Safety Application Example Using GuardShield Light Curtains (Safe 4, Micro 400, or 440L), with ArmorBlock Guard I/O and SmartGuard Controller Light Curtain with On-machine Components Safety Rating: Category 4, according to EN954-1 Introduction... 1 Important User Information... 2 General Safety Information... 3 Description... 3 Setup and Wiring... 4 Configure... 8 Safety System Demonstration... 23 Additional Resources... 24 Introduction This application example describes how to connect the GuardShield safety light curtain to an ArmorBlock Guard I/O module and control 700S safety contactors with a SmartGuard 600 safety controller. Features and Benefits On-machine installation with quick disconnect wiring Light curtain detection Programmable safety logic
2 Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://literature.rockwellautomation.com) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. 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. 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, and recognize the consequence. Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.
3 General Safety Information This application example is for advanced users and assumes that you are trained and experienced in safety system requirements. A risk assessment should be performed to make sure all task and hazard combinations have been identified and addressed. The risk assessment may require additional circuitry to reduce the risk to a tolerable level. Safety circuits must take into consideration safety distance calculations which are not part of the scope of this document. Contact Rockwell Automation to find out more about our safety risk assessment services. Description This machine safeguarding example shows the wiring configuration and programming setup for an application where the SmartGuard 600 controller controls a GuardShield light curtain that is connected to an ArmorBlock Guard I/O module. The SmartGuard 600 controller is programmed using RSNetWorx for DeviceNet software. You must be familiar with that software to use this document. Safety Function Access to the hazardous area is allowed during all parts of the machine cycle. When the light curtain field is blocked by an object (for example a hand or arm), the hazards monitored by the light curtain must stop before the operator can reach them. While the light curtain is blocked, the hazards cannot restart. When the light curtain is cleared, the hazards will not restart. A separate action, such as pressing the restart button, must initiate the hazards. For this example, the hazards are controlled by the two 700S Safety control relays.
4 Example Bill of Materials This application example uses these components. You can use any one of the three GuardShield light curtain options. Catalog Number 440L-P4J1280YD 445L-P4L1320YD 445L-P4C1200 FP Light Curtain Option 400L GuardShield light curtain 14mm resolution, 1280mm protected height GuardShield Safe 4 light curtain GuardShield Micro 400 light curtain Catalog Number Description Quantity See above GuardShield light curtain 1 871A-TS5-DM1 and 889D-F8AB-5 Field-attachable 5-pin QD cordset, 8-pin micro QD, 5m, female 1 1 1732DS-IB8XOBV4 ArmorBlock Guard I/O module 1 1752-L24BBB SmartGuard 600 safety controller 1 700S-CFB440DLC Safety control relay 2 800FM-F6MX10 Push button (reset) 1 Setup and Wiring For detailed information on installing and wiring, refer to the product manuals listed in the Additional Resources on page 20. The three diagrams on the following pages illustrate the wiring for each of the three light curtains listed in the Example Bill of Materials.
5 Wiring for GuardShield Light Curtain 440L-P4J1280YD
6 Wiring for GuardShield Safe 4 Light Curtain 445L-P4L1320YD
7 Wiring for GuardShield Micro 400 Light Curtain 445L-P4C1200 FP
8 Configure Light curtains must be installed so that operators cannot access the hazard by reaching over, under, or around the light curtain. The location of the light curtain with respect to the hazard must take into account the response time of the safety system to shut down the hazard. Safety system response time is dependent on the actual configuration of the system. The operator must not be able to reach through the light curtain and reach the hazard until it is brought to a safe state. GuardShield 440L Light Curtain When connected to the ArmorBlock Guard I/O module, the light curtain cannot perform the following functions as the connections are not available: No external device monitoring (EDM) No auxiliary output signal The EDM function is performed by the SmartGuard 600 controller. The SmartGuard 600 controller can also generate an auxiliary signal to indicate the status of the light curtain, but this is not included in this application example. In Guard Only mode, the output of the light curtain turns off when the light curtain is interrupted and turns back on immediately when the light curtain is cleared. In Restart Interlock mode, the light curtain output turns off immediately when interrupted but does not turn back on until the scanning area is clear and an external restart signal is received. This application example uses the Restart Interlock function of the light curtain. The switch settings of the GuardShield receiver are as follows. DIP Switch Setting Function 1 OFF Interlock at interruption of the sensing area, restart 2 OFF by actuation of a momentary signal. 3 ON EDM disabled. 4 OFF Fixed blanking disabled. 5 OFF Floating blanking disabled. 6 OFF 7 OFF Beam coding disabled 8 OFF Not used. The GuardShield 440L sender switch settings remain in the factory default configuration.
