Guardmaster 440C-CR30 Configurable Safety Relay Building … · The Guardmaster® 440C-CR30 configurable safety relay building block monitors the status of the 440C-CR30 safety relay

Guardmaster 440C-CR30 Configurable Safety Relay Building BlockConnected Components Accelerator Toolkit

Quick Start

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 respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

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 trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

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.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

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 the Getting Started CCAT with System Design Assistant Quick

Start, publication CC-QS035

Rockwell Automation Publication CC-QS038A-EN-P - August 2015 3

http://literature.rockwellautomation.com/idc/groups/literature/documents/qs/cc-qs035_-en-p.pdf

Where to Start

Notes:

4 Rockwell Automation Publication CC-QS038A-EN-P - August 2015

Table of Contents

Preface About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Available Connected Components Accelerator ToolkitBuilding Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1Guardmaster 440C-CR30 Configurable Safety Relay Setup

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Connect the USB Cable to the Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . 13Configure the Communication Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Review the 440C-CR30 Software Configurable Safety RelayQuick Start Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chapter 2System Validation Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

Understand the Machine Functions Screen . . . . . . . . . . . . . . . . . . . . . 28Set Up the Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Understand the Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Understand the Fault Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Verify the Configuration Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Verify the Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Troubleshoot a Wiring Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Appendix A440C-CR30 Configurable Safety Relay User-defined Function Block

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Appendix BGlobal Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43


Table of Contents

Notes:


Preface

About This Publication

The Guardmaster® 440C-CR30 configurable safety relay building block monitors the status of the 440C-CR30 safety relay through a Modbus RS-232C interface. This quick start provides instructions for how to connect the Micro800® programmable logic controller (PLC) with the safety relay for status updates. Use this quick start to configure a monitoring system for your 440C-CR30 safety relay.

To help with the design and installation of your system, application files and other information are provided on the Connected Components Accelerator Toolkit (CCAT). The CCAT provides bills of materials (BOM), CAD drawings for panel layout and wiring, control programs, human machine interface (HMI) screens, and more. With these tools and the built-in best-practices design, you are free to 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 beginning of each chapter contains the following information. Read these sections carefully before you begin work in each chapter:

• Before You Begin - The chapters in this quick start do not have to be completed in the order in which they appear. However, this section defines the minimum amount of preparation that is required before completing the current chapter.

• What You Need - This section lists the tools that are required to complete the steps in the current chapter, including, but not limited to, hardware and software.

• Follow These Steps - This section illustrates the steps in the current chapter and identifies the steps that are required to complete the examples.


http://www.rockwellautomation.com/rockwellautomation/products-technologies/connected-components/tools/accelerator-toolkit.page


Preface

Terminology

Term (Abbreviation) Definition

Application Sequence Programs User-modified programs that work together with the standard-state machine logic to control what the machine does while in the abort, clear, reset, run, and stop states.

Auto/manual operation When the PanelView™ 800 terminal is in Auto mode, the controller logic controls the machine and monitors machine status. When the PanelView 800 terminal switches to Manual mode, the terminal takes over control. Command buttons and numeric entry fields are available only when the machine is in Manual mode.

Bill of Materials (BOM) A list of components that are needed for your system.

Building block (BB) Tools to accelerate and simplify the development of a Micro800 controller-based application. A typical building block includes a starting Bill of Material (BOM), Computer-Aided Design (CAD) drawings, Micro800 controller programs, PanelView 800 terminal applications, and a quick start document.

Computer-Aided Design (CAD) A computer-based system that is developed to facilitate design of mechanical parts.

Connected Components Accelerator Toolkit (CCAT) Software with application files and other information to speed the design and startup of component-based machines.

CCAT project A project that consists of these items:• A ProposalWorks™-based bill of materials• A set of CAD drawings (dimensions and 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 for configuring or programming Micro800 controllers, PanelView 800 terminals, PowerFlex® drives, and other component-level products.

Connected Components Workbench project A project consists of one or more of the following:• Micro800 controller configuration• Up to 256 Micro800 programs, each with program local variables• Micro800 global variables• PanelView 800 terminal application• PowerFlex drive parameter lists

Global variables Project variables that any program can access, including all I/O and system variables.

State Machine control code Machine logic for coordinating overall machine operation that is based on states. The state machine broadcasts commands and receives feedback information from each of the building blocks via user-modified application sequence programs.

