The Guardmaster¢â€‍¢ 440C-CR30 Software ... The Guardmaster 440C-CR30 Software Configurable Safety Relay

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  • The Guardmaster™ 440C-CR30 Software Configurable Safety Relay Training Demo Lab

    For Classroom Use Only!

  • Important User Information

    This documentation, whether, illustrative, printed, “online” or electronic (hereinafter “Documentation”) is intended for use only as a learning aid when using Rockwell Automation approved demonstration hardware, software and firmware. The Documentation should only be used as a learning tool by qualified professionals. The variety of uses for the hardware, software and firmware (hereinafter “Products”) described in this Documentation, mandates that those responsible for the application and use of those Products must satisfy themselves that all necessary steps have been taken to ensure that each application and actual use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards in addition to any applicable technical documents. In no event will Rockwell Automation, Inc., or any of its affiliate or subsidiary companies (hereinafter “Rockwell Automation”) be responsible or liable for any indirect or consequential damages resulting from the use or application of the Products described in this Documentation. Rockwell Automation does not assume responsibility or liability for damages of any kind based on the alleged use of, or reliance on, this Documentation. No patent liability is assumed by Rockwell Automation with respect to use of information, circuits, equipment, or software described in the Documentation.

    Except as specifically agreed in writing as part of a maintenance or support contract, equipment users are responsible for:

    • properly using, calibrating, operating, monitoring and maintaining all Products consistent with all Rockwell Automation

    or third-party provided instructions, warnings, recommendations and documentation;

    • ensuring that only properly trained personnel use, operate and maintain the Products at all times;

    • staying informed of all Product updates and alerts and implementing all updates and fixes; and • all other factors affecting the Products that are outside of the direct control of Rockwell Automation.

    Reproduction of the contents of the Documentation, in whole or in part, without written permission of Rockwell Automation is prohibited. Throughout this manual we use the following notes to make you aware of safety considerations:

    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.

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

    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 • recognize the consequence

    Labels may be located on or inside the drive to alert people that dangerous voltage may be present.

    Labels may be located on or inside the drive to alert people that surfaces may be dangerous temperatures.

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    The Guardmaster 440C-CR30 Software Configurable Safety Relay Lab

    Contents

    Before you begin ........................................................................................................................................... 4

    About this lab .................................................................................................................................................................................... 4

    Tools & prerequisites ........................................................................................................................................................................ 4

    E-Stop Application ......................................................................................................................................... 5

    Build and Download the Configuration File to the CR30 ................................................................................................................. 12

    Operation of the Configured Safety Circuit ..................................................................................................................................... 14

    Gate Switch and E-Stop Application ........................................................................................................... 17

    Configuring the Indicator LEDs ....................................................................................................................................................... 27

    Build and Download the Configuration File to the CR30 ................................................................................................................. 28

    Operation of the Configured Safety Circuit ..................................................................................................................................... 29

    Verification and Validation, Including Fault Detection and Visualization ......................................................................................... 32

    I/O Expansion via Single Wire Safety ......................................................................................................... 38

    Guard Locking Application .......................................................................................................................... 42

    Operating the Guard Lock Application ............................................................................................................................................ 50

    Zone Control Application (Optional – Time Permitting) .............................................................................. 52

    Operating the Safety Zone Control Application............................................................................................................................... 57

    Maintenance Mode Application (Optional – Time Permitting) ..................................................................... 59

    Operating the Maintenance Mode Application ................................................................................................................................ 70

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    Before you begin

    About this lab

    The Guardmaster™ 440C-CR30 Software Configurable Safety Relay (CR30) is a new safety logic device from Rockwell

    Automation™. In the context of a machine safety application, the CR30 fills the same purpose as a safety monitoring relay or

    safety PLC – it monitors the status of several safety input devices and through simple logic configuration can control multiple

    independent outputs. It is certified for use in safety applications up to and including Safety Integrity Level (SIL) 3 and

    Performance Level (PL) e in which the de-energized state is the safe state.

    The CR30 is based on the Micro800™ platform. The housing is red to signify it as a ‘safety device’ and to distinguish it from the

    gray-colored ‘standard controllers’.

    The CR30 has 22 embedded safety rated inputs and outputs and accepts up to two plug-in modules, each of which has 4

    standard inputs and 4 standard outputs. The CR30 must be configured using a personal computer (PC) running the Allen-

    Bradley™ Connected Components Workbench™ (CCW).

    This lab provides an introduction to the CR30 and includes several example applications.

    This lab takes approximately 80 minutes to complete.

    Tools & prerequisites

    For this Hands-On lab, you will need the following hardware and software.

    � Connected Component Workbench Standard Edition, Revision 8 (released September , 2015)

    � The CR30 Training Demo

    � All CR30 configuration files will be built from scratch in this lab

    � The PanelView Component program is pre-loaded onto the c400 in the demo – configuration of that device is beyond the

    scope of this lab

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    E-Stop Application

    We will start with the implementation of a simple E-Stop circuit. The CR30 detects when the E-Stop is pushed and immediately

    removes power from the actuators, causing the hazardous motion to stop. Furthermore, as long as the E-Stop is engaged, the

    safety circuit will prevent any hazardous motion. The safety circuit must be manually reset after the E-Stop has been released.

    We will use a simple push button with N.O. contacts for the reset.

    1. Double click the Connected Components Workbench icon to open the software.

    2. In the Device Toolbox, expand the Catalog section, expand the Safety folder, and then double click the 440C-

    CR30 to add this safety relay to the project.

    The default position of the device toolbox is on the right, but it could be anywhere on the workspace

    depending on how your preferences are set in CCW. If you don’t see the Device Toolbox on the workspace,

    click View and then select Device Toolbox from the dropdown menu.

    3. Click “OK”.

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    4. In the Project Organizer, double click on the Guardmaster 440C-CR30. The device will open on the

    workspace.