Allen-Bradley Guardmaster 440C-CR30, Quick Start Manual

Page 1: ...Guardmaster 440C CR30 Configurable Safety Relay Building Block Connected Components Accelerator Toolkit Quick Start ...

Page 2: ...n Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Labels may also be on or inside the equipment to provide specific precautions Allen Bradley CompactLogix Connected Components Workbench Guardmaster Micro800 Micro820 Micro830 Micro850 PanelView PowerFlex ProposalWorks PS 2 Rockwell Automation Rockwell Software and Stratix are trademark...

Page 3: ...15 3 Where to Start To complete your building block project follow this path Chapter 1 Guardmaster 440C CR30 Configurable Safety Relay Setup Chapter 2 System Validation Read theGettingStartedCCAT with System Design Assistant Quick Start publication CC QS035 ...

Page 4: ...4 Rockwell Automation Publication CC QS038A EN P August 2015 Where to Start Notes ...

Page 5: ...egin 15 What You Need 15 Follow These Steps 16 Review the System Overview 17 Configure the Controller Communication Ports 19 Configure the PanelView 800 Terminal Communication Settings 20 Connect Your Devices 22 Download Your Program to the Controller 22 Configure the IP Address of Your PanelView 800 Terminal 26 Transfer Your HMI Application to the PanelView 800 Terminal 26 Validate Your System 28...

Page 6: ...6 Rockwell Automation Publication CC QS038A EN P August 2015 Table of Contents Notes ...

Page 7: ...o focus on the design of your machine control and not on design overhead tasks The CCAT is available on the Connected Components Accelerator Toolkit DVD publication CC QR002 or through the Rockwell Automation Software Download and Registration System SDRS site at http www rockwellautomation com rockwellautomation products technologies connected components tools accelerator toolkit page The beginni...

Page 8: ...nd schematics A Connected Components Workbench project HMI screens A set of Quick Start documents A project document with information about the project components and links to reference materials Connected Components Workbench software Software environment forconfiguringorprogrammingMicro800controllers PanelView 800terminals PowerFlex drives and other component level products Connected Components ...

Page 9: ...30 configurable safety relay to communicate with a PanelView 800 terminal via Modbus communication protocol Guardmaster 440C CR30 Configurable Safety Relay User Manual publication 440C UM001 Provides detailed information on how to install configure operate and troubleshoot a Guardmaster 440C CR30 configurable safety relay Micro830 and Micro850 Programmable Controllers User Manual publication 2080 ...

Page 10: ...10 Rockwell Automation Publication CC QS038A EN P August 2015 Preface Notes ...

Page 11: ...the 440C CR30 safety relay Before You Begin Review the Getting Started Connected Components Accelerator Toolkit with System Design Assistant Quick Start publication CC QS035 Apply power to your 440C CR30 safety relay What You Need Personal computer with an available USB port 440C CR30 22BBB safety relay USB cable for programming the safety relay Connected Components Workbench software version 8 00...

Page 12: ...igurable Safety Relay Setup Follow These Steps To configure your 440C CR30 safety relay complete these steps Start Connect the USB Cable to the Safety Relay on page 13 Review the 440C CR30 Software Configurable Safety Relay Quick Start Guide on page 14 Configure the Communication Settings on page 13 ...

Page 13: ...iver did not install unplug the USB cable and plug it in again Figure 1 Connect the Safety Relay to Your Computer Configure the Communication Settings To configure the safety relay communication settings for the Micro800 controller follow these steps 1 Launch the Connected Component Workbench version 8 software 2 To add the 440C CR30 safety relay to your project from the Device Tool box open Catal...

Page 14: ... menu lists choose these options Driver Modbus RTU Baud Rate 19200 Parity None 6 Download the configuration to the safety relay 7 Select the device from the connection browser and click OK to begin download Review the 440C CR30 Software Configurable Safety Relay Quick Start Guide Follow the instructions in the 440C CR30 Software Configurable Safety Relay Quick Start Guide publication 440C QS001 to...

