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Rockwell Automation Publication IASIMP-QS005H-EN-P - April 2016

Chapter 1

      Risk Assessment and System Design

Risk Assessment Example for Robot Cell Application

The following is an example of a robot cell risk assessment worksheet including both task and hazard identification and 
risk estimation.

Figure 3 - Line Name: XYZ Assembly and Inspection Station 

This application consists of an assembly and inspection station with this equipment.

• Manual Loading Station #1 (A) 
• Panel Assembly Feed Conveyor (B) 
• 6-axis  Servo  Robot  (C) 
• Automated inspection station (D) 
• Overhead  Transfer  Gantry  (E) 
• Finished Part Transfer Elevator (F) 

B

Panel Assy. 

Feed Conveyor

F

Parts Transfer 
Elevator

Part Positioning Station #1 and #2

D

Inspection 

Station

A

Load Station #1

C

Robot

E

Overhead Transfer Gantry

Summary of Contents for 1756-L71S

Page 1: ...t Catalog Numbers 1756 L61S 1756 L62S 1756 L63S 1756 LSP 1756 L71S 1756 L72S 1756 L73S 1756 L7SP 1756 L73SXT 1756 L7SPXT 1768 L43S 1768 L45S 1756 L72EROMS 1769 L30ERMS 1769 L33ERMS 1769 L36ERMS Quick Start OriginalInstructions ...

Page 2: ...formation 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 Labels may also be on or inside the equipment to provide specific precautions WARNING Identifies information...

Page 3: ... Techniques for Hazard Control 22 Incorporate Protective Systems and Measures 22 Safety Specification Example for Robot Cell Application 23 Load Station 1 23 Panel Assembly Feed Conveyor B 24 How Rockwell Automation Can Help 25 Chapter2 Hardware Selection and Safety Wiring Layout Introduction 27 Before You Begin 27 What You Need 27 Follow These Steps 28 Select Hardware 28 Defining Module and Safet...

Page 4: ... I O Faceplates 70 Import Add On Instruction for Digital Guard I O Faceplate 70 Create Controller Tags for Digital Guard I O Faceplate 71 Create GuardIO_AOI Instances in Standard Program Routines for Each Digital Guard I O Faceplate 73 Configure Guard I O Module Add On Instruction Message Instructions for each Digital Guard I O Faceplate 78 Faceplate Logic for Analog Guard I O Faceplates 82 Import...

Page 5: ... Controller Project 130 Import SmartGuard 600 Faceplate Add On Instruction and Logic Rungs to Your Logix Controller Project 132 Create an Instance of Your SmartGuard 600 Faceplate Add On Instruction in Your CompactLogix Project Routine 137 Configure CompactLogix Communication 141 Save and Download Your Program 142 Chapter5 FactoryTalk View ME Software Integration Introduction 143 Before You Begin ...

Page 6: ...ion Options 173 Analog Guard I O Module Faceplate Online Help Options 174 Safety Instruction Faceplate Overview 174 Safety Instruction Faceplate Fault Views 175 Safety Instruction Faceplate Diagnostic Views 175 AppendixA Robot Cell Application Example with GuardLogix or SmartGuard 600 Controller Introduction 177 Robot Cell Module and Safety Zone Configuration 178 Robot Cell Safety Logic Examples 1...

Page 7: ...Logix 5370 information row to Table 6 29 Revised instructions and graphics in Access Other Allen Bradley CAD Drawings section 45 Added LogixDesigner software version information to What You Need section 47 Updated website URL for Safety Accelerator Toolkit in What You Need section 47 Added publication 1769 UM022 to What You Need section 47 Revised information and graphicin third bullet point 53 Ad...

Page 8: ...8 Rockwell Automation Publication IASIMP QS005H EN P April 2016 Summary of Changes Notes ...

Page 9: ...safety application Chapter 1 Risk Assessment and System Design Chapter 2 Hardware Selection and Safety Wiring Layout Chapter 3 GuardLogix Controllers Logic Integration Chapter 5 FactoryTalk View ME Software Integration Chapter 6 Safety System Application Guide Chapter4 SmartGuard 600 Controllers Logic Integration ...

Page 10: ...10 Rockwell Automation Publication IASIMP QS005H EN P April 2016 Where to Start Notes ...

Page 11: ...ers in this quick start do not have to be completed in the order in which they appear but this section defines the minimum amount of preparation required before you complete the current chapter What You Need This section lists the tools that are required to complete the steps in the current chapter This includes but is not limited to hardware and software Follow These Steps This illustrates the st...

Page 12: ...odules Guard I O DeviceNet Safety Modules User Manual publication 1791DS UM001 Provides information to use Guard I O DeviceNet Safety modules Guard I O EtherNet IP Safety Modules Installation Instructions publication 1791ES IN001 Provides information to install CompactBlock Guard I O EtherNet IP Safety modules Guard I O EtherNet IP Safety Modules User Manual publication 1791ES UM001 Provides infor...

Page 13: ...ned which safety components you ll need you ll learn how to use the Safety Accelerator Toolkit to layout your system wiring integrate logic routines in your safety application program and use faceplates designed to facilitate HMI Before You Begin Become familiar with the local national and international standards including consensus standards that govern machine safety The safety standards that wo...

Page 14: ... A hazard control technique must be defined for each hazardous motion including each mode of operation such as Automatic Jog or Cycle Stop and each demand on the safety system such as E stop device activated or safety gate opened This is essential so that the energy source is properly controlled in all interactions with the machine and all demand scenarios on the safety system Start Safety Strateg...

Page 15: ...o the system 6 Administrative Requirements and Training develop and implement administrative requirements as well as operator technician and affected personnel training 7 Validation performed prior to production release to verify that the safety system meets the requirements set forth by the risk assessment and performs at the proper level of fault tolerance prescribed by the chosen methodology Id...

Page 16: ... of risk mitigation to the hazard Task and Hazard Identification All of the hazards at the machine must be identified and listed in terms of their nature and location Examples of hazards include crushing shearing entanglement part ejections fumes radiation heat noise and more For each hazard be sure to identify the energy source and component that could cause the injury such as a crushed arm due t...

Page 17: ...of tools are available It s important to use these types of processes to help define the level of risk Figure 1 Risk Graph for Performance Level for a Safety Function ISO 13849 1 2006 Figure 2 Risk Graph for ISO13849 1 2006 Category Determination Must be determined for each safety function S Severity F Frequency or Duration of Exposure P Avoidance Probability P2 P1 P2 P1 P2 P1 P2 P1 F2 F1 F2 F1 S2...

Page 18: ...isk estimation Figure 3 Line Name XYZ Assembly and Inspection Station This application consists of an assembly and inspection station with this equipment Manual Loading Station 1 A Panel Assembly Feed Conveyor B 6 axis Servo Robot C Automated inspection station D Overhead Transfer Gantry E Finished Part Transfer Elevator F B Panel Assy Feed Conveyor F Parts Transfer Elevator Part Positioning Stati...

Page 19: ... the Transfer Elevator F 8 The Transfer Elevator F indexes one position to complete the cycle The machine operating modes as defined by the operators are Automatic Manual and Jog with gates open The Jog mode operation is required for the movement of the following equipment Equipment Movement Robot C 5 axis End of Arm EOA tooling Overhead Transfer Gantry E X axis Y axis End of Arm EOA tooling Parts...

Page 20: ...e housekeeping procedures for floor cleaning S2 F1 A1 R3B Slips or tripping due to raised edges or floor discontinuity S2 F2 A1 R2A Verify that the floor area does not have any discontinuitieshigher than 3 16 in S2 F1 A1 R3B 3 Place part into loadingfixture Part loading is complete upon stacklight indication Part position OK Mechanical impact Pinch or Crush hazard due to robot motion S2 F2 A2 R1 I...

Page 21: ...atings Severity of Injury Frequency Exposure Avoidance Residual Risk Footnote 1 Tasks in the general areaof the work cell where a person may be tempted to enter the hazardous area Mechanicalimpact Pinch or crush hazard due to robot motion S2 F2 A2 R1 Safeguarding a Use hard guards to prevent access to the hazardous area b Use a light curtain to prevent access to guarded area such as workers climbi...

Page 22: ...sible This usually results in a combination of measures Incorporate Protective Systems and Measures If access to a hazardous area is not required the solution may be to safeguard it within the body of the machine or by some type of fixed enclosing guard If access is required it is necessary to make sure that access can only be gained while the machine is in a safe state Protective measures such as...

Page 23: ... places the part into Load Station 1 A When the part is in position the operator initiates the part ready sequence The operator is also responsible for repositioning any miss picked parts moving empty racks out of the way and moving full racks into position for loading Maintenance personnel adjust and repair fixtures as needed The part fixture has sensors to indicate that the part is loaded proper...