9 GuardShield 445L Safe 4 Light Curtain The GuardShield Safe 4 light curtain does not have dipswitches and does not require any physical configuration changes. However, the SmartGuard 600 controller and ArmorBlock Guard I/O module configuration and programming sections in the example assume that the light curtain was wired properly in accordance with the wiring diagram on page 6. GuardShield 445L Micro 400 Light Curtain The GuardShield Micro 400 light curtain doesn not have dipswitches and does not require any physical configuration changes. However, since the Micro 400 light curtain is a three-box system, it must be wired to an MSR42 safety relay as shown in the wiring diagram on page 7. RSNetWorx for DeviceNet Software This application example uses three devices that can be seen in the graphics tab of RSNetWorx for DeviceNet software. Node 1 is used to configure and program the SmartGuard Controller (node 2) and the ArmorBlock Guard I/O module (node 3). See the SmartGuard 600 Controller Safety Reference Manual, publication 1752-RM001 for instructions on setting up the network.
10 ArmorBlock Module Setup The light curtain is connected to Input Position A of the AmorBlock Guard I/O module. The connector has five pins, which perform the following functions. Pin Name GuardShield 440L and Micro 400 Light Curtains Function GuardShield Safe 4 Light Curtain 1 Test Output 1 Restart interlock signal +24V supply 2 Safe Input 1 OSSD1 (safety output 1) OSSD2 (safety output 2) 3 Input Common 24V common 24V common 4 Safe Output 0 OSSD2 (safety output 2) OSSD1 (safety output 1) 5 Test Output 0 +24V supply Shield 1. On the network graph (in the offline mode), double-click the node 3 icon. 2. Click the Safety Configuration tab. Set Up Input Points The Safety Configuration for the inputs and test outputs must be set up as shown below. The light curtain does not use an output connection. 1. Double-click the Input Points 00/01 line. Position A corresponds to Input Points 00/01.Since this is a dual channel circuit with OSSD connections, the operation (parameter 55) is selected to be Equivalent, that is, both signals should open and close at the same time and should always be in the same state. 2. Click the current value field of parameter 55.
11 3. From the pull-down menu, choose Equivalent. The modes for both channels (parameters 25 and 29) are set to Safety, as they perform a safety function. Since the light curtain performs its own crossfault (Channel 1 to Channel 2 short) checking, you do not need to set up pulse testing. The Test Sources remain set to None. Test Output Points Two test outputs are assigned. 1. Scroll down and double-click Test Output Points. 2. Set Test Output 00 and Test Output 01 as shown in the table. Test Output GuardShield 440L and Micro 400 Light Curtains Function GuardShield Safe 4 Light Curtain 00 Power Supply Not Used 01 Standard Power Supply Test Output 01 is used to restart the light curtain. The remaining test outputs are not used.
12 GuardShield 440L and Micro 400 Light Curtains GuardShield Safe 4 Light Curtain No output points are used in this application. The 700S safety control relays are controlled by the SmartGuard 600 controller. 3. When completed, click Apply. 4. Click OK.
13 SmartGuard Controller Connections Two connections, an input and an output, are set for the SmartGuard controller when using GuardShield 440L light curtains. For GuardShield Safe 4 and Micro 400 light curtains, only the input connection is required. Input Connections Follow these steps to create an input connection. 1. In the graph view, double-click the SmartGuard controller icon to open the Controller Properties dialog box. 2. Click the Safety Connection tab.
14 3. Double-click the 1732DS line to add connections. 4. For the Connection Name, choose [IN] Safety. 5. Set the Connection type to Point to Point or Multicast. 6. Click Add. 7. If you are using a GuardShield Safe 4 light curtain, go to Review and Apply Connections on page 15. Otherwise, continue with Output Connection (GuardShield 440L and Micro 400 Light Curtains). Output Connection (GuardShield 440L and Micro 400 Light Curtains) 1. Double-click the 1732DS line to add the output connection. 2. Choose [OUT] Test for the output Connection Name. This signal powers the restart of the light curtain. 3. Choose Point to Point for the Connection Type. The signal is intended to go to only one point, the GuardShield light curtain. This is treated as a test signal from the input connection, but it is not a pulsed test signal.
15 4. Click Add. Review and Apply Connections GuardShield 440L and Micro 400 Light Curtains 1. After completing the safety connection selections, expand the connections by clicking on the + signs. 2. Use the vertical scroll bar to review the connections and click Apply. GuardShield Safe 4 Light Curtain
16 SmartGuard Controller I/O Setup This section describes how to set up the local input and output of the SmartGuard controller. The restart button is connected to an input of the SmartGuard controller. The SmartGuard controller outputs turn on two 700S safety control relays. The status of the 700S relays is fed back as an input to the SmartGuard controller. So this application needs two inputs, one pulse test output and two outputs. 1. Click the Local Input/Test Output tab. The General tab lists the inputs. 2. Set up the inputs as shown below. The restart input is a standard input. The relay feedback signal is pulse tested to check for potential faults (shorts to 24V). The wire connected to Terminal 0 of the SmartGuard controller is used to restart (to energize) the output of the 700S safety relays.
