Allen-Bradley GuardPLC 160 User manual

Installation Instructions

GuardPLC 1600 Controllers

Catalog Numbers 1753-L28BBB-M, 1753-L28BBB-P

Topic Page

Important User Information 2

About the GuardPLC 1600 Controller 3

General Safety 3

Install the Controller 4

Mount the Controller 5

Ground the Controller 5

Wire the Controller 6

Make Communication Connections 12

Reset Push Button 14

Controller Tests 15

Status Indicators 16

Specifications 17

Additional Resources 20

Rockwell Automation Publication 1753-IN001C-EN-P - June 2010

Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment.

Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication

SGI-1.1 available from your local Rockwell Automation sales office or online at

http://www.rockwellautomation.com/literature/) describes some important differences between solid-state

equipment and hard-wired electromechanical devices. Because of this difference, and also because of the

wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must

satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages

resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many

variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot

assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits,

equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell

Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

ATTENTION: 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

consequences.

SHOCK HAZARD: Labels may be on or inside the equipment, for example,

drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example,

drive or motor, to alert people that surfaces may reach dangerous

temperatures.

IMPORTANT Identifies information that is critical for successful application and

understanding of the product.

Rockwell Automation Publication 1753-IN001C-EN-P - June 2010

About the GuardPLC 1600 Controller

The GuardPLC 1600 controller is a programmable electronic system featuring 20 digital inputs,

8 digital outputs, and 4 connections for GuardPLC Ethernet communication.

General Safety

Prevent Electrostatic Discharge

ATTENTION: Personnel responsible for the application of safety-related

programmable electronic systems (PES) shall be aware of the safety

requirements in the application of the system and shall be trained in using the

system.

ATTENTION: This equipment is sensitive to electrostatic discharge, which can

cause internal damage and affect normal operation. Follow these guidelines

when you handle this equipment:

•Touch a grounded object to discharge static potential.

•Wear an approved wrist-strap grounding device.

•Do not touch connectors or pins on component boards.

•Do not touch circuit components inside the equipment.

•Use a static-safe workstation, if available.

•Store the equipment in appropriate static-safe packaging when not in use.

Digital Outputs

Digital Inputs

Voltage Supply

Connection

Ethernet Ports (on top of controller)

Ethernet Ports (on bottom of controller)

Rockwell Automation Publication 1753-IN001C-EN-P - June 2010

Environment and Enclosure

Install the Controller

Follow these steps to install the GuardPLC 1600 controller.

1. Mount the controller to a DIN rail.

2. Ground the controller.

3. Wire the controller.

4. Make communication connections.

This publication describes these steps in detail.

ATTENTION: This equipment is intended for use in a Pollution Degree 2

industrial environment, in overvoltage Category II applications (as defined in

IEC publication 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 may be difficulties

with electromagnetic compatibility in residential and other environments due

to conducted as well as 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 will be present and appropriately designed to prevent personal

injury resulting from 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 may contain additional

information regarding specific enclosure type ratings that are required to

comply with certain product safety certifications.

In addition to this publication, see:

•Industrial Automation Wiring and Grounding Guidelines, Rockwell

Automation publication 1770-4.1, for additional installation requirements.

•NEMA 250 and IEC 60529, as applicable, for explanations of the degrees of

protection provided by different types of enclosure.

Rockwell Automation Publication 1753-IN001C-EN-P - June 2010

Mount the Controller

The controller cannot be panel-mounted. Mount the controller to a DIN rail by following these

steps.

1. Hook the top slot over the DIN rail.

2. Insert a flathead screwdriver into the gap

between the housing and the latch and pull

the latch downward.

3. Hold the latch down as you push the housing

back onto the DIN rail.

4. Release the latch to lock the device onto the

rail.

Ground the Controller

The controller is functionally grounded through its DIN rail connection. A protective

earth-ground connection is required and is provided through a separate grounding screw on the

upper left of the housing and marked with the grounding symbol .

You must also provide an acceptable grounding path for each device in your application. For

more information on proper grounding guidelines, refer to the Industrial Automation Wiring

and Grounding Guidelines, publication 1770-4.1.

IMPORTANT For effective cooling, mount the controller following these guidelines.

•Mount the controller horizontally.

•Provide a gap of at least 100 mm (3.94 in.) above and below the controller.

•Select a location where air flows freely or use an additional fan.

•Do not mount the controller over a heating device.

TIP To remove the controller from the DIN rail, insert a flathead screwdriver

into the gap between the housing and the latch and pull the latch

downward as you lift the controller off of the rail.

ATTENTION: This product is grounded through the DIN rail to chassis ground.

Use zinc-plated yellow-chromate steel DIN rail to assure proper grounding. The

use of other DIN rail materials (for example, aluminum or plastic) that can

corrode, oxidize, or are poor conductors, can result in improper or intermittent

grounding. Secure the DIN rail to the mounting surface approximately every

200 mm (7.8 in.) and use end-anchors appropriately.