Page 24: ...ations and lubricate and repair equipment as needed The Panel Assembly Feed Conveyor has sensors to indicate when a part is in position at Positioning Station 1 for rough alignment and at Positioning Station 2 for final alignment and part holding for assembly A stack light annunciates proper part positioning with a green light and improper loading with a red light The Panel Assembly Feed Conveyor ...

Page 25: ...ess of the method selected the system engineer must determine the method and type of safety protection for the identified hazards Rockwell Automation recommends you follow a formal Risk Assessment process Rockwell Automation currently uses the ANSI RIA R15 06 1999 model as our standard risk assessment methodology and options for ISO and IEC based risk assessments For hazard assessment risk assessm...

Page 26: ...26 Rockwell Automation Publication IASIMP QS005H EN P April 2016 Chapter 1 Risk Assessment and System Design Notes ...

Page 27: ...ecommended in Chapter 1 Make sure that you have installed the required software and have access to the Internet if you are not using the Safety Accelerator Toolkit DVD What You Need Personal computer with internet access for downloading software and files AutoCAD program to open the dwg files or Adobe Acrobat Reader software to open pdf files Safety Accelerator Toolkit DVD SAFETY CL002 or visit th...

Page 28: ...ision tree to determine your safety controller platform Start Select Hardware page 28 Defining Module and Safety Zone Tags page 30 Lay Out Your Safety Wiring page 36 Do you need safety and standard logic in the same controller No No Do you need support for CIP Safety on DeviceNet networks Do you needsupport for CIP Safety on DeviceNet networks 1756 GuardLogix Controller Yes Yes Yes 1768 Compact Gu...

Page 29: ...utputs Table 6 Capabilities and Performance Controller Platform Capacity Functionality Performance GuardLogix 1756 Up to 125 nodes max Safety andstandard control logic Extensive suite of safety application instructions CIP Safety on Ethernet ControlNet and DeviceNet Superior ease of use High performance integrated safety Use GuardLogix calculator and estimating tools tocalculate performance Compac...

Page 30: ...tems in the safety project To complete the Safety Zone Configuration worksheet follow these steps 1 Determine the number of zones in your application You need to fill out a Safety Zone Configuration worksheet for each zone in your application 2 Browse to the Guard I O and SmartGuard Modules directory in the toolkit If the toolkit has been loaded onto your personal computer the hard drive path is C...

Page 31: ...one Configuration worksheet and enter a Zone Name For this example we entered Zone1 The ZoneName will be inserted in many of the Zone Tags listed in the worksheet You will use the tag names in this worksheet in your application logic developed in Chapter 3 for GuardLogix Controllers and Chapter 4 for SmartGuard 600 controllers 5 Type a Safety Module Name for each module used in the Safety Zone and...

Page 32: ...onal computer the hard drive path is C Program Files RA_Simplification SafetyGuardLogix Files Guard IO and SmartGuard Modules 2 Select the safety module configuration file that corresponds to your first safety I O module make a copy and name it using the ModuleName listed in the Safety Zone Configuration Worksheet For this example we selected GLX Guard IO Configuration xls copied the file and name...

Page 33: ...ellGuard1 as a module name The zone name and module name will be automatically inserted in the input and output tags listed in the worksheet 5 You may also enter the module catalog number and safety category although it is not critical for toolkit use 6 Fill in the Device Name for each input on your module If your application requires Category 3 or Category 4 each device typically requires two inp...

Page 34: ...evice Name field 9 For safety outputs fill in the Device Name and use the pull down list to choose the Device Type Category 3 or Category 4 outputs typically require either two devices with one output channel each or a single device with dual channel outputs Use the dual channel column For Category 2 each output single channel has its own name Use the single channel column TIP The device names wil...

Page 35: ...ckwell Automation Publication IASIMP QS005H EN P April 2016 35 Hardware Selection and Safety Wiring Layout Chapter 2 The following example illustrates a completed worksheet for a CAT 4 safety input module ...

Page 36: ...e safety I O safety device and various project drawings The diagrams include power and control wiring If you do not have CAD software use the PDF files to build your system drawing Access and Gather Drawings from Toolkit Refer to your bill of materials and follow these steps to access the safety system drawings 1 Browse to the System Wiring Diagrams directory in the toolkit If the toolkit has been...

Page 37: ...d the desired file format DXF DWG or PDF For this example the CAT4 DWG directory was chosen A number of drawings for different devices I O and controllers are included Drive Safety Wiring Safety Controller Power Other Safety Devices Guard I O Module Wiring Drive I O Safety Controller I O Ethernet Switch Wiring Panel Layout Drawings Kinetix and PowerFlex Safe Torque Off Wiring Title Safety Controll...

Page 38: ... I O drawings Edit Project Drawing Set These steps provide general instructions for how to maximize the use of the toolkit s drawing library in creating a safety system layout and wiring drawing set AutoCAD or AutoCAD Electrical software is recommended to take full advantage of the drawing editing steps included in this chapter and the library s device wiring references and attributes that move wi...

Page 39: ...l 2016 39 Hardware Selection and Safety Wiring Layout Chapter 2 3 Add and select the toolkit library drawings you copied in the previous section 4 Open the original Title Sheet drawing and edit the drawing list and title blocks specific to your applications ...

Page 40: ...Hardware Selection and Safety Wiring Layout 5 Open Drive or Drive Safety Torque Off Wiring Drawings and edit drawings specific to your application 6 Open your Safety Controller Power Drawing and edit controller connections and edit or add other device power supply connections ...

Page 41: ...Rockwell Automation Publication IASIMP QS005H EN P April 2016 41 Hardware Selection and Safety Wiring Layout Chapter 2 7 Open other Safety Device Drawings and edit drawings specific to your application ...

Page 42: ...n and Safety Wiring Layout 8 Open Guard I O and or SmartGuard 600 Safety Input and Output Drawings Copy and paste safety devices that represent your specific safety I O configuration from one sheet to another This example shows Cat 4 drawings for a 1791ES IB16 module and a light curtain device ...

Page 43: ...ell Automation Publication IASIMP QS005H EN P April 2016 43 Hardware Selection and Safety Wiring Layout Chapter 2 9 Open Safety Controller Network and or Ethernet Switch Drawings and modify your application ...

Page 44: ...nsiderations for Safety Drawings The drawings were created with AutoCAD Electrical The project files are included in the DWG directory The path references in the project file are the default AutoCAD Electrical installation path Some safety input devices such as Electronic Sensors Cat 2 and Cat 3 only have safety category restrictions so they are not included on every category Guard I O module draw...

Page 45: ... product CAD drawings 1 Open your browser and go to http www rockwellautomation com global support select design configure page On the home page click Product Drawings 2 Enter the catalog number of the product 3 Click Submit The Configuration Results window opens showing what documents are available for that catalog number 4 Click AutoCad Drawing 2D DXF 5 Download the drawing to a destination of y...

Page 46: ...46 Rockwell Automation Publication IASIMP QS005H EN P April 2016 Chapter 2 Hardware Selection and Safety Wiring Layout Notes ...

Page 47: ... SAFETY CL002 or visit the Integrated Architecture Tools and Resources website at http www rockwellautomation com global products technologies integrated architecture tools overview page Product manuals GuardLogix Controllers User Manual publication 1756 UM020 Compact GuardLogix Controllers User Manual publication 1768 UM002 Compact GuardLogix 5370 Controllers User Manual publication 1769 UM022 Gu...

Page 48: ...evice Logic page 56 Import Your Safety Output Device Logic page 62 Add Safety Input and Safety Output Device Logic for Each Safety Zone page 67 Adding Your Faceplate Logic page 67 Faceplate Logic for Safety Instruction Faceplates page 68 Faceplate Logic for Digital Guard I O Faceplates page 70 Faceplate Logic for Analog Guard I O Faceplates page 82 MapDigitalandAnalogGuardIO_AOITags to Safety Zone...

Page 49: ...n_V20 ACD If the toolkit has been loaded onto your personal computer the hard drive path is C Program Files RA_Simplification SafetyGuardLogix Files Guard IO and SmartGuard Modules These application files include pre configured Guard I O module configurations based on network and safety category type to assist you in configuring your safety I O modules TIP The steps in this chapter show a 1756 Gua...

Page 50: ...50 Rockwell Automation Publication IASIMP QS005H EN P April 2016 Chapter 3 GuardLogix Controllers Logic Integration ...

Page 51: ... created in Chapter 2 choose your Guard I O module to match the catalog number and safety category This example shows a 1791ES IB16 in a Cat 4 Ethernet application 3 Right click the module and choose Copy IMPORTANT The 1756 GuardLogix controller and 1756 communication modules support both Guard I O EtherNet IP and DeviceNet modules The 1768 Compact GuardLogix controller and 1768 ENBT communication...

Page 52: ...r application file This example uses an EtherNet IP network Yours could be a DeviceNet or EtherNet IP network 5 To edit module properties for your application right click the I O module and choose Properties 6 Rename the I O module according to your Fill Out the Safety Module Configuration Worksheet which you created in Chapter 2 7 Change the IP Address EtherNet IP networks or Node Address DeviceN...

