decimal hex 100 64h Appendix E EtherNet IP 1 0 Assemblies The following are input assemblies available over EtherNet IP for the Guardmaster 440C CR30 safety relay Table 41 440C CR30 Input Assemblies Byte Bit7 Bit 0 0 Reserved Minor Fault Major Fault Connection Run Mode Faulted 1 Reserved High Byte Low Byte 2 3 Verification ID 4 5 Major Fault Type Mm Major Fault Code Mm 6 7 Minor Fault Type m Minor Fault Instance 8 9 Minor Fault Code o Byte Bit7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 10 Pt 07 Data Pt 06 Data Pt 05 Data Pt 04 Data Pt 03 Data Pt 02 Data Pt 01 Data Pt 00 Data 11 Pt 15 Data Pt 14 Data Pt 13 Data Pt 12 Data Pt 11 Data Pt 10 Data Pt 09 Data Pt 08 Data 12 Reserved Pt 21 Data Pt 20 Data Pt 19 Data Pt 18 Data Pt 17 Data Pt 16 Data 13 Plug in 2 Plug in 2 Plug in 2 Plug in 2 Plug in 2 Plug in 2 Plug in 2 Plug in 2 Pt 07 Data Pt 06 Data Pt 05 Data Pt 04 Data Pt 03 Data Pt 02 Data Pt 01 Data Pt 00 Data 14 SMF 8 Data SMF7Data SMF6Data SMF5Data SMF4Data SMF3Data SMF2Data SMF1Data 15 SMF 16 Data SMF 15 Data SMF14Data SMF13Data SMF12Data SMF11Data SMF10Data SMF9 Data 16 SMF 24 Data SMF 23 Data SMF22
133. on Ethernet port Immunity conducted RF e IEC 61000 4 6 Rockwell Automation Publication 440C UM001D EN P March 2015 10V rms with 1 kHz sine wave 80 AM from 150 kHz 80 MHz 147 AppendixA Specifications Table 40 Certifications Certification Description cULus UL Listed Industrial Control Equipment certified for US and Canada See UL File E361015 CE European Union 2004 108 EC EMC Directive compliant with e EN61326 1 Meas Control Lab Industrial Requirements EN 61000 6 2 Industrial Immunity EN 61000 6 4 Industrial Emissions EN 60947 1 Auxiliary Devices CTick Australian Radiocommunications Act compliant with AS NZS CISPR 11 Industrial Emissions EtherNet IP ODVA conformance tested to EtherNet IP specifications Note When product is marked See the Product Certification link at http www ab com for Declarations of Conformity Certificates and other certification details 148 Rockwell Automation Publication 440C UM001D EN P March 2015 Agency Certifications Compliance to European Union Directives Appendix B Regulatory Approvals e UL Listed Industrial Control Equipment certified for US and Canada e CE marked for all applicable directives e C Tick marked for all applicable acts e CCC Mark e S Mark This product has the CE mark and is approved for installation within the European Union and EEA regions It has been designed and tested to meet the following directive
134. on has been verified by the user Valid verification ID values 0001 9999 0000 Configuration is not verified PtxxData BOOL Data Off On status for input output point echoed back from the safety relay This is used to verify proper communication only No field side verification is done 0 Off 1 0n Plugin2InPtxxData 1 BOOL Data Off On status for input output point echoed back from the safety relay slot 2 plug in module This is used to verify proper communication only No field side verification is done 0 0ff 1 0n Plugin20utPtxxData 0 BOOL Data Off On status for input output point echoed back from the safety relay slot 2 plug in module This is used to verify proper communication only No field side verification is done 0 0ff 1 0n MajorFaultType SINT Major Fault Type Indicates the major fault type of the safety relay 01H Hardware Fault 02H Safety Input Fault 04H Safety Output Fault 08H Power Fault 10H Communication Fault 20H Configuration Fault 40H Time Monitoring Fault 80H Plug in Fault Rockwell Automation Publication 440C UM001D EN P March 2015 163 Appendix F Tag Definitions Name Data Type Tag Definition MajorFaultCode SINT Major Fault Code Indicates the specific major fault code for the corresponding major fault type See Table 45 for additional details MinorFaultType SINT Minor Fault Type Indicates the type of function block that is faulted 10H S
135. ow the output of the Logic block responds to the input signals and the Restart signal Both inputs must be HI when the Restart signal occurs for the output to go HI If any of the inputs go LO the output goes LO 78 Rockwell Automation Publication 440C UM001D EN P March 2015 OR with Restart ao e o TUE ia Gate Switch aol e Test Source A 12 Test Source 8 13 Advanced Sett v E02 0 H o cunin auo foe e o r LogicLevels AandB Chapter 10 Figure 97 AND with Restart Timing Diagram HI Restart LO HI o Input 1 LO AND 1 Input 2 Output The OR with Restart accepts 2 24 inputs and requires a Restart input At least one input must be HI when the Restart button is pressed The CCW automatically recognizes the Restart function blocks and allows you to select one Once selected the Restart is no longer available for other logic blocks Figure 98 shows an example with a gate switch and a light curtain Either the gate must be closed or the light curtain clear Then the Restart input must be pressed The output of the logic block goes HI on the trailing edge of the restart signal Figure 98 Example OR with Restart oae orr e f018 pT gt o bd ORwith bd Pass Restart Through 9019 PT L Feedback None bd 2 lt Restat SMF3 Reset Type Automatic Inputs 2 v iv Rockwell Automation Publication 440C UM001D EN P March 2015 79
136. pport FFFFH Unregistered fault Contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support Rockwell Automation Publication 440C UM001D EN P March 2015 169 Appendix F Tag Definitions Notes 170 Rockwell Automation Publication 440C UM001D EN P March 2015 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical and application notes sample code and links to software service packs You can also visit our Support Center at https rockwellautomation custhelp com for software updates support chats and forums technical information FAQs and to sign up for product notification updates In addition we offer multiple support programs for installation configuration and troubleshooting For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com services online phone Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwel
137. put Test Pulse A to Input Pulse Test B with the safety output ON e The Modbus address 000505 goes HI immediately showing that the fault was detected e About 4 seconds later the fault is acted upon e Modbus address 000393 Bit 0 of SMF1 goes HI e The Safety Output goes off e On the CCW Logic tab the E stop and gate inputs go off and both logic blocks show red color e The CCW Project tab shows Recoverable Fault Figure 130 Mouse Over E stop Block Safety Monitoring e o Emergency Stop je Test Source A 12 Test Source B 13 Rockwell Automation Publication 440C UM001D EN P March 2015 117 Chapter 16 118 Troubleshooting Remove the fault e The Modbus address 000505 goes LO immediately showing that the fault was removed e Modbus address 000393 Bit 0 of SMF1 remains HI e On the CCW Logic tab both the E stop and gate logic blocks continue to show red color e The safety output remains off Cycle the E stop e Modbus address 000393 Bit 0 of SMF1 goes LO e On the CCW Logic tab the E stop block turns green and the gate block remains red Cycle the gate e On the CCW Logic tab the gate block turns green The safety system is back to an operating state and waiting for the reset button to be pressed Rockwell Automation Publication 440C UM001D EN P March 2015 Exclusive Access Password Protection Chapter 17 Security and Password Guardmaster 440C sa
