Rockwell Automation Allen-Bradley Guardmaster 440C-CR30 Application Technique Download

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Application Technique

Safety Function: Cable Pull Switch with a Configurable Safety
Relay

Products: Lifeline 4 Cable Pull Switch, Guardmaster 440C-CR30 Configurable Safety Relay, 100S-C Safety Contactors

Safety Rating: CAT. 3, PLd to ISO 13849-1: 2008

Topic

Page

Important User Information

General Safety Information

Introduction

Safety Function Realization: Risk Assessment

Lifeline 4 Cable Pull Switch Safety Function

Safety Function Requirements

Functional Safety Description

Bill of Material

Setup and Wiring

Configuration

Calculation of the Performance Level

Verification and Validation Plan

Verification of the Configuration

Additional Resources

Summary of Contents for Allen-Bradley Guardmaster 440C-CR30

Page 1: ...08 Topic Page Important User Information 2 General Safety Information 3 Introduction 3 Safety Function Realization Risk Assessment 3 Lifeline 4 Cable Pull Switch Safety Function 4 Safety Function Requ...

Page 2: ...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 pe...

Page 3: ...ol system Part of the risk reduction process is to determine the safety functions of the machine In this application the performance level required PLr by the risk assessment is Category 3 Performance...

Page 4: ...start stop system The safety functions in this application technique each meet or exceed the requirements for Category 3 Performance Level d CAT 3 PLd per ISO 13849 1 and control reliable operation pe...

Page 5: ...re connected to two safety contactors K1 and K2 These safety contactors are wired in series to the motor When the contactors drop out motion at the motor stops Each safety contactor is equipped with a...

Page 6: ...lectrical Schematic Configuration Configure the 440C CR30 relay by using Connected Components Workbench software release 6 01 or later A detailed description of each step is beyond the scope of this d...

Page 7: ...Relay Configure the 440C CR30 Relay Follow these steps to configure the Guardmaster 440C CR30 relay by using Connected Components Workbench software 1 In Connected Components Workbench software choos...

Page 8: ...plug in module space and choose the 2080 IQ4OB4 module TIP TheI Omoduleisshowninstandardgray becauseitisnotasafetyI Omodule Thatispermissibleinthisapplication becausethe standard I O module is not use...

Page 9: ...figurable Safety Relay 5 Click the Edit Logic button to open the Connected Components Workbench Workspace 6 From the View pull down menu choose Toolbox Configure the Inputs Follow these steps to confi...

Page 10: ...automatically assigns the next unused terminal for a newly added device The terminals can be changed to any unused input terminal but in this case leave the default Because the Lifeline 4 cable pull...

Page 11: ...ety Function Cable Pull Switch with a Configurable Safety Relay 7 Because this reset block is used to reset the Immediate OFF Output in the case of a fault change this to use the non safety plug in mo...

Page 12: ...lt to PT which is pulse testing Leave this default setting as well 2 Using the pull down menu next to each item in the Immediate OFF safety output function block change the following values a Change F...

Page 13: ...urable Safety Relay 1 From the Toolbox select and drag the AND logic function and release it under the Logic Level A header as shown 2 Connect the logic by completing the following steps a Click the b...

Page 14: ...tween the Safety Device function block this is the Lifeline 4 cable pull switch and the lower blue dot of the AND gate as shown 4 Connect the blue dot on the right side of the AND gate to the blue dot...

Page 15: ...figure ten input status indicators and six output status indicators These status indicators can be very helpful while testing the system during installation and commissioning They are also useful for...

Page 16: ...icators as follows 6 Assign the Output LED status indicators as follows Confirm the Validity of the Build Follow these steps to confirm the validity of the logic by using the Build feature in Connecte...

Page 17: ...details the error so that it may be corrected After you correct the error you need to perform the build again Save and Download the Project Follow these steps to save and download the project 1 From t...

Page 18: ...itch with a Configurable Safety Relay 5 Click Download 6 In the Connection Browser expand the AB_VBP 1 Virtual Chassis and select the Guardmaster 440C CR30 22BBB 7 Click OK 8 Click Yes to change from...

Page 19: ...d Verification and Validation Plan on page 22 before proceeding with Verification of the Configuration on page 28 Calculation of the Performance Level When properly implemented these safety functions...

Page 20: ...ntactor output subsystem is different Because these are electro mechanical devices the Lifeline 4 cable pull switch and safety contactor data includes the following Mean Time to Failure dangerous MTTF...

Page 21: ...n they impair the effective operations of any safeguarding measures Due to the single mechanical actuator of the E stop a fault exclusion must be considered In most instances the fault exclusion requi...

Page 22: ...A checklist is typically used to document the validation of the safety control system Prior to validating the system confirm that the Guardmaster 440C CR30 configurable safety relay has been wired and...

Page 23: ...nd the K1 and K2 contactors must not activate 18 Reset the Lifeline 4 cable pull switch The machine must not start The 440 CR30 relay must not respond Contactors K1 and K2 must not activate 19 Press b...

Page 24: ...The red Fault status LED of the 440C CR30 relay must blink 19 Remove the jumper 20 Press but do not release the 440C CR30 relay Reset button The 440C CR30 relay must not respond and the K1 and K2 con...

Page 25: ...ink 2 Reconnect the wire to E1_02 Press but do not release the 440C CR30 relay Reset button The 440C CR30 relay must not respond and the K1 and K2 contactors must not activate 3 Release the 440C CR30...

Page 26: ...jumper 27 Press but do not release the 440C CR30 relay Reset button The 440C CR30 relay must not respond and the K1 and K2 contactors must not activate 28 Release the 440C CR30 relay Reset button The...

Page 27: ...relay is ON 8 Remove the jumper Press and release the Reset button for the 440C CR30 relay The 440C CR30 relay must not respond 9 Cycle power to the 440C CR30 relay The 440C CR30 relay responds The 4...

Page 28: ...the software connection 3 Release the E stop The machine must not start The 440C CR30 relay must not respond Monitor the status indicator LEDs for proper operation and monitor the 440C CR30 relay for...

Page 29: ...Switch with a Configurable Safety Relay 3 Click Verify 4 Answer all the questions and check each box if completed 5 Click Generate 6 Click Yes to proceed with the verification 7 Click Yes to change t...

Page 30: ...CR30 relay that the system verification and functional tests have been completed The unique verification ID can be used to check if changes have been made to a configuration file Any change to the con...

Page 31: ...figurable safety relay to communicate with a PanelView Component terminal via Modbus communication protocol Guardmaster 440C CR30 Configurable Safety Relay User Manual publication440C UM001 Provides d...

Page 32: ...back Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwell...

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