Rockwell Automation 440C User Manual

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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).

AllenBradley, 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 LevelA, 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

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

234 556

Status Indicators

13 14

15 16

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

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 AllenBradley 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 1492EAHJ35) 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 606641), 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 flameretardant 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

ENISO 13849-1

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 (16AWG)

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

Input Terminal Block

Input/Output Terminal Block

10 11

12A2

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

Congured for Pulse Test Output

Input/Output Terminal Block

+2 4 V DC

24 V Common

3mA Typical

+DC

24V

COM

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

13 14 15 16 17 18 19 20 21

+DC

24V

COM

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

COM

12A2

Input/Output Terminal Block

13 14 15 16 17 18 19 20 21

. Connect the diode as close as

Diode

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). Pin2 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

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)

687

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

Configuring the CR30 Chapter 4

21. Click Ye s to change the safety relay back to Run mode.

22. The CCW generates a Safety Verification ID. Click OK to continue.

23. Confirm the Verification ID in the CCW.

The ID is stored in the CR30. During power-up, the CR30 uses this number during its self-testing to help ensure its internal processors are functioning properly. When the configuration is uploaded from the CR30, the CCW shows the Verification ID. The ID is not stored with the CCW project file.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 31

Chapter 4 Configuring the CR30

Verification Digits

1, 2, 3, and 4

All Values

are 0

Verification Digit 1

Val ue is 7

Viewing the Verification ID without CCW

During machine lifecycle, it is required to check whether the system requirements are still valid. The LEDs can be used to view the verification ID without the use of the CCW and compare the documented verification ID of the technical file of the machine.

If the CR30 configuration has not been verified, the ID is 0000. Press and release the Verification button. The IN 0 LED is green. The OUT 1, 2, 3, and 4 LEDs are green. After five seconds, the LEDS will revert to show the status of the inputs and outputs as configured in the CCW.

Figure 11 - Verification ID is 0000 (Not Verified)

If the CR30 configuration has been verified, pressing the Verification button will cycle the LEDs through each verification digit. In the following example, the Verification ID is 7916.

Press and release the verification button once.

Figure 12 - First Verification Digit

32 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Press the Verification button within five seconds.

Verification Digit 2

Val ue is 9

Verification Digit 3

Val ue is 1

Veri ficat ion D igit 4

Value is 6

Figure 13 - Second Verification Digit

Press the Verification button within five seconds.

Figure 14 - Third Verification Digit

Configuring the CR30 Chapter 4

Press the Verification button within five seconds.

Figure 15 - Fourth Verification Digit

After five seconds, the LED will revert to show the status of the inputs and outputs as configured in the CCW.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 33

Chapter 4 Configuring the CR30

Multiple Block Connections

Multiple blocks can be connected between:

• Safety Monitoring Functions and Logic Level A

• Logic Level A and Logic Level B, and

• Logic Level B and Safety outputs

This is done by clicking the desired input and output connection points. The CCW automatically determines whether the connection can be made.

Figure 16 - Multiple Block Connections

34 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Pulse Testing

The CR30 performs three types of pulse testing functions:

• N.O. inputs

• N.C. inputs

• Outputs

Chapter 5

Normally Open Input Pulse Testing

When a safety input is configured for normally open (N.O.) operation, the CR30 periodically checks the status of the input. The purpose of the test pulse is to detect short circuits in the wiring to 24V DC, 0V and between two channels. This test is independent of the “Input Test Pulses”. Six terminals (12…17) can be configured for normally open operation.

When a terminal is configured for N.O. operation, the CR30 tests the status of each terminal by generating a test pulse as shown in Figure 17

The normally open input pulse testing cannot be configured to be on or off. If the terminal is configured to be N.O., the pulse testing is performed by the CR30.

Figure 17 - N.O. Terminal Test Pulse

24V

0 640μs

When multiple terminals are configured for normally open operation, the CR30 tests each one at 500 ms intervals. This test sequence is repeated every 6.4 seconds.

In Figure 18 on page 36 operation, and are tested. Terminals 13 and 16 are configured for normally closed (N.C.) operation, therefore the test pulse does not occur on these two terminals.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 35

, terminals 12, 14, 15, and 17 are configured for N.O.

Chapter 5 Pulse Testing

IMPORTANT

Figure 18 - Test Sequence

1 432 5 6

Normally Closed Input Pulse Testing

erminal 12

erminal 13

erminal 14

erminal 15

erminal 16

erminal 17

500ms intervals

Terminals 12…17 can be configured to generate test pulse outputs. These signals are used to test for short circuits in the wiring to 24V DC, 0V and between two channels that are wired to separate test pulse sources (one channel that is sourced from an odd number terminal [13, 15, and 17], and the other one from an even number terminal [12, 14, and 16]).

Safety systems requiring a Category 4 structure per ISO13849-1 and SIL 3 rating per IEC61508 must use pulse testing for the dual channel N.C. contacts. Pulse testing for Category 3, 2, and 1 structures and SIL 2 and 1 ratings is recommended.

The CR30 generates three distinct pulses, called A, B, and C. Each pulse is 1.7 ms wide. Pulse Test B immediately follows Pulse Test A. Pulse Test C immediately follows Pulse Test B. The pulse tests are repeated every 25 ms.

The timing diagram in Figure 19

shows an example of the pulse testing when the

respective terminals are configured for A, B, and C.

Figure 19 - Timing Diagram

Terminal 12 - A

erminal 13 - B

erminal 14 - C

36 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Terminal 15 - A

erminal 16 - B

erminal 17 - C

24V

1.7ms

25ms

Pulse Testing Chapter 5

IMPORTANT

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

Main Transistor

Terminal 13

Terminal 12

24V

Terminal 20

Terminal 21

24V

0 125ms

50μs

The purpose of the test pulses is to detect short circuits from the input signal to 24V DC, 24V common, and shorts from one input signal to another input signal. If one input signal is assigned to Test Pulse A and another signal is assigned to Test Pulse B (or C), then a short circuit from one input to the other is detected by the CR30, and the CR30 de-energizes the outputs of those safety functions using the two inputs. In this example, you cannot select terminal 12 as one test pulse source and terminal 15 as the second test pulse source, as both of these produce the “A” pulse.

The CCW automatically prevents the user from selecting two of the same pulses when dual channel inputs and two test sources are selected.

Output Pulse Testing

Internally, the CR30 provides dual channel capability to turn off its safety outputs. Conceptually, think of this as a main output transistor feeding individual output transistors. The CR30 repeats a test process where it tests the main transistor twice and then sequentially tests each individual output twice. After successful completion of the tests, the CR30 repeats the test sequence.

Safety systems requiring a Category 4 structure per ISO13849-1 and SIL 3 rating per IEC61508 must use pulse testing for the dual channel outputs. Pulse testing for Category 3, 2, and 1 structures and SIL 2 and 1 ratings is recommended.

Figure 20 - Output Pulse Testing

When the main transistor is tested, a 50 μs test pulse appears simultaneously on all outputs. The main transistor is tested again 125 ms later.

Figure 21 - Main Transistor Test

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 37

Chapter 5 Pulse Testing

Then a sequence occurs in which each output is individually tested twice. The test pulse is 50 μs wide. The test pulses occur every 250 ms and switch to the next output configured with testing.

Figure 22 - Test Pulse Sequence

Terminal 12

erminal 13

erminal 20

erminal 21

24V

0 250 500ms

38 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Chapter 6

Input Filter

Input filtering gives the CR30 the ability to filter out noise and, in some cases, inadvertent operation.

Sometimes, an operator presses a push button and immediately realizes that they pressed the wrong button and immediately releases the button. In muting applications, an object, moving down a conveyor, might stop just at the point where the muting sensor is deactivated and then back off enough that the muting sensor is reactivated.

When an input filter time (t1) is specified, an input channel is allowed to go to the LO state while the other channel is in the HI state for that length of time without the output of the instruction going to the LO state. However, the output goes to the LO state when both input channels are in the LO state simultaneously. The input filter operates on both the leading edge and trailing edge of the input signals. If specified, the filter time must be included in the response time calculation.