138. r and other hazards if necessary are connected to terminals 18 and 19 The muting lamp is connected to terminal 13 this terminal should be configured with no pulse testing Filament lamps will not be affected by pulse testing but LED lamps may appear to flicker if pulse testing is enabled Figure 50 Example Schematic for 2 Sensor L Type Muting 24V DC Light Curtain 00 01 02 03 04 05 06 07 08 09 10 11 CR30 4 Muting Lamp Contactors 24V Com for Conveyor Power Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 For simplicity the power and ground connections of the light curtain and muting sensors are not shown The light curtain and muting sensors must have the same reference 24V Com as the CR30 for proper operation For proper operation the muting sensors are on normally closed when not muting and the light curtain OSSD outputs are also on the light curtain is clear Figure 51 Muting Time for 2 Sensor L Type Muting LC Muting sensor 1 I Muting sensor 2 Loo Muting lamp nn Nn EJE E S S S MIA mM ATA A 30ms lt t p t lt muting time t lt synchronization gt time 30ms lt t kH t lt synchronization time Table 6 shows the muting and synchronization times that are selectable in the CCW These times are selected independently For example you can select two minute muting time a 50
139. r local Rockwell Automation technical support representative For contact information see 20H 01 CRC Error in the configuration file http rockwellautomation com support 02 CRC of configuration file different from EEPROM 03 Mismatch between 1 0 uC A and 1 0 pC B in configuration files 04 Invalid ID numbers for configuration files 05 Mismatch between configured plug in and plug in Do one of the following detected on slot 2 e Verify plug in physically present in the slot matches the i R i configuration 21 Mismatch between configured plug in and plug in e Reattempt download of the safety relay configuration detected on slot 1 A AR p Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support 40H 01 03 Timing fault Do one of the following e Power cycle the safety relay Reconfigure the safety relay Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support 80H 20 Memory module restore failed Do one of the following Verify Memory Module is properly seated in slot 1 21 Memory module backup failed Po
140. rEsSOTS idan tata ta lel outbid Cee lary 23 Embedded Serial Port Wiring sssseresrsrrrsrrrrrerrrrrrr renar sa 23 Power Cycling assessor Baden dn RE E ES 24 Rockwell Automation Publication 440C UM001D EN P March 2015 5 Table of Contents Configuring the CR30 Pulse Testing Input Filter Discrepancy Time Safety Block Renaming Chapter4 Begin Configuration sssesesersrrrererrrrrrr reser reser reses ta 25 dele WW OLKSP ACE enserra n ue oranda rna ss lea on ARE 26 Download the Configurations 9055 05 5 3 000 sche aneyeessseseeseees 28 Validation and Verification sssesserrerererrrerrrrrr erreneren 29 Validato aa curs Ro Aa SR VA Rigg A A acs 29 Verifications iers ata ha etan foes tad E RA FART 30 Viewing the Verification ID without CCW 08 32 Multiple Block Connections seesessersrrsrrrrrrerrrrrr rer rr ra 34 Chapter 5 Normally Open Input Pulse Testing ssssssessersererrererr rr rr ra 35 Normally Closed Input Pulse Testing sssessrresererrerrrrrrra 36 Output Pulse Testing er sperirer ei isore nas Ea 37 Chapter 6 Input Filtera E E ae pant BIR ont RE 39 Chapter 7 Discrepan y MAC icp crs haat na nteney pedes eadra nas auaa eia 41 Chapter 8 Generali sven ed EN Potente NS geal Ue gia ee Re 43 Naming Error Indication sssseesesrerererrrrrrrrerr ere rr rr rr ra 44 Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Logic Levels A and B
141. read use status information from the CR30 and can send reset and restart signals to the CR30 Rockwell Automation Publication 440C UM001D EN P March 2015 107 Chapter 15 Modbus Communication Figure 120 Modbus RTU Communication PanelView C600 amp Micro830 To Ethernet Network PanelView C600 2711C T6T Modbus Master Ethernet Port 10 100Base T 1761 CBL PM02 Cable 2080 SERIALISOL A A oh a daceavagaaagacaeas Ethernet Cables Micro830 2080 LC30 24QBB Sa paOCODOOOSOOOOO N CR30 Standard Cable 440C CR30 22BBB USB A Male to B Male Modbus Slave 108 Rockwell Automation Publication 440C UM001D EN P March 2015 Modbus Communication Chapter 15 Reading CR30 Status In the Micro800 family the Msg_Modbus block must be used In the example ladder diagram below a Micro830 reads the status of the first five input wiring terminals of the CR30 e Rung 1 When a push button which is connected to terminal 03 of the Micro830 is pressed the Micro830 sends a Modbus message to the CR30 e Rung 2 The format of the data in LocalAddr is a WORD The first block ANY TO DINT converts the WORD to a DINT The second block compares the DINT to the value of 1 with an AND_MASK The third block checks to see if the value is 1 If the value is 1 then the output terminal IO EM DO 00 goes HI Figure 121 Read Ladder Diagram You s
142. rpose terminals 12 17 e P1 00 P1 03 plug in 1 terminals 00 03 e P2 00 P2 03 plug in 2 terminals 00 03 e SP 00 SP 15 Modbus inputs 00 05 You can modify the number of inputs within the range of 1 4 You can use the default Input Filter or choose to modify this setting Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 Figure 37 Example Feedback Schematic with Two Feedback Contacts Connected in Series to One Input Terminal 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 A1 a2 12 13 14 15 16 17 18 19 20 21 24V Com Figure 38 Example Feedback Schematic with Four Feedback Contacts Connected Individually to Four Input Terminals 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 A1 a2 12 13 14 15 16 17 18 19 20 21 24V Com Gate Switch The Gate Switch function block sets the parameters for typical safety gate interlock switches In the CCW click and drag or double click the block to an available Safety Monitoring Function spot Figure 39 Gate Switch Function Block AX Project63 Connected Components Workbench Standard Edition Administrator File Edit View Debug Tools Communications Window Help Dees alo e O Q al a JIS ERRI aTa jh 4h S I si Application Language Toolbox gi Guardmaster 440C CR30 Logic gt KOANE 4 Safety Monitoring Functions EADS od hk Pointer
