Rockwell Automation 440C User Manual
User Manual — Original Language
Guardmaster® 440C-CR30 Configurable Safety Relay
Catalog Number 440C-CR30-22BBB
Important User Information
IMPORTANT
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.
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.
Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
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).
AllenBradley, Connected Components Workbench, ControlFLASH, Guardmaster, GuardShield, Micro800, Micro830, PanelView, PowerFlex, Rockwell Software, SafeZone, S ensaGuard, and Zero-Force Touch Buttons are
trademarks of Rockwe ll Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Preface
Read this preface to familiarize yourself with the rest of the manual. It provides
information concerning:
• who should use this manual
• the purpose of this manual
• related documentation
• conventions used in this manual
Who Should Use this Manual
Purpose of this Manual
Additional Resources
Use this manual if you are responsible for designing, installing, configuring, or
troubleshooting control systems that use the CR30 safety relay.
You should have a basic understanding of electrical circuitry and familiarity with
safety related control systems. If you do not, obtain the proper training before
using this product.
This manual is a reference guide for the CR30 safety relay, plug-in modules and
accessories. It describes the procedures you use to install, wire, and troubleshoot
your relay. This manual:
• explains how to install and wire your relay
• gives an overview of the CR30 safety relay system
Refer to the Online Help provided with Connected Components Workbench™
software for more information on configuring your CR30 safety relay.
These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
2711C-UM001_-EN-P PanelView™ Component HMI Terminal User Manual
440C-QS001_-EN-P Guardmaster® 440C-CR30 Software Configurabl e Safety
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Product Certifications website, http://www.ab.com
Allen-Bradley Industrial Automation Glossary, AG-7.1 A glossary of industrial automation terms and
Relay Quick Start Guide
Provides general guidelines for installing a Rockwell
Automation industrial system.
Provides declarations of conformity, certificates, and
other certification details.
abbreviations.
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.
You can download the latest version of Connected Components Workbench for
your CR30 at
http://compatibility.rockwellautomation.com/Pages/
MultiProductDownload.aspx?Keyword=Free&crumb=112
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 3
Preface
Definitions
Publication AG-7.1 contains a glossary of terms and abbreviations used by
Rockwell Automation to describe industrial automation systems. Below is a list of
specific terms and abbreviations used in this manual.
•CCW – The Connected Components Workbench. This is a software
package that allows the user to configure a CR30, program a Micro800®
controller and configure a PanelView™ HMI.
•CR30 – Is the Cat. No. 440R-CR30-22BBB software configurable safety
relay, described in this user manual.
•HI – Logic state of being ON.
•LO – Logic state of being OFF.
•Logic Block – On the CCW grid, a logic block resides in any of the four
columns. A logic block is either: 1) a Safety Monitoring Function, 2) Logic
LevelA, 3) Logic Level B, or 4) Safety Output Function.
•Logic Level A (LLA) – This column is used to perform logic processes on
a number of inputs to create a desired output state.
•Logic Level B (LLB) - This column is used to perform logic processes on a
number of inputs to create a desired output state.
•N.C. (Normally Closed) – An electrical contact whose normal state (i.e.,
no pressure or electrical potential applied) is in the closed position.
•N.O. (Normally Open) – An electrical contact whose normal state (i.e.,
no pressure or electrical potential applied) is in the open position.
• OSSD (Output Signal Switching Device) – This is typically a pair of
solid state signals that are pulled up to the DC source supply. The signals
are usually tested for short circuits to the DC power supply, short circuits
to the DC common and shorts circuits between the two signals.
•Reaction Time - Describes the time between the true states of one input
to the ON state of the output.
•Recovery Time - Describes the time required for the input to be in the LO
state before returning to the HI state.
•Response Time - Describes the time between the trigger of one input to
the OFF state of the output.
•Safety Function – This describes the complete sensing of the action (e.g.
open a safety gate) to execution the final output device (e.g. turning off a
pair of contactors).
•Safety Monitoring Function (SMF) – This is the input block on the
Connected Components Workbench for the CR30.