Figure 23 - Input Filtering

Output

t1 t1

Channel A

Channel B

Input filtering can set in 25 ms increments, from 0…1000 ms. The default value is 0 ms.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 39

Chapter 6 Input Filter

The input filtering is set in the Advanced Settings of each safety monitoring block. Figure 24

shows that the Enabling Switch function with the input filter is

set to 4 (4 x 25 = 100 ms).

Figure 24 - Enabling Switch

40 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Chapter 7

Discrepancy Time

Safety Monitoring functions using dual inputs have a feature that allows the CR30 to test for the timing of the operation of both channels. In most cases, the outputs of dual channel safeguarding devices change state within a few milliseconds of each other. In some cases, the second channel can change state much later than the first.

In these later cases, you want to allow (that is, make sure that) both channels return to their “safety” state within a specified time relative to each other. For example, the “safety” state of dual N.C. input is when both inputs are in the closed state. Channel A can close before Channel B or Channel B can close before Channel A. The CR30 allows you to specify a discrepancy time in 50 ms increments, from 0…3 seconds.

Figure 25 - Discrepancy Time

Channel A

Channel B

Output

t <= Discrepancy Time

The discrepancy is set in the Advanced Settings of each safety monitoring block. The following example shows the Gate Switch function with the discrepancy time set to 2 (2 x 50 = 100 ms).

When the discrepancy setting is set to zero, the CR30 does not test for discrepancy. The duration between the operation of channel one and channel two is infinite. The default value 100 ms.

Figure 26 - Setting Discrepancy Time

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 41

Chapter 7 Discrepancy Time

Notes:

42 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Safety Block Renaming

Chapter 8

General

With Release 7 of the Connected Components Workbench (CCW) and Release7 of the CR30 firmware, the names of both the safety monitoring functions and safety output functions can be edited. The editing rules follow IEC61131-3, section 2.1.2.

This feature is important because it allows you to distinguish between multiple occurrences of the same function blocks during the design, wiring, and troubleshooting phases.

The name change is initiated in one of two ways:

1. Simply double-click the name inside the block

2. Highlight the block and press F2.

The typical editing keys (Home, End, Backspace, Delete, Left Arrow, Right Arrow, Page Up, Page Down, and Mouse Click) can be used to edit the name.

When the block is selected for editing, the name appears in a light blue box, and the name is highlighted in light blue background, as shown in Figure 27

Figure 27 - Block Name Selected for Editing

Follow these simple rules for naming the blocks:

• Names must begin with a letter (upper or lower case) or an underscore

• Names cannot have spaces

• Names can contain letters, numbers, and underscores (no special

characters)

• Name length can be anywhere from 1…30 characters

• Letter case is not significant

• Multiple leading or consecutive embedded underscores are not allowed

• Trailing underscores are not allowed

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 43

Chapter 8 Safety Block Renaming

Naming Error Indication

After tabbing off, pressing enter, or mousing off the block, the CCW evaluates the integrity of the name. If valid, the name appears in black letters. If invalid, the CCW shows a naming error in two ways:

1. A red box around the name

2. An error message in the build results

Figure 28 - Red Box Indicates Naming Error

This example block has two errors:

1. The name starts with a period (“.”).

2. The name contains a space.

Figure 29 - Build Error List

After clicking the Build button, the Error List shows the name errors. In the example above, SMF1 and SOF1 have naming errors.

When a naming error occurs, the project cannot be built and downloaded to the CR30. Then naming errors must be corrected. However, the project can be saved and reopened with the naming errors.

44 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Chapter 9

Safety Monitoring Functions

Many types of safeguarding and safety devices and safety related signals can be connected as inputs to the CR30. The Connected Components Workbench (CCW) facilitates the selection and connection of the device. Each block is assigned the next available settings for input terminals, test sources number of inputs, pulse testing, discrepancy time, and input filter.

Emergency Stop

The Emergency Stop function block sets the parameters for typical emergency stop push buttons. In the CCW, click and drag (or double-click) the block to an available Safety Monitoring Function spot. When mechanical operated contacts are used, these contacts must be direct-acting contacts.

Figure 30 - Emergency Stop Function Block

The available input selections for the Emergency Stop inputs are:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

You can modify the number and types of inputs:

• 2 N.C.

• 2 OSSD

• 1 N.C.

Pulse testing can be disabled or set to 2 Sources. When 2 Sources is selected, the next available test sources are automatically selected. You can modify the sources afterward.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 45

Chapter 9 Safety Monitoring Functions

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

You can use the default Discrepancy Time and Input Filter or choose to modify these settings.

Figure 31 - Example Schematic of a Dual Channel E-stop Without Test Pulses

Figure 32 - Example Schematic of a Dual Channel E-stop Using Test Pulses A and B

Enabling Switch

The Enabling Switch function block sets the parameters for typical enabling (or hold-to-run) devices. In the CCW, click and drag (or double-click) the block to an available Safety Monitoring Function spot. When mechanical operated contacts are used, these contacts must be direct-acting contacts.

Note: This function block is intended to be used only in applications with a 3position enabling switch that only allows activation of its outputs (closed contacts) when the operator presses and holds the switch into its middle position. The switch has to be designed using a mechanical force to reset to its default off (contact open) position.

Figure 33 - Enabling Switch Function Block

46 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Safety Monitoring Functions Chapter 9

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

The available input selections for the Enabling Switch inputs are:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

You can modify the number and types of inputs:

• 2 N.C.

• 2 OSSD

• 1 N.C.

Pulse testing can be disabled or set to 2 Sources. When 2 Sources is selected, the next available test sources are automatically selected. You can modify the sources afterward.

You can use the default Discrepancy Time and Input Filter or choose to modify these settings.

Figure 34 - Example Schematic of a Dual Channel Enabling Switch Without Test Pulses

Figure 35 - Example Schematic of a Dual Channel Enabling Switch Using Test Pulses A and B

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 47

Chapter 9 Safety Monitoring Functions

Feedback Monitoring

The Feedback function block is used in safety systems to monitor the status of output devices (like safety contactors). When the output device is off, a HI signal is fed back to the input of the CR30 to indicate that the device is indeed off. When the output device is energized, the feedback signal goes LO. If the output device remained energized, the feedback signal remains LO and the CR30 will not energize the output. The feedback contacts can be positive-guided, mechanically linked, or mirrored contacts.

The CR30 accepts 1, 2, 3, or 4 inputs into each feedback block. All inputs must be HI for the output of the block to go HI.

In the CCW, click and drag (or double-click) the block to an available Safety Monitoring Function spot.

Figure 36 - Feedback Monitoring Function Block

The available input selections for the Feedback Monitoring are:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

• P1_00…P1_03 (plug-in 1 terminals 00…03)

• P2_00…P2_03 (plug-in 2 terminals 00…03)

• SP_00…SP_15 (Modbus inputs 00…05)

You can modify the number of inputs within the range of 1…4.

You can use the default Input Filter or choose to modify this setting.

48 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Safety Monitoring Functions Chapter 9

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

K1 K2

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

K1 K4K3K2

K1 K2 K3 K4

Figure 37 - Example Feedback Schematic with Two Feedback Contacts Connected in Series to One Input Terminal

Figure 38 - Example Feedback Schematic with Four Feedback Contacts Connected Individually to Four Input Terminals

Gate Switch

The Gate Switch function block sets the parameters for typical safety gate interlock switches. In the CCW, click and drag (or double-click) the block to an available Safety Monitoring Function spot.

Figure 39 - Gate Switch Function Block

The available input selections for the Gate Switch inputs are:

• EI_00…EI_11 (embedded input terminals 00…11)

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 49

• MP_12…MP_17 (multi-purpose terminals 12…17)

Chapter 9 Safety Monitoring Functions

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

You can modify the number and types of inputs:

• 2 N.C.

• 2 OSSD

• 1 N.C.

Pulse testing can be disabled or set to 2 Sources. When 2 Sources is selected, the next available test sources are automatically selected. You can modify the sources afterward.

You can use the default Discrepancy Time and Input Filter or choose to modify these settings.