143. s Emergency Stop Safety Monitoring 1 Enabling Switch Feedback Monitoring SMF 1 Gate Swich Ew e o x Gate Switch ba H Light Curtain ELOL o Mating Reset Restart 0 Safety Mats ma Single Wire Safety Input Two Hand Control z Alternative Device 4 Logic Functions h Pointer D AND D OR Project Organizer Test Source A 12 Test Source B 13 Advanced Settings Name Project63 Guardmaster_440C_CR30 The available input selections for the Gate Switch inputs are e EI 00 EI 11 embedded input terminals 00 11 e MP_12 MP_17 multi purpose terminals 12 17 Rockwell Automation Publication 440C UM001D EN P March 2015 49 Chapter 9 50 Safety Monitoring Functions You can modify the number and types of inputs e 2NC e 2 OSSD e INC Pulse testing can be disabled or set to 2 Sources When 2 Sources is selected the next available test sources are automatically selected You can modify the sources afterward You can use the default Discrepancy Time and Input Filter or choose to modify these settings Figure 40 cee Schematic of a Dual Channel Safety Gate Switch Without Test Pulses 24V DC SSA SN crn A1A2 12 13 14 15 16 17 18 19 20 21 24V Com Figure 41 Example Schematic of a Dual Channel Safety Gate Switch Using Test Pulses A and B 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 B a1 a2 12 13 14 15 16 17 18 1
144. s Machine Safety Directive This product is designed and tested to meet the European Council Directive 2006 42 EC on machinery and the following standards e IEC EN 61508 Functional safety of electrical electronic programmable electronic safety related systems e IEC EN 62061 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems e EN ISO 13849 1 Safety of machinery Safety related parts of control systems Part 1 General principles for design This product is intended for use in an industrial environment EMC Directive This product is designed and tested to meet the European Council Directive 2004 108 EC on Electromagnetic Compatibility EMC and the following standards e EN 61000 6 4 Generic Standards Emission Standard for Industrial Environments e EN 61000 6 2 Generic Standards Immunity for Industrial Environments This product is intended for use in an industrial environment Rockwell Automation Publication 440C UM001D EN P March 2015 149 Appendix B Regulatory Approvals Notes 150 Rockwell Automation Publication 440C UM001D EN P March 2015 Important User Information Appendix C Configuration Reference Document The Configuration Reference Document must be stored together with technical documentation of the machine It includes information about the validity of a configuration that is created for the machine This docu
145. s Reaction time of sensor device Oms considered as 0 ms since mechanical device only SMF Configured Input Filter time 250 ms 10x25 ms 250 ms Reset Restart SOF configured for Automatic 0s Logic Internal execution time to process 100 ms input signal routing and output processing 2 SOF No On delay configured for SOF 0s Actuator Assuming a contactor with a 10 ms response time of 10ms Total 360 ms It takes 360 ms to enable the outputs when the E stop is active closed contacts Table 35 For SMF2 Safety Mat Comment Value Feedback Disabled for SOF Oms Safety Sensors Reaction time of sensor device Oms considered as 0 ms since mechanical device only SMF Input Filter Disabled Oms Reset Restart SOF configured for Automatic Oms Logic Internal execution time to process 100 ms input signal routing and output processing 2 SOF No On delay configured for SOF 0s Actuator Assuming a contactor with a 10 ms response time of 10 ms Total 110 ms It takes 110 ms to enable the outputs when the Safety Mat is released Rockwell Automation Publication 440C UM001D EN P March 2015 E00 a0 E02 03 ELOS ELLOS Specifications Appendix A Figure 139 Example 2 Same as Figure 138 on page 143 but with manual monitored reset and feedback monitoring Satety Monitoring SMF Safety Output P f resor es MPA2 NoPT e ass o vee seated
146. s according to 35 above table Logic Internal execution time to process 45 ms input signal routing and output processing SOF No off delay configured 0s Actuator Assuming a contactor with a 30 ms response time of 30 ms Total 3 075 s Response Time Occurrence of Nonrecoverable Faults and Failures Nonrecoverable faults are detected by internal monitoring measures applied to monitor the safety integrity of the system These faults are independent of the logic configuration Once detected the CR30 forces the safe state within the internal process cycle time of 45 ms 142 Rockwell Automation Publication 440C UM001D EN P March 2015 Specifications Appendix A Reaction Time 1 00 e101 1 02 1 03 Emergency Stop Test Source A 12 Test Source B 13 2NC 2 Sources v Inputs Pulse Testing Discrepancy Time xS0ms Input Filter x2Sms gt A Safety Mat e Test Source A 14 bd Test Source B 15 v Advance Rockwell Automation Publication 440C UM001D EN P March 2015 The reaction time is the time to enable the safety output function when activating the safety input devices and performing a valid reset operation The overall reaction time of the safety function considers the whole safety chain including the safety input device logic device and actuator The reaction time must be calculated for each safety function Table 33 shows the possible chain with all consid
147. s an example schematic of the connection of the SWS from other modules in the GSR family of relays The CR30 and GSR modules must be connected to the same 24V Common Figure 67 SWS Connection Schematic 24V DC fl oo 01 02 03 04 05 o6 o7 os oo 1o 11 aijn At L1a CR30 GSR Module GSR Module azl AZT 24V Com Rockwell Automation Publication 440C UM001D EN P March 2015 65 Chapter 9 Safety Monitoring Functions Two Hand Control 66 The CR30 can be configured to operate in two different types of two hand control which are specified in ISO 13851 The two types are e Type IIIA for low risk safety systems e Type IIIC for high risk safety systems Mechanically palm operated buttons Bulletin 800P or the electronic output push buttons Bulletin 800Z Zero Force Touch Buttons should be used as actuating devices for two hand control The CR30 requires two buttons to be actuated simultaneously and maintained to turn the two hand safety monitoring function ON To meet the simultaneity requirement the two buttons must be actuated within 500 ms of each other Figure 68 Two Hand Control Function Block Toolbox bidet Guardmaster_440C_CR30 Logic Guardmaster 440C CR 4 Safety Monitoring Functions z j Pointer Emergency Stop Safety Monitoring Enabling Switch Feedback Monitoring Sa Gate Switch E00 ve oxo p Light Curtain ao e orx Two Hand Control Muting Reset Restart E03