•Safety Output Function (SOF) – This is the output block on the
Connected Components Workbench for the CR30.
•Single Wire Safety (SWS) – This is a unique, safety rated signal sent over
one wire to indicate a safety status. The SWS can be used in Category 4,
Performance Level e, per ISO 13849-1 and Safety Integrity Level (SIL) 3,
per IEC 62061 and IEC 61508.
4 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Preface
Overview
Installation
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Who Should Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 1
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CR30 Hardware Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Max Number of Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Obtain Connected Components Workbench. . . . . . . . . . . . . . . . . . . 13
USB Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Serial Port Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 2
Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIN Rail Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Enclosure Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preventing Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power, Ground, and Wiring
Chapter 3
Wiring Requirements and Recommendation . . . . . . . . . . . . . . . . . . . . . . . 19
Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Grounding the Configurable Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connecting a Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Wire Input Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Input Devices with Mechanical Contacts. . . . . . . . . . . . . . . . . . . . . . . 22
Input Devices with OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wire Output Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Use Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Embedded Serial Port Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 5
Table of Contents
Chapter 4
Configuring the CR30
Pulse Testing
Input Filter
Discrepancy Time
Begin Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
The Workspace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Download the Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Validation and Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Validation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Viewing the Verification ID without CCW. . . . . . . . . . . . . . . . . . . . . 32
Multiple Block Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Chapter 5
Normally Open Input Pulse Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Normally Closed Input Pulse Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Output Pulse Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Chapter 6
Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Chapter 7
Discrepancy Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Safety Block Renaming
Safety Monitoring Functions
Chapter 8
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Naming Error Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Chapter 9
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Enabling Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Feedback Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Gate Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Light Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Muting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2-Sensor T-Type Muting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2-Sensor L-Type Muting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4-Sensor Muting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Muting Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Muting Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Safety Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SensaGuard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Single Wire Safety Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Two-Hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Type IIIA Two-hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Type IIIC Two-Hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Logic Levels A and B
Table of Contents
Alternate Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Single Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Dual Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Dual Channel OSSD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Dual Channel N.C./N.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Three Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Chapter 10
Pass Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
AND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
OR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
XOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
NAND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
NOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
NOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
AND with Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
OR with Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Safety Outputs
Plug-in Modules
LEDs
Chapter 11
Input Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Immediate OFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ON Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
OFF Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Muting Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Chapter 12
Insert Module into Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2080-IQ4OB4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2080-IQ4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2080-OB4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2080-OW4I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Chapter 13
Input and Output LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Controller Status LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Modbus Communication
Chapter 14
Modbus Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Example Architectures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Reading CR30 Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Sending Reset to CR30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 7
Table of Contents
Chapter 15
Troubleshooting
Security and Password
Recoverable Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Nonrecoverable Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Troubleshooting with the CCW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Troubleshooting with Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Example Fault Analysis – Crossfault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Chapter 16
Exclusive Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Password Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Work with a Locked Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Upload from a Password-Protected Safety Relay. . . . . . . . . . . . . . . . 110
Connect to a Password-Protected Safety Relay . . . . . . . . . . . . . . . . . 110
Download to a Password-Protected Safety Relay. . . . . . . . . . . . . . . . 110
Configure Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Set Safety Relay Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Change Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Clear Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Lost Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Using the Memory Module
Reports
Chapter 17
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Project Backup and Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Back-up Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Restore Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Chapter 18
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
8 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Appendix A
Table of Contents
Specifications
SIL Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Performance Level/Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Environmental. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Reaction Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Recovery Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Response Times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
System Response Time Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Response Time - Demand of the Safety Function. . . . . . . . . . . . . . . 125
Monitoring Time - Occurrence of Recoverable Faults and Failures. . .
127
Test Pulse Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Multi-Channel Signal Evaluation and Discrepancy Monitoring . 130
Sequence and Timing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Integral Test Pulses of Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . 130
Response Time - Occurrence of Nonrecoverable Faults and Failures .