Page 15: ...hapter 1 Verify that the devices are connected as shown in the wiring diagrams see Figure 2 Figure 3 or Figure 4 Apply power to the devices What You Need Micro800 controller 440C CR30 22BBB safety relay 4 inch or larger PanelView 800 terminal Stratix Ethernet switch if you use a CIP on Ethernet connection One pair of 1761 CBL HM02 cables Three pairs of USB programming cables A to B or Ethernet cab...

Page 16: ...e 17 Validate Your System on page 28 Configure the Controller Communication Ports on page 19 Configure the PanelView 800 TerminalCommunicationSettings on page 20 Connect Your Devices on page 22 Download Your Program to the Controller on page 22 Transfer Your HMI Application to the PanelView 800 Terminal on page 26 Start Configure the IP Address of Your PanelView 800 Terminal on page 26 ...

Page 17: ...l directly to the Ethernet port on the Micro850 controller by using an Ethernet cable All connection methods are explained in this manual but choose only one method for your project The 440C CR30 safety relay can be connected directly to the embedded serial port of the Micro800 The safety relay can also be connected to a serial plug in module when the embedded serial port is already configured to ...

Page 18: ... Safety Relay Figure 4 Connection for Micro830 and 440C CR30 Safety Relay 440C CR30 Safety Relay Connector Micro800 Controller Terminal Pin 7 Rx Pin 4 Tx Pin 2 G IP Address 192 168 1 2 1761 CBL HM02 440C CR30 Safety Relay Ethernet Cable Micro850 IP Address 192 168 1 3 440C CR30 Safety Relay Modified 1761 CBL HM02 1761 CBL PM02 Micro830 ...

Page 19: ...rial communication port has these communication settings Figure 5 Default Communication Configuration for the 440C CR30 Safety Relay To communicate with the 440C CR30 safety relay you must configure the embedded serial port or serial plug in module of the Micro800 controller with these configuration settings Figure 6 Embedded Serial Port Settings for the Micro800 Controller ...

Page 20: ...default Connected Components Workbench project follow these steps 1 To open the PanelView 800 application editor in the Project Organizer double click the PanelView 800 device icon The PanelView 800 Communication Settings pane appears in the main project window 2 Configure the appropriate communication settings For CIP Serial communication configure the settings that are shown here ...

Page 21: ...Rockwell Automation Publication CC QS038A EN P August 2015 21 System Validation Chapter 2 For CIP on Ethernet communication configure the settings that are shown here ...

Page 22: ...tion with CIP Ethernet for our application example Figure 7 Device Connections Download Your Program to the Controller To download your program to the controller follow these steps 1 Connect your personal computer to the controller use either an Ethernet or USB connection If you are prompted to install any drivers install the recommended drivers IP Address 192 168 1 2 1761 CBL HM02 440C CR30 Safet...

Page 23: ... Rockwell Automation sample code website follow these steps 2 From the project organizer open the local variables of device name M800_CR30_Sts 3 Search for Channel in local variable list 4 Update the initial value of the variable to the channel number of your serial communication port regarding the port location In this example we use the embedded serial communication port channel 2 Channel 2 Chan...

Page 24: ... the bottom of your project window for a build success message Example Output Pane Build Successful If the build is successful continue to step 7 If the build is unsuccessful an errors list appears Continue to step a Example Output Pane Error List a Double click an error description to go to that error b Correct each error c Repeat step 2 step 6 until the build is successful and continue to step 7...

Page 25: ...038A EN P August 2015 25 System Validation Chapter 2 8 From the Connection Browser select your controller and click OK For USB connection For Ethernet connection 9 If prompted to change the controller mode to Remote Program mode click Yes ...

Page 26: ...e as your Micro800 controller For example in this Quick Start we set the IP address of the PanelView terminal to 192 168 100 2 4 To return to the Main menu press Main Transfer Your HMI Application to the PanelView 800 Terminal To transfer your HMI application to the PanelView 800 terminal by using Connected Components Workbench software follow these steps 1 Be sure that your PanelView 800 terminal...

Page 27: ...3 Select the PanelView 800 terminal and click OK 4 Verify that the download completed successfully 5 From the Main menu of your PanelView 800 terminal press File Manager 6 On the File Manager screen select Internal as your Source 7 Select your application CR30_T6T_M800_ETNEIP_r8 8 Press Run ...