148. s view provides the fault type and status The device automatically exits RUN mode and switches to Program mode You cannot change the operation mode Mouse over the fault status area to get more information Figure 128 Mouse Over Fault in Project Tab Guaedmaster 4406 CRI0 x Guardmaster_440C_CR30 Guardmaster_440C_CR30 440C CR30 22888 Begsesesec od Ay Vertication ID Remote Mode Fault To see a list of the recent faults click Faults in the Safety Tree The recent faults appear in the fault pane Click the Export button to export the faults to a comma separated value csv file The default path for Win7 for saving the exported fault log file is the folder at C Users lt user name gt documents CCW Fault log Rockwell Automation Publication 440C UM001D EN P March 2015 115 Chapter 16 Troubleshooting Figure 129 Recent Fault List Guardmaster 440C CR30 Guardmaster 440C CR30 Download Upload Edit Logic Build Vent 440C CR30 22888 e IS SSOSSSS ESSE Verification ID Remote Program baw Mode Run a Safety Relay Safety Relay Faults Serial Port Recent Faults USB Port f LED ll 4 Faults Code 17 Pulse test failure terminal 18 Modbus Mapping 4 Plug In Modules Fault Index 08 2080 IQ4084 Type 03 Safety Output HW Fault Empty Code 17 Pulse test failure terminal 18 Fault Index 09 Type 03 Safety Output HW Fault Code 17 Pulse
149. se outputs These signals are used to test for short circuits in the wiring to 24V DC 0V and between two channels that are wired to separate test pulse sources one channel that is sourced from an odd number terminal 13 15 and 17 and the other one from an even number terminal 12 14 and 16 IMPORTANT Safety systems requiring a Category 4 structure per 1S013849 1 and SIL 3 rating per 1EC61508 must use pulse testing for the dual channel N C contacts Pulse testing for Category 3 2 and 1 structures and SIL 2 and 1 ratings is recommended The CR30 generates three distinct pulses called A B and C Each pulse is 1 7 ms wide Pulse Test B immediately follows Pulse Test A Pulse Test C immediately follows Pulse Test B The pulse tests are repeated every 25 ms The timing diagram in Figure 19 shows an example of the pulse testing when the respective terminals are configured for A B and C Figure 19 Timing Diagram Pai 1 7ms Terminal 12 A a 24V Terminal 13 B gy 24V Er eee Terminal 14 C oy 24V 1 Terminal 15 A gy 24V Terminal 16 B gy 24V r AA T Terminal 17 C gy i 0 25ms Rockwell Automation Publication 440C UM001D EN P March 2015 Output Pulse Testing Pulse Testing Chapter 5 The purpose of the test pulses is to detect short circuits from the input signal to 24V DC 24V common and shorts from one input signal to another input signal If one input signal is assigned to Test
150. shows the muting and synchronization times that are selectable in the CCW These times are linked For example if you select a 10 s muting time then the synchronization time between MS1 and MS2 is 3 s To use a synchronization time of 6 s you must select a 60 s muting time Note The synchronization time also depends on the input filter time settings for the muting sensor inputs Synchronization time total 2 x Input Filter Time Synch Time Table 7 Muting and Synchronization Times for Four Sensor Muting 10s 35 20s 35 30s 35 60s 1 min 6s 300 s 5 min 305 900 s 15 min 905 1800 s 30 min 180 s 3 min 3600 s 1 hr 180 s 3 min 28800 s 8 hr 180 s 3 min Infinite Infinite Rockwell Automation Publication 440C UM001D EN P March 2015 59 Chapter 9 Reset 60 Safety Monitoring Functions Muting Override The muting function has an optional override input Use the override to turn on the conveyor to clear objects through the sensors in the case of a muting sequence or timing fault To use the override simply enable the feature in the safety monitoring function block The muting override can be either a single or dual input and can also use input pulse testing if desired When the muting override input turns on the safety outputs controlled by the muting function turn on until the override time expires or the override input turns off The muting override can be set between
151. sible or liable for indirect or consequential damages resulting from the use or application of this equipment Resource Description Guardmaster 440C CR30 Software Configurable Safety A detailed description of module functionality Relay User Manual publication 440C UM001_ EN P configuration installation procedure and information on how to use the Guardmaster Software Configurable Safety Relay 440C CR30 Industrial Automation Wiring and Grounding Guidelines Provides general guidelines for installing a Rockwell publication 1770 4 1 Automation industrial system Rockwell Automation Publication 440C UM001D EN P March 2015 151 Appendix C Configuration Reference Document Configuration Reference Document Device Information Device Name From Name Field General View Description From Description Field General View Vendor Allen Bradley Catalog ID 440C CR30 22BBB Safety Relay Firmware Version Found in the Device Details Window of CCW Project Information Project Name As stored in the configuration tool Project File Name From file name Software revision From Help gt About CCW Verification ID Generated in verification window Approval Project Developer Name Date Signature 152 Rockwell Automation Publication 440C UM001D EN P March 2015 Upgrade the Firmware Appendix D ControlFLASH Firmware Upgrade 1
152. sive atmosphere Harmful contaminants or dirt could cause improper operation or damage to components In extreme cases you may need to use air conditioning to help protect against heat buildup within the enclosure Rockwell Automation Publication 440C UM001D EN P March 2015 17 Chapter2 Installation Notes 18 Rockwell Automation Publication 440C UM001D EN P March 2015 Wiring Requirements and Recommendation Chapter 3 Power Ground and Wiring system AN WARNING Before you install and wire any device disconnect power to the Observe all electrical codes dictating the maximum current allowable for each wire size Current above the maximum ratings can cause wiring to overheat which can cause damage WARNING Calculate the maximum current in each power and common wire Allow for at least 50 mm 2 in between I O wiring ducts or terminal strips and the relay Route incoming power to the relay by a path separate from the device wiring Where paths must cross their intersection must be perpendicular Do not run signal or communications wiring and power wiring in the same conduit Wires with different signal characteristics should be routed by separate paths Separate wiring by signal type Bundle wiring with similar electrical characteristics together Separate input wiring from output wiring Label wiring to all devices in the system Use tape shrink tubing or other dependable means for labeling purposes In a