Figure 40 - Example Schematic of a Dual Channel Safety Gate Switch Without Test Pulses

Figure 41 - Example Schematic of a Dual Channel Safety Gate Switch Using Test Pulses A and B

Figure 42 - Example Schematic of a Dual Channel Safety Gate Switch Using OSSD Outputs

50 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Safety Monitoring Functions Chapter 9

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

OSSD1

Receiver

Transmitter

OSSD2

Light Curtain

The Light Curtain function block sets the parameters for light curtains that have dual OSSD outputs. In the CCW, click and drag (or double-click) the block to an available Safety Monitoring Function spot. This block can be used for other devices, like laser scanners, with OSSD outputs.

Figure 43 - Light Curtain Function Block

The available input selections for the Light Curtain inputs are:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

You can use the default Discrepancy Time and Input Filter or choose to modify these settings.

Figure 44 - Example Schematic of a Light Curtain

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 51

Chapter 9 Safety Monitoring Functions

Muting

Muting is the temporary automatic suspension of the protective function of a safeguarding device like a light curtain. The muting function allows the transport of material through a light curtain without stopping a conveyor. To distinguish between material and persons, a certain sequence of events and timings are used.

Muting sensors are mounted in a certain pattern, and the material must pass by the sensors and light curtain within specified time limits. If the muting sensor sequence is incorrect or the timing parameters are violated, the conveyor is turned off. An override signal moves the material through the light curtain after a violation.

Figure 45 - Muting Function Block

The light curtain (LC) signals can use the following terminals:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

The muting (S1…S4) and override (OV) signals can use the following terminals:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

• P1_00…P1_03 (plug-in 1 terminals 00…03)

• P2_00…P2_03 (plug-in 2 terminals 00…03)

52 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Safety Monitoring Functions Chapter 9

Machine

MS1 MS2

Muting Lamp

Material

Conveyor

You can use the default Discrepancy Time and Input Filters or choose to modify these settings.

The CR30 safety relay has three distinct types of muting, where the sequence and timing of signals that are monitored by the CR30 allows objects to pass through the light curtain without shutting down the machine process. The three types are:

• 2-sensor T-Type

• 2-sensor L-Type

• 4-sensor

2-Sensor T-Type Muting

The sensors and light curtain form the shape of an upside down “T”, when viewed from the side. The muting sensors (MS) are mounted to form an “X” sensing pattern where the sensing beams cross near the center of the light curtain (LC).

Figure 46 - 2-Sensor T-Type Muting Arrangement

The material must first break the two muting sensors and then the light curtain. The order in which the muting sensors are block is not critical, but the synchronization time (the time between block one sensor and the other sensor) must be met. The muting lamp turns on when both sensors are blocked and the light curtain is muted. The conveyor can move in the forward or reverse direction.

In the example below, the OSSD outputs of the light curtain are connected to terminals 00 and 01. The two muting sensors are connected to terminals 02 and

03. The momentary, normally open override switch is connected between terminals 12 to 04 to take advantage of pulse testing. Contactor K1 and K2, which provide power to the conveyor (and to other hazards), are connected to terminals 18 and 19.

The muting lamp is connected to terminal 13; this terminal should be configured with no pulse testing. Filament lamps will not be affected by pulse testing, but LED lamps may appear to flicker if pulse testing is enabled.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 53

Chapter 9 Safety Monitoring Functions

Figure 47 - Example Schematic for 2-Sensor T-Type Muting

+24V DC

Light Curtain

MS1

24V Com

OSSD A

CR30

A1 15 20 21160618A2

MS2

OSSD B

020100 03 04

12 13 14

Override

Muting Lamp

071908 10 11

Contactors

for Conveyor Power

For simplicity, the power and ground connections of the light curtain and muting sensors are not shown. The light curtain and muting sensors must have the same reference (24V Com) as the CR30 for proper operation.

For proper operation, the muting sensors are on (normally closed) when not muting, and the light curtain OSSD outputs are also on (the light curtain is clear).

Figure 48 - Muting Time for 2-Sensor T-Type Muting

Muting sensor 1

Muting sensor 2

Muting lamp

muted

t > 30ms

t > 50ms

30ms <= t t < synchronization time

t < muting time

Ta b l e 4 shows the muting and synchronization times that are selectable in the

CCW. These times are linked. For example, if you select a 10 s muting time, then the synchronization time between MS1 and MS2 is 3 s. To use a synchronization time of 6 s, you must select a 60 s muting time.

Note: The synchronization time also depends on the input filter time settings for the muting sensor inputs. Synchronization time (total) = 2 x Input Filter Time + Synch Time

54 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

t > 30ms

30ms <= t t < synchronization time

Safety Monitoring Functions Chapter 9

IMPORTANT

Table 4 - Muting and Synchronization Timing Selections

Muting Time Synchronization Time Muting Time Synchronization Time

10 s 3 s 900 s (15 min) 90 s

20 s 3 s 1800 s (30 min) 180 s (3 min)

30 s 3 s 3600 s (1 hr) 180 s (3 min)

60 s (1 min) 6 s 28,800 s (8 hr) 180 s (3 min)

300 s (5 min) 30 s Infinite Infinite

2-Sensor L-Type Muting

The sensors and light curtain form the shape of the letter “L”, when viewed from the side. The muting sensors (MS) are mounted on one side of the light curtain (LC).

Figure 49 - 2-Sensor L-Type Muting Arrangement

MS2

MS1

Machine

Conveyor

Material

Muting Lamp

Muted LC

The material must first break MS1, then MS2 and then the light curtain. As the material progresses, the material must clear MS1 and then MS2. The muting lamp turns on and the light curtain is muted after MS2 is blocked. The conveyor can only move one direction.

The 2-L muting arrangement must only be used for material exiting the hazard area. It must not be used for material entering the hazard area.

In the example below, the OSSD outputs of the light curtain are connected to terminals 00 and 01. The two muting sensors are connected to terminals 02 and

03. The momentary, normally open override switch is connected between terminals 12 to 04 to take advantage of pulse testing. Contactor K1 and K2, which provide power to the conveyor (and other hazards if necessary), are connected to terminals 18 and 19.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 55

Chapter 9 Safety Monitoring Functions

Muting sensor 1

Muting sensor 2

Muting lamp

t > 30ms

t > 50ms

30ms <= t t < synchronization time

t < muting time

muted

Figure 50 - Example Schematic for 2-Sensor L-Type Muting

+24V DC

Light Curtain

MS1

24V Com

OSSD A

CR30

A1 15 20 21160618A2

MS2

OSSD B

020100 03 04

12 13 14

Override

Muting Lamp

071908 10 11

Contactors

for Conveyor Power

For proper operation, the muting sensors are on (normally closed) when not muting, and the light curtain OSSD outputs are also on (the light curtain is clear).

Figure 51 - Muting Time for 2-Sensor L-Type Muting

56 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Safety Monitoring Functions Chapter 9

Machine

MS1MS2MS3MS4

Muting Lamp

Material

Muted LC

Conveyor

Ta b l e 5 shows the muting and synchronization times that are selectable in the

CCW. These times are selected independently. For example, you can select two minute muting time, a 500 ms synchronization time between MS1 and MS2, and a 1000 ms synchronization time between MS2 and the light curtain.

Note: The synchronization time also depends on the input filter time settings for the muting sensor inputs. Synchronization time (total) = 2 x Input Filter Time + Synch Time

Table 5 - Muting and Synchronization Times for ‘2L’ Muting

Muting Time Units Available Values Synchronization Time Available Values

Seconds 1…59 MS1 to MS2 50…10,000 ms in

Minutes 1…59 MS2 to LC

Hours 1…23

Days 1…10

50ms increments

4-Sensor Muting

The sensors and light curtain form the shape of an upside down “T”, when viewed from the side. Two muting sensors (MS) are mounted on either side of the light curtain (LC).

Figure 52 - 4-Sensor Muting

The material can travel in either direction; breaking MS1 first and MS4 last or breaking MS4 first and MS1 last. The muting lamp turns on and the light curtain is muted after the second sensor is blocked. The object must be large enough to break all four sensors.