Tags A PanelView 800 term for variables.

User-defined Function Blocks (UDFBs) Function block instructions that can be used like standard function block instructions within any Connected Components Workbench programming language. Anyone that uses Connected Components Workbench software can write these functions blocks. Many UDFBs are posted on the Rockwell Automation sample code website:http://samplecode.rockwellautomation.com/idc/groups/public/documents/webassets/sc_home_page.hcst.

User-defined Object (UDO) A collection of PanelView 800 terminal screen objects that can be pasted into a new screen.


http://samplecode.rockwellautomation.com/idc/groups/public/documents/webassets/sc_home_page.hcst

Preface

Available Connected Components Accelerator Toolkit Building Blocks

For the most up-to-date listing of available Connected Components Accelerator Toolkits and related quick starts, refer to these resources:

• Rockwell Automation Connected Components Accelerator Toolkit website athttp://www.rockwellautomation.com/rockwellautomation/products-technologies/connected-components/tools/accelerator-toolkit.page

• Connected Components Accelerator Toolkit Building Block Project Descriptions Quick Reference,publication CC-QR003

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

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.

Resource Description

Guardmaster 440C-CR30 Software Configurable Safety Relay Quick Start Guide, publication 440C-QS001

Provides information on how to configure a Guardmaster 440C-CR30 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-UM002

Provides a reference guide for Micro830® and Micro850® controller systems. This publication also contains procedures on how to install, wire, and troubleshoot your controller.

Micro800 Digital and Analog Plug-in Modules and Accessories User Manual, publication 2080-UM004

Provides an overview and procedures for installing, wiring, and troubleshooting Micro800 plug-in modules and accessories.

Micro820 20-point Programmable Controllers User Manual, publication 2080-UM005

Provides a reference guide for Micro820™ controller systems. It also contains procedures on how to install, wire, and troubleshoot your controller.

PanelView 800 HMI Terminals User Manual, publication2711R-UM001

Provides information for configuring the PanelView 800 terminal.

PanelView 800 HMI Terminals Installation Instructions, publication 2711R-IN001

Provides instructions on how to install, wire, ground, and troubleshoot PanelView 800 terminals.


http://literature.rockwellautomation.com/idc/groups/literature/documents/qs/440c-qs001_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/440c-um001_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2080-um002_-en-e.pdf

2080-UM004

http://www.rockwellautomation.com/literature/

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2080-um005_-en-e.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/2711r-um001_-en-e.pdf



http://literature.rockwellautomation.com/idc/groups/literature/documents/qr/cc-qr003_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/in/2711r-in001_-en-p.pdf

Preface

Notes:


Chapter 1

Guardmaster 440C-CR30 Configurable Safety Relay Setup

This chapter provides information for how to configure the hardware for 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


http://literature.rockwellautomation.com/idc/groups/literature/documents/qs/cc-qs035_-en-p.pdf

Chapter 1 Guardmaster 440C-CR30 Configurable 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


Guardmaster 440C-CR30 Configurable Safety Relay Setup Chapter 1

Connect the USB Cable to the Safety Relay

Connect a USB cable between the safety relay and your personal computer. The driver for the safety relay is automatically installed. If the driver 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 Catalog > Safety and double-click the 440C-CR30 safety relay.

3. In the project organizer, double-click the safety relay.


Chapter 1 Guardmaster 440C-CR30 Configurable Safety Relay Setup

4. To configure the communication parameters, select Serial Port.

5. From the Common Settings pull-down 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 configure the safety relay.



Chapter 2

System Validation

This chapter provides information for how to configure the controller and human machine interface (HMI) so the devices are communicating correctly. After the configuration is complete, you can validate the system for monitoring the status of the 440C-CR30 safety relay.

Before You Begin• Complete the steps in Chapter 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 cables for personal computer to Micro800 controller

communication• Personal computer with available USB port and Ethernet connection with Connected Components Workbench

software, version 8.00, installed


Chapter 2 System Validation

Follow These Steps

To validate your system, complete these steps.