153. sss ere reses ss aerate 72 Three Channel 5s ss saa skans gid ssd ieee A 73 Chapter 10 Pasy Ehroug Meseia od seeks SNR EAA 75 AA D a a a TT 75 O e EE EEEE E A A E EE E A E See ee 76 AOR N A a SA 76 MAND e A A E A a aa 77 NOR a herent ol a EATS 77 NOT aceite ee et RER KEN ERNER SNS Rtel re IEA ts lk nth rh Ne 77 AND with Restart 5 0 00300 aenea EE aA st ante nul ated 78 OR with Restart eraila ene a a a a ou cian oh kill f tad 79 Rockwell Automation Publication 440C UM001D EN P March 2015 7 Table of Contents Safety Outputs Plug in Modules Automation Controller Communications LEDs Chapter 11 Input Connection tig ti em eee Reape g rd AR BARN 81 PGCE sean sta sosdesd ono oie eo EEE RNA ANA E 81 Reset Sica nines 26 se aaa game a at ee 81 DADA yr tiatrastey arters TEET EEEE EAA nuke whee eee SS 81 Output CORRECTIONS ae ss rs GA eave ete aa EAE AAA 81 TmmedtiateOPr Bi GG sas Akva E E ARA TA heii sit tt ANA RANG 82 ON Delay inene e eSa nE te wet crue re a eer chee 83 OFF Delays ieta er a e ol rue lecteur all AN 84 JOf riean Ea NE a EE ave ENENG 85 M ting Lamps 42 scan spa eenaa ska oa RA EREE NE E ERORE EDAS 85 Chapter 12 Insert Module into Controller ssssesssrrrsssrrrrrrr rss rr rer resa 87 2OSO NOAA BEE e T EA Send MSS oes See SS 88 2080104 eiaa RS e ne bi vada tod toma baad 89 208050 BA os sedis chore Bi eA rent Manes Jot acetates dt OND etd rer oh 89 2 0802O WAI te sie ee i ed eles ee NS tes et inte cr Ad 90 Insta
154. st Pulse Evaluation ices ah ea Pana poet een cadre 140 Multi Channel Signal Evaluation and Discrepancy Monitoring 140 Sequence and Timing Faults sssrssererererrrrererr rss 140 Integral Test Pulses of Safety Outputs 0 0c cee 140 Response Time Occurrence of Nonrecoverable Faults and Failures 142 Reaction TING 5 Ae f der be a ac blek bre RR aR Bee AA RAA a dig aa Rees 143 440C ENET Module Specifications ssseseersrssereerrrea 146 Appendix B Agency CertificationS ssssessrersererererrrrerrrrer rr reser rer ra 149 Compliance to European Union Directives sssserrsrerrrrs 149 Machine Safety Directive sssserserrsrrsrererrrrrerrr ere ras 149 EMG Directives a bad saci aw ks bk Wades e Ure RA RR eh 149 Appendix C Important User Information sseessererrrrsrsrrrrrsrrrrrre erat 151 Appendix D Upgrade the FirmwWare sseserrerrrsrrererrrrrrrrrerr rr rer resta 153 Unrecognized Device s sssesersrrrrrrrrrrere reser reser rer rna 157 Appendix E Inp tAss embliess ninrin ndelse Ne de a 161 Ou tp tAssemblicsa Les ss ci yin aie sd eden de deg ta E a E EE 162 Appendix F TAS Definitions s sarana ers oeaan gina tases E Eaa 163 Rockwell Automation Publication 440C UM001D EN P March 2015 Intended Use Hardware Features Chapter 1 Overview The Cat No 440C CR30 22BBB CR30 relay is a software configurable safety relay This device is intended to be part of the safety relat
155. sword is also backed up to the memory backup module Cat No 2080 MEMBAK RTC Rockwell Automation Publication 440C UM001D EN P March 2015 119 Chapter 17 Security and Password Com patibility The Safety Relay Password feature is supported on e Connected Components Workbench version7 and later e Guardmaster 440C safety relays with revision 7 or later firmware Users with earlier versions of the software and or hardware are advised to upgrade the software and firmware See Upgrade the Firmware on page 153 for instruction on firmware upgrades Work with a Locked Safety The following workflows are supported on compatible Guardmaster 440C safety Rel ay relays firmware revision 7 or later and CCW version 7 or later Upload from a Password Protected Safety Relay 1 Launch the CCW software project with your Guardmaster 440C safety relay configuration 2 Double click the Guardmaster 440C safety relay in the Project Organizer to open the Safety Relay workspace 3 Select Upload from the pull down menu in the safety relay header 4 Select the target safety relay in the Connection Browser 5 When requested provide the safety relay password Connect to a Password Protected Safety Relay 1 Launch the CCW software project with your Guardmaster 440C safety relay configuration 2 Double click the Guardmaster 440C safety relay in the Project Organizer to open the Safety Relay workspace 3 Select Connect from the pull down menu i
156. t ResetCfg TriggerType Enter a 1 to have the block execute every time that the ladder is scanned LocalCfg Cmd Enter a 5 to instruct the block to write to a coil that is turn on an input of the CR30 ResetCfg ElementCnt Enter a 1 to write only 1 bit ResetAddr The results are placed in Local Addr There is no need to make changes Figure 124 Reset Local Variables ResetTrgt MODBUSTARPARA E Read Write ResetTrgt Addr UDINT 1 Read Write ResetTrgt Node USINT 1 Read Write ResetCig MODBUSLOCPARA Read Write ResetCfg Channel UNT 5 Read Write ResetCig TriggerType USINT 1 Read Write ResetCfg Cmd USINT 5 Read Write ResetCig ElementCnt VINT 1 Read Write E ResetAddr MODBUSLOCADDR 5 Read Write Rockwell Automation Publication 440C UM001D EN P March 2015 111 Chapter 15 Modbus Communication Notes 112 Rockwell Automation Publication 440C UM001D EN P March 2015 Recoverable Faults LEDs Chapter 16 Troubleshooting Faults fall into two categories e Recoverable e Nonrecoverable Recoverable faults are those faults that can be corrected without having to cycle the power to the CR30 Nonrecoverable faults require power cycling to recover after the fault is corrected Recoverable faults can be cleared by eliminating the cause of the fault and cycling the inputs that are associated with the fault The output that is connected to an input with that fault is switched off
157. t are e MP 12 MP 17 multi purpose terminals 12 17 Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Monitoring Functions Chapter 9 Pulse testing can be set to 1 Source 2 Sources or Disabled When 1 or 2 Sources is selected the next available test sources are automatically assigned by the CCW You can modify the sources afterward You can use the default Discrepancy Time and Input Filter or choose to modify these settings The two terminals do not necessarily have to be consecutive Figure 78 Example Schematic for 2 N C without Test Pulse 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 A1 a2 12 13 14 15 16 17 18 19 20 21 24V Com Figure 79 Example Schematic for 2 N C with Two Test Pulses Sources 24V DC 00 01 02 03 04 05 06 07 08 09 10 11 CR30 A B a1 a2 12 13 14 15 16 17 18 19 20 21 24V Com Dual Channel OSSD Safeguarding devices with OSSD outputs generate their own test pulses to detect for short circuit conditions or have other methods of detecting short circuit conditions When configured for dual channel OSSD the CR30 ignores the test pulses Table 8 shows examples of products that use dual channel OSSD outputs Table 8 Products Using Dual Channel OSSD Outputs Product Types Product Name Light Curtains GuardShield Laser Scanners SafeZone SafeZone Multizone Gate Interlocks SensaGuard SensaGu