132
Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Regulatory Approvals
Configuration Reference Document
ControlFLASH Firmware Upgrade
Appendix B
Agency Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Compliance to European Union Directives. . . . . . . . . . . . . . . . . . . . . . . . 137
Machine Safety Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
EMC Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Appendix C
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Appendix D
Upgrade the Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Unrecognized Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 9
Table of Contents
Notes:
10 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Overview
Chapter 1
Intended Use
Hardware Features
The Cat. No. 440C-CR30-22BBB (CR30) relay is a software-configurable safety
relay. This device is intended to be part of the safety-related control system of a
machine. The CR30 must be configured using a personal computer (PC)
running the Allen-Bradley Connected Components Workbench™ (CCW). The
CR30 accommodates up to 24 safety monitoring functions. Examples of safety
monitoring functions are single channel input, dual channel input, two hand
control, reset, and feedback.
It is based on the Micro800 platform. The housing is red to signify it as a safety
device and to distinguish it from the grey-colored standard controllers.
Figure 1 - CR30 Relay
The CR30 has 22 embedded safety rated inputs and outputs and accepts up to
two plug-in modules, each of which has four standard inputs and four standard
outputs.
The CR30 can be configured to accept two single-wire safety inputs and to
provide two single-wire safety outputs. This feature allows the CR30 to be an
integral part of an extensive machine safeguarding system.
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 11
Chapter 1 Overview
CR30 Hardware Details
Figure 2 - Hardware Details
1
234 556
7
Status Indicators
12
13
14
15
16
17
18
10
Description Description
1 Status indicators 10 Verification button
2 Plug-in latch 11 Din Rail mounting latch
3 Plug-in screw hole 12 Input status
4 40-pin high-speed plug-in connector 13 Power status
5 I/O and Power terminal blocks 14 Run status
6 Mounting screw hole/mounting foot 15 Fault status
7 Right-side cover 16 Lock status
8 RS-232 non-isolated serial port 17 Serial communications status
9 Type B connector USB 18 Output status
11
698
Max Number of Inputs and Outputs
Many of the inputs and outputs can be configured for different roles. The
following table shows the maximum number of terminals for a specific function.
Assigning a configurable terminal to one role reduces the risks of its use as
another role and reduce the allowed maximum number of terminals for other
functions.
Function Max Allowed Function Max Allowed
Safety inputs, normally closed up to 18 Pulse test outputs up to 6
Safety inputs, normally open up to 6 OSSD safety outputs up to 10
Single-wire safety input up to 2 Non-pulsed (standard) outputs up to 6
Single-wire safety output up to 2
12 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Overview Chapter 1
Software
The CR30 is software configurable using the Rockwell Automation Connected
Components Workbench (CCW). Connected Components Workbench is a set
of collaborative tools that supports the CR30 safety relays. CCW is based on
Rockwell Automation and Microsoft® Visual Studio® technology. The CCW is
used to configure the CR30, program the Micro800 controllers, and configure
many PowerFlex® drives and PanelView™ graphic display terminals.
Obtain Connected Components Workbench
The Connected Components Workbench is free and can be downloaded from:
http://compatibility.rockwellautomation.com/Pages/
MultiProductDownload.aspx?Keyword=Free&crumb=112
To help you configure your relay through the Connected Components
Workbench software, you can refer to the Connected Components Workbench
Online Help (provided with the software).
USB Connection
The CR30 has a USB interface for connection to a personal computer for
configuration. Use a standard USB A Male to B Male cable for connecting to the
relay.
Serial Port Connection
The embedded serial port is used to transfer control and status to other
AllenBradley products. The CR30 only supports RS-232 protocol. The
connection is not isolated. The RS-232 signals are referenced to the relay power
ground.
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 13
Chapter 1 Overview
Notes:
14 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Installation
Chapter 2
Mounting Dimensions
DIN Rail Mounting
Mounting dimensions exclude mounting feet or DIN Rail latches.
Figure 3 - DIN Rail Mounting [mm (in.)]
100 (3.94)
90 (3.54)
Maintain spacing from objects such as enclosure walls, wireways, and adjacent
equipment. Allow 50.8 mm (2 in.) of space on all sides for adequate ventilation. If
optional accessories/modules are attached to the relay, such as the power supply
Cat. No. 2080-PS120-240VAC, make sure that there is 50.8 mm (2 in.) of space
on all sides after attaching the optional parts.