Page 53: ...onfigurations that you added in steps 1 4 include the settings required to work with the Guard I O faceplates and AOI instructions These required digital I O configuration settings include Set Input Status to Combined Status Muting for all modules Set Output Data to Combined for all modules with both safety inputs and outputs Set Output Data to Combined Status for all modules with only safety outp...

Page 54: ...our application This example includes an additional module a 1791ES IB8XOBV4 module named CellGuard2 10 Check your Safety Network Numbers SNN The copy and paste module configuration procedure can create Guard I O modules with the same SNNs on different bridge modules Follow steps 11 15 to create a unique SNN for the Guard I O modules on each communication bridge module 11 To change the SNN right c...

Page 55: ... 12 In the Module Properties dialog box click next to the SNN field to open the Safety Network Number dialog box 13 Click Generate to generate a new time based SNN 14 When the new SNN appears in the Number field click Copy 15 Paste the new SNN to all other Guard I O modules under the same communication bridge module ...

Page 56: ...your SafetyProgram and choose New Routine Create routines for each of the safety zones you documented in your Safety Zone Configuration worksheet from Chapter 2 This example shows a single routine named Zone1 Import Your Safety Input Device Logic Follow these steps to add safety input logic for each safety input device in each zone 1 Open your safety zone routine 2 Right click the initial rung and...

Page 57: ...ctory for your analog input device routines If the toolkit has been loaded onto your personal computer the hard drive path is C Program Files RA_Simplification SafetyGuardLogix Files Safety Device Routines RSL5k_Vxx_or _Later 4 Select the XML file based on the device type of the first input device listed on your first Safety Module Configuration worksheet and click Import ISO 13849 1 requires that...

Page 58: ... listed in the import configuration are used as placeholders for unused tags Refer to the rung comments for more information 6 Type the DeviceName from your Safety Module Configuration worksheet into the tag names on the Import Configuration dialog box In addition for a dual channel analog input logic import type the ModuleName of the Analog Module into the ModuleName_Ch0Ch1_InputStatus tag 7 Sele...

Page 59: ... input device is connected Some analog input device imports include Ch0 references that must be updated to specific channel for that input 9 Double click the Guard I O module input tag 10 If the input device has a ModuleName O output tag select the ModuleName O field 11 Click the pull down arrow to browse to the Guard I O module to which this input device is connected 12 Double click the Guard I O...

Page 60: ... Lamp is wired to Test Output 2 and unlock solenoid is to Test Output 00 Reassignment of the tags will need to be made to match your unique safety wiring configuration The Reset isassigned to a tag named Cmd_ZoneName_FaultReset representing a command triggered by an HMI or hardwired input within a Safety_Output_CAT3_CAT4 Safety Logic Routine The same Fault Reset tag Cmd_ZoneName_FaultReset for thi...

Page 61: ...dule Configuration worksheet 16 Double click each of your other module input or output tags within your safety logic and browse to the associated input and output tags listed in your Safety Module Configuration worksheet 17 Repeat the Import Your Safety Input Device Logic steps on pages 56 61 for each safety input device listed in the first zone of the Safety Zone Configuration worksheet you creat...

Page 62: ... 3 Browse to the Safety Device Routines RSL5k_V16_or_Later RSL5k_V17_or_Later or RSL5k_V20_or_Later directory in the toolkit and select the CAT2 or CAT3_CAT4 subdirectory based on your output device safety category requirements 4 Select the device type of the first output device listed on your first Safety Module Configuration worksheet and click Import ISO 13849 1 requires that manual reset funct...

Page 63: ...utput device from your Safety Module Configuration worksheet into the tagnames on the Import Configuration dialog box 7 In the DeviceName1 through DeviceName8 tags type the DeviceNames for the input devices that control this output in this zone If you do not have 8 input devices leave the unused DeviceName tag fields as is This example shows 7 inputs If you have more than 8 input devices you need ...

Page 64: ...Click the pull down arrow to browse to the Guard I O module to which this safety output is connected 10 Double click the module s input tag 11 Click ModuleName O field 12 Click the pull down arrow to browse to the Guard I O module to which this safety output is connected 13 Double click the module s output tag 14 Click OK to complete the import ...

Page 65: ...t will typically be used on all of the safety input and output instructions within its safety zone Safety Input Interlock Rung This rung includes 8 safety device input interlocks with tag names Sts_ZoneName_DeviceName1_InputOK through Sts_ZoneName_DeviceName8_InputOK that energize the Sts_ZoneName_InputsOK OTE instruction These interlocks can be driven by the individual safety device input logic r...

Page 66: ...7 If your Guard I O module is a 1791DS IB4XOW4 1791DS IB8XOB8 1791DS IB8OXBV4 or 1732DS IB8XOBV4 then double click ModuleName I OutputStatus in the Output Enable Rung and choose ModuleName I CombinedOutputStatus tag from the pull down list 18 Double click the Feedback 1 and Feedback 2 tags on the CROUT safety output instruction and browse to the Guard I O module input tags assigned to the feedback...

Page 67: ...d input and output logic for the Robot_Cell Application example used in this toolkit Adding Your Faceplate Logic The toolkit features three pre configured faceplates The digital Guard I O module faceplate lets you view the status of the safety circuits and logic and provides diagnostics for safety demands and faults You will need to add one Guard I O Add On Instruction AOI for each digital I O mod...

Page 68: ... 1 Under Data Types in RSLogix 5000 software right click User Defined and choose Import Data Type 2 Browse to the Safety Instruction Faceplate files in the toolkit and open the ME_Safety_Faceplate_Files folder If the toolkit has been loaded onto your personal computer the hard drive path is C Program Files RA_Simplification SafetyGuardLogix Files Safety Instruction Faceplate Files ME_SafetyInstruc...

Page 69: ... type folder Create Faceplate Animation Tags for Safety Instruction Faceplates When you create an HMI safety instruction faceplate that corresponds to a safety instruction you also need to create a tag that stores the animation information for that faceplate This tag will have the same data type you imported in the last section Follow these steps to create an animation tag 1 Expand your controller...

Page 70: ... Data Type The Class for these tags must be Standard You will create a faceplate animation tag for every safety instruction you wish to monitor Faceplate Logic for Digital Guard I O Faceplates Import Add On Instruction for Digital Guard I O Faceplate Follow these steps to load the Add On Instruction logic that will let you use these digital Guard I O faceplates 1 In your RSLogix 5000 application f...

Page 71: ...ction appears in your project s Add On Instruction folder Create Controller Tags for Digital Guard I O Faceplate Prior to creating an instance of the digital GuardIO_AOI you must create tags within the controller application You need to add these six tags for each of your digital Guard I O modules which you listed in your Safety Zone Configuration worksheet from Chapter 2 Table 7 Guard I O Module ...

Page 72: ...ller Tags and choose New Tag 3 In the New Tag dialog box type the tag name based on the Guard I O Module Tags table on page 71 and enter the ModuleName for the associated Guard I O module found on the Safety Zone Configuration worksheet you completed in Chapter 2 4 Choose the appropriate data type and scope for each tag based on the Guard I O Module Tags table on page 71 The Class for these tags m...

Page 73: ...for Each Digital Guard I O Faceplate You must create a GuardIO_AOI instance for each Guard I O module in your application 1 Open the intended standard program routine and add a rung 2 Select the GuardIO_AOI from the Add On Instructions tab 3 Double click the GuardIO_AOI tag name field 4 Type the ModuleName of the first Guard I O module from your Safety Module Configuration worksheet This example s...

Page 74: ...Chapter 3 GuardLogix Controllers Logic Integration 5 Right click in the tag name field and choose New tag name where tag name is the name you typed 6 In the New Tag dialog box verify that your settings match what is shown below Change where needed to match 7 Click OK ...

Page 75: ...ags which you created in the Create Controller Tags for Digital Guard I O Faceplate section of this chapter 10 Double click the Set_SafetyIOModuleSelect field and type in the value that matches your module catalog number as shown in this table Table 8 Set Safety I O Module Type Set_SafetyIOModuleSelect Value Guard I O Module Catalog Number 1 1791DS IB8XOB8 2 1791DS IB12 3 1791DS IB4XOW4 4 1791DS I...

Page 76: ...te files folder within the Guard I O and SmartGuard Faceplate Files toolkit directory If the toolkit has been loaded onto your personal computer the hard drive path is C Program Files RA_Simplification SafetyGuardLogix Files Guard IO and SmartGuard Faceplate Files ME Faceplate Files 14 Select the GuardIO_AOI_Map file and click Import 15 Click the ModuleName I field 16 Click the pull down arrow to ...

