Safety Application Example Using TLS3-GD2 Guardlocking Interlock with ArmorBlock Guard I/O and SmartGuard Controller Guardlocking with On-machine Components Safety Rating: Category 3, according to EN954-1 Introduction... 1 Important User Information. 2 General Safety Information. 3 Description. 3 Setup and Wiring.. 4 Configure DeviceNet Network... 6 Develop SmartGuard Controller Logic 19 Additional Resources. 23 Introduction This safety application example describes how to connect the TLS3-GD2 guardlocking interlock to an ArmorBlock Guard I/O module and control the TLS3-GD2 with a SmartGuard 600 safety controller. Features and Benefits On-machine installation with quick disconnect wiring Guardlocking interlocks 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. Publication SAFETY-AT012C-EN-P March 2009
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. Description Contact Rockwell Automation to find out more about our safety risk assessment services. This machine safeguarding application example shows the wiring configuration and programming setup in which the SmartGuard 600 controller controls a TLS-GD2 guardlocking interlock that is connected to an ArmorBlock Guard I/O connection block module. The SmartGuard 600 controller is programmed using RSNetWorx for DeviceNet software. You must be familiar with this software to use this document. Safety Function The safety gate remains closed and locked while the machine is running. Access to the hazardous area is accomplished by applying a signal to the solenoid in the TLS3-GD2 interlock. While the TLS3-GD2 interlock is unlocked or the gate is open, the hazards cannot start. For this example, the hazards are controlled by two 700S safety control relays. The TLS3-GD2 interlock is a solenoid-operated guardlocking interlock used to maintain a gate in a locked state until a signal is received from the machine control. The TLS3 interlock has two normally-closed contacts that monitor the status of the actuator and two normally-closed contacts that monitor the status of the solenoid. Internally, two jumpers are needed, one from terminals 12 to 41, and a second from 22 to 51. The jumpers are installed in the factory for the part number listed in the example bill of materials. This wiring configuration places the actuator contacts in series with the solenoid contacts. This allows the safety system to prevent startup when either the door is open or if the door is unlocked. Publication SAFETY-AT012C-EN-P-March 2009
4 To maintain the integrity of the Category 3 safety performance level (single fault tolerance), the TLS3-GD2 interlock must be installed per its installation instructions and operated within the following specifications: Alignment of actuator over the expected life Protection against overspeed of the actuator Mechanical stops provided to prevent the actuator from hitting the TLS3-GD2 housing during closing Mounted with robust hardware Using the TLS3-GD2 interlock in an environment for which it is designed. Example Bill of Material This application example uses these components. Catalog Number Description Quantity 440G-T2NBBPH-2R TLS3-GD2 interlock with 8-pin QD connector 1 871A-TS5-DM1 and 889D-F8AB-5 Field-attachable 5-pin QD cordset, 8-pin micro QD, 5m, female 2 1 440G-A27143 Flexible actuator for TLS-GD2 interlock 1 1732DS-IB8XOBV4 ArmorBlock Guard I/O 1 1752-L24BBB SmartGuard 600 safety controller 1 700S-CFB440DLC Safety control relay 2 800FM-F6MX10 Push button (reset) 1 800FM-FA2 and 800F-MX10 Alternate action push button (lock release) latch with N.O. contact 1 1 Setup and Wiring For detailed information on installing and wiring, refer to the product manuals listed in the Additional Resources on page 23. Currently, there is no cordset available that connects the TLS3-GD2 (8-pin) directly to the M12 connectors on the ArmorBlock Guard I/O module (5-pin). The two QD cordsets listed in the Bill of Material on page 4 let you construct a Y cable, as shown below. Publication SAFETY-AT012C-EN-P March 2009
5 Wiring Publication SAFETY-AT012C-EN-P-March 2009
6 Configure the DeviceNet Network This application example uses three devices as seen in the graphics tab of RSNetWorx for DeviceNet software. Node one is used to configure and program the SmartGuard controller (node two) and the ArmorBlock Guard I/O module (node three). Refer to the SmartGuard 600 Controllers User Manual, publication 1752-UM001, and the SmartGuard 600 Controllers Safety Reference Manual, publication 1752-RM001, for information on using the SmartGuard 600 controller on a DeviceNet network. ArmorBlock Guard I/O Module Setup These steps explain how to set up the ArmorBlock Guard I/O module parameters, test the outputs, and turn on the test pulses. 1. On the network graph (in the offline mode), double-click the node three icon. 2. Click the Safety Configuration tab. In the wiring diagram, the TLS3-GD2 interlock is connected to Input Points 02/03. 3. Double-click the Input Points 02/03 line. 4. Since this is a dual-channel circuit with two normally-closed contacts, set the operation (parameter 57) to Equivalent. This is so both contacts are open and closed at the same time and should always be in the same state. 5. Click the current value field of parameter 57. 6. From the pull-down menu, choose Equivalent. The modes for both channels (parameters 33 and 37) are configured as Safety Pulse Test, as they perform a safety function. Different test sources for each channel are used to detect crosschannel shorts (a fault condition). Publication SAFETY-AT012C-EN-P March 2009