In the example below, the OSSD outputs of the light curtain are connected to terminals 00 and 01. The four muting sensors are connected to terminals 02 to

05. The momentary, normally open override switch is connected between terminals 12 to 06 to take advantage of pulse testing. Contactor K1 and K2, which provide power to the conveyor (and other hazards if necessary), are connected to terminals 18 and 19.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 57

Chapter 9 Safety Monitoring Functions

Figure 53 - Example Schematic for 4-Sensor Muting

+24V DC

Light Curtain

MS1

MS3

24V Com

OSSD A

CR30

A1 15 20 21160618A2

OSSD B

020100 03 04

12 13 14

MS2

MS4

Muting Lamp

071908 10 11

Override

Contactors

for Conveyor Power

For proper operation, the muting sensors are on (normally closed) when not muting, and the light curtain OSSD outputs are also on (the light curtain is clear).

Figure 54 - Muting Time for 4-Sensor Muting

Muting sensor 1 (4)

Muting sensor 2 (3)

Muting sensor 3 (2)

muted

Muting sensor 4 (1)

Muting lamp

30ms <= t t < synchronization time

t > 30ms

t > 50ms

t > 30ms

t < muting time

t > 30ms

30ms <= t t < synchronization time

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Safety Monitoring Functions Chapter 9

Ta b l e 6 shows the muting and synchronization times that are selectable in the

Note: The synchronization time also depends on the input filter time settings for the muting sensor inputs. Synchronization time (total) = 2 x Input Filter Time + Synch Time

Table 6 - Muting and Synchronization Times for Four Sensor Muting

Muting Time Synchronization Time

10 s 3 s

20 s 3 s

30 s 3 s

60 s (1 min) 6 s

300 s (5 min) 30 s

900 s (15 min) 90 s

1800 s (30 min) 180 s (3 min)

3600 s (1 hr) 180 s (3 min)

28800 s (8 hr) 180 s (3 min)

Infinite Infinite

Muting Override

The muting function has an optional override input. Use the override to turn on the conveyor to clear objects through the sensors in the case of a muting sequence or timing fault.

To use the override, simply enable the feature in the safety monitoring function block. The muting override can be either a single- or dual-input and can also use input pulse testing if desired.

When the muting override input turns on, the safety outputs controlled by the muting function turn on until the override time expires or the override input turns off. The muting override can be set between 5…1275 seconds, in 5 second increments.

Muting Lamp

The muting lamp shows four states.

• OFF – light curtain is not muted.

• ON – light curtain is muted.

• 1 Hz blink rate – muting sequence fault.

• 3 Hz blink rate – muting is overridden (the Override input is on).

The muting lamp is not monitored. If the lamp burns out, the muting function continues to work properly.

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Chapter 9 Safety Monitoring Functions

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24V Com

250ms to

3000 ms

Reset

The reset block is used in safety functions that require a manual intervention to turn on the safety system.

Figure 55 - Reset Function Block

To prevent inadvertent actuation of the reset block, the reset requires a leading edge and trailing edge within a specific time frame. The pulse width must be between 250…3000 ms. If the pulse width is too short or too long, the reset function will not be executed.

Figure 56 - Reset Timing

The reset block is a Safety Monitoring Function in the CCW. For a valid Reset operation, according to the requirements specified in the approved safety concept, you must use the default Reset timing and leave the input filter setting “0”.

The filter setting is enabled in CCW versions previous to Rev 7. A filter time setting greater than “0” extends the Reset Timing by 2 x Filter Time.

The reset input signal can come from either one input wiring terminal or over the Modbus communication input. The available input selections are:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

• P1_00…P1_03 (plug-in 1 terminals 00…03)

• P2_00…P2_03 (plug-in 2 terminals 00…03)

• SP_00…SP_15 (Modbus inputs 00…15)

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Safety Monitoring Functions Chapter 9

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Reset

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

+24V DC

24V Com

250ms to

3000 ms

Figure 57 - Wiring Connection for a Reset Signal to Terminal 00

The reset block works with one or more output blocks. When an output block requires a manual reset, the CCW shows all available reset inputs that can be used.

Restart

The restart function works with an AND or OR logic block in Logic Level A and Logic Level B. When all inputs are satisfied, exercising the restart input causes the restart function go be effective. If the Restart function is already effective, the Restart input has no affect.

The Restart can only be used with one AND or OR logic block.

Figure 58 - Restart Function Block

The Restart Function requires a leading edge and trailing edge within a specific time frame. The pulse width must be between 250…3000 ms. If the pulse width is too short or too long, the Restart function will not be executed.

Figure 59 - Restart Timing

The available input selections for the Restart are:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

• P1_00…P1_03 (plug-in 1 terminals 00…03)

• P2_00…P2_03 (plug-in 2 terminals 00…03)

• SP_00…SP_15 (Modbus inputs 00…15)

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Chapter 9 Safety Monitoring Functions

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24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

Restart

For a valid Restart operation, according to the requirements specified in the approved safety concept, you must use the default Restart timing and leave the input filter setting “0”.

The filter setting is enabled in CCW versions smaller than Rev 7. A filter time setting greater than “0” extends the Reset Timing by 2 x Filter Time.

Figure 60 - Wiring Connection for a Restart Signal to Terminal 02 with Inputs on Terminals 00 and 01

Safety Mat

Four wire safety mats can be connected to the CR30. The four wires create two channels. Stepping on the safety mat creates a short circuit between channel 1 and 2. To detect the short circuit, input pulse testing is used. The mats must be connected to the input test pulses.

Figure 61 - Safety Mat Function Block

The safety mat can be connected to the following terminals:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

You can use the default Discrepancy Time and Input Filter or choose to modify these settings.

For input test pulses, terminals 12…17 are available. The CCW automatically selects another test pulse pattern for each input.

An example schematic shows a safety mat that is connected to terminals 0 and 1.

62 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

The mat uses test pulses that are generated at terminals 12 and 13.

Figure 62 - Example Schematic for a Safety Mat

+24V DC

24V Com

Safety Mat

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

Safety Monitoring Functions Chapter 9

SensaGuard

The SensaGuard™ function block sets the parameters for interlocks having dual OSSD outputs. In the CCW, click and drag (or double-click) the block to an available Safety Monitoring Function spot. This block can be used for other devices with OSSD outputs.

Figure 63 - SensaGuard Function Block

The available input selections for the SensaGuard inputs are:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

You can use the default Discrepancy Time (See Discrepancy Time on page 41 and Input Filter (See Input Filter

Figure 64 - Example Schematic of a SensaGuard Interlock

+24V DC

24V Com

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 63

White (Aux)

Gray (OSSD1) Pink (OSSD2)

CR30

A1 15 20 21160618A2

Brown Yellow

Red

Green

Blue

020100 03 04

12 13 14

on page 39) or choose to modify these settings.

2 4 8

1 3

5 6

071908 10 11

)

Chapter 9 Safety Monitoring Functions

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24V Com

GSR Module

L11A1

GSR Module

L11A1

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

Single Wire Safety Input

When configured for this type of input, the CR30 expects a Single Wire Safety (SWS) input signal from a GSR relay or a safeguarding device that has an SWS output signal. The GSR relay family includes the CI, SI, DI, DIS, GLP, GLT, EM, and EMD modules. Each of these modules provides the SWS signal on terminal L11.

Figure 65 - Single Wire Safety Function Block

Only terminals 10 and 11 of the CR30 can be configured to receive the SWS signal.

• EI_10…EI_11 (embedded input terminals 10…11)

The SWS signal is a long pulse followed by a short pulse, which is repeated while the signal is active. The SWS is active when the safety outputs of a GSR safety relay are ON. When the SWS is inactive, the SWS signal is 0V. The timing and voltage characteristics of the SWS waveform are shown in Figure 66

Figure 66 - SWS Waveform

4ms

0.7ms

1ms

+24 V

0 V

0.5ms

Active (ON) Inactive (OFF)

Figure 67 shows an example schematic of the connection of the SWS from other

modules in the GSR family of relays. The CR30 and GSR modules must be connected to the same 24V Common.