158. te Switch function block to the first block in the work space The CCW automatically assigns embedded input terminals EI_00 and ET 01 to the function block The terminal connection parameters can be changed by you Click and drag the immediate Output to the first Safety Output block in the workspace The CCW automatically assigns embedded output terminals EO_18 and EO_19 to the output block In addition the output terminals are pulse tested PT The terminal connection parameters can be changed by you Use the pull down menu to change the Immediate Output Reset from Manual to Automatic Click the input connection shown in blue when no connection is made of the Immediate Off output block Click the output connection of the Emergency Stop button shown in blue when no connection is made The CCW automatically creates two Pass Through blocks in Logic Level A and Logic Level B and makes the connection Click the second tab to compile and download the configuration GD Proyect32 Connected Components Workbench Standard ES ten Admurestrator Sa File Edt View Debug Tools Communications Window Help Dadaan Fes Bib ava s EEE st pape Catalog i Contreters ajoe I sec croo 22088 t il Motor conte pj Grope Termite Rockwell Automation Publication 440C UM001D EN P March 2015 27 Chapter4 Configuring the CR30 Download the Configuration 28 Download initiates the transfer of
159. terminal of the CR30 The CR30 uses the minimal RS 232 connection only transmit TxD receive RxD and ground connections are required The CR30 does not require nor perform any handshaking therefore the Request To Send RTS Clear To Send CTS and Carrier Detect DCD are not used The CR30 only supports RS 232 The RS485 signals which are used by some products with the 8 pin mini DIN connector are not used Rockwell Automation Publication 440C UM001D EN P March 2015 23 Chapter3 Power Ground and Wiring Power Cycling 24 Figure 9 Pinouts Receive Transmit 24V Common 1 RS 485 notused 5 DCD not used yellow 2 GND green 6 CTS not used white 3 RTS not used red 7 TxD brown 4 RxD orange 8 RS 485 not used Table 3 shows a recommended list of cables for the serial connection between the CR30 and other Allen Bradley products They may also be suitable for third party products DIN connectors were originally standardized by the Deutsches Institut fiir Normung DIN the German national standards organization Many variations of this connector exist To help ensure compatibility select a cable from the following table Table 3 Cables Cat No Description Length 1761 CBL HM02 8 pin Mini DIN to 8 pin Mini DIN 2m 6 5 ft 1761 CBL AP00 8 pin Mini DIN to 9 pin D shell 0 5 m 1 5 ft 1761 CBL PM02 8 pin Mini DIN to 9 pin D shell 2m 6 5 ft The CR30
160. test failure terminal 18 Fault Index 10 Type 03 Safety Output HW Fault E Code 17 Pulse test failure terminal 18 Refresh Fault Log bport Troubleshooting with Many faults can be reported to an HMI or PLC using Modbus Table 21 shows a Modbus list of the Modbus addresses for faults Table 21 Modbus Addresses for Faults Modbus Address Parameter 000265 Processor HW fault 000266 Safety Input HW fault 000267 Safety Output HW fault 000268 Power supply fault Main transistor fault 000269 Communication fault 000270 Configuration fault wrong revision invalid configuration 000271 Time out Clock monitoring 000272 Plug in fault 000393 000416 Fault bit 0 of SMF 0 23 000417 000440 Fault bit 1 of SMF 0 23 000441 000464 Fault bit 2 of SMF 0 23 000465 000488 Fault bit 3 of SMF 0 23 000489 000504 Retrigger Fault SOF 0 23 000505 000512 Cross Fault of Terminals 12 17 000849 000860 Fault log 116 Rockwell Automation Publication 440C UM001D EN P March 2015 Troubleshooting Chapter 16 Table 22 shows the fault bit message for the type of functions that are selected for the Safety Monitoring Function block Table 22 Fault Messages for the SMF Type SMF Type Fault Bit 3 Fault Bit 2 Fault Bit 1 Fault Bit O 1 Channel Reserved Reserved Reserved Input circuit shorted to 24V 2 Channel Two Reserved The left and right buttons h
161. th an authorized session you can change the password on a target safety relay through the Connected Components Workbench software The target safety relay must be in Connected status 1 On the Device Details toolbar click the Secure button Select Change Password KY Project157 Connected Components Workbench Standard Edition File Edit View Debug Tools Communications Window Help Py als alo 7 H B Q FI F Application Language Project Organizer Guardmaster_440C_CR30 Guardmaster_440C_CR30 3 me Download Upload Secure Name Project157 m Guardmaster_440C_CR30 440C CR30 22BBB Ay Verification ID Remote Mode Fault Not Faulted The Change Safety Relay dialog appears 122 Rockwell Automation Publication 440C UM001D EN P March 2015 Security and Password Chapter 17 2 Enter the Old Password New Password and confirm the new password TA Connected Components Workbench 9 Change the password used to protect the safety relay Old Password seeeeeeces New Password eooo Confirmation ssssessses 3 Click OK The safety relay requires the new password to grant access to any new session IMPORTANT Keep the password carefully If lost you have to flash the safety relay to reset the password The project in the safety relay is lost but a new project can be downloaded Clear Password With an authorized session you can clear the password on a targ
162. the equipment can be impaired Begin Configu ration 1 In the Device Toolbox expand the Safety Catalog 2 Double click the 440C CR30 22BBB to open it in the Project Organizer X Connected Components Workbench Standard Edition Administrator So File Edit View Tools Communications Window Help a A E ETEN JE O Ola IFRS a Vr LERTE ATH ub So ome SA Ch LQ Sof Apphcation languag a 4 General Project Creation There are no usable controls in this group Drag an item onto this text to add it to the toolbox To start the project choose a device from the Device Toolbox using Discover or by dragging it from the Catalog to Project Organizer Alternatively double click on a device to add it to Project Organizer c vill Controllers G a Drives How Do I Access help contents manuals and online support from Help menu For more information visit CCW a 440C CR30 22888 4 2 ij v l Motor Control Choose a device from the Device Tooker using Discover or by TA Most Conant Companen Wostnarch 2 Graphic Terminals dragging from the Catalog Project Organizer Name v Show page on startup amp Error List Bi Output Ready Rockwell Automation Publication 440C UM001D EN P March 2015 25 Chapter4 Configuring the CR30 3 Double click the icon in the Project Organizer to open the project 4 Click the Edit Logic button to begin the configuration process AR Project36 Connected Components Workbench