80 (3.15)
The module can be mounted using the following DIN Rails:
35 x 7.5 x 1 mm (EN 50 022 - 35 x 7.5).
To mount the module on a DIN Rail:
1. Use a flat-blade screwdriver in the DIN Rail latch and pry it downwards
until it is in the unlatched position.
2. Hook the top of the DIN Rail mounting area of the relay onto the DIN
Rail, and then press the bottom until the relay snaps onto the DIN Rail.
3. Push the DIN Rail latch back into the latched position.
Use DIN Rail end anchors (Allen-Bradley Cat. Nos. 1492-EAJ35 or
1492EAHJ35) for vibration or shock environments.
To remove the module from the DIN Rail, pry the DIN Rail latch downwards
until it is in the unlatched position.
For environments with greater vibration and shock concerns, use the panel
mounting method, instead of DIN Rail mounting.
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 15
Chapter 2 Installation
Panel Mounting
Figure 4 - Panel Mounting [mm (in.)]
86 (3.39)
100 (3.94)
The preferred mounting method is to use four M4 (#8) screws per module. Hole
spacing tolerance: ±0.4 mm (0.016 in.).
Follow these steps to install your relay using mounting screws.
1. Place the relay against the panel where you are mounting it. Make sure that
the relay is spaced properly.
2. Mark drilling holes through the mounting screw holes and mounting feet
then remove the relay.
3. Drill the holes at the markings, then replace the relay and mount it.
Leave the protective debris strip in place until you are finished wiring the relay
and any other devices.
16 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Installation Chapter 2
Enclosure Considerations
Most applications require installation in an industrial enclosure to reduce the
effects of electrical interference and environmental exposure. Pollution Degree 2
is an environment where normally only non-conductive pollution occurs except
that occasionally temporary conductivity that is caused by condensation can be
expected. Overvoltage Category II is the load level section of the electrical
distribution system. At this level, transient voltages are controlled and do not
exceed the impulse voltage capability of the product insulation.
This equipment is intended for use in a Pollution Degree 2 industrial
environment, in overvoltage Category II applications (as defined in
IEC 606641), at altitudes up to 2000 m (6562 ft) without derating. This
equipment is considered Group 1, Class A industrial equipment according to
IEC/CISPR 11. Without appropriate precautions, there could be difficulties
with electromagnetic compatibility in residential and other environments due to
conducted and radiated disturbances.
This equipment is supplied as open-type equipment. It must be mounted within
an enclosure that is suitably designed for those specific environmental conditions
that are present. It must also be appropriately designed to prevent personal injury
as a result of accessibility to live parts. The enclosure must have suitable
flameretardant properties to prevent or minimize the spread of flame, complying
with a flame spread rating of 5VA, V2, V1, V0 (or equivalent) if non-metallic.
The interior of the enclosure must be accessible only by the use of a tool.
Subsequent sections of this publication contain more information regarding
specific enclosure type ratings that are required to comply with certain product
safety certifications.
Preventing Excessive Heat
For more information, see:
• Industrial Automation Wiring and Grounding Guidelines, publication
1770-4.1
• NEMA Standard 250 and IEC 60529, as applicable, for explanations of
the degrees of protection that is provided by different types of enclosure.
For most applications, normal convective cooling keeps the controller within the
specified operating range. Verify that the specified temperature range is
maintained. Proper spacing of components within an enclosure is usually
sufficient for heat dissipation.
In some applications, other equipment inside or outside the enclosure produce a
substantial amount of heat. In this case, place blower fans inside the enclosure to
help with air circulation and to reduce “hot spots” near the controller.
More cooling provisions are necessary when high ambient temperatures are
encountered. Do not bring in unfiltered outside air. Place the controller in an
enclosure to help protect it from a corrosive atmosphere. Harmful contaminants
or dirt could cause improper operation or damage to components. In extreme
cases, you may need to use air conditioning to help protect against heat buildup
within the enclosure.