7 7. Set parameter 34 to Test Source 2. 8. Set parameter 38 to Test Source three. 9. In the same dialog, scroll down and double-click Test Output Points. 10. Turn on the test pulses by setting the current value of Test Output 02 Mode to Pulse Test. 11. Repeat this for Test Output 03 Mode by clicking the Not Used value in the desired row. Publication SAFETY-AT012C-EN-P-March 2009
8 12. Select Pulse Test from the Current Value pull-down menu. 13. Scroll down and double-click Output Points 02/03. The TLS3-GD2 solenoid is connected to output points two and three. The default operation is Dual. 14. Click the value for the Output 02 Mode and change it from Not Used to Safety. 15. Click the value for the Output 03 Mode and change it from Not Used to Safety. 16. Make sure the other output points are set as Not Used. 17. Click Apply and OK. Publication SAFETY-AT012C-EN-P March 2009
9 SmartGuard 600 Controller Connections 1. On the Graph view, double-click the SmartGuard controller icon (or right-click the icon and choose Properties). 2. Click the Safety Connection tab. 3. Double-click the 1732DS line to add connections. Publication SAFETY-AT012C-EN-P-March 2009
10 4. You must make these two connections. An input connection for the TLS-GD2 actuator/solenoid status signals. For this application, select (IN) Safety. An output connection to control the solenoid in the TLS3-GD2 interlock. For this application, select (OUT) Test, as shown. 5. After selecting the connections, click Add. 6. For the connection name, select (IN) Safety. 7. Select the Connection Type as either Point to Point or Multicast. Publication SAFETY-AT012C-EN-P March 2009
11 8. Set the output Connection Name as [OUT] Combined. This signal powers the solenoid of the TLS3-GD2 interlock. 9. Set the Connection Type Point to Point. This signal is intended to go to only one point, the solenoid of the TLS3-GD2 interlock. Publication SAFETY-AT012C-EN-P-March 2009
12 10. After completing the safety connections, click the + signs to expand the input and output connections. Use the scroll bar to review the connections. 11. Click Apply. Publication SAFETY-AT012C-EN-P March 2009
13 SmartGuard 600 Controller I/O Setup This section describes how to set up the local inputs and outputs of the SmartGuard controller. The reset and solenoid lock release buttons are connected to the inputs 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. 1. Click the Local Input/Test Output tab. The General tab lists the inputs. 2. Set up the inputs as shown. The Reset Button and the Lock Release are standard inputs. The Relay Feedback signal is pulse-tested to check for potential faults (shorts to 24V). Publication SAFETY-AT012C-EN-P-March 2009
14 The wire connected to Terminal 0 of the SmartGuard controller is used to reset (that is, to energize) the 700S safety relays after the safety gate is closed. 3. Set I/O Comment to Reset Button. 4. Set the two Channel Mode parameters to Standard Input and Single Channel. 5. Click OK. Publication SAFETY-AT012C-EN-P March 2009
The wire connected to Terminal 1 of the SmartGuard controller set provides safety status information about the 700S safety relays. 6. Set the I/O comment to Relay Feedback. This will be used as a single channel that will use a pulse test. 7. Make sure the Channel Mode pull-down menu is set to Test Pulse From Test Out. 8. Set the Test Source to Test Output0. 9. Set the Dual Channel, Channel Mode parameter to Single Channel. 10. Click OK. 15 Publication SAFETY-AT012C-EN-P-March 2009
16 The wire connected to Terminal two generates a command to power the solenoid to release the lock of the TLS3-GD2 interlock. 11. Set the I/O Comment for Input two for Lock Release. This will be used as a single channel safety input. Both the Off and On Delays should remain at 0 as no delays are needed. 12. Click OK. Publication SAFETY-AT012C-EN-P March 2009
17 General I/O Configuration 1. Click the Test Output tab. 2. Double-click the 00 line. 3. Set up the Mode for Test Output 00 as Pulse Test Output. This will be used to check the integrity of the status signal from the 700S safety control relays. Publication SAFETY-AT012C-EN-P-March 2009
18 Test Output Configuration The following steps explain how to set up each output. When completed, your screen should be similar to the screen below. 1. Click the Local Output tab. 2. Double-click the 00 line (or highlight the line and click Edit) to access the Edit Local Output Terminal dialog box shown below. 3. Enter a description of the device in the I/O Comment field. 4. Set the Channel Mode to Safety Pulse Test. 5. Set Channel Mode to Dual Channel since dual relays are used. When this is selected for the first device, the second device is automatically set for Dual Channel. 6. Repeat steps 2 5 for the second output. Publication SAFETY-AT012C-EN-P March 2009 7. Click Apply when complete.