Page 77: ... tag 18 Click the ModuleName O field 19 Click the pull down arrow to browse to your first Guard I O module 20 Double click the module s output tag 21 Type the ModuleName of the first Guard I O module listed in your Safety Zone Configuration worksheet into both the ModuleName_InputData and ModuleName_OutputData tags 22 Click OK to complete the import ...

Page 78: ...eate GuardIO_AOI Instances in Standard Program Routines for Each Digital Guard I O Faceplate steps 1 23 on pages 73 78 for each of the Guard I O modules you wish to use with the pre configured faceplate ConfigureGuardI OModuleAdd OnInstruction Message Instructions foreachDigitalGuardI OFaceplate For each of your module Add On Instructions configure the MSG_1 instruction to return status informatio...

Page 79: ...le which results in a Service Code of e 4 Fill in the Class Instance and Attribute fields using this table Table 9 Guard I O Module Configuration Data Guard I O Module Class Instance Attribute 1791DS IB8XOB8 4 803 3 1791DS IB12 4 786 3 1791DS IB4XOW4 4 819 3 1791DS IB8XOBV4 4 884 3 1791DS IB16 4 869 3 1732DS IB8XOBV4 4 884 3 1732DS IB8 4 868 3 1791ES IB8XOBV4 4 884 3 1791ES IB16 4 869 3 1734 OB8S ...

Page 80: ...n tab on the Message Configuration dialog box 6 Set the Message Path by clicking Browse and choosing the intended Guard I O module from the I O Configuration tree 7 Click OK to accept the message path 8 Click OK on the Message Configuration dialog box to accept the MSG1 configuration 9 To configure the MSG_2 instruction click the message instruction dialog button for MSG_2 ...

Page 81: ...lds to match what is shown in the above example Logic within the GuardIO_AOI modifies the Class Instance and Attribute depending upon the module selected and which Guard I O point faults 13 To access Message communication select the Communication tab on the Message Configuration dialog box 14 Set the Message Path by clicking Browse and choosing the intended Guard I O module from the I O Configurat...

Page 82: ...e steps 1 16 on pages 78 81 for each of the GuardIO_AOI instructions in your application See Appendix A for the completed faceplate logic for the Robot Cell Module and Safety Zone Configuration used in this toolkit Faceplate Logic for Analog Guard I O Faceplates Import Add On Instructions for Analog Guard I O Faceplates 1 In your RSLogix 5000 application file right click Add On Instructions and ch...

Page 83: ...oose the GuardIO_Analog_AOI file and click Import The Guard I O Add On Instruction appears in your project s Add On Instruction folder 4 To choose GuardIO_Analog_Safety_AOI file follow steps 1 through 3 and click Import The Guard I O Analog Add On Instruction should also appear in your project s Add On Instruction folder ...

Page 84: ...he intended standard program routine and add a rung 2 Select the GuardIO_Analog_AOI from the Add On Instructions tab 3 Double click the GuardIO_Analog_AOI tag name field 4 Type the ModuleName of the first Analog Guard I O module from your Safety Module Configuration worksheet This example shows an Add On Instruction named E_IE4S that is associated with a Analog Guard I O module of the same name 5 ...

Page 85: ...1 6 for each safety analog module in your system Create a GuardIO_Analog_AOI_Safety Instance in a Safety Program Routine You must also create a GuardIO_Analog_AOI_Safety instance for each Guard I O module in your application 1 Open the intended Safety program routine and add a rung This will most likely be the program routine for the safety zone that this module will be used for 2 Select the Guard...

Page 86: ..._AOI_Safety tag name field 4 Type the ModuleName_S of the first Analog Guard I O module from your Safety Module Configuration worksheet This example shows an Add On Instruction named E_IE4S_S that is associated with a Analog Guard I O module named E_IE4S 5 Right click in the tag name field and choose New tag name where tag name is the name you typed ...

Page 87: ...dialog box verify that your settings match what is shown below Change where needed to match 7 Click OK 8 Assign the Safety Analog Input Module s input tag to the Safety Analog GuardIO_AOI Module field The Module assignment in this example is Enet_Adapter 1 I which is the input tag of the IE4S module in slot 1 of the Point I O chassis ...

Page 88: ...dLogix Controllers Logic Integration 9 Double click each of the Chx_User tags and enter value of 1 if the channel on the module is being used or a value of 0 if the channel is not used The channel assignment in this example show channels 0 1 and 2 being used and channel 3 not used ...

Page 89: ...tags 1 Select the Analog GuardIO_AOI instance rung in your Standard Task for the safety analog module that includes a tachometer input 2 Right click your Analog GuardIO_AOI instance rung and chose Import Rung 3 Browse to the ME Faceplate files folder within the Guard I O and SmartGuard Faceplate Files toolkit directory If the toolkit has been loaded onto your personal computer the hard drive path ...

Page 90: ...in the Final Names column and click the arrow key to browse to the Analog GuardIO_AOI instance tag For this example the Analog GuardIO_AOI tag named E_IE4S was selected 7 Select each of the remaining tags in the Final Names column and replace ModuleName text with the same name as the Analog GuardIO_AOI tag name For this example ModuleName was replaced with E_IE4S in each of the remaining tags ...

Page 91: ...el 2 tags of the analog input module 9 Click OK to complete tachometer reset mapping tag rungs Two rungs appear just below the Analog GuardIO_AOI instance rung 10 Double click the E_IE4S Cmd_ChxTachReset tag on the XIC instruction of the first rung and click the drop down arrow 11 Browse to and select the Analog GuardIO_AOI s Cmd_ChxTachReset tag For this example E_IE4S Cmd_Ch2TachReset tag was se...

Page 92: ...e following rungs 12 Choose Logic Map Safety Tags to map the associated standard controller tachometer reset tags to the safety tachometer reset tags 13 Select the standard tag name field and click the pull down arrow 14 Locate the ModuleName_ChxHMITachReset_Map output tag of the first rung you imported in the previous steps and double click to place in the standard tag name field For this example...

Page 93: ...l down arrow 16 Locate the associated ModuleName_ChxHMITachReset safety tag and double click to place in the safety tag name field For this example E_IE4S_Ch2HMITachReset safety tag was selected 17 Repeat steps 1 16 for all of the tachometer analog channels of each module The following is an example of mapping four tachometer channels from an analog module named E_IE4S ...

Page 94: ...e Import Rung 3 Browse to the ME Faceplate files folder within the Guard I O and SmartGuard Faceplate Files toolkit directory If the toolkit has been loaded onto your personal computer the hard drive path is C Program Files RA_Simplification SafetyGuardLogix Files Guard IO and SmartGuard Faceplate Files ME Faceplate Files 4 Select the GuardIO_AOI_Map_2 file and click Import Alternatively if the sa...

Page 95: ...ModuleName and then click the pull down arrow to browse to your configured GuardIO_AOI tags as listed in your Safety Zone configuration worksheet 7 Double click the GuardIO_AOI tag to select it If your zone has less than 6 safety modules leave any unused tags names as is If your zone has more than 6 safety modules you will need to add more instructions after the import is complete This examples sh...

Page 96: ...ion IASIMP QS005H EN P April 2016 Chapter 3 GuardLogix Controllers Logic Integration 9 After the import is complete the imported safety reset and fault reset logic rungs should look similar to rungs 2 and 3 in the example shown here ...

Page 97: ...nstruction branches that are not assigned GuardIO_AOI tags by right clicking the branch and choosing Delete branch level 11 Choose Logic Map Safety Tags to map the associated standard controller tags to the safety tags 12 Select the standard name field and click the pull down arrow 13 Select both the Cmd_ZoneName_FaultReset_Map and Cmd_ZoneName_SafetyReset_Map tags ...

Page 98: ...f the zones you wish to use 1the pre configured faceplates for Configure Logix Communication This procedure assumes that your communication method to the GuardLogix controller is via the Ethernet protocol and that your Logix Ethernet module has already been configured For additional information refer to the GuardLogix Controllers User Manual publication 1756 UM020 or the Compact GuardLogix Control...

Page 99: ...ur Logix Ethernet module and click OK The IP address shown is an example Yours will be different 6 Click Close 7 Select RSWho from the Communication menu 8 In the RSWho window expand the Ethernet communication module until your controller is visible 9 Verify that you can browse to your Logix controller 10 Minimize the RSLinx application window and return to your RSLogix 5000 project window TIP If ...

Page 100: ... to download to controller The safety partner is missing or unavailable Cancel the download process Install a compatible safety partner before attempting to download Unabletodownloadtocontroller Thefirmwarerevisionofthesafetypartneris not compatible with the primary controller Update the firmware revision of the safety partner Choose Update Firmware Choose the required revision and click Update Co...

Page 101: ...nx Classic and FactoryTalk View Machine Edition software on your personal computer or workstation What You Need RSLogix 5000 software RSNetWorx for DeviceNet software RSLinx software Safety Accelerator Toolkit DVD SAFETY CL002 or visit the Integrated Architecture Tools and Resources website at http www ab com go iatools Product manuals SmartGuard 600 Controllers User Manual publication 1752 UM001 ...