, for more installation requirements.
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 17
Chapter 2 Installation
Notes:
18 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Wiring Requirements and
IMPORTANT
Recommendation
Chapter 3
Power, Ground, and Wiring
WARNING: Before you install and wire any device, disconnect power to the
system.
WARNING: Calculate the maximum current in each power and common wire.
Observe all electrical codes dictating the maximum current allowable for each
wire size. Current above the maximum ratings can cause wiring to overheat,
which can cause damage.
• Allow for at least 50 mm (2 in.) between I/O wiring ducts or terminal
strips and the relay.
• Route incoming power to the relay by a path separate from the device
wiring. Where paths must cross, their intersection must be perpendicular.
• Do not run signal or communications wiring and power wiring in the same
conduit. Wires with different signal characteristics should be routed by
separate paths.
• Separate wiring by signal type. Bundle wiring with similar electrical
characteristics together.
• Separate input wiring from output wiring.
• Label wiring to all devices in the system. Use tape, shrink-tubing, or other
dependable means for labeling purposes. In addition to labeling, use
colored insulation to identify wiring based on signal characteristics. For
example, you can use blue for DC wiring and red for AC wiring.
• Disabling pulse testing on safety-related terminals, including dedicated
safety outputs and test-pulse source evaluating input signals, requires
protection (for example, cable conduit) and separated wiring of safety
signals to exclude potential cross loop faults.
Fault exclusions for conductors and wiring must follow the requirements
according to EN ISO 13849-2 Table D.3 and D.4. A fault exclusion can reduce the
overall safety rating of the related safety function to a maximum of PL
ENISO 13849-1
d
per
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 19
Chapter 3 Power, Groun d, and Wir ing
Wire Size
Table 1 - Wiring Requirements
Wire Size
Type Mi n Max
Copper Stranded 0.326 mm2
(22 AWG)
1.31 mm2
(16AWG)
Rated @ 90 °C (194 °F)
insulation min.
Terminal Assignments
Some terminals are designed to have one specific function. Some terminals can
perform multiple functions; these terminals must be configured in the
application software.
Table 2 - Terminal Assignments
Terminal Function
00 Safety Input (N.C.)
01 Safety Input (N.C.)
02 Safety Input (N.C.)
03 Safety Input (N.C.)
04 Safety Input (N.C.)
05 Safety Input (N.C.)
06 Safety Input (N.C.)
07 Safety Input (N.C.)
08 Safety Input (N.C.)
09 Safety Input (N.C.)
10 Safety Input (N.C.) or Single Wire Safety Input
11 Safety Input (N.C.) or Single Wire Safety Input
+24V DC A1 Power Supply (+24V, -15%, +10%)
COM 0V A2 Power Supply (0V)
12 Test Output or OSSD High Side or Safety Input (N.C.) or Safety Input N.O. or standard diagnostic.
13 Test Output or OSSD High Side or Safety Input (N.C.) or Safety Input N.O. or standard diagnostic.
14 Test Output or OSSD High Side or Safety Input (N.C.) or Safety Input N.O. or standard diagnostic.
15 Test Output or OSSD High Side or Safety Input (N.C.) or Safety Input N.O. or standard diagnostic.
16 Test Output or OSSD High Side or Safety Input (N.C.) or Safety Input N.O. or standard diagnostic.
17 Test Output or OSSD High Side or Safety Input (N.C.) or Safety Input N.O. or standard diagnostic.
18 OSSD High Side
19 OSSD High Side
20 OSSD High Side or Single-wire Safety Output
21 OSSD High Side or Single-wire Safety Output
20 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Grounding the Configurable
+DC
24V
COM
0V
Input Terminal Block
Input/Output Terminal Block
09
10 11
12A2
A1
13 14 15 16 17 18 19 20 21
+2 4V DC
24V Common
00 01 02 03 04 05 06 07 08
Safety Relay
Power, Ground, and Wiring Chapter 3
WARNING: All devices that are connected to the RS-232 communication port
must be referenced to controller ground, or be floating (not referenced to a
potential other than ground). Failure to follow this procedure can result in
property damage or personal injury.