163. tomation Publication 440C UM001D EN P March 2015 13 Chapter 1 Overview Notes 14 Rockwell Automation Publication 440C UM001D EN P March 2015 Mounting Dimensions Chapter 2 Installation DIN Rail Mounting Mounting dimensions exclude mounting feet or DIN Rail latches Figure 3 DIN Rail Mounting mm in 100 3 94 80 3 15 vol ajal nanna o 22 i Se oo 329 Maintain spacing from objects such as enclosure walls wireways and adjacent equipment Allow 50 8 mm 2 in of space on all sides for adequate ventilation If optional accessories modules are attached to the relay such as the power supply Cat No 2080 PS120 240VAC make sure that there is 50 8 mm 2 in of space on all sides after attaching the optional parts The module can be mounted using the following DIN Rails 35 x 7 5 x 1 mm EN 50 022 35 x 7 5 To mount the module on a DIN Rail 1 Use a flat blade screwdriver in the DIN Rail latch and pry it downwards until it is in the unlatched position 2 Hook the top of the DIN Rail mounting area of the relay onto the DIN Rail and then press the bottom until the relay snaps onto the DIN Rail 3 Push the DIN Rail latch back into the latched position Use DIN Rail end anchors Allen Bradley Cat Nos 1492 EAJ35 or 1492 EAHJ35 for vibration or shock environments To remove the module from the DIN Rail pry the DIN Rai
164. tomation Publication 440C UM001D EN P March 2015 155 Appendix D ControlFLASH Firmware Upgrade 9 Click Finish Eh ControiFLASH 440C CR30 22886 lo ota ControlFLASH 12 00 01 DANGER The target module is about to be Control Cancel now To begin the update now press Fish Catalog Number 440C CR30 22888 Seral Number FFFFFFFF Curert Revision 7 006 New Revision 7 006 10 Click Yes to initiate the update ControlFLASH a i Are you sure ycu want to begin updating the target device Yes No The next screen shows the download progress press Catalog Number 440C CR30 22BBB Serial Number FFFFFFFF Current Revision 7 006 New Revision 7 006 Transmitting update 2 of 2 block 420 of 1690 PL 11 When the flash update is complete you see a status screen similar to the following Click OK to complete the update Update Status x Catalog Number 440C CR30 22BBB ox Serial Number FFFFFFFF Current Revision 7 006 View Log New Revision 7 006 FR Error ps bsr aaO 156 Rockwell Automation Publication 440C UM001D EN P March 2015 ControlFLASH Firmware Upgrade Appendix D 12 The Welcome to ControlFlash window appears again Click Cancel Control e Are you sure you want to end this ControlFLASH session pies Eee Unrecognized Device If the device comes up as Unrecognized the EDS file must be uploaded 1 Right click
165. tomation systems Below is a list of specific terms and abbreviations used in this manual CCW The Connected Components Workbench This is a software package that allows the user to configure a CR30 program a Micro800 controller and configure a Panel View HMI CR30 Is the Cat No 440R CR30 22BBB software configurable safety relay described in this user manual HI Logic state of being ON LO Logic state of being OFF Logic Block On the CCW grid a logic block resides in any of the four columns A logic block is either 1 a Safety Monitoring Function 2 Logic Level A 3 Logic Level B or 4 Safety Output Function Logic Level A LLA This column is used to perform logic processes on a number of inputs to create a desired output state Logic Level B LLB This column is used to perform logic processes on a number of inputs to create a desired output state N C Normally Closed An electrical contact whose normal state i e no pressure or electrical potential applied is in the closed position N O Normally Open An electrical contact whose normal state i e no pressure or electrical potential applied is in the open position OSSD Output Signal Switching Device This is typically a pair of solid state signals that are pulled up to the DC source supply The signals are usually tested for short circuits to the DC power supply short circuits to the DC common and shorts circuits between the two sig
166. tput of Plug in 2 Terminals 0 00 0 03 000305 000328 State of Safety Monitoring Function SMF 1 24 000329 000344 State of Logic Level A Instance LLA 1 16 000345 000360 State of Logic Level B Instance LLB 1 16 000361 000376 State of Safety Output Function SOF 1 16 Rockwell Automation Publication 440C UM001D EN P March 2015 105 Chapter 15 106 Modbus Communication Modbus Address Parameter 000377 000392 Ready to start of SOF 1 16 000393 000416 Fault bit 0 of SMF 1 24 00 No error 01 Crossloop 10 Simultaneity fault 11 One channel open after reset 000417 000440 Fault bit 1 of SMF 1 24 000441 000464 Fault bit 2 of SMF 1 24 000465 000488 Fault bit 3 of SMF 1 24 000489 000504 Retrigger Fault SOF 1 16 000505 000512 Cross Fault of Terminals 12 17 000521 000761 Input Assembly Data see Appendix E page 161 for details 000513 000520 Reserved 000762 000848 000849 000860 Fault log 1 When a Logic Level A block is automatically created as a Pass Through the block does not occupy memory and cannot be read over Modbus This can be viewed in the CCW as a block with no title Pass Through blocks in Logic Level B can be read over Modbus Figure 117 Non Readable Pass through Blocks Logic Level A Pass Through Logic Level B LLB1 e Pass Through LLB2 e Pass o Through Rockwell Automation Pub
167. uirements specified in the approved safety concept you must use the default Reset timing and leave the input filter setting qr The filter setting is enabled in CCW versions previous to Rev 7 A filter time setting greater than 0 extends the Reset Timing by 2 x Filter Time The reset input signal can come from either one input wiring terminal or over the Modbus communication input The available input selections are e EI 00 EI 11 embedded input terminals 00 11 e MP 12 MP 17 multi purpose terminals 12 17 e P1 00 P1 03 plug in 1 terminals 00 03 e P2 00 P2 03 plug in 2 terminals 00 03 e SP_00 SP_15 Modbus inputs 00 15 Figure 57 Wiring Connection for a Reset Signal to Terminal 00 24V DC d Reset 00 01 02 03 04 05 06 07 08 09 10 11 CR30 A1 a2 12 13 14 15 16 17 18 19 20 21 24V Com The reset block works with one or more output blocks When an output block requires a manual reset the CCW shows all available reset inputs that can be used Rockwell Automation Publication 440C UM001D EN P March 2015 61 Chapter 9 Restart 62 Safety Monitoring Functions The restart function works with an AND or OR logic block in Logic Level A and Logic Level B When all inputs are satisfied exercising the restart input causes the restart function go be effective If the Restart function is already effective the Restart input has no affect The Restart can only
168. upport representative For contact information see http rockwellautomation com support 02H 01 18 Safety input pulse test failure Code corresponds to Do one of the following specific terminal that is faulted 1 e Check wiring for shorts to 24V or other channels e Power cycle the safety relay Reconfigure the safety relay Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support 19 Cross loop inputs of input shift register Do one of the following e Power cycle the safety relay 20 21 Input data transfer fault Reconfigure the safety relay Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support 04H 01 10 Safety output plausibility failure short of failure on Do one of the following power up Code 01 10 corresponds to terminals Check wiring for shorts to 24V or other channels 12 21 respectively Power cycle the safety relay 11 20 Safety output pulse test failure Code 11 20 Reconfigure the safety relay corresponds to terminals 12 21 respectively Validate the e