19 Develop SmartGuard Controller Logic In this section you will program the logic, save your setup, and browse the network. 1. Click the Logic tab. 2. Click the Edit button. 3. Program the logic as shown. 4. When finished, click File. 5. Click Apply. 6. Click Exit to return to the 1752-L24BBB dialog. 7. Click Apply. 8. Click OK. 9. In the RSNetWorx window, click the Online button. 10. Save the file with an appropriate name. 11. Click Yes to upload or download. RSNetWorx software begins to browse the network. 12. When the three nodes are found, click Cancel to stop the browsing. 13. Right-click the SmartGuard controller icon (node two) and choose Download to Device. 14. Click Yes 15. Right-click the ArmorBlock icon (node three) and choose Download to Device. 16. Click Yes. Publication SAFETY-AT012C-EN-P-March 2009
20 17. Double-click the SmartGuard controller icon. 18. Click the Mode/Cycle Time tab. 19. Click the Change Mode button. 20. In the Change Mode dialog, click Execute. 21. 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 MS and NS status indicators on the ArmorBlock Guard I/O module are solid green. Publication SAFETY-AT012C-EN-P March 2009
21 Safety System Demonstration The following steps show how to monitor the operation of the safety system. 1. In the 1752-L24BBB window, click the Logic tab. 2. Click the Edit button. 3. In the Logic window, click Function > Monitor Device. The logic diagram should appear as shown below (the icons are colorcoded). The Relay Feedback, Pt02Data_C01 and Pt2Data_C02 should be bright green, to indicate their signals are present. The outputs are colored blue when they are off. 4. Press and hold the Reset Button. The Reset Button turns bright green. 5. Release the Reset Button. The Reset Button turns light green. The 700S safety control relays energize and their icons turn bright green. 6. Try to remove the actuator from the TLS3-GD2 interlock. The actuator should be locked and cannot be removed. Publication SAFETY-AT012C-EN-P-March 2009
22 7. Press the Lock Release Button (an alternate action type button). The solenoid in the TLS3-GD2 interlock becomes energized. This causes the 700S safety control relays to drop out and their icons turn back to blue. The TLS3-GD2 interlock is now unlocked and Pt02 and Pt03 Input icons turn light green. The Lock Release icon and Pt02 and Pt03 icons turn bright green. 8. Remove the actuator from the TLS3-GD2 interlock. No change takes place in the logic diagram because the solenoid contacts are connected in series with the actuator contacts. 9. Press the Reset Button. Its icon turns bright green, but the 700S safety control relays remain off because the safety gate is open. 10. Insert the actuator into the housing. 11. Press the Reset Button. Again, the 700S Relays remain off because the TLS3-GD2 interlock is unlocked. The solenoid is powered. 12. Press the Lock Release button. The solenoid in the TLS3-GD2 interlock de-energizes and locks the actuator in place. 13. Press and release the Reset Button to energize the 700S relays to complete the demonstration. Fault Tests The following tests demonstrate some of the fault protection of the safety system. This is not a comprehensive list of faults. Interlock Short from TLS3-GD2 inputs (11, 12, 21, 22, 41, 42, 51 and 52) to ground Solenoid Short from TLS3-GD2 terminal A1 to ground when the solenoid is energized Output Short from either 700S terminal A1 to ground when the relays are energized Output Short from A1 of one 700S to A1 of the other 700S Publication SAFETY-AT012C-EN-P March 2009
23 To reset the system to operational state, remove the fault. Cycle the TLS3-GD2 contacts by pressing the Lock Release button twice (once to unlock and once to lock). Feedback Short from in 700S feedback signal from terminal three of the SmartGuard controller to ground. This yields a P1 fault of SmartGuard controller. The icon in the logic diagram turns red. Feedback Short from in 700S feedback signal from terminal three of the SmartGuard controller to 24V dc. This yields a P1 fault. The icon in the logic diagram turns red. The 700S relays are energized and will remain energized. If they are deenergized, they cannot be re-energized until the fault is cleared. To reset the system to an operational state: 1. Return to the 1752-L24BBB dialog. 2. Change the error latch time (990 is OK). 3. Click Apply. 4. Click Yes to download the new latch time. 5. Change the mode of the SmartGuard controller to Execute. Additional Resources For more information about the products used in this example, refer to these resources. Resource ArmorBlock Guard I/O DeviceNet Installation Instructions, publication 1732DS-IN001 Guard I/O DeviceNet Safety Modules User Manual, publication 1791DS-UM001 SmartGuard 600 Controllers Safety Reference Manual, publication 1752-RM001 TLSGD2-Compact Tongue Operated Safety Interlock Switch with Guard Locking, publication SAFAPP-CA511A Description Provides installation and specification information for ArmorBlock I/O modules. Provides instructions on installing, operating, and troubleshooting Guard I/O DeviceNet Safety Modules. Provides information on SIL3 and CAT4 safety system requirements, including functional verification test intervals, system reaction time, and PFD/PFH values. Provides safeguarding applications for TLS-GD2 Guardlocking Interlock. 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. Publication SAFETY-AT012C-EN-P-March 2009
Allen-Bradley, ArmorBlock Guard I/O, Rockwell Automation, SmartGuard, and RSNetWorx are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication SAFETY-AT012C-EN-P March 2009 Supersedes Publication SAFETY-AT012B-EN-P August 2008 Copyright 2009 Rockwell Automation, Inc. All rights reserved. Printed in U.SA.