This product is intended to be mounted to a grounded mounting surface such as
a metal panel. See the Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
, for more information.
Connecting a Power Supply
Power for the relay is provided by an external 24V DC power supply source.
To comply with the CE Low Voltage Directive (LVD), the I/O must be powered
by a DC source compliant with Safety Extra Low Voltage (SELV) or Protected
Extra Low Voltage (PELV).
To comply with UL restrictions, I/O must be powered by DC sources whose
secondary circuits are isolated from the primary circuit by double insulation or
reinforced insulation. The DC power supply must satisfy the requirements for
Class 2.
The following Rockwell Automation power supplies are SELV- and PELVcompliant, and they meet the isolation and output hold-off time requirements of
the CR30 relay:
• 2080-PS120-240VAC
• 1606-XLP30E
• 1606-XLP50E
• 1606-XLP50EZ
• 1606-XLP72E
• 1606-XLP95E
• 1606-XLDNET4
• 1606-XLSDNET4
Figure 5 - Power Supply
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 21
Chapter 3 Power, Groun d, and Wir ing
10 11
12A2A1
13 14 15 16 17 18 19 20 21
Input Terminal Block
Congured for
Pulse Test Output
Input/Output Terminal Block
+2 4 V DC
24 V Common
3mA Typical
+DC
24V
COM
0V
0900 01 02 03 04 05 06 07 08
Must have common reference.
Input Terminal Block
Input/Output Terminal Block
+2 4 V DC
24 V Common
OSSD1
Receiver
++
--
Transmitter
OSSD2
10 11
12A2
A1
13 14 15 16 17 18 19 20 21
+DC
24V
COM
0V
0900 01 02 03 04 05 06 07 08
Wire Input Devices
Input Devices with Mechanical Contacts
WARNING: Applying an inappropriate DC or any AC voltage can result in a loss
of safety function, product damage, or serious injury. Properly apply only the
specified voltage to relay inputs.
Input devices with mechanical contact outputs, such as emergency stop buttons
and safety limit switches, use both a safety input terminal and a test output
terminal. This enables the circuit to achieve a Category 4 rating.
When safety devices are connected via test outputs to an input circuit on the
CR30 relay, the recommended wire length is 30 m (98.4 ft) or less.
Figure 6 - Input Devices with Mechanical Contacts
Input Devices with OSSD Outputs
Devices, such as light curtains, laser scanners, and solid-state interlocks, having
current-sourcing PNP semiconductor outputs (OSSD) have built-in test pulses
(or other method of detecting faults). These devices are connected directly to the
inputs of the CR30 relay safety and do not use a test output. These devices must
have a common reference with the CR30.
Figure 7 - Input Devices with OSSD Outputs
22 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Power, Ground, and Wiring Chapter 3
Wire Output Devices
Use Surge Suppressors
Because of the potentially high current surges that occur when switching
inductive load devices, such as motor starters and solenoids, the use of some type
of surge suppression to help protect and extend the operating life of the relays
output is required. By adding a suppression device directly across the coil of an
inductive device, you prolong the life of the outputs. You also reduce the effects
of voltage transients and electrical noise from radiating into adjacent systems.
The following diagram shows an output with a suppression device. We
recommend that you locate the suppression device as close as possible to the load
device. Since the outputs are 24V DC, we recommend 1N4001 (50V reverse
voltage) to 1N4007 (1000V reverse voltage) diodes for surge suppression for the
OSSD safety outputs, as shown in Figure 8
possible to the load coil.