Figure 67 - SWS Connection Schematic

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Safety Monitoring Functions Chapter 9

Two-Hand Control

The CR30 can be configured to operate in two different types of two-hand control, which are specified in ISO 13851. The two types are:

• Type IIIA (for low-risk safety systems)

• Type IIIC (for high-risk safety systems)

Mechanically palm-operated buttons (Bulletin 800P) or the electronic output push buttons (Bulletin 800Z Zero-Force Touch Buttons™) should be used as actuating devices for two hand control. The CR30 requires two buttons to be actuated simultaneously and maintained to turn the two-hand safety monitoring function ON. To meet the simultaneity requirement, the two buttons must be actuated within 500 ms of each other.

Figure 68 - Two-Hand Control Function Block

The two-hand controls can be connected to the following terminals.

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

You can use the default Input Filter or choose to modify these settings.

When test pulses are used, the CCW automatically selects another test pulse pattern for each input. The two-hand control can use input test pulses from following terminals:

• MP_12…MP_17 (multi-purpose terminals 12…17)

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Chapter 9 Safety Monitoring Functions

Type IIIA Two-hand Control

The Type IIIA uses only one normally open contact for each hand. This configuration can be set up with or without the use of test pulses. The test pulses provide short circuit fault detect between channels and between channel and 24V.

Figure 69 - Example Wiring Connection for a Type IIIA Two-hand Control without Test Pulses

+24V DC

071908 10 11

24V Com

CR30

A1 15 20 21160618A2

020100 03 04

12 13 14

Figure 70 - Wiring Connection for a Type IIIA Two-hand Control with the Test Pulses

+24V DC

071908 10 11

24V Com

CR30

A1 15 20 21160618A2

020100 03 04

12 13 14

Type IIIC Two-Hand Control

The Type IIIC uses a normally open and a normally closed contact for each hand.

Figure 71 - Example Wiring Connection for a Type IIIC Two-hand Control without Test Pulses

+24V DC

071908 10 11

24V Com

CR30

A1 15 20 21160618A2

020100 03 04

12 13 14

When test pulses are used, the CR30 will detect a short from Channel 1 to Channel 2 after 3.7 seconds and turn the output OFF. To clear the fault, release both buttons.

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Safety Monitoring Functions Chapter 9

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24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

Figure 72 - Wiring Connection for a Type IIIC Two-hand Control with Test Pulses

The timing diagram for the two-hand control is shown in Figure 73. The Type IIIA uses only the N.O. contact of the button. The Type IIIC uses both the N.C. and the N.O. contacts.

Figure 73 - Two-hand Control Timing Diagram

1 432 5 6 7 8

Hand 1 N.C.

Hand 1 N.O.

Hand 2 N.C.

Hand 2 N.O.

Logic Output

must be less than 500ms

Description Description

1 Hand 1 button is pressed. 5 Hand 2 button is pressed.

2 Hand 2 button must be pressed within 500 ms

for the output logic to turn ON.

3 Releasing either hand button causes the logic

output to turn off.

4 Both hand buttons must be released to start a

new cycle.

6 Hand 1 button must be pressed within 500 ms

for the output logic to turn ON.

7 Releasing either hand button causes the logic

output to turn off.

8 Both hand buttons must be released to star t a

new cycle.

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Chapter 9 Safety Monitoring Functions

Alternate Device

The Alternate Device provides the flexibility to create other types of input monitoring blocks. Use this block for the following types of input functions:

• Single channel OSSD

• Single channel N.C.

• Dual channel OSSD

• Dual channel 2 N.C.

• Dual channel 1 N.C./1 N.O.

• Three channel N.C.

• Three channel OSSD

Figure 74 - Alternate Device Function Block

Single Channel

Single channel safety monitoring functions require only one connection to an input terminal. The single channel input must only be used in low-risk safety systems.

The available input terminals are:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

You can use the default Input Filter or choose to modify this setting.

When test pulses are used, the CCW automatically selects the test pulse pattern. The single channel N.C. can use input test pulses from following terminals:

• MP_12…MP_17 (multi-purpose terminals 12…17)

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24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

Figure 75 - Example Schematic for Single Channel N.C. without Test Pulse

Figure 76 - Example Schematic for Single Channel N.C. with Test Pulse

+24V DC

071908 10 11

24V Com

CR30

A1 15 20 21160618A2

020100 03 04

12 13 14

Figure 77 - Example Schematic for Single Channel OSSD

+24V DC

24V Com

CR30

A1 15 20 21160618A2

Safeguarding Device

020100 03 04

12 13 14

071908 10 11

Dual Channel

Dual channel safety monitoring functions require two independent circuit connections to the CR30. Dual channel inputs are used for medium and high risk applications.

You can modify the number and types of inputs:

• 2 N.C.

• 2 OSSD

• 1N.C./1 N.O.

The available input selections for the dual-channel OSSD and two N.C. inputs are:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

The available input selections for the N.O. contact are:

• MP_12…MP_17 (multi-purpose terminals 12…17)

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Chapter 9 Safety Monitoring Functions

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24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

Pulse testing can be set to 1 Source, 2 Sources, or Disabled. When 1 or 2 Sources is selected, the next available test sources are automatically assigned by the CCW. You can modify the sources afterward.

You can use the default Discrepancy Time and Input Filter or choose to modify these settings.

The two terminals do not necessarily have to be consecutive.

Figure 78 - Example Schematic for 2 N.C. without Test Pulse

Figure 79 - Example Schematic for 2 N.C. with Two Test Pulses Sources

Dual Channel OSSD

Safeguarding devices with OSSD outputs generate their own test pulses to detect for short circuit conditions or have other methods of detecting short circuit conditions. When configured for dual channel OSSD, the CR30 ignores the test pulses.

Ta b l e 7

Table 7 - Products Using Dual Channel OSSD Outputs

Short circuits are detected by the safeguarding device, and the safeguarding device turns off its safety outputs. Devices with OSSD outputs are capable of operating in high risk applications.

70 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

shows examples of products that use dual channel OSSD outputs:

Product Types Product Name

Light Curtains GuardShield™

Laser Scanners SafeZone™, SafeZone Multizone

Gate Interlocks SensaGuard™, S ensaGuard with Integrated Latch

Guardlocking Interlocks TLS-ZR, 440G-LZ

Safety Monitoring Functions Chapter 9

+24V DC

24V Com

Safeguarding Device

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

+24V DC

24V Com

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

Figure 80 - Example Schematic for Two OSSD

Dual Channel N.C./N.O.

The N.C./N.O. configuration applies the diversity concepts, where one contact is open and the other contact is closed. The contact, while in an open state, cannot be welded closed. The CR30 turns off its safety outputs when either channel changes state. Both channels must change state for proper performance.

Figure 81 - Example Schematic for N.C./N.O. without Test Pulse

Figure 82 - Example Schematic for N.C./N.O. with One Test Pulse

Figure 83 - Example Schematic for N.C./N.O. with Two Test Pulses

If a short circuit occurs on terminal 12 to 24V, the CR30 turns off its safety outputs within 35 ms. Remove the fault and cycle the contacts to clear the fault.

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Chapter 9 Safety Monitoring Functions

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CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

If a short circuit occurs on terminal 12 to ground, the CR30 turns off its safety outputs within 3.3 seconds. Remove the fault and cycle the contacts to clear the fault.

If a short circuit occurs from terminal 12 to terminal 13, the CR30 turns off its safety outputs within 35 ms. Remove the fault and cycle the contacts to clear the fault.

Three Channel

The CR30 can accept three channels into one safety monitoring function. All three inputs must be HI to satisfy the input. If any one of the inputs goes LO, the output of safety monitoring function goes LO and turns off its associated output devices. The three N.C. inputs can be operated without input test pulses, with one input test pulse, with only two input test pulses, or with three input test pulses.

The available input selections for the three channel inputs are:

• EI_00…EI_11 (embedded input terminals 00…11)

• MP_12…MP_17 (multi-purpose terminals 12…17)

Pulse testing can be set to 1 Source, 2 Sources, 3 Sources, or Disabled. When 1, 2, or 3 Sources is selected, the next available test sources are automatically assigned by the CCW. You can modify the sources afterward.

You can use the default Discrepancy Time and Input Filter or choose to modify these settings.

The three terminals do not necessarily have to be consecutive.