Page 102: ...e Pre configured Configuration File 1 Browse to the Guard I O and SmartGuard Modules directory in the toolkit If the toolkit has been loaded onto your personal computer the hard drive path is C Program Files RA_Simplification SafetyGuardLogix Files Guard IO and SmartGuard Modules Configure Your SmartGuard 600 Controller and Safety I O page 102 Start Create Your Safety Zone Logic page 116 SaveandDo...

Page 103: ...uard IO CAT 4 Open the RSNetWorx DNT file appropriate for your application s safety category level 2 Double click the DNT file to launch RSNetWorx for DeviceNet application file If RSNetWorx for DeviceNet does not launch make sure that RSNetWorx for DeviceNet software has been installed and is at version 9 1 or later For this example we opened SmartGuard Guard IO CAT 4 dnt 3 Save the file before y...

Page 104: ... 1 Select the Graph tab at the bottom of the spreadsheet to view controllers and modules in a graphical form 2 Reference your Safety Zone Configuration spreadsheet and select all of the controllers and Guard I O modules that are not in your application Use the Ctrl key and left mouse button to select the individual controllers and modules For this example all modules except one SmartGuard 600 Cont...

Page 105: ...n Chapter 4 4 For systems with more than one Guard I O module of the same type right click the Guard I O module and select Copy 5 Right click in the Graphic view and choose Paste to add additional modules to your system 6 Double click the node number below each device and type the desired DeviceNet node number ...

Page 106: ...ontrollers Logic Integration 7 To configure the controller s safety connections right click the SmartGuard 600 controller and choose Properties 8 Select the Safety Connection tab 9 To auto configure the Guard I O modules right click each Guard I O module and choose Auto Add Default Connections ...

Page 107: ...llers Logic Integration Chapter 4 10 For a Cat 2 application or for a Cat 4 input only Guard I O module remove the Test Output connection that is created with the Auto Add Default connections as it is not required For this example the Test Output connection for 1732DS IB8 CAT 4 is removed ...

Page 108: ... x Ch B Test Output x 1 1 Cycle Time x 2 2 Cycle Time x 2 Dual Channel Equivalent 100 1000 Safety Pulse Test 3 Used as safety input Not Used Cycle Time x 2 Cycle Time x 2 Dual Channel Equivalent 100 1000 Safety Volt freecontacts 1 Normally Closed 1 Normally Open 4 Test pulse from test output Ch A Test Output x Ch B Test Output x 1 1 Cycle Time x 2 Cycle Time x 2 Dual Channel Equivalent 100 1000 Sa...

Page 109: ... To access SmartGuard 600 local input and test output properties right click the SmartGuard controller and choose Properties 2 On the Properties dialog box choose the Local Input Test Output tab 3 On the General tab select each of the inputs 00 15 and click Edit to access the individual local input configuration dialog box ...

Page 110: ...when you are achieving a Category 4 input circuit This mode assumes that you have connected your input device to a Pulse Test Source and then wired to this input terminal This enables detection of short circuits with the power supply line positive side earth faults and short circuits with other input signal lines channel to channel shorts The controller must know that the input signal is being pul...

Page 111: ...atus of two inputs to be evaluated and reflected in I O tags The Discrepancy Time between changes in the status of two inputs can also be evaluated The combinations that can be set are pre defined The Discrepancy Time can be set between 0 and 65530 ms in 10 ms increments Both inputs must change state within the Discrepancy Time or an error occurs 9 Click OK to save the local safety input configura...

Page 112: ... Output Mode based on the following table 15 Click OK on the Test Output Configuration dialog box to accept the test output configuration 16 Click OK on the overall Local Input Test Output dialog box to save the local input and test output configuration 17 Repeat Steps 1 through 14 to configure each input and test output in your system Test Output Mode Description Not Used The corresponding Test O...

Page 113: ...s 1 To access SmartGuard 600 local output properties right click the SmartGuard controller and choose Properties Table 11 Typical Safety Output Configuration Parameters Output Device Type Category Channel Mode Dual Channel Mode Coil 4 Safety Pulse Test Dual Channel 3 Safety Dual Channel 2 Safety Pulse Test Single Channel Solid state actuators non reactive to pulse testing 4 2 2 Must be a Category ...

Page 114: ...ontrollers Logic Integration 2 On the Properties dialog box choose the Local Output tab 3 Select each of the outputs 00 07 and click Edit to access the individual local input configuration dialog boxes 4 Type the output name into the I O Comment field For this example we typed ROBOTCONTACTOR A ...

Page 115: ... on When the output is off short circuits with the power supply line positive side can be detected Ground faults can also be detected Safety Pulse Output A test pulse is sent whenthe output is on This enables detectionof shortcircuits with the power supply line positive side whether the output is on or off Ground faults and short circuits between output signals can also be detected IMPORTANT If a ...

Page 116: ...a workspace where programming is performed Programs are created from function blocks input tags and output tags The basic elements are dragged from the Function List to the workspace and placed where you desire them The I O are connected with connection lines A maximum of 254 logic functions and function blocks can be used on maximum of 32 pages You can create custom blocks made up of predefined b...

Page 117: ...Integration Chapter 4 Select Zone Inputs 1 To access the Logic Editor right click the SmartGuard controller and choose Properties 2 In the SmartGuard Properties dialog box select the Logic tab and click Edit to open the Logic Editor 3 Select the Input tab within the Logic Editor to access the inputs ...

Page 118: ... the previous section The inputs shown are for the Robot Cell Example yours will be specific to your application 5 Select and drag all of the safety inputs required for your initial zone control onto the Logic Editor Page 1 Two E stop two light curtains and one feedback safety input are used in this simple zone control example Group safety input channels as shown for easier function block connecti...

Page 119: ...he second instance of your safety controller to display any standard reset inputs needed for your application For this example eight standard reset inputs are listed 7 Select and drag any standard reset inputs required for your initial zone control onto the Logic Editor Page 1 Reset bit 0 is used in this simple zone control example ...

Page 120: ...locks and Connect Inputs 1 Within the Logic Editor select the FunctionBlock tab to access device and logic function blocks 2 Select and drag the associated Safety Device function block for your initial safety input pair to the right of the inputs on the Logic Editor page For this example we added the E STOP safety device block to the Logic Editor page ...

Page 121: ...ollers Logic Integration Chapter 4 3 Click drag and drop safety input channels onto the associated Safety Device function block 4 Repeat steps 1 through 3 for all safety inputs For this example the Light Curtain Monitoring function block was also added and connected to the safety inputs ...

Page 122: ...puts when both ESTOP and Light Curtain inputs are OK 2 Click drag and drop Safety Device output pins onto the associated Logic function blocks 3 Repeat steps 1 and 2 for all paired Safety Device blocks Import Zone Function Block and Connect Inputs 1 Within the Logic Editor choose Import from the FunctionBlock menu 2 Browse to the Files Safety Device Routines SmartGuard directory in the toolkit and...

Page 123: ... safety inputs such as E stops light curtains or gate switches that must have a status of OK to energize a set of safety outputs Inside the logic of the Zone FB an Inputs OK input represents a summation of all of the monitored safety inputs The Restart block monitors this import If the input is OK a low high low transition of the Restart input energizes the output of the Restart block If the outpu...

Page 124: ... 4 SmartGuard 600 Controllers Logic Integration 5 Close the Zone FB Logic Editor 6 Select and drag the Zone FB block to the right of the input blocks on the Logic Editor page 7 Click drag and drop the Safety Input Logic Block output pin onto the Zone FB s Inputs OK input pin ...

Page 125: ...FB s Restart and Feedback input pins respectively Select Zone Outputs and Connect to Zone Function Block 1 To access your zone outputs select the Output tab in the Logic Editor 2 Expand your safety controller to display the safety outputs you configured in the previous section The safety outputs shown here are for the Robot Cell example Your outputs will be specific to your application ...

Page 126: ...p safety output pins onto the associated Zone FB output pins For this example the Zone FB outputs 01 and 02 are connected to SmartGuard 600 safety outputs to control Cat 4 dual safety contactors for the robots For Cat 2 only one actual output is required so an unconnected or unnamed safety output may be connected to the second Zone output pin The Zone FB Restart Required output is also connected t...

Page 127: ...tegration Chapter 4 6 To create additional zone logic for your application click Add Page and OK and repeat all of the Create Your Safety Zone Logic steps starting on page 116 Save and Download Your RSNetWorx Project 1 Close the Logic Editor 2 Click Apply and then OK to close the Properties dialog box ...

Page 128: ...n 3 Click Save to save the RSNetWorx project 4 Click Online to go online to the DeviceNet network 5 On the Browse for Network dialog box navigate to your DeviceNet network under your SmartGuard controller and click OK The software browses for all nodes on the network 6 Click Cancel after your highest node has been found ...