Figure 8 - Surge Suppressors
+24V DC
+DC
24V
A1
COM
0V
12A2
Input/Output Terminal Block
13 14 15 16 17 18 19 20 21
. Connect the diode as close as
Diode
K1
Surge
Suppressor
Embedded Serial Port Wiring
24 V Common
Example suppressors include:
• 100-FSD250 for Bulletin 100S Contactors
• 1492-LD4DF terminal block with built-in 1N4007 diode
The embedded serial port is a non-isolated RS-232 serial port that is targeted to
be used for short distances (<3 m) to devices such as HMIs (for example,
PanelView). Pin2 and the shield are both internally connected to the -24V
Common (A2) terminal of the CR30.
The CR30 uses the minimal RS-232 connection; only transmit (TxD), receive
(RxD) and ground connections are required. The CR30 does not require nor
perform any handshaking, therefore the Request To Send (RTS), Clear To Send
(CTS), and Carrier Detect (DCD) are not used.
The CR30 only supports RS-232. The RS485 signals, which are used by some
products with the 8-pin mini DIN connector, are not used.
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 23
Chapter 3 Power, Groun d, and Wir ing
T
Figure 9 - Pinouts
Receive
ransmit
Pin RS-232 Example Pin RS-232 Example
1 RS-485 (not used) 5 DCD (not used)
2GND 6CTS (not used)
3 RTS (not used) 7 TxD
4RxD 8RS-485 (not used)
3
687
21
4
5
24V Common
Ta b l e 3 shows a recommended list of cables for the serial connection between the
CR30 and other Allen-Bradley products. They may also be suitable for thirdparty products.
DIN connectors were originally standardized by the Deutsches Institut für
Normung (DIN), the German national standards organization. Many variations
of this connector exist. To help ensure compatibility, select a cable from the
following table.
Table 3 - Cables
Power Cycling
Cat. No. Description Length
1761-CBL-AM00 8-pin Mini DIN to 8-pin Mini DIN 0.5 m (1.5 ft)
1761-CBL-HM02 8-pin Mini DIN to 8-pin Mini DIN 2 m (6.5 ft)
1761-CBL-AP00 8-pin Mini DIN to 9-pin D-shell 0.5 m (1.5 ft)
1761-CBL-PM02 8-pin Mini DIN to 9-pin D-shell 2 m (6.5 ft)
The CR30 is categorized as Data Communications Equipment (DCE). The
PanelView HMI's are Data Terminal Equipment (DTE). This is important when
point-to-point wiring connections are made. When DTE communicates with
DCE, the connections are pin x to pin x. When DTE communicates with other
DTE, a cross over is required (for example, TxD must be connected to RxD).
The state of the CR30 upon power-up depends on its state when power was
turned off. The Run LED indicates the state of the CR30.
1. Program Mode (RUN LED off )
The CR30 is in program mode upon power-up.
2. Run Mode with Program Not Verified (RUN LED flashing)
The CR30 returns to Run mode. Run mode without verification is good
for only 24 hours on continuous running.
3. Run Mode with Program Verified (RUN LED solid green)
The CR30 returns to Run mode with no limitation on the run duration.
24 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Chapter 4
Configuring the CR30
This manual assumes that the Connected Components Workbench has been
loaded and describes basic operations. Use the online help for configuring the
safety functions.
ATT EN TI ON : Activities including installation, adjustments, putting into service,
use, assembly, disassembly, and maintenance are required to be conducted by
suitably trained personnel in accordance with applicable code of practice. If this
equipment is used in a manner that is not specified by the manufacturer, the
protection that is provided by the equipment can be impaired.
Begin Configuration
1. In the Device Toolbox, expand the Safety Catalog.
2. Double-click the 440C-CR30-22BBB to open it in the Project
Organizer.
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 25
Chapter 4 Configuring the CR30
3. Double-click the icon in the Project Organizer to open the project.
4. Click the Edit Logic button to begin the configuration process.
The Workspace
The workspace is split into a grid of four columns: Safety Monitoring (the
inputs), Logic Level A, Logic Level B, and Safety Output.
By expanding the Toolbox on the left, blocks can be added to the Workspace and
safety functions can be created.
Figure 10 - Workspace
26 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Configuring the CR30 Chapter 4
5. Click and drag the Gate Switch function block to the first block in the
work space.