Review the System Overview on page 17

Validate Your System on page 28

Configure the Controller Communication Ports on page 19

Configure the PanelView 800 Terminal Communication Settings

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


System Validation Chapter 2

Review the System Overview

The PanelView 800 Graphic Terminal can be connected to the Micro800 controller with a CIP serial or CIP-on-Ethernet connection:

• For a CIP serial connection, use a 1761-CBL-PM02 cable to connect the PanelView 800 terminal to the embedded serial port of the Micro800 controller.

• For a CIP-on-Ethernet connection, connect the PanelView 800 terminal to the Stratix Ethernet switch. Then use the Ethernet patch cords to connect the Stratix Ethernet switch to the embedded Ethernet port of the Micro800 controller.

• For a CIP-on-Ethernet connection to a Micro850 controller, you can connect the terminal 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 communicate with a PanelView 800 terminal.

Figure 2 - Connection for Micro820 and 440C-CR30 Safety Relay With a Modified 1761-CBL-HM02 Cable

To modify the 1761-CBL-HM02 cable, follow these steps.

1. Cut the 1761-CBL-HM02 cable to the required length.

2. Identify the wire that is connected to pins 2, 4, and 7 of the PS/2™ connector.

3. Connect the wire to the respective terminal according to this table.

IP Address: 192.168.1.2

Modified 1761-CBL-HM02

Micro820IP Address: 192.168.1.3

440C-CR30 Safety Relay

Ethernet Cable



Figure 3 - Connection for Micro850 and 440C-CR30 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


Ethernet Cable

Micro850 IP Address: 192.168.1.3

440C-CR30 Safety RelayModified 1761-CBL-HM02

1761-CBL-PM02

Micro830



Configure the Controller Communication Ports

By default, the 440C-CR30 safety relay serial 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



Configure the PanelView 800 Terminal Communication Settings

To modify these settings in the 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.



For CIP-on-Ethernet communication, configure the settings that are shown here.



Connect Your Devices

There are three network layouts that are identified in Review the System Overview on page 17. In this Quick Start, we picked the Connection 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


Ethernet Cable

IP Address: 192.168.1.3



To modify the settings for the project that are generated from CCAT version 2 or the project Starting_CR30_M800_r8 downloaded from the 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 Channel 5 Channel 6 Channel 7


http://search.rockwellautomation.com/search?site=sample_code&client=samplecode&output=xml_no_dtd&proxystylesheet=samplecode


5. In your Connected Components Workbench project, from the Project Organizer, right-click your controller icon and choose Build.

6. When the program is finished building, check the Output pane at 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.

7. From the Project Organizer, right-click your controller icon and choose Download.



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.



Configure the IP Address of Your PanelView 800 Terminal

To configure a static IP address on the PanelView 800 terminal, follow these steps.

1. From the Main menu, press Communication to open the Communication screen.

2. Press Set Static IP Address.

3. Configure the IP Address and Mask values so that they are in the same range 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 is connected with your personal computer via an Ethernet switch or Ethernet cable.

2. In the Project Organizer, right-click the PanelView 800 device icon and choose Download.

The Connection Browser window appears.



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.



Validate Your System

In this section, you review the Machine Functions screen and explore the Status and Command screens to test the manual control of the building block.

Understand the Machine Functions Screen

The Machine Functions screen is the screen that links to the installed building blocks. When this screen is first loaded, you can complete the following tasks:

• Return to the Machine Overview screen by pressing the X in the upper right-hand corner of the screen.• View a device in detail by pressing its button.• View the current machine Auto/Manual state.• Change the current machine Auto/Manual state.• Clear machine faults, start/stop the machine (while 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 there is a fault, or an alarm is present.

Set Up the Configuration Screen

To set up the 440C-CR30: Configure IO Description screen, follow these steps.

1. From the Machine Functions screen, switch the Operation mode to Manual.

2. Press the device.

The Configuration screen for the device appears. There are a total of four configuration screens.

3. Type the name of each terminal of the 440C-CR30 safety relay.

There are a total of 22 embedded terminals and two plug-in terminals.

4. Record a description of each connection in the table on the next page.



Terminal Name Enter a description of the connection or the name of the safety device that is connected to the corresponding terminal.

IN_0

IN_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 2- IN_1

Plugin Slot 2- IN_2

Plugin Slot 2- IN_3

Plugin Slot 2- IN_4







5. At any time, press X in the top-right corner to return to the previous screen and press the Next page button to configure the terminals on the next page.