Page 129: ...er 4 7 Right click your SmartGuard controller node and choose Download to Device The software notifies you when the download has completed successfully 8 Double click your SmartGuard controller node to open the Properties dialog box 9 Select the Mode Cycle Time tab 10 Click Change Mode 11 Select Execute and click OK ...

Page 130: ... and provide diagnostics for safety demands and faults To support these faceplates standard logic needs to be added to your CompactLogix or GuardLogix controller If you are using a SmartGuard 600 controller with EtherNet IP capabilities 1752 L24BBBE use the steps in Copy SmartGuard 600 Module Configuration to Your Logix Controller Project on page 130 to add the required logic to support the SmartG...

Page 131: ...n folder 3 Right click ETHERNET MODULE SmartGuard_600 and choose Copy 4 Open your existing Logix controller project and paste the ETHERNET MODULE SmartGuard_600 module into your I O Configuration For this example the SmartGuard 600 modules was added to the network of the CompactLogix L35E Local Ethernet port 5 Double click the SmartGuard 600 module to open it s Properties dialog box ...

Page 132: ... Logic Rungs to Your Logix Controller Project The toolkit includes pre configured logic for the SmartGuard 600 faceplate as well 1 Right click Add On Instructions and choose Import Add On Instruction 2 Browse to the ME Faceplate Files folder within the Guard I O and SmartGuard Faceplate Files toolkit directory If the toolkit has been loaded onto your personal computer the path is C Program Files R...

Page 133: ... the Add On Instruction file named ENIP_SmartGuard_AOI L5X and click Import 4 Click OK on the Import Configuration dialog box to execute the import The ENIP_SmartGuard_AOI appears in the Add On Instruction folder of your Logix controller 5 Double click your Main Routine or the routine in which you want to use the faceplate logic ...

Page 134: ...7 Browse to the ME Faceplate Files folder within the Guard I O and SmartGuard Faceplate Files toolkit directory If the toolkit has been loaded onto your personal computer the path is C Program Files RA_Simplification SafetyGuardLogix Files Guard IO and SmartGuard Faceplate Files ME Faceplate Files 8 Select the Add On Instruction file named ENIP_SmartGuard_AOI_Map L5X and click Import ...

Page 135: ...e then rename both the SmartGuard_600 I tag and the SmartGuard_600_InputData tag otherwise skip this step a Click the pull down arrow next to the SmartGuard_600 I input tag in the Final Name column A b In the pull down menu browse to your SmartGuard 600 Ethernet module input tag and select it B c Select the SmartGuard_600_InputData tag in the Final Name column and type over the existing name with ...

Page 136: ...rd Faceplate Files ME Faceplate Files 13 Select ENIP_SmartGuard_AOI_Map_2 L5X and click Import to import the additional SmartGuard 600 faceplate rungs 14 Select Tags from the Import Content organizer on the Import Configuration dialog box 15 If you did not use the default SmartGuard 600 name for your SmartGuard Ethernet module then rename the SmartGuard_600 O tag as follows a Click the pull down a...

Page 137: ...ation Chapter 4 The additional two imported rungs will appear in your routine Create an Instance of Your SmartGuard 600 Faceplate Add On Instruction in Your CompactLogix Project Routine 1 Right click on the rung just after the imported output tag mapping rungs within you project routine and choose Add Rung ...

Page 138: ...MP QS005H EN P April 2016 Chapter 4 SmartGuard 600 Controllers Logic Integration 2 Select the Add On element group tab and click the ENIP_SmartGuard_AOI instruction button An instance of the ENIP_SmartGuard_AOI instruction appears in the rung ...

Page 139: ... Ethernet module tag within the pull down dialog box In this example we selected the SmartGuard 600 Ethernet module tag named SmartGuard_600 C 4 Assign the Ref_input Data tag a Double click the Ref_Input Data tag entry field D b Click the pull down arrow E c Double click the SmartGuard 600 InputData tag in the pull down dialog box In this example we chose the SmartGuard 600 input data tag named Sm...

Page 140: ... the Ref_OutputData tag entry field and type SmartGuard_600_OutputData A If you did not use the default SmartGuard 600 Ethernet module tag enter Your SmartGuard 600 Ethernet Module Name_OutputData b Right click the entered output data tag and select the tag name you typed in the previous step to open the New Tag dialog box B c Click OK to create the new tag A B ...

Page 141: ...Ethernet protocol and that your Logix Ethernet module has already been configured For additional information refer to these publications 1769 CompactLogix Controllers User Manual for catalog numbers 1769 L31 1769 L32C 1769 L32CR 1769 L32E or 1769 L35E publication 1769 UM011 CompactLogix System User Manual for catalog numbers 1769 L20 1769 L30 publication 1769 UM007 Follow these steps to configure ...

Page 142: ...expand the Ethernet communication module until your controller is visible 9 Verify that you can browse to your CompactLogix controller 10 Minimize the RSLinx application window and return to your RSLogix 5000 project window Save and Download Your Program Follow these steps to save your program and download it to your CompactLogix controller 1 Save the program by choosing File Save from the menu ba...

Page 143: ...let you control and monitor your Guard I O modules or SmartGuard 600 I O Use safety instruction faceplates for displays that monitor the status and diagnostic information of GuardLogix controller safety application instructions This example shows a pre configured Guard I O Goto display button that can launch the on top display or faceplate for the particular Guard I O module The faceplate includes...

Page 144: ...ition software version 6 1 or later Safety Accelerator Toolkit DVD SAFETY CL002 or visit the Integrated Architecture Tools and Resources website at http www ab com go iatools Follow These Steps Start Create a Runtime File page 159 ConfigureYourSafetyInstructionFaceplates page 145 Adding Pre configured Goto Buttons to Your FactoryTalk View ME Application page 151 Configure Your Guard I O or SmartGu...

Page 145: ...tion to which you want to add the faceplates 2 Right click on Displays and choose Add Component Into Application 3 Browse to the Safety Instruction Faceplate files in the toolkit and open the ME_SafetyInstruction_Faceplate_Files folder 4 Select the SafetyInstruction_Faceplate gfx 5 Add the faceplate parameter file by right clicking on Parameters and choosing Add Component Into Application IMPORTAN...

Page 146: ...eter file you just added to open it 9 Edit the Device Shortcut name to match the GuardLogix controller that you configured for both parameter 1 and parameter 2 This example shows a shortcut name for a controller named GuardLogix 10 Type the Safety Instruction tag name for the safety instruction you want to monitor This example shows a safety instruction tag named Zone1_LOCKINGSW1 11 Type the name ...

Page 147: ...ename the parameter file by right clicking the file choosing Rename and typing the new parameter file name It is recommend that you use the safety instruction name from within the parameter 14 Create a separate parameter file for each safety instruction This example shows two parameter files configured for the safety instruction named Zone1_LOCKINGSW1 and the safety instruction named Zone1_ROBOTCO...

Page 148: ...ays and choose Add Component Into Application 3 Browse to the ME Faceplate Files folder within the Guard I O and SmartGuard Faceplate files directory If the toolkit has been loaded onto your personal computer the hard drive path is C Program Files RA_Simplification SafetyGuardLogix Files Guard IO and SmartGuard Faceplate Files ME Faceplate Files 4 Select the GuardIO_Faceplate gfx for Guard I O dig...

Page 149: ...Guard I O and SmartGuard Faceplate files directory 7 Select the ME_GuardIO_Parameter file for Guard I O digital modules or select GuardIO_Analog_Parameter for Guard I O analog modules 8 Double click the parameter file you just added to open it 9 Edit the Device Shortcut name to match the GuardLogix controller that you configured or the CompactLogix controller to which your SmartGuard 600 controlle...

Page 150: ...I typically the AnalogModuleName Second parameter name should be the name of the safety GuardIO_Analog_AOI_Safety AOI typically the AnalogModuleName_S This example shows a parameter for an analog module name IE4S 11 Close the parameter file 12 Rename the parameter file by right clicking the file choosing Rename and typing the new parameter file name Using the ModuleName from within the parameter i...

Page 151: ...ion 1 Add the safety instruction Guard I O or SmartGuard bitmap images into your FTViewME application by right clicking Images and choosing Add Component Into Application 2 Browse to the appropriate faceplate files on the toolkit DVD and open the desired folder 3 Select the Bitmap images you need for the type of I O module or safety instruction that you have and click Open Choose the generic safet...

Page 152: ... file and click Open The selected display appears under Displays in your application 7 Create a new Display or open your existing system display This example shows a new display named Robot_Cell_Main For these Browse to Guard I O Goto Button Display C Program Files RA_Simplification SafetyGuardLogix Files Guard I O and SmartGuard Faceplate File ME_GotoButtons Safety Instruction Goto Button Display...