The CCW automatically assigns embedded input terminals EI_00 and
EI_01 to the function block. The terminal connection parameters can be
changed by you.
6. Click and drag the immediate Output to the first Safety Output block in
the workspace.
The CCW automatically assigns embedded output terminals EO_18 and
EO_19 to the output block. In addition, the output terminals are pulse
tested (PT). The terminal connection parameters can be changed by you.
7. Use the pull-down menu to change the Immediate Output Reset from
Manual to Automatic.
8. Click the input connection (shown in blue when no connection is made)
of the Immediate Off output block.
9. Click the output connection of the Emergency Stop button (shown in
blue when no connection is made).
The CCW automatically creates two Pass Through blocks in Logic Level
A and Logic Level B and makes the connection.
10. Click the second tab to compile and download the configuration.
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 27
Chapter 4 Configuring the CR30
IMPORTANT
Download the Configuration
Download initiates the transfer of the configuration file of your CR30 project to
the CR30 safety relay. The download process automatically performs a file
transfer verification to help ensure that the project configuration and
configuration in the CR30 is valid and equal. Successful file transfer verification
allows you to change the CR30 operation mode to Run and execute the safety
function.
Transfer file verification only checks inconsistency of the configuration in the
project and the relay such as connection errors and corrupted files.
After file transfer, the configured safety function itself is still not verified. The
responsible personnel must check whether the configured safety function
meets the safety requirements according to the risk assessment and fulfills all
applicable standard and regulations
11. Click the Download icon to build and download the configuration to
the CR30.
12. Expand the navigation tree.
13. Select the CR30.
14. Click OK.
28 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
15. File transfer successful or failed.
a. File transfer successful.
Click Ye s to change the relay to Run mode. For unverified
configuration, this allows the CR30 to operate for a maximum duration
of 24 hours to perform relevant tests to validate the safety function.
Click No to maintain the relay in Program mode and continue with the
verification process.
b. File transfer failed.
If the transfer file verification failed, the following message occurs.
Click OK and repeat steps 11…15.
Configuring the CR30 Chapter 4
Validation and Verification
To complete the safety system requirements, the configuration of the CR30 must
be validated and verified. At the first download, any configuration is in an
unverified state. This means that you have not confirmed that the configuration
and installation meets all specified operational and environmental requirements
of the machine to which CR30 is to be fitted.
ATT EN TI ON : Before installation, a risk assessment must be performed to
determine whether the specifications of this device are suitable for all
foreseeable operational and environmental characteristics of the machine to
which it is to be fitted. At regular intervals during the life of the machine, check
whether the characteristics foreseen remain valid.
Validation
You must perform appropriate testing to validate the configured safety function
of the CR30. Entering Run mode after first download enables operation of a
maximum duration of 24 hours to execute relevant tests of the safety function.
The CR30 displays the execution of an unverified configuration by a flashing
Power LED. After 24 hours, the CR30 stops operation and the power to the
CR30 must be cycled to restore the operation for another 24 hours.
Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 29
Chapter 4 Configuring the CR30
IMPORTANT
Verification
After validation, you can assign a unique verification ID to the current
configuration in Connected Components workbench. Any change to a verified
configuration invalidates the verification ID and requires a new validation and
verification process.
To complete the validation and verification, you finally have to acknowledge that
the safety configuration and installation meets the operational and
environmental specification of the machine. Relevant documentation:
• Details of the authorized and responsible personnel
• Revision of the firmware of the CR30
• Version of the Connected Components workbench
• Identification of the configured safety function and project
The verification process must be documented in the safety system
technical file.
Use the Configuration Reference Document
report feature in CCW release 7 or higher.
on page 139 or the verification
16. The CCW must be connected to the CR30 during verification.
17. The CR30 must be in Program mode.
18. Click the Ve r i f y button (the Safety Verification window appears).
19. Answer all questions and check each box, if completed.
20. Click Generate.
ATT EN TI ON : The verification process should be documented in the safety
system technical file.
30 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014
Loading...