6. When you arrived at the last 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 slot 2.

See Table 1 on page 31 for a description of the status indicators.



Table 1 - 440C-CR30 Safety Relay Status Indicators

Terminal Name Red Gray Green

IN_0

Not applicable.

The respective terminal is not activated. The respective terminal is activated.

IN_1

IN_2

IN_3

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 2- IN_1

Plugin Slot 2- IN_2

Plugin Slot 2- IN_3

Plugin Slot 2- IN_4







Understand the Fault Screens

There are two types of fault screens. A generic fault screen that shows the overall fault status, and a minor fault screen that reports 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 the Minor Fault button.

Figure 9 - Minor Fault Screen



Verify the Configuration Screens

Based on the safety configuration information in Guardmaster 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




Verify the Status Screen

Based on the safety configuration information in Guardmaster 440C-CR30 Software Configurable Safety Relay Quick Start Guide, publication 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 status is grey.

After a reset, the status is green.




Perform a Reset

To perform a reset, follow these steps.

1. To perform a reset, use Connected Components Workbench software to go online with the controller 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 can wire a physical push button.



Troubleshoot a Wiring Fault

To troubleshoot 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.



3. Press Minor Fault to access the fault detail.

The Minor Fault Help screen reports a 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.



Notes:


Appendix A

440C-CR30 Configurable Safety Relay 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


Appendix A 440C-CR30 Configurable Safety Relay User-defined Function Block

Table 2 - RA_MDBUS_CR30_STS_UDFB

Parameter Name Description Data Type

FBEN FALSE = The function block is not activated.TRUE = The function block is activated.FALSE -> TRUE = Initialize or Reset the function block.

BOOL

Channel Indicates which communication port is used.2 = the embedded plug-in port.5 = the first plug-in slot.6 = the second plug-in slot.7 = the third plug-in slot.8 = the fourth plug-in slot.9 = the fifth plug-in slot.

UINT

NodeAddr Indicates the slave or node address of the 440C-CR30 safety relay. USINT

Interval Indicates the output update rate in milliseconds. DINT

ModbusInput A 16-bit variable that is mapped to the Modbus address 000001… 000016 of the 440C-CR30 safety relay. INT

FBENO FALSE = The function block is not activated.TRUE = The function block is activated.

BOOL

FB_Q FALSE = The function 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 configured, or the configured device is not activated.

UDINT

SMF_Fault Indicates the fault status of each SMF device that is configured in the 440C-CR30 safety relay. For example, bit 0 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

SOF_STS Indicates the status of each safety output function (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 so on.TRUE = The corresponding device is configured and activated.FALSE = No device is configured, or the configured device is not activated.

–

EXT_Parameters See Table 4 on page 42. –


440C-CR30 Configurable Safety Relay User-defined Function Block Appendix A

CR30_STS An array of DINT that consolidates the Modbus statuses of the 440C-CR30 safety relay. This parameter lets other Allen-Bradley® controllers read the status through CIP messaging.Each array data represents the output of this UDFB. This list corresponds to the UDFB output of each array.CR30_STS[1] = IO_Sts.EM_IO_StsCR30_STS[2] = IO_Sts.P1_Input_StsCR30_STS[3] = IO_Sts.P1_Output_StsCR30_STS[4] = IO_Sts.P2_Input_StsCR30_STS[5] = IO_Sts.P2_Output_StsCR30_STS[6] = SMF_STSCR30_STS[7] = SMF_FaultCR30_STS[8] = SOF_STSCR30_STS[9] = Ext_Parameters.MDBUS_Serial_Input_DataCR30_STS[10] = Ext_Parameters.Fault_StsCR30_STS[11] = Ext_Parameters.LLACR30_STS[12] = Ext_Parameters.LLBCR30_STS[13] = Ext_Parameters.SOF_Rdy_StsCR30_STS[14] = Ext_Parameters.SMF_Fault_Bit_0CR30_STS[15] = Ext_Parameters.SMF_Fault_Bit_1CR30_STS[16] = Ext_Parameters.SMF_Fault_Bit_2CR30_STS[17] = Ext_Parameters.SMF_Fault_Bit_3CR30_STS[18] = Ext_Parameters.SOF_Retrig_FaultCR30_STS[19] = Ext_Parameters.Cross_Fault_StsCR30_STS[20] = Fault_Log.Log1CR30_STS[21] = Fault_Log.Log2CR30_STS[22] = Fault_Log.Log3CR30_STS[23] = Fault_Log.Log4CR30_STS[24] = Fault_Log.Log5CR30_STS[25] = Fault_Log.Log6CR30_STS[26] = Fault_Log.Log7CR30_STS[27] = Fault_Log.Log8CR30_STS[28] = Fault_Log.Log9CR30_STS[29] = Fault_Log.Log10CR30_STS[30] = Fault_Log.Log11CR30_STS[31] = Fault_Log.Log12