Figure 84 - Example Schematic for Three N.C. without Test Pulses

+24V DC

020100 03 04

CR30

A1 15 20 21160618A2

12 13 14

24V Com

Figure 85 - Example Schematic for Three N.C. with One Test Pulse Source

071908 10 11

72 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Safety Monitoring Functions Chapter 9

+24V DC

24V Com

ABC

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

Figure 86 - Example Schematic for Three N.C. with Three Test Pulse Sources

Figure 87 - Example Schematic for Three OSSD

+24V DC

Safeguarding Device

24V Com

CR30

A1 15 20 21160618A2

020100 03 04

12 13 14

071908 10 11

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Chapter 9 Safety Monitoring Functions

Notes:

74 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Chapter 10

Logic Levels A and B

The Connected Components Workbench (CCW) has two levels that allow you to apply simple logic to create more sophisticated safety systems. The logic levels are labeled A and B on the CCW workspace. The logic functions are available in the Toolbox.

Figure 88 - Logic Levels A and B on the CCW Workspace

Pass Through

AND

When a logic level is not used, the CCW automatically creates a Pass Through block.

The AND block accepts 2…24 inputs. When all inputs are HI, the output of the block is HI. If any of the inputs is LO, the output of the block is LO.

The AND block is often used when multiple E-stops must be released and multiple safety gates must be closed for the safety system to be energized.

Figure 89 - AND Logic Block

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Chapter 10 Logic Levels A an d B

Table 8 - AND Logic Table for Two Inputs

Input 1Input 2Output

000

010

100

111

XOR

The OR block accepts 2…24 inputs. If any of the inputs are HI, the output of the block is HI. If all inputs go LO, the output of the block goes LO.

The OR block is often used with enabling devices.

Figure 90 - OR Logic Block

Table 9 - OR Logic Table for Two Inputs

Input 1Input 2Output

000

011

101

111

The XOR block accepts 2…24 inputs. The output of the XOR block is HI when any input is HI. The output is LO when multiple inputs are HI or if all inputs are LO.

Figure 91 - XOR Logic Block

Table 10 - XOR Logic Table for Two Inputs

Input 1Input 2Output

000

011

101

110

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Logic Levels A and B Chapter 10

NAND

NOR

The NAND block accepts 2…24 inputs. The NAND performs the opposite of an AND block. The output of the NAND block is LO when all inputs are HI. When any input is LO, the output is HI.

Figure 92 - NAND Logic Block

Table 11 - NAND Logic Table for Two Inputs

Input 1Input 2Output

001

011

101

110

The NOR block performs the opposite of the OR block. When any input is HI, the output is LO. When all inputs are LO, the output is HI.

NOT

Figure 93 - NOR Logic Block

Table 12 - NOR Logic Table for Two Inputs

Input 1Input 2Output

001

010

100

110

The NOT block accepts only one input. The NOT inverts the input signal. When the input is LO, the output is HI. When the input is HI, the output is LO.

Figure 94 - NOT Logic Block

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Chapter 10 Logic Levels A an d B

Table 13 - NOT Logic Table for Two Inputs

Input Output

AND with Restart

The AND with Restart accepts 2…24 inputs and requires a Restart input. All inputs must be HI when the Restart button is pressed.

The CCW automatically recognizes the Restart function blocks and allows you to select one. Once selected, the Restart is no longer available for other logic blocks.

Figure 95

shows an example with a gate switch and a light curtain. Both the gate must be closed and the light curtain clear. Then, the Restart input must be pressed. The output of the logic block goes HI on the trailing edge of the restart signal.

Figure 95 - Example of AND with Restart

Figure 96 - Logic of the Restart Function with Two Input AND

Restart

Input 1

Input 2

The timing diagram shows how the output of the Logic block responds to the input signals and the Restart signal. Both inputs must be HI when the Restart signal occurs for the output to go HI. If any of the inputs go LO, the output goes LO.

78 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Figure 97 - AND with Restart Timing Diagram

Restart

Input 1

AND

Input 2

Output

Logic Levels A and B Chapter 10

OR with Restart

The OR with Restart accepts 2…24 inputs and requires a Restart input. At least one input must be HI when the Restart button is pressed.

The CCW automatically recognizes the Restart function blocks and allows you to select one. Once selected, the Restart is no longer available for other logic blocks.

Figure 98

shows an example with a gate switch and a light curtain. Either the gate must be closed or the light curtain clear. Then, the Restart input must be pressed. The output of the logic block goes HI on the trailing edge of the restart signal.

Figure 98 - Example OR with Restart

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Chapter 10 Logic Levels A an d B

Figure 99 - Logic of the Restart Function with Two Input OR

Restart

Input 1

Input 2

The timing diagram shows how the output of the Logic block responds to the input signals and the Restart signal. Either or both inputs can be HI when the Restart signal occurs for the output to go HI. If all inputs go LO, the output goes LO.

Figure 100 - OR with Restart Timing Diagram

Restart

Input 1

Input 2

Output

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Chapter 11

Safety Outputs

The safety output blocks are the fourth stage of the configuration. Many of the blocks have common features.

Input Connection

Feedback

Reset

Timing

Each output block has one input connection. This input connection can be connected to only Logic Level B blocks.

The Immediate OFF, ON Delay, and OFF Delay blocks have a feedback parameter. To use the feedback parameter, a feedback input block must be declared. If a feedback input block is not available, the feedback parameter is set to “None”, and can be considered to be always HI.

The reset parameter must be set to either automatic or manual.

• If set to automatic, the output turns on when the input received from the Logic Level B block is HI.

• If the reset is set to manual, a reset input block must be declared. Before the reset button is pressed, the input that is received from the Logic Level B block must be HI. Then, the output turns on if the reset button must be pressed and held for at least 0.25 s and released within 3 s.

Timing is used in the ON Delay, OFF Delay, and Jog functions.

The timing can be set between 50…300,000 ms (5 minutes) in 50 ms increments.

Output Connections

The output of the block can be connected to one or more of the following wiring terminals:

• 12…17 Multi-Purpose (MP)

• 18…21 Embedded Output (EO)

• 00…03 plug-in 1 module (not safety rated)

• 00…03 plug-in 2 module (not safety rated)

The multi-purpose outputs can be configured to operate with pulse test (PT) or without test pulses (No PT). The embedded terminals always operate with test pulses. Terminals 20 and 21 can be configured as Single Wire Safety (SWS) output.

WARNING: The plug-in outputs must only be used for nonsafety rated purposes.

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Chapter 11 Safety Outputs

Immediate OFF

The Immediate OFF block is used to turn off output terminals immediately upon a demand that is placed on a safety function.

Figure 101

Estop block through Logic Level LLB1. The feedback signal is provided by SMF2 and manual reset by SMF3. The output is connected to:

• Terminals 18 and 19 for dual channel safety switching of the machine

• Plug-in 1 terminal 00 for status indication.

Figure 101 - Immediate OFF Configuration

shows the Immediate OFF output block that is connected to an

hazards.

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Safety Outputs Chapter 11

ON Delay

The ON Delay block turns on the output after the specified time delay expires.

Figure 102

block through Logic Level LLB1. The feedback signal is provided by SMF2 and manual reset by SMF3. The time delay is set to 20. The output will turn on 1000 ms (20x50 ms) after the reset button is released. The output is connected to:

• Terminals 18 and 19 for dual channel safety switching of the machine

• Terminal 20, which is configured as a Single Wire Safety (SWS) output.

• Plug-in 1 terminal 00 for status indication.

Figure 102 - ON Delay Configuration

shows the ON Delay output block that is connected to an E-stop

hazards.

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Chapter 11 Safety Outputs

OFF Delay

The OFF Delay block turns off the output after the specified time delay expires.

The retriggerable parameter can be set to enabled or disabled.

• When enabled, the input to the OFF Delay block can go HI again during the timing cycle, and the output remains HI.

• When disabled, the timing cycle runs to completion, regardless of changes to the input.

Figure 103

block through Logic Level LLB1. The feedback signal is provided by SMF2 and manual reset by SMF3. The time delay is set to 30. The output will turn off 1500 ms (30x50 ms) after the gate is opened. The output is connected to:

• Terminals 18 and 19 for dual channel safety switching of the machine

• Terminal 20, which is configured as a Single Wire Safety (SWS) output.