169. urtain Two Hand Control Alternative Device Muting Light Curtain settings Muting Override settings Test pulse evaluation Test Pulses 1 or 2 sources or 3 sources D gt 0 d Inputs 2NC v Pulse Testing 2 Sources v Discrepancy 2 Time Sms Input Filter 625mms o o 0 v SMF Emergency Stop Enabling Switch Gate Switch Two Hand Control Alternative Device Muting Override settings Input Discrepancy Time Discrepancy Time 2 gt 0 SMF Range 0 05 3s Emergency Stop Enabling Switch Gate Switch Kg 7 Light Curtain Discrepancy m Two Hand Control i Si lt Alternative Device en 5 Muting Light Curtain settings 3 Muting Override settings Two Hand Discrepancy Monitoring Default 0 5 s SMF The maximum amount of time Two Hand Control between activation of Hand 1 and Hand 2 to enable SMF Muting Sequence Muting Type 2 Sensor T Type 2 SMF Sensor L Type 4 Sensor Muting Defines the type of muting application and thus the valid sequence of clearing or blocking the muting sensors and protective device bims S2 LC Synch Time 1 50ms Max Mute Time Time Units Seconds Time Rockwell Automation Publication 440C UM001D EN P March 2015 Evaluation Method Muting Synchronization time Configuration Synch Time 0 05 10s The maximum amount of time that is allowed between clearing or blocking of the muting sensor inputs before generating a fault Biu 2 Se
170. v an o Feedback Inputs 1 84 Rockwell Automation Publication 440C UM001D EN P March 2015 Safety Outputs Chapter 11 Jog The Jog block turns on the output for a specified duration while the jog input is held HI If the Jog input goes LO the output immediately turns off Figure 104 shows the Jog output block that is connected to an enabling switch block through Logic Level LLB1 The reset is set to automatic The time delay is set to 40 The output will turn on for a maximum of 2000 ms 40x50 ms after the enabling switch is closed The output is connected to e Terminals 18 and 19 for dual channel safety switching of the machine hazards e Terminal 20 which is configured as a Single Wire Safety SWS output e Plug in 1 terminal 03 for status indication Figure 104 Jog Configuration Safety Monitoring Logic Level A Logic Level B Safety Output SMF 1 uw vee a o Pass o Pass a o icy es EON pT Enabling h ETA m M 1 nabling Switc Through Through f foo oir Tene Daly p iea mss Test Source A 12 pi 03 Reset Type Automatic Test Source B 13 X o Advanced Setting e Muting Lam p The Muting Lamp block works with the Muting safety monitoring function The muting lamp is not monitored If the lamp burns out or becomes disconnected the muting function continues to function properly Figure 105 shows the muting lamp output block connected to the mute function in SMF1 The output is
171. wer cycle the safety relay Initiate backup or restore If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support 41 Plug in slot 1 Parity failure Do one of the following e Verify plug in physically present in the slot matches the 42 Plug in slot 1 Communication error rr i eee 43 Plug in slot 1 Plug in Type not supported Reattempt download of the safety relay configuration Validate the electrical installation and appropriate 81 Plug in slot 2 Parity failure measures to reduce noise and suppress surges are taken 32 Plugin slot 2 G iati If the fault persists contact your local Rockwell Automation UIHINSOE ETOMMUNIGA NON error technical support representative For contact information see 83 Plug in slot 2 Plug in type not supported http rockwellautomation com support 166 Rockwell Automation Publication 440C UM001D EN P March 2015 Type 10H Code 01H Table 46 Minor Faults Cause Pulse Test Failure Channel shorted to 24V or another channel 02H Reset Held On A transition of the reset input from ON 1 to OFF 0 did not occur within 3 seconds Tag Definitions Appendix F Recovery Method Do one of the following e Check wiring for shorts to 24V or other channels e Power cycle the safety relay Reconfigure the safety relay Validate the electrical installation and appropriate
172. what happens next depending on whether DHCP BOOTP is enabled on the module If DHCP BOOTP is Description Enabled Asks for an address from a DHCP BOOTP server The server also assigns other Transport Control Protocol TCP parameters Not enabled Uses the IP address along with other TCP configurable parameters stored in nonvolatile memory Use RSLinx Classic Studio 5000 or Connected Components Workbench Software Follow the procedures outlined in the online help that accompanies this software to set the network address Status Indicators The three status indicators on the module provide diagnostic information about the module and its connections to the network Table 18 Status Indicators Indicator Status Description MS Off The plug in module does not have power Check the safety relay power supply Flashing green The port is in standby mode it does not have an IP address Verify that the DHCP server is running Green The port is operating correctly No action is required Red The safety relay is holding the port in reset or the safety relay has faulted Clear the fault If the fault will not clear replace the plug in Flashing red green The module is performing its power up self test No action is required NS Off The port is not initialized it does not have an IP address Verify that the DHCP server is running Flashing green The port has an IP address but no CIP connections are est
173. xceeded Too much time elapsed between mute sensors being blocked Do one of the following e Verify there is no obstruction of the mute sensor e Verify the application times are appropriate e Check wiring for shorts to 24V or other channels e Power cycle the safety relay Reconfigure the safety relay Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support 14H Combination of faults detected See all of the following fault codes 04H e 10H 20H Discrepancy Fault The configured amount of time that the inputs are allowed to be in an inconsistent state expired Do one of the following e Check wiring for shorts to 24V or other channels If appropriate adjust the Discrepancy Time for the Safety Monitoring Function e Power cycle the safety relay Reconfigure the safety relay Validate the electrical installation and appropriate measures to reduce noise and suppress surges are taken If the fault persists contact your local Rockwell Automation technical support representative For contact information see http rockwellautomation com support Rockwell Automation Publication 440C UM001D EN P March 2015 167 Appendix F Tag Definitions Type Code 10H 40H

Guardmaster 440C-CR30 Configurable Safety Relay User Manual

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