Array

Fault Log Fault log of the 440C-CR30 safety relay. –

FB_Error FALSE = No function block error.TRUE = A function block error exists.

–

FB_Error code The error description corresponds to the respective bit when the status is TRUE.Bit 0 = Connection loss.Bit 1 = Invalid node address.Bit 2 = Other communication error.Bit 3 = Node address out of range.

UINT

Table 2 - RA_MDBUS_CR30_STS_UDFB (Continued)



Appendix A 440C-CR30 Configurable Safety Relay User-defined Function Block

Table 3 - CR30_IO_STS


P1_Input_Sts Indicates plug-in 1 input status. For example, bit 0 represents the status of input 0, and bit 1 represents the status of input 1, and so on. TRUE = The corresponding input is activated.FALSE = The corresponding input is not activated.

SINT

P1_Output_Sts Indicates plug-in 1 output status. For example, bit 0 represents the status of output 0, and bit 1 represents the status of output 1, and so on.TRUE = The corresponding output is activated.FALSE = The corresponding output is not activated.

SINT

P2_Input_Sts Indicates plug-in 2 input status. For example, bit 0 represents the status of input 0, and bit 1 represents the status of input 1, and so on.TRUE = The corresponding input is activated.FALSE = The corresponding input is not activated.

SINT

P2_Output_Sts Indicates plug-in 2 output status. For example, bit 0 represents the status of output 0, and bit 1 represents the status of output 1, and so on.TRUE = The corresponding output is activated.FALSE = The corresponding output is not activated.

SINT

EM_IO_Sts Indicates embedded terminal status. For example, bit 0 represents 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


MDBUS_Serial_Input_Data Modbus serial input data. UINT

Fault_Sts The error description corresponds to the respective bit when the status is TRUE.Bit 0 = Processor hardware fault.Bit 1 = Safety Input hardware fault.Bit 2 = Safety Output hardware fault.Bit 3 = Power supply fault or main transistor fault.Bit 4 = Communication fault.Bit 5 = Configuration fault (wrong revision, invalid configuration).Bit 6 = Time out (clock monitoring).Bit 7 = Plug-in fault.

USINT

LLA State of logic level A instances (LLA) 0…15. UINT

LLB State of logic level B instances (LLB) 0…15. UINT

SOF_Rdy_Sts Ready-to-start of SOF 00…15. UINT

SMF_Fault_Bit_0 Fault bit 0 of SMF 0…23.00 = No error.01 = Crossloop.10 = Simultaneous fault.11 = One channel open after reset.

DWORD

SMF_Fault_Bit_1 Fault bit 1 of SMF 0…23. DWORD



SOF_Retrig_Fault Retrigger fault SOF 0…15. DWORD

Cross_Fault_Sts Cross-fault of terminals 12…17. USINT


Appendix B

Global Variables

This appendix contains the global variables that are used for user program interfacing.

Table 5 - Global Variables

Variable Name Variable Description Data Type

Safety_Sts_SMF_Fault Indicates the fault status of each SMF device that is configured in the 440C-CR30 safety relay. For example, bit 0 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 not completed execution.TRUE = The function block has completed execution.