Page 28: ...hile in Auto mode and go to the machine state diagram overview screen The border of the device button changes color to indicate a specific status For the 440C CR30 safety relay the button border colors indicate the following status A green border indicates that the safety relay is active and operating A gray border indicates that the safety relay is inactive and stopped A red border indicates that...

Page 29: ..._1 IN_2 IN_3 IN_4 IN_5 IN_6 IN_7 IN_8 IN_9 IN_10 IN_11 IO_12 IO_13 IO_14 IO_15 IO_16 IO_17 OUT_18 OUT_19 OUT_20 OUT_21 Plugin Slot 1 IN_1 Plugin Slot 1 IN_2 Plugin Slot 1 IN_3 Plugin Slot 1 IN_4 Plugin Slot 1 OUT_1 Plugin Slot 1 OUT_2 Plugin Slot 1 OUT_3 Plugin Slot 1 OUT_4 Plugin Slot 2 IN_1 Plugin Slot 2 IN_2 Plugin Slot 2 IN_3 Plugin Slot 2 IN_4 Plugin Slot 2 OUT_1 Plugin Slot 2 OUT_2 Plugin Sl...

Page 30: ...ast configuration page press the Config Done button The IO_Sts page button appears 7 To go to the Status screen press the IO_Sts page button 8 If you want to change the names again press the Edit Config button Understand the Status Screen There are a total of four status screens They represent terminal status for embedded terminals 0 21 and the plug in module that is attached to plug in slot 1 and...

Page 31: ...IN_4 IN_5 IN_6 IN_7 IN_8 IN_9 IN_10 IN_11 IO_12 A cross fault occurred at the respective terminal IO_13 IO_14 IO_15 IO_16 IO_17 OUT_18 Not applicable OUT_19 OUT_20 OUT_21 Plugin Slot 1 IN_1 Plugin Slot 1 IN_2 Plugin Slot 1 IN_3 Plugin Slot 1 IN_4 Plugin Slot 1 OUT_1 Plugin Slot 1 OUT_2 Plugin Slot 1 OUT_3 Plugin Slot 1 OUT_4 Plugin Slot 2 IN_1 Plugin Slot 2 IN_2 Plugin Slot 2 IN_3 Plugin Slot 2 IN...

Page 32: ...rts the minor fault details This generic fault screen reports the type of major fault and indicates which terminal experienced a minor fault When there is a major fault the details of the fault appear on this screen Figure 8 Generic Fault Screen When there is a minor fault at a particular terminal the number that corresponds to the respective terminal is red To access the minor fault screen press ...

Page 33: ...ster 440C CR30 Software Configurable Safety Relay Quick Start Guide publication 440C QS001 verify that the I O is configured as shown in Figure 10 through Figure 12 Press Next Page to go to the different configuration screens Figure 10 Configure I O Description Input Screen Figure 11 Configure I O Description Output Screen Figure 12 Configure I O Description Plugin Slot 1 Screen ...

Page 34: ...lication 440C QS001 verify that the terminal status is correct as shown in Figure 13 through Figure 14 When the emergency stop and safety gate are at their safe position the input status for these devices is green After a download the safety relay OUT_18 and OUT_19 is activated once you perform a reset Figure 13 Before you Perform a Reset Figure 14 After you Perform a Reset Before a reset the stat...

Page 35: ...ontroller and change the Terminal variable in the M800_CR30_Sts program 2 In the M800_CR30_Sts program change the Terminal variable from 0 to 1 and then back to 0 Changing the Terminal variable is like triggering bit zero of the Modbus serial input data of the 440C CR30 safety relay to activate a safety reset You can also change the reset signal in the safety logic to any other terminal where you ...

Page 36: ...hoot a wiring fault follow these steps 1 To simulate a wire break fault remove the wire from terminal 1 2 Press Fault Help to access the help screen for more information The indicator numbers represent the Safety Monitoring Function SMF from the safety logic Indicator 1 turns red to indicate that the minor fault occurred at SMF 1 ...

Page 37: ... Fault Bit 2 The description of this fault corresponds to the type of device that is connected In this example SMF 1 is an emergency stop button a 2 channel device Therefore see the description for the 2 channel device 4 Connect the wire at terminal 1 5 Press and then release the emergency stop button 6 To enable the safety relay OUT_18 and OUT_19 activate the reset signal ...