• Terminal 00 of Plug-in 2 for status reporting

Figure 103 - OFF Delay Configuration

shows the OFF Delay output block that is connected to a gate switch

hazards.

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Safety Outputs Chapter 11

Jog

The Jog block turns on the output for a specified duration while the jog input is held HI. If the Jog input goes LO, the output immediately turns off.

Figure 104

block through Logic Level LLB1. The reset is set to automatic. The time delay is set to 40. The output will turn on for a maximum of 2000 ms (40x50 ms) after the enabling switch is closed. The output is connected to:

• Terminals 18 and 19 for dual channel safety switching of the machine

• Terminal 20, which is configured as a Single Wire Safety (SWS) output.

• Plug-in 1 terminal 03 for status indication.

Figure 104 - Jog Configuration

shows the Jog output block that is connected to an enabling switch

hazards.

Muting Lamp

The Muting Lamp block works with the Muting safety monitoring function.

The muting lamp is not monitored. If the lamp burns out or becomes disconnected, the muting function continues to function properly.

Figure 105

in SMF1. The output is connected to:

• Terminal 14, a multi-purpose terminal with no pulse testing (No PT).

• Plug-in 1 terminal 00 for more status indication.

• The muting lamp should be connected to terminals without pulse testing.

Figure 105 - Muting Lamp Configuration

shows the muting lamp output block connected to the mute function

Pulse testing does not affect filament lamps, but LED lamps can appear to flicker if pulse testing is enabled.

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Chapter 11 Safety Outputs

Notes:

86 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Chapter 12

Plug-in Modules

The CR30 accepts up to two plug-in I/O modules. Ta b l e 1 4 shows which modules are available for the firmware that is installed in the CR30.

Table 14 - Plug-in Modules for the CR30

Module Description Firmware Release

2080-IQ4OB4 4 sinking inputs + 4 sourcing outputs 6 and later

2080-IQ4 4 sinking inputs 7 and later

2080-OB4 4 sourcing outputs 7 and later

2080-OW4I 4 electro-mechanical relay outputs 7 and later

Insert Module into Controller

ATT EN TI ON : The input and output signals of these modules are not safety

rated. They must only be used for standard control functions.

Follow the instructions to insert and secure the plug-in module to the controller.

Figure 106 - Plug-in Module

1. Position the plug-in module with the terminal block facing the front of the

controller as shown.

2. Snap the module into the module bay.

3. Using a screwdriver, tighten the 10…12 mm (0.39…0.47 in.) M3

selftapping screw to 0.2 N•m (1.48 lb•in) torque.

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Chapter 12 Plug-in Modules

COMI-02 I-03

A1 A2

B2B1 B3 B4 B6

COMI-00 I-01

2080-IQ4OB4

A3 A4 A6

-24DC O-02 O-03

+24DC O-00 O-01

+24V DC

24V Com

COMI-02 I-03

A1 A2

B2B1 B3 B4 B6

COMI-00 I-01

2080-IQ4OB4

A3 A4 A6

-24DC O-02 O-03

+24DC O-00 O-01

+24V DC

24V Com

2080-IQ4OB4

The 2080-IQ4OB4 has four sinking inputs and four sourcing outputs. The COM connection B3 is internally connected to A3. This COM connection is for the inputs (without it, the inputs do not turn on). Terminal B4 must be connected to the +24V supply to provide power to the outputs terminals O00…O-03.

Figure 107 - 2080-IQ4OB4 Schematic Showing Four Standard Input Signals

Figure 108 - 2080-IQ4OB4 Schematic Showing Four Standard Output Signals

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Plug-in Modules Chapter 12

COMI-02 I-03

A1 A2

B2B1 B3 B4 B6

COM CO MI-00 I-01

2080-IQ4

A3 A4 A6

COM NU NU

NU NU

+24V DC

24V Com

NU NU

A1 A2

B2B1 B3 B4 B6

NU NU

2080-OB4

A3 A4 A6

-24DC-24DC O-02 O-03

+24DC+24DC O-00 O-01

+24V DC

24V Com

2080-IQ4

The 2080-IQ4 has four sinking inputs. The four COM connections, A3, A4, B3, and B4 are internally connected. At least one COM connection must be connected to 24V Com (without it, the inputs do not turn on).

Figure 109 - 2080-IQ4 Schematic Showing Four Standard Input Signals

2080-OB4

The 2080-OB4 has four sourcing outputs. Terminals B3 and B4 are internally connected; one of these terminals must be connected to +24V DC. Terminals A3 and A4 are internally connected; one of these terminals must be connected to 24V Com.

Figure 110 - 2080-OB4 Schematic Showing Four Standard Output Signals

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Chapter 12 Plug-in Modules

2080-OW4I

The 2080-OW4I has four electromechanical relays with normally open (FormA) contacts.

Figure 111 - 2080-OW4I Schematic Showing Four Standard Output Signals

+24V DC

24V Com

B2B1 B3 B4 B6

CM0 O-0 CM1 O-1 CM2 O-2

A1 A2

2080-OW4I

NU NUNU NUCM3 O-3

A3 A4 A6

90 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Chapter 13

Module

Input

Output

LEDs

The CR30 has 21 LEDs on the upper left front of the module. These 21 LEDs fall into three categories:

• Input status

• Module status

• Output status

Figure 112 - LEDs

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 91

Chapter 13 LEDs

Input and Output LEDs

To access and configure the LEDs in the CCW,

1. In the Project Organizer, double-click Guardmaster_440C-CR30*.

2. Click LED Configuration.

3. Configure the filter type and value for input and output LEDs.

First select one of four Filter Types for each LED:

1. Not Used

2. Te rm i na l St at us

3. Safety Monitoring Function Status

4. Safety Output Function Status

Then select the instance for each Filter Type.

Monitoring a function is advantageous when the input and output logic blocks have multiple inputs or outputs. A single LED can provide status information about multiple inputs or outputs, when it provides the status of an input or output block.

92 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

In the previous example:

a. Input LED 1 is monitoring a terminal status. In this case, it is

monitoring terminal 01. When the signal to terminal 1 is HI, the LED is on. When the signal to terminal 1 is LO, the LED is off. If this were a single channel input, then the LED provides all information that we need to know about the input.

b. Input LED 2 is monitoring safety monitoring function 1. If the LED is

on, then we know that all inputs are satisfied for whatever function (for example, dual channel input, muting, or two-hand control) is being monitored.

c. Output LED 3 is monitoring the status of a Safety Output Function. In

this case, SOF 1 is being monitored. If SOF 1 is driving four outputs (two safety, one diagnostic, and one Modbus), we expect all four outputs to be HI when LED 3 is on.

LEDs Chapter 13

Controller Status LEDs

The CR30 has five module status LEDs that are described in Ta b l e 1 5 .

Table 15 - Status LEDs

LED Color Indicates

POWER Off No input power or power error condition

Green Power on

RUN Off Program mode

Green Run mode

Flashing Green [2 Hz] Application is running but not verified

FAULT Off No fault detected

Red Flashing [2 Hz] Application fault detected, recoverable

Red Controller hardware faulted, non-recove rable

LOCK Off Not used

COM Off No communications

Green Communications by serial port or USB

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 93

Chapter 13 LEDs

Notes:

94 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Chapter 14

Modbus Communication

The CR30 uses Modbus RTU communications to transfer status information and control signals to Micro800® controllers and human-machine interfaces like the Allen-Bradley PanelView.

The Modbus configuration of the CR30 is fixed to Modbus RTU slave at address1.

For more information on PanelView, refer to the following documents:

• User Manual: 2711C-UM001_-EN-P

• Quick Start Guide: 440C-QS001_-EN-P

Modbus Mapping

The CR30 Modbus addresses are mapped to parameters shown in Ta b l e 1 6 . The addresses in the range of 1…512 can be accessed as coils. The fault log can be accessed by holding register reads; each address contains 16 bits of data.