Page 153: ...fetyInstruction or Goto_GuardIO display and copy your desired GotoDisplay button objects Copy InstructionName2 if you are using the CBIM CPM CBSSM or CBCM instructions 9 Open your system display 10 Right click Display and choose Paste 11 Repeat steps 8 10 for each safety instruction Guard I O or SmartGuard module in your application or ...

Page 154: ...oryTalk View ME Software Integration Associate Each Button to a Faceplate and Parameter File 1 Click the copied Goto Display button and select View Object Explorer 2 In the Object Explorer double click the Goto Display button to open the Goto Display Button Properties dialog or or ...

Page 155: ... IASIMP QS005H EN P April 2016 155 FactoryTalk View ME Software Integration Chapter 5 3 On the General tab click next to the Display field 4 In the Component Browser display box select the desired faceplate display and click OK or or ...

Page 156: ...kwell Automation Publication IASIMP QS005H EN P April 2016 Chapter 5 FactoryTalk View ME Software Integration 5 Click next to the Parameter file field 6 Select the associated parameter file and click OK or or ...

Page 157: ...016 157 FactoryTalk View ME Software Integration Chapter 5 7 To rename the Goto Display buttons double click the MultistateIndicator object in the Object Explorer A 8 Select the States tab on the Multistate Indicator Properties dialog B or or A A A B B B C C C ...

Page 158: ...Replace ModuleName with the name of the Analog Module s GuardIO_Analog_AOI_Safety instance tag name typically ModuleName_S 12 Replace the Device Shortcut with the Device Shortcut name you configured in this FactoryTalkView ME application for your GuardLogix controller This expression causes the caption to blink when a demand or fault code is present on the module 13 Repeat steps 1 12 for each Goto...

Page 159: ...When you have copied all the objects you need for your display you can delete the Goto Display file from your application by right clicking the file and choosing Delete Create a Runtime File Create a runtime file to test and download your FactoryTalk View ME application by choosing Application Create Runtime Application ...

Page 160: ...160 Rockwell Automation Publication IASIMP QS005H EN P April 2016 Chapter 5 FactoryTalk View ME Software Integration Notes ...

Page 161: ...e faceplate views which provide the information you need to monitor your safety system and quickly diagnose take action and restart your system Before You Begin Complete both the Logix and FactoryTalk View ME software integration of your safety system including download and test What You Need Hardware installation and wiring complete with power applied Logic application file downloaded to your 175...

Page 162: ...iew Demand Indication page 164 Digital Guard I O Module Faceplate Input Status View Fault Indication page 165 Digital Guard I O Module Faceplate Output Status View page 167 Digital Guard I O Module Faceplate Online Configuration Options page168 Digital Guard I O Module Faceplate Online Help Options page 169 Analog Guard I O Faceplate Overview page 169 Analog Guard I O Module Faceplate Input Status...

Page 163: ...ons Safety System Overview Display The Goto Display buttons provided in the toolkit include a multi state indicator text object to which you may have assigned a tag to provide status of whether the assigned Guard I O module has faulted or has a demand on one of the inputs The display below illustrates that the CellGuard1 module is in a faulted or demand state red indicator text and the CellGuard2 ...

Page 164: ...Help information for the view To close the faceplate click the Close button in the upper right corner of the display Digital Guard I O Module Faceplate Input Status View Demand Indication This Guard I O faceplate view illustrates a 16 point Guard I O module s 0 7 input channel status The IN 0 7 button is lighter to confirm this view The faceplate provides State Demand and Cycle indication for each...

Page 165: ...put Status View Fault Indication This Guard I O faceplate view illustrates a fault of locking switch 1A and 1B inputs When inputs or outputs are in a fault state both the State and Cycle indicators for that input are red The Alarm button on the toolbar flashes yellow black This condition typically requires the operator to correct the input or output fault cycle the input or output and press Fault ...

Page 166: ... Guard I O and SmartGuard I O information represented in the tables on the following page Help Button Black Arrow Key Code hex Error Content Probable Cause Recommended Action 01 Configuration invalid The configuration isinvalid Configure the module correctly 02 External test signal error 1 The power source positive side is in contact with the input signal line 2 Short circuit between input signal ...

Page 167: ...ce positiveside isincontactwiththeoutput signal line 2 Trouble with the internal circuit 1 Check the wiring 2 Replace the module 05 Error in the other dual channel output Dualchannelsaresetandanerroroccurredintheotherchannel Remove the error in the other channel 06 Internal relay output circuit error Trouble with the internal circuit 1791DS IB4XOW4 module only Replace the module 07 Relay error Tro...

Page 168: ...Faceplate lets you modify the Faceplate Titles and Device Descriptions specific to your application Follow these steps to modify this information 1 Press the Configuration button on the toolbar so that the button border is highlighted 2 Then press the title or device description you desire to update The popup keyboard appears 3 Type the desired text and press Enter Configuration Button ...

Page 169: ...d I O module fault condition and activates the Error Content view A black bell indicates normal status with no faults A yellow black flashing bell indicates a fault condition The Configuration button lets you edit the Analog Guard I O faceplate name or Device Descriptions The Input Output Selector buttons let you select which view is shown The Help button let you select Help information for the vi...

Page 170: ...button to reset the associated safety instruction and press the Safety Reset button to reset the safety module s and zone s safety logic To access the specific Fault Error Channel and Module information press the Alarm button on the toolbar This Channel and Module fault view illustrates a fault of analog input Channel 1 When channel inputs or module are in a fault state the border of the indicator...

Page 171: ...ported by the input or module To access the probable cause of the reported error press the Help button on the toolbar For further diagnostic help press the black arrow key at the bottom of the view to access Recommended Action information This diagnostic information is triggered by the reported module error code The input and module error code information provided is in accordance with the Analog ...

Page 172: ...or Signal Timing 110 Undefined error If Problem Persists Replace Module 111 Flash enable fault ADC s FLASH Memory Drawing Too Much Current If Problem Persists Replace Module 112 Serial pattern fault Serial Communication Pattern Errors Detected Check Field Wiring for Proper Grounding Shielding Verify that Temperature Within Enclosure is not Excessive If Problem Persists Replace Module 113 Channel u...

Page 173: ... O Faceplate lets you modify the Faceplate Titles and Device Descriptions specific to your application Follow these steps to modify this information 1 Press the Configuration button on the toolbar so that the button border is highlighted 2 Then press the title or device description you desire to update The popup keyboard appears 3 Type the desired text and press Enter Configuration Button ...

Page 174: ...Fault button launches the fault Probable Cause and Recommended Actions views The Diagnostics button launches the diagnostic Probable Cause and Recommended Actions views To rename the faceplate click in the title bar type the new name by using the popup keyboard and press Enter To close the faceplate click the Close button in the upper right corner of the display The GuardLogix Safety Application I...

Page 175: ...mmended Actions view shows a possible solution for the problem Click the arrow to return to the Probable Cause view Safety Instruction Faceplate Diagnostic Views The Probable Cause view explains the diagnostic Click the arrow to move to the Recommended Actions view The Recommended Actions view provides steps for clearing the diagnostic Click the arrow to return to the Probable Cause view Recommend...

Page 176: ...176 Rockwell Automation Publication IASIMP QS005H EN P April 2016 Chapter 6 Safety System Application Guide Notes ...

Page 177: ...rdware selection Logix integration and FactoryTalk View ME integration steps in this quick start The safety zone in this example is comprised of these guarding devices inputs four E stop buttons two locking switch solenoid devices and a light curtain The zone features two safety contactors outputs for powering the robot control Communication with the Guard I O modules is over an EtherNet IP networ...

Page 178: ...rd1 Safety Module 2 CellGuard2 Safety Module 3 Safety Module 4 Safety Module 5 Safety Module 6 Standard I O Fault Reset Tag Standard HMI Fault Reset Tag 1 Cmd_FaultReset Safety Fault Reset Tag Cmd_Zone1_FaultReset Standard I O Safety Reset Tag Standard HMI Safety Reset Tag 1 Cmd_SafetyReset Safety Safety Reset Tag Cmd_Zone1_SafetyReset Inputs OK Tag Sts_Zone1_InputsOK SmartGuard 600 System Zone Co...

Page 179: ... Automation Publication IASIMP QS005H EN P April 2016 179 Robot Cell Application Example with GuardLogix or SmartGuard 600 Controller Appendix A The completed worksheet for the 1791ES IB16 module is shown below ...

Page 180: ...me _ DeviceName InputOK Contactor feedback only used in ROUT instruction The auxiliary feedback contacts on both ROBOTCONTACTOR outputs are wired in series to a single safety output Test Outputs Device Name Test Output Tag Name Output 00 ModuleName O Test00Data Output 01 ModuleName O Test01Data Output 02 ModuleName O Test02Data Output 03 ModuleName O Test03Data Output 04 ModuleName O Test04Data Ou...