DIN Rail

(1) Top Slot

Latch

(3)

(2)

Rockwell Automation Publication 1753-IN001C-EN-P - June 2010

Wire the Controller

The following sections describe how to connect the voltage supply and wire the controller’s

digital inputs and outputs.

Connect the Voltage Supply

The 24V DC voltage supply must feature galvanic isolation (in accordance with

EN 60950 or UL 1950) since inputs and outputs are not electrically isolated from the processor.

To comply with CE Low Voltage Directives (LVD) and UL restrictions, you must use either a

Safety Extra Low Voltage (SELV), or a Protected Extra Low Voltage (PELV) power supply to

power this controller. A SELV supply cannot exceed 30V rms, 42.4V peak, or 60V DC under

normal conditions and under single-fault conditions. A PELV supply has the same rating and is

connected to protected earth.

The supply voltage is connected via a 4-pin connector that accommodates wire sizes up to

2.5 mm2(14 AWG). You need to connect only one wire to L+ and one wire to L-. Both L+ and

L- terminals are internally connected, so you can daisy-chain 24V DC power from the

GuardPLC controller to other devices in the panel by using the remaining terminal.

IMPORTANT Protect the controller with a slow-blowing fuse.

IMPORTANT The GuardPLC 1600 controller can draw up to 8 A. The controller needs 0.5 A

to operate. Up to 7.5 A can be used to source voltage power for inputs and

outputs connected to the controller.

ATTENTION: Do not reverse the L+ and L- terminals or damage to the

controller will result. There is no reverse polarity protection.

Rockwell Automation Publication 1753-IN001C-EN-P - June 2010

Safety-related Digital Inputs

The controller has 20 digital inputs whose status is indicated via status indicators when the

controller is in RUN mode.

LS+ is a voltage source that provides 24V DC for a group of four dry contact inputs. There are

five groups on the GuardPLC 1600 controller.

If devices require 24V DC to operate and use the same power source as the controller, then wire

the outputs of the device directly to inputs on the controller.

123456

1234

1L-

L-L- L+ L+

L-DO 2

(2A)

1LS+- LS+ LS+ LS+ LS+L-

234

13 14 15 16 17 18

5L-

678

19 20 21 22 23 24

9L-

10 11 12

25 26 27 28 29 30

13 L-

14 15 16

31 32 33 34 35 36

17 L-

18 19 20

37 38 39 40 41 42

19 20 21 22 23 2413 14 15 16 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

789101112

78910

5L- L-DO 6

(2A)

7 8

11 12

COMM1

MODBUS

RS-485

24V DC

COMM2 COMM3 RUN

24 V DC

GuardPLC Ethernet

10/100 BaseT

PROG

ERROR

FAULT

FORCE

OSL

PROFIBUS

3(—) 4

(—)

3(—) 4

(—)

1753-L28BBBM

20 DC Inputs

8 DC Outputs

1LS+- L-

234

13 14 15 16 17 18

13 14 15 16 23 24

L-L- L+ L+

24V DC

24VDC

Power

Supply

COM

Connection of Voltage Supply to

Input Device

123456

1234

1L-

L-L- L+ L+

L-DO 2

(2A)

1LS+- LS+ LS+ LS+ LS+L-

234

13 14 15 16 17 18

5L-

678

19 20 21 22 23 24

9L-

10 11 12

25 26 27 28 29 30

13 L-

14 15 16

31 32 33 34 35 36

17 L-

18 19 20

37 38 39 40 41 42

19 20 21 22 23 2413 14 15 16 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

789101112

78910

5L- L-DO 6

(2A)

7 8

11 12

COMM1

MODBUS

RS-485

24V DC

COMM2 COMM3

RUN

24 V DC

GuardPLC Ethernet

10/100 BaseT

PROG

ERROR

FAULT

FORCE

OSL

PROFIBUS

(—)

1753-L28BBBM

20 DC Inputs

8 DC Outputs

1LS+- L-

234

13 14 15 16 17 18

13 14 15 16 23 24

L-L- L+ L+

24V DC

COM

24VDC

Power

Supply

COM

Light Curtain

(or any Safety Input)

Connection of Voltage Supply to

Input Device

Rockwell Automation Publication 1753-IN001C-EN-P - June 2010

Devices with their own dedicated power supply can also be connected. Connect the reference

pole of the external power supply to the L- reference pole of the input.

The safe state of an input is indicated by a 0 signal being passed to the user program logic. If the

test routines detect a fault in the digital inputs, a 0 signal is processed in the user program for the

defective channel. When a fault occurs, the inputs are switched off (0).