Table 16 - Modbus Addresses

Modbus Address Parameter

000001…000016 Modbus serial input data

000025…000028 Input Data for Plug-in 1 Terminals I-00…I-03

000033…000036 Output Data for Plug-in 1 Terminals O-00…O-03

000265 Processor HW fault

000266 Safety Input HW fault

000267 Safety Output HW fault

000268 Power supply fault / Main transistor fault

000269 Communication fault

000270 Configuration fault (wrong revision, invalid configuration)

000271 Time out (Clock monitoring)

000272 Plug-in fault

000273…000294 State of Embedded Terminals 00…21

000297…000300 Input of Plug-in 2 Terminals I-00…I-03

000301…000304 Output of Plug-in 2 Terminals O-00…O-03

000305…000328 State of Safety Monitoring Function (SMF) 0…23

000329…000344 State of Logic Level A Instance (LLA) 0…15

000345…000360 State of Logic Level B Instance (LLB) 0…15

000361…000376 State of Safety Output Function (SOF) 0…15

(1)

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Chapter 14 Modbus Communication

Modbus Address Parameter

000377…000392 Ready-to-start of SOF 00…15

000393…000416 Fault bit 0 of SMF 0…23

00: No error 01: Crossloop 10: Simultaneity fault 11: One channel open after reset

000417…000440 Fault bit 1 of SMF 1…24

000441…000464 Fault bit 2 of SMF 1…24

000465…000488 Fault bit 3 of SMF 1…24

000489…000504 Retrigger Fault SOF 1…16

000505…000512 Cross Fault of Terminals 12…17

000513…000848 Reserved

000849…000860 Fault log

(1) When a Logic Level A block is automatically created as a Pass Through, the block does not

occupy memory and cannot be read over Modbus. This can be viewed in the CCW as a block with no title. Pass Through blocks in Logic Level B can be read over Modbus.

Figure 113 - (Non-)Readable Pass-through Blocks

96 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Modbus Communication Chapter 14

1761-CBL-HM02 8 Pin mini DIN to 8 Pin mini DIN

Standard Cable USB A Male to B Male

Micro830 2080-LC30-24QBB Modbus Master

CR30 440C-CR30-22BBB Modbus Slave

Example Architectures

Some examples of how the CR30 is used with Modbus are shown in Figure 114.

In the example below, a PanelView C600 is connected to the serial port of the CR30. The C600 is configured over its Ethernet port. The C600 can read status information from the CR30 and can send reset and restart signals to the CR30.

Figure 114 - Modbus RTU Communication — PanelView C600

To Ethernet DHCP-enabled Network

PanelView C600 2711C-T6T Modbus Master

Ethernet Port 10/100Base-T

Ethernet Cables

1761-CBL-PM02 Cable

8-pin Mini DIN RS232

RS-232 Serial Port 9-pin D-shell

CR30 440C-CR30-22BBB Modbus Slave

In this example, a Micro830® is connected to the CR30 by the 8-pin DIN serial port connections. The Micro830 can read/use status information from the CR30 and can send reset and restart signals to the CR30.

Figure 115 - Modbus RTU Communication — Micro830

In the example below, a PanelView C600 is connector the serial port of the Micro830 and the Micro830 is connected to the CR30 through a SERIALISOL plug-in module. The Micro830 can read/use status information from the CR30 and can send reset and restart signals to the CR30.

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Chapter 14 Modbus Communication

2080-SERIALISOL

Ethernet Cables

To Ethernet Network

Ethernet Port 10/100Base-T

PanelView C600 2711C-T6T Modbus Master

Standard Cable USB A Male to B Male

Micro830 2080-LC30-24QBB

CR30 440C-CR30-22BBB Modbus Slave

RXD TXD

GND

1761-CBL-PM02 Cable

Figure 116 - Modbus RTU Communication — PanelView C600 & Micro830

98 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Modbus Communication Chapter 14

Reading CR30 Status

In the Micro800 family, the Msg_Modbus block must be used.

In the example ladder diagram below, a Micro830 reads the status of the first five input wiring terminals of the CR30.

• Rung 1: When a push button, which is connected to terminal 03 of the Micro830, is pressed, the Micro830 sends a Modbus message to the CR30

• Rung 2: The format of the data in LocalAddr is a ' WORD'. The first block ANY_TO_DINT converts the 'WORD' to a 'DINT'. The second block compares the DINT to the value of 1 with an AND_MASK. The third block checks to see if the value is 1. If the value is 1, then the output terminal _IO_EM_DO_00 goes HI.

Figure 117 - Read Ladder Diagram

You should configure local variables. In this example, they are labeled LocalCfg, TargetCfg, and LocalAddr.

• LocalCfg must be configured as a MODBUSLOCPARA data type. TargetCfg must be configured as a MODBUSTARPARA data type. LocalAddr must be configured as a MODBUSLOCADDR data type.

• TargetCfg.Addr - Select the first value from the Modbus Mapping table for the CR30. In this case, the initial value is set to 000273 (leading zeros must be included), which is mapped to terminal 00 of the CR30.

• TargetCfg.Node - Enter a value of 1. The CR30 is fixed at Node 1.

• LocalCfg.Channel - Select the serial port location. Enter a 2 if the

embedded serial port is used. Enter a 5 to use the serial port in the fist plugin slot.

• LocatCfg.TriggerType - Enter a 0 to have the block execute only once. Each time the push button that is connected to terminal _IO_EM-DI-00 is pressed, message is sent once.

• LocalCfg.Cmd - Enter a 1 to instruct the block to read a 'coil' (which is mapped to the CR30).

• LocalCfg.ElementCnt - Enter a 5 read the status if 5 inputs (starting at 000273 and ending at 000277).

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Chapter 14 Modbus Communication

• LocalAddr - The results are placed in LocalAddr. There is no need to make changes.

Figure 118 - Read Local Variables

Sending Reset to CR30

The Reset function must use a separate Modbus message block. Another constraint that must be considered is reset signal must be between 0.5…3 s long. In the example below, a momentary button is connected to embedded terminal _IO_EM_DI_02.

• Rung 3: The push button initiates a TONOFF timer. The timer is set for a 100ms delay ON and a 1100 ms delay OFF. This provides a reset signal of 1 s.

• Rung 4: The Modbus message is sent with every scan of the ladder. The reset is executed because the reset value goes from 0 to 1 and back to 0 within the acceptable range of 0.5…3 s.

• Rung 5: When the TONOFF block goes LO, embedded output _IO_EM_DO_01 goes LO and moves the value of 0 into Reset Addr.

• Rung 6: When the TONOFF block goes HI, embedded output _IO_EM_DO_01 goes HI and moves the value of 1 into Reset Addr.

Figure 119 - Reset Ladder Diagram

100 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014

Rockwell Automation 440C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Preface

Who Should Use this Manual

Purpose of this Manual

Additional Resources

Definitions

Table of Contents

Overview

Intended Use

Hardware Features

CR30 Hardware Details

Max Number of Inputs and Outputs

Software

Obtain Connected Components Workbench

USB Connection

Serial Port Connection

Installation

Mounting Dimensions

DIN Rail Mounting

Panel Mounting

Enclosure Considerations

Preventing Excessive Heat

Power, Ground, and Wiring

Wire Size

Terminal Assignments

Connecting a Power Supply

Wire Input Devices

Input Devices with Mechanical Contacts

Input Devices with OSSD Outputs

Wire Output Devices

Use Surge Suppressors

Embedded Serial Port Wiring

Power Cycling

Configuring the CR30

Begin Configuration

The Workspace

Download the Configuration

Validation and Verification

Validation

Verification

Viewing the Verification ID without CCW

Multiple Block Connections

Pulse Testing

Normally Open Input Pulse Testing

Normally Closed Input Pulse Testing

Output Pulse Testing

Input Filter

Discrepancy Time

Safety Block Renaming

General

Naming Error Indication

Safety Monitoring Functions

Emergency Stop

Enabling Switch

Feedback Monitoring

Gate Switch

Light Curtain

Muting

2-Sensor T-Type Muting

2-Sensor L-Type Muting

4-Sensor Muting

Muting Override

Muting Lamp

Reset

Restart

Safety Mat

SensaGuard

Single Wire Safety Input

Two-Hand Control

Type IIIA Two-hand Control

Type IIIC Two-Hand Control

Alternate Device

Single Channel

Dual Channel

Dual Channel OSSD

Dual Channel N.C./N.O.