Page 181: ...tomation Publication IASIMP QS005H EN P April 2016 181 Robot Cell Application Example with GuardLogix or SmartGuard 600 Controller Appendix A The completed worksheet for the SmartGuard 600 local I O is shown below ...

Page 182: ...llGuard1 I Pt01Data 0 Circuit Reset none 0 Fault Reset Cmd_Zone1_FaultReset 0 RIN ROBOT CELL SAFETY LOGIC EXAMPLE This Safety Logic Example should only be used and applied in accordance with the Safety Concepts and Requirements covered in the GuardLogix Controller Systems Safety Reference Manual Publication 1756 RM093 1 Zone1_LOCKINGSW1 O1 Sts_Zone1_LOCKINGSW1_InputOK 2 Sts_Zone1_OutputEnable ONS ...

Page 183: ...lt Reset Cmd_Zone1_FaultReset 0 RIN LOCKINGSW2 CAT3_CAT4 Safety Logic 5 Zone1_LOCKINGSW2 O1 Sts_Zone1_LOCKINGSW2_InputOK 6 Sts_Zone1_OutputEnable ONS Wrk_Zone1_LOCKINGSW2_OutputEnable_ONS Wrk_Zone1_LOCKINGSW2_EntryDelay_Latch Wrk_Zone1_LOCKINGSW2_EntryDelay_Timer DN EN DN Timer On Delay Timer Wrk_Zone1_LOCKINGSW2_EntryDelay_Timer Preset 0 Accum 0 TON Wrk_Zone1_LOCKINGSW2_EntryDelay_Latch 7 Wrk_Zon...

Page 184: ...T4 Safety Logic 9 Zone1_ESTOP1 O1 Sts_Zone1_ESTOP1_InputOK 10 O1 CI CRHO II FP Emergency Stop ESTOP Zone1_ESTOP2 Reset Type AUTOMATIC Channel A CellGuard1 I Pt06Data 0 Channel B CellGuard1 I Pt07Data 0 Circuit Reset none 0 Fault Reset Cmd_Zone1_FaultReset 0 ESTOP ESTOP2 CAT3_CAT4 Safety Logic 11 Zone1_ESTOP2 O1 Sts_Zone1_ESTOP2_InputOK 12 O1 CI CRHO II FP Emergency Stop ESTOP Zone1_ESTOP3 Reset Ty...

Page 185: ... Channel A CellGuard1 I Pt10Data 0 Channel B CellGuard1 I Pt11Data 0 Circuit Reset none 0 Fault Reset Cmd_Zone1_FaultReset 0 ESTOP 15 Zone1_ESTOP4 O1 Sts_Zone1_ESTOP4_InputOK LIGHTCURTAIN1 CAT3_CAT4 Safety Logic 16 O1 CI CRHO LCB LCM II FP Light Curtain LC Zone1_LC1 Reset Type AUTOMATIC Channel A CellGuard1 I Pt12Data 0 Channel B CellGuard1 I Pt13Data 0 Input Filter Time 0 Mute Light Curtain Overr...

Page 186: ...1_ESTOP4_InputOK Sts_Zone1_LC1_InputOK Sts_Zone1_InputsOK Output Enable Rung 19 Cmd_Zone1_SafetyReset ONS Wrk_Zone1_SafetyReset_ONS Cmd_Zone1_OutputEnable Sts_Zone1_InputsOK CellGuard2 I CombinedOutputStatus Zone1_ROBOTCONTACTOR FP Cmd_Zone1_OutputEnable 20 O1 O2 O1FF O2FF FP Redundant Output ROUT Zone1_ROBOTCONTACTOR Feedback Type NEGATIVE Enable Cmd_Zone1_OutputEnable 0 Feedback 1 CellGuard2 I P...

Page 187: ...GSW2ChB 03 02 S LOCKINGSW2ChA 03 06 S ESTOP2ChA 03 05 S ESTOP1ChB 03 04 S ESTOP1ChA 03 14 S Feedback 03 00 Reset 03 01 S ROBOTCONTACTOR B 03 00 S ROBOTCONTACTOR A 03 01 S LOCKINGSW1ChB 03 00 S LOCKINGSW1ChA 03 10 S ESTOP4ChA 03 11 S ESTOP4ChB 03 02 S ResetRequired OpenReq 1 LOCKSW1 2 LOCKSW2 3 ESTOP1 4 ESTOP2 5 ESTOP3 6 ESTOP4 7 LC1 8 Zone1IN Restart Feedback InputsOK O1 O2 RestartRequi ZoneFB 9 1...

Page 188: ...SafetyOutputStatus 0 Sts_SafetyOutputReadback 0 Sts_TestOutputStatus 0 Sts_SafetyOutputData 0 Ref_MSG1 CellGuard1_MSG1 Ref_MSG2 CellGuard1_MSG2 Ref_ExtendedData CellGuard1_ExtendedData Ref_InputData CellGuard1_InputData Ref_OutputData CellGuard1_OutputData Set_SafetyIOModuleSelect 9 Ref_ErrorCode CellGuard1_ErrorCode GuardIO_AOI 2 Copy File Source CellGuard2 I Dest CellGuard2_InputData 0 Length 2 ...

Page 189: ... Controller Appendix A Figure 7 GuardLogix Faceplate Logic continued Figure 8 Ethernet SmartGuard 600 Faceplate Logic 4 Safety Reset CellGuard1 Cmd_SafetyReset Safety Reset CellGuard2 Cmd_SafetyReset Cmd_Zone1_SafetyReset_Map 5 Fault Reset CellGuard1 Cmd_FaultReset Fault Reset CellGuard2 Cmd_FaultReset Cmd_Zone1_FaultReset_Map End ...

Page 190: ...190 Rockwell Automation Publication IASIMP QS005H EN P April 2016 Appendix A Robot Cell Application Example with GuardLogix or SmartGuard 600 Controller Notes ...

Page 191: ...d CAT4 safety input device logic routines for this zone CONFIGURATION DETAILS The ROUT instructions are the primary safety instructions within this routine The ZoneName_DeviceName ROUT instruction tag names Zone1_ROBOTCONTACTOR1 and Zone1_ROBOTCONTACTOR2 identify the specific instruction for the unique safety output devices This routine assumes that the auxiliary feedback channels for each device ...

Page 192: ...o all the other robot contactor ROUT rungs the safety output and feedback tags are unique to specific Guard I O Module and output devices 4 O1 O2 O1FF O2FF FP Redundant Output ROUT Zone1_ROBOTCONTACTOR2 Feedback Type NEGATIVE Enable Cmd_Zone1_OutputEnable 0 Feedback 1 CellGuard3 I Pt00Data 0 Feedback 2 CellGuard3 I Pt00Data 0 Fault Reset Cmd_Zone1_FaultReset 0 ROUT 5 Zone1_ROBOTCONTACTOR2 O1 Zone1...

Page 193: ...ftware tools to help you estimate how a system will perform GuardLogix Safety Calculator The first tool called the GuardLogix Calculator uses a spreadsheet that provides three worst case performance estimates based on how the GuardLogix controller specifically the safety task and the safety I O was configured and distributed on DeviceNet networks The GuardLogix safety calculator was the original s...

Page 194: ... also provides multiple network functionality within the application adding Ethernet communication to the original DeviceNet only implementation Safety reaction time performance is based on how the safety task is configured in the GuardLogix controller and the settings for the safety I O modules used in the GuardLogix project The wizard interface in the GuardLogix Estimator lets you move forward o...

Page 195: ...k settings on the Controller Settings tab Use the Input Module Delays and Output Module Delays tabs to enter settings for your safety I O modules Based on the settings you enter and the network configurations you plan to use the estimator provides a series of examples to choose from These examples let you evaluate the effects of different settings and network configurations ...

Page 196: ... You can select DeviceNet EtherNet IP or a combination of DeviceNet and EtherNet IP networks The estimator provides three performance numbers to consider for use No fault Reaction Time ms This value is the worst case performance of the system when it is running normally without errors or faults ...

Page 197: ...time because a risk assessment of the application indicates it is sufficient In an example light curtain application where an operator is loading material the safety system lets the load occur only at a non hazardous phase of machine operation Since the operator knows when to load material it s unlikely that they would try to load during a hazardous phase The chances of the operator attempting to ...

Page 198: ...e MSWord document Macro Security Settings in Excel 2007 pdf included with the GuardLogix tools Microsoft Excel 2003 If you have MSExcel 2003 installed follow these steps to install the wizard 1 Run set up exe to install all the necessary components The set up program installs all of the required files in the default directory or the directory you designate 2 After the installation is complete laun...

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Page 200: ...des Find the Direct Dial Code for your product Use the code to route your call directly to a technical support engineer http www rockwellautomation com global support direct dial page Literature Library Installation Instructions Manuals Brochures and Technical Data http www rockwellautomation com global literature library overview page Product Compatibility and Download Center PCDC Gethelp determi...

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