Follow the closed-circuit principle for external wiring when connecting sensors. To create a safe

state in the event of a fault, the input signals revert to the de-energized state (0). The FAULT

status indicator activates.

Digital Input Terminals

TIP For more information on input wiring, see the GuardPLC Controller Systems

User Manual, publication number 1753-UM001.

123456

1234

1L-

L-L- L+ L+

L-DO 2

(2A)

1LS+- LS+ LS+ LS+ LS+L-

234

13 14 15 16 17 18

5L-

678

19 20 21 22 23 24

9L-

10 11 12

25 26 27 28 29 30

13 L-

14 15 16

31 32 33 34 35 36

17 L-

18 19 20

37 38 39 40 41 42

19 20 21 22 23 2413 14 15 16 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

789101112

78910

5L- L-DO 6

(2A)

7 8

11 12

COMM1

MODBUS

RS-485

24V DC

COMM2 COMM3

RUN

24 V DC

GuardPLC Ethernet

10/100 BaseT

PROG

ERROR

FAULT

FORCE

OSL

PROFIBUS

(—)

1753-L28BBBM

20 DC Inputs

8 DC Outputs

1LS+- L-

234

13 14 15 16 17 18

13 14 15 16 23 24

L-L- L+ L+

24V DC

24VDC

Power

Supply

COMCOM

24VDC

Power

Supply

COM

Light Curtain

(or any Safety Input)

Connection of Devices with Dedicated Power Supplies

1LS+- LS+LS+LS+LS+L-

234

13 14 15 16 17 18

5L-

678

19 20 21 22 23 24

9L-

10 11 12

25 26 27 28 29 30

13 L-

14 15 16

31 32 33 34 35 36

17 L-

18 19 20

37 38 39 40 41 42

19 20 21 22 23 2413 14 15 16 17 18 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Rockwell Automation Publication 1753-IN001C-EN-P - June 2010

Terminals accommodate wires up to 1.5 mm2(16 AWG). See the terminal torque specifications

on page 17. Digital inputs are connected to these terminals.

LS+, not L+, should be used for short-circuit protection. Each LS+ features individual

short-circuit and EMC protection that make it important to use LS+ for only its four related

inputs.

Terminal Number Designation Function

13 LS+ Sensor supply for inputs 1…4

14 1 Digital input 1

15 2 Digital input 2

16 3 Digital input 3

17 4 Digital input 4

18 L- Reference pole

19 LS+ Sensor supply for inputs 5…8

20 5 Digital input 5

21 6 Digital input 6

22 7 Digital input 7

23 8 Digital input 8

24 L- Reference pole

25 LS+ Sensor supply for inputs 9 …12

26 9 Digital input 9

27 10 Digital input 10

28 11 Digital input 11

29 12 Digital input 12

30 L- Reference pole

31 LS+ Sensor supply for inputs 13…16

32 13 Digital input13

33 14 Digital input 14

34 15 Digital input 15

35 16 Digital input 16

36 L- Reference pole

37 LS+ Sensor supply for inputs 17…20

38 17 Digital input 17

39 18 Digital input 18

40 19 Digital input 19

41 20 Digital input 20

42 L- Reference pole

Rockwell Automation Publication 1753-IN001C-EN-P - June 2010

Line Control

Line control is a short-circuit and line-break monitoring system (that is, E-stop inputs) that can

be configured for the GuardPLC 1600 system. Up to eight digital outputs (DO1…DO8) can be

configured as pulsed outputs. The example below shows two pulse outputs connected to the

digital inputs (DI) of the same system. As a result, the connections to the digital inputs (DI) are

monitored.

Inputs are set to 0, a fault code is generated, and the FAULT status indicator is on when:

•a short-circuit occurs between two parallel connections.

•two connections are reversed.

•earth fault occurs on one of the lines (only with earthed reference pole).

•a line breaks or one of the contacts opens (that is, when one of the E-stop off switches is

pressed in the example above).

Safety-related Digital Outputs

The controller has eight digital outputs (DO1…DO8) whose status is indicated via status

indicators.

An output is in a safe state when it is de-energized. When a fault occurs, all outputs are switched

off.

Outputs 1…3 and 5…7 can have a load of 0.5 A at an ambient temperature of 60 °C (140 °F).

Outputs 4 and 8 can each have a load of 1 A at an ambient temperature of 60 °C (140 °F), or up

to 2 A at an ambient temperature of 50 °C (122 °F).

With an overload, one or all of the outputs are turned off. When the overload is eliminated, the

outputs are activated again according to the specified value.

Although the external line of an output is not monitored, a short-circuit will be indicated.

IMPORTANT For information on how to configure inputs and outputs for line control, see

the GuardPLC Controller Systems User Manual, publication 1753-UM001.

Emergency OFF 1 Emergency OFF 2

DO 1 2

DI 1 2 DI 3 4

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