Page 38: ...38 Rockwell Automation Publication CC QS038A EN P August 2015 Chapter 2 System Validation Notes ...

Page 39: ...elay User defined Function Block This appendix describes the available User defined Function Block UDFB and the associated inputs and outputs This UDFB reads the status of the 440C CR30 safety relay and displays the status in an intuitive manner Figure 15 RA_MDBUS_CR30_STS_UDFB User defined Function Block ...

Page 40: ...block has not completed execution TRUE The function block has completed execution BOOL IO_Sts See Table 3 on page 42 SMF_STS Indicates the status of each SMF device that is configured in the 440C CR30 safety relay For example bit 0 represents the status of SMF 1 and bit 1 represents the status of SMF 2 and so on TRUE The corresponding device is configured and activated FALSE No device is configure...

Page 41: ...SOF_Rdy_Sts CR30_STS 14 Ext_Parameters SMF_Fault_Bit_0 CR30_STS 15 Ext_Parameters SMF_Fault_Bit_1 CR30_STS 16 Ext_Parameters SMF_Fault_Bit_2 CR30_STS 17 Ext_Parameters SMF_Fault_Bit_3 CR30_STS 18 Ext_Parameters SOF_Retrig_Fault CR30_STS 19 Ext_Parameters Cross_Fault_Sts CR30_STS 20 Fault_Log Log1 CR30_STS 21 Fault_Log Log2 CR30_STS 22 Fault_Log Log3 CR30_STS 23 Fault_Log Log4 CR30_STS 24 Fault_Log...

Page 42: ...is not activated SINT EM_IO_Sts Indicates embedded terminal status For example bit 0represents the status of terminal 0 and bit 1 represents the status of terminal 1 and so on TRUE The corresponding terminal is activated FALSE The corresponding terminal is not activated DINT Table 4 CR30_EXT_Parameter Parameter Name Description Data Type MDBUS_Serial_Input_Data Modbus serial input data UINT Fault_...

Page 43: ...testhefaultstatusofeachSMFdevicethatisconfiguredinthe440C CR30safetyrelay Forexample bit0 represents the fault status of SMF 1 and bit 1 represents the fault status of SMF 2 and so on TRUE The corresponding device is faulted FALSE The corresponding device is not faulted DINT Safety_Sts_Fault_Log Fault log of the 440C CR30 safety relay CR30_Fault_Log Safety_Sts_Comm_OK FALSE The function block has ...

Page 44: ...STS 15 Ext_Parameters SMF_Fault_Bit_1 CR30_STS 16 Ext_Parameters SMF_Fault_Bit_2 CR30_STS 17 Ext_Parameters SMF_Fault_Bit_3 CR30_STS 18 Ext_Parameters SOF_Retrig_Fault CR30_STS 19 Ext_Parameters Cross_Fault_Sts CR30_STS 20 Fault_Log Log1 CR30_STS 21 Fault_Log Log2 CR30_STS 22 Fault_Log Log3 CR30_STS 23 Fault_Log Log4 CR30_STS 24 Fault_Log Log5 CR30_STS 25 Fault_Log Log6 CR30_STS 26 Fault_Log Log7 ...

Page 45: ...BOOL Safety_Err_FaultBit_1 Fault bit 1 status BOOL Safety_Err_FaultBit_2 Fault bit 2 status BOOL Safety_Err_FaultBit_3 Fault bit 3 status BOOL Safety_Err_MajorFault Major fault typically indicatesthat there is a hardware fault in the 440C CR30 safety relay BOOL Safety_Err_RetrigFault Retrigger fault status BOOL Safety_Err_CrossFault Cross fault status BOOL Safety_Err_MinorFault True A minor fault ...

Page 46: ...plug in 1 P2_xxx_Sts the status of plug in 2 EM_IO_Sts the status of the embedded terminal CR30_IO_STS Safety_Sts_SOF Indicates the status of each SOF device that is configured in the 440C CR30 safety relay For example bit 0 represents the status of SOF 1 and bit 1 represents the status of SOF 2 and soon TRUE The corresponding device is configured and activated FALSE No device is configured or the...

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