BOOL


Appendix B Global Variables

Safety_Sts_LocalAddr An array of DINT that consolidates the Modbus statuses of the 440C-CR30 safety relay. This variable allows other Allen-Bradley controllers to read the status through CIP messaging.Each array data represents the output of this UDFB. This list corresponds to the UDFB output to each array.CR30_STS[1] = IO_Sts.EM_IO_StsCR30_STS[2] = IO_Sts.P1_Input_StsCR30_STS[3] = IO_Sts.P1_Output_StsCR30_STS[4] = IO_Sts.P2_Input_StsCR30_STS[5] = IO_Sts.P2_Output_StsCR30_STS[6] = SMF_STSCR30_STS[7] = SMF_FaultCR30_STS[8] = SOF_STSCR30_STS[9] = Ext_Parameters.MDBUS_Serial_Input_DataCR30_STS[10] = Ext_Parameters.Fault_StsCR30_STS[11] = Ext_Parameters.LLACR30_STS[12] = Ext_Parameters.LLB CR30_STS[13] = Ext_Parameters.SOF_Rdy_StsCR30_STS[14] = Ext_Parameters.SMF_Fault_Bit_0CR30_STS[15] = Ext_Parameters.SMF_Fault_Bit_1CR30_STS[16] = Ext_Parameters.SMF_Fault_Bit_2CR30_STS[17] = Ext_Parameters.SMF_Fault_Bit_3CR30_STS[18] = Ext_Parameters.SOF_Retrig_FaultCR30_STS[19] = Ext_Parameters.Cross_Fault_StsCR30_STS[20] = Fault_Log.Log1CR30_STS[21] = Fault_Log.Log2CR30_STS[22] = Fault_Log.Log3CR30_STS[23] = Fault_Log.Log4CR30_STS[24] = Fault_Log.Log5CR30_STS[25] = Fault_Log.Log6CR30_STS[26] = Fault_Log.Log7CR30_STS[27] = Fault_Log.Log8CR30_STS[28] = Fault_Log.Log9CR30_STS[29] = Fault_Log.Log10CR30_STS[30] = Fault_Log.Log11CR30_STS[31] = Fault_Log.Log12

DINT

Safety_Cmd_CommRset A manual-mode variable that resets the messaging instruction when triggered from the HMI terminal. BOOL

Safety_Cmd_CommRset_Auto An auto-mode variable that resets the messaging instruction when triggered from a user program. BOOL

Safety_EM_IO_Des A 22-array variable that represents the names of the 22 embedded terminals.[0] represents embedded terminal 0, [1] represents embedded terminal 1, and so on.

STRING

Table 5 - Global Variables (Continued)



Global Variables Appendix B

Safety_P1_IO_Des An 8-array variable that represents the names of up to eight terminals for plug-in 1.[0] = IN_1[1] = IN_2[2] = IN_3[3] = IN_4[4] = OUT_1[5] = OUT_2[6] = OUT_3[7] = OUT_4

STRING

Safety_P2_IO_Des An 8-array variable that represents the names of up to eight terminals for plug-in 2.[0] = IN_1[1] = IN_2[2] = IN_3[3] = IN_4[4] = OUT_1[5] = OUT_2[6] = OUT_3[7] = OUT_4

STRING

Safety_Sts_NameCfgOK This variable reports the status of the configuration.True = Completed.False = Not completed.

BOOL

Safety_Cmd_EditName Trigger this variable to update the terminal names. BOOL

Safety_Cmd_EditNameDone Trigger this variable to indicate that the name configuration is complete. BOOL

Safety_Err_FaultBit_0 Fault bit 0 status. BOOL




Safety_Err_MajorFault Major fault typically indicates that 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 is detected in one of the terminals.False = A minor fault is not detected in one of the terminals.

BOOL

Safety_CR30_Remote_CommReset A single-array variable that you can use with a CIP table write to reset the messaging instruction. DINT

Safety_CR30_Sts_OK A single-array variable that reports the status of Safety_CR30_Sts_OK status for use with a remote messaging command (for example, CIP table read command from a CompactLogix™ controller).0 = Safety_CR30_Sts_OK is FALSE.1 = Safety_CR30_Sts_OK is TRUE.

DINT




Appendix B Global Variables

Safety_Sts_SMF 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 configured, or the configured device is not activated.

DINT

Safety_Sts_IO This variable represents the status of the respective terminals.P1_xxx_Sts = the status of 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 so on.TRUE = The corresponding device is configured and activated.FALSE = No device is configured, or the configured device is not activated.

INT

Safety_Sts_ER TRUE = A communication error exists between the 440C-CR30 safety relay and the Micro800 controller.FALSE = No communication error exists between the 440C-CR30 safety relay and the Micro800 controller.

BOOL




Publication CC-QS038A-EN-P - August 2015Copyright © 2015 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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