17 3. Set I/O Comment to Restart Button. 4. Set the channel mode parameter to Used as standard input and the Dual Channel Mode to Single Channel, as shown. 5. Click OK. The wire connected to Terminal 1 of the SmartGuard controller provides safety status information about the 700S safety relays. 6. Set the I/O comment to Relay Feedback. This is used as a single channel that with a pulse test. Note the Channel mode is set to Test pulse from test out. 7. Set the Test Source to Test Output 0.
18 8. Set the Dual Channel mode parameter to Single Channel. 9. Click OK. 10. Click the Local Input/Test Output tab. 11. Double-click the 00 line (or highlight the line and click Edit).
19 12. Set the mode for Test Output 00 as Pulse Test Output. This is used to check the integrity of the status signal from the 700S safety control relays. Set Up Outputs Follow these steps to set up each output. 1. Click the Local Output tab. 2. When finished, click Apply. 3. Double-click the 00 line (or highlight the line and click Edit). 4. Type a description of the device in the I/O Comment field.
20 5. Set the Channel Mode to Safety Pulse Test. Operation of the relays is a safety function. 6. Set Dual Channel > Channel Mode to Dual Channel. Dual relays are used. When this selection is made for the first device, the second device is automatically set for Dual Channel. 7. Double-click the 01 line. 8. Repeat steps 4 6 for the second output. When you are finished, both outputs are configured.
21 SmartGuard Controller Logic This section shows how to set up the logic and save it. 1. Click the Logic tab. 2. Click Edit. 3. Set up the logic as shown in the diagrams below. GuardShield 440L and Micro 400 Light Curtains GuardShield Safe 4 Light Curtain 4. When finished, click File. 5. Click Apply. 6. Exit to return to the 1752-L24BBB window. 7. Click Apply and then OK.
22 8. In the RSNetWorx window, click the Online button. 9. Save the file with an appropriate name. 10. Click Yes to upload or download. RSNetWorx software begins to browse the network. 11. When the three nodes are found, click Cancel to stop the browsing. 12. Right-click the SmartGuard controller icon (node 2). 13. Select Download to Device and click Yes. 14. Right-click the ArmorBlock icon (node 3). 15. Select Download to Device and click Yes. 16. Double-click the SmartGuard icon. 17. Click the Mode/Cycle Time tab. 18. Click Change Mode.
23 19. In the Change Mode dialog box, click Execute. 20. Click OK. The SmartGuard controller is now in Run mode. Both the MS and NS status indicators on the SmartGuard controller are solid green. The Network and Module status indicators on the ArmorBlock Guard I/O module are solid green. Safety System Demonstration Follow these steps to monitor the operation of the safety system. 1. In the 1752-L24BBB window, click the Logic tab. 2. Click Edit. 3. In the Logic window, click Function > Monitor Device. The icons in the logic diagram are color-coded. The Relay Feedback should be bright green, as the signal is present because the normally closed contacts of the relays are closed. The outputs are colored blue and are off. 4. Press and hold the restart button. The restart button icon turns bright green. 5. Release the restart button. The restart button turns light green. The 700S safety control relays energize and their icons turn bright green. 6. Place an object in the light curtain field. The 700S safety contactors de-energize. 7. Press the restart button with the object in the field. The 700S safety control relays remain de-energized. 8. Remove the object from the light curtain. The 700S relays remain off. 9. Block the light curtain.
24 10. Press and hold the restart button. 11. While holding the restart button, remove the object from the light curtain field. The 700S safety relays remain off. 12. Release the restart button. The 700S safety relays remain off. 13. Press and release the restart buttons to energize the 700S safety control relays. Additional Resources For more information about the products used in this example, refer to these resources. Resource ArmorBlock Guard I/O Module Installation Instructions, publication 1732DS-IN001 Guard I/O DeviceNet Safety Modules User Manual, publication 1791DS-UM001 SmartGuard 600 Controller Safety Reference Manual, publication 1752-RM001 Description Provides installation instructions for the ArmorBlock Guard I/O DeviceNet Safety Module. Provides general safety guidelines on using Guard I/O DeviceNet Safety Modules. Provides instructions for using SmartGuard 600 Controller. Safety Products Catalog, publication S116 Provides information on Guardshield Light Curtains. You can view or download publications at http://literature.rockwellautomation.com. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative. Allen-Bradley, ArmorBlock Guard I/O, Rockwell Automation, RSNetWorx, and SmartGuard are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Supersedes Publication SAFETY-AT013B-EN-P March 2009 Copyright 2009 Rockwell Automation, Inc. All rights reserved. Printed in U.SA.