Allen-Bradley SmartGuard 600 User manual

SmartGuard 600

Controller

Catalog Number 1752-L24BBB

User Manual

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://literature.rockwellautomation.com) 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.

SmartGuard, Rockwell Automation, Allen-Bradley, Logix, ControlLogix, Guard I/O, POINT I/O, RSLogix 5000, RSNetWorx for

DeviceNet, and RSLinx are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

WARNING Identifies information about practices or circumstances that can cause

an explosion in a hazardous environment, which may lead to personal

injury or death, property damage, or economic loss.

IMPORTANT Identifies information that is critical for successful application and

understanding of the product.

ATTENTION Identifies information about practices or circumstances that can lead

to personal injury or death, property damage, or economic loss.

Attentions help you identify a hazard, avoid a hazard, and recognize

the consequence

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

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

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

motor, to alert people that surfaces may reach dangerous

temperatures.

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Table of Contents

Preface

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . 11

Purpose of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Common Techniques Used in This Manual. . . . . . . . . . . . . . 12

Understanding Terminology . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 1

Overview

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

About the SmartGuard 600 Controller. . . . . . . . . . . . . . . . . . 13

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Configuration and Programming. . . . . . . . . . . . . . . . . . . 16

Status and Error Monitoring . . . . . . . . . . . . . . . . . . . . . . 16

Safety Concept of the Controller . . . . . . . . . . . . . . . . . . . . . 17

Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Chapter 2

Installing and Wiring the

SmartGuard 600 Controller

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 19

Understanding Node Addressing . . . . . . . . . . . . . . . . . . . . . 22

Setting the Node Address . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Setting the Communication Rate . . . . . . . . . . . . . . . . . . . . . 23

Mounting the SmartGuard Controller . . . . . . . . . . . . . . . . . . 24

Grounding the SmartGuard Controller . . . . . . . . . . . . . . . . . 25

Connecting a Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . 25

Make Communication Connections . . . . . . . . . . . . . . . . . . . 26

Connect to the DeviceNet port . . . . . . . . . . . . . . . . . . . . 27

Connect to USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Wiring the SmartGuard 600 Controller . . . . . . . . . . . . . . . . . 28

Wire Input Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Wire Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Chapter 3

Set Up Your DeviceNet Network

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Connect a Computer to the DeviceNet Network . . . . . . . . . . 35

Configure a Driver for the Network . . . . . . . . . . . . . . . . 36

Make Sure the Driver Works. . . . . . . . . . . . . . . . . . . . . . 36

Commission All Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Browse the Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Configuration Signature. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Safety Reset (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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4Table of Contents

Set Passwords (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Set or Change a Password . . . . . . . . . . . . . . . . . . . . . . . 41

Forgotten Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chapter 4

Manage the Safety Network

Number

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Safety Network Number (SNN) Formats . . . . . . . . . . . . . . . . 43

Time-based Safety Network Number (Recommended) . . . 44

Manual Safety Network Number (SNN) . . . . . . . . . . . . . . 44

Assignment of the Safety Network Number (SNN) . . . . . . . . 45

Automatic (Time-based) . . . . . . . . . . . . . . . . . . . . . . . . . 45

Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Set the Safety Network Number (SNN) in All Safety Nodes . . 45

Safety Network Number (SNN) Mismatch . . . . . . . . . . . . . . . 47

Safety Network Number (SNN) and Node Address Changes . 47

Chapter 5

Configure Local I/O

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Configure Local Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . 49

Example: Input Channel as Test Pulse from Test Output . 52

Automatic Adjustment of On- and Off-delay Times . . . . . 53

Configure Local Test Outputs . . . . . . . . . . . . . . . . . . . . . . . 53

Configure Local Safety Outputs . . . . . . . . . . . . . . . . . . . . . . 56

Chapter 6

Configure Your Controller for

DeviceNet Communications

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Set Up the Controller as a Safety Master . . . . . . . . . . . . . . . . 59

Configure CIP Safety I/O Targets on the DeviceNet

Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Configure Safety I/O Connections. . . . . . . . . . . . . . . . . . 62

Set Up the Controller as a Safety Slave . . . . . . . . . . . . . . . . . 64

Create Safety Slave I/O Data. . . . . . . . . . . . . . . . . . . . . . 65

Using the Safety Generic Profile in RSLogix 5000 Software 69

SmartGuard Controller to SmartGuard Controller Safety

Interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Set Up the Controller as a Standard Slave. . . . . . . . . . . . . . . 73

Create Standard Slave I/O Data . . . . . . . . . . . . . . . . . . . 73

Add the SmartGuard Standard Slave to the Standard

Master’s Scanlist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Chapter 7

Set Controller Modes

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Set Automatic Execution Mode (Optional) . . . . . . . . . . . . . . 79

Set Standalone Communication Mode (Optional) . . . . . . . . . 80

Change Controller Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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Table of Contents 5

Chapter 8

Create Your Application Program

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

The Logic Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Programming Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Logic Functions and Function Blocks . . . . . . . . . . . . . . . 85

Input Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Output Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

I/O Comment Function . . . . . . . . . . . . . . . . . . . . . . . . . 88

Programming Restrictions. . . . . . . . . . . . . . . . . . . . . . . . 88

Create a Function Block Program. . . . . . . . . . . . . . . . . . . . . 89

Add an Input or Output Tag. . . . . . . . . . . . . . . . . . . . . . 89

Add a Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Connect the Tags to the Function Block . . . . . . . . . . . . . 90

Edit Function Block Parameters . . . . . . . . . . . . . . . . . . . . . . 90

In/Out Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Optional Output Point Selections . . . . . . . . . . . . . . . . . . 92

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Find Function Blocks with Open Connections . . . . . . . . . . . 93

Programming on Multiple Pages . . . . . . . . . . . . . . . . . . . . . 94

Save the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Update the Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Monitor the Program Online . . . . . . . . . . . . . . . . . . . . . . . . 96

Program Execution Sequence . . . . . . . . . . . . . . . . . . . . . . . 97

User-defined Function Blocks . . . . . . . . . . . . . . . . . . . . . . . 98

Create User-defined Function Blocks . . . . . . . . . . . . . . . 98

Password Protect User-defined Function Blocks . . . . . . 100

Reuse User-defined Function Block Files. . . . . . . . . . . . 101

Precautions for Reusing User-defined Function Blocks. . 102

Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Chapter 9

Download and Verify

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Download the DeviceNet Network Configuration . . . . . . . . 105

Verify Your DeviceNet Safety Configuration . . . . . . . . . . . . 107

Start the Safety Device Verification Wizard . . . . . . . . . . . . . 107

Determine if Devices Can Be Verified . . . . . . . . . . . . . . . . 108

Select Devices to Verify. . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Review the Safety Device Verification Reports . . . . . . . . . . 111

Lock Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

View the Safety Device Verification Wizard Summary . . . . . 113

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6Table of Contents

Chapter 10

Monitor Status and Handle Faults

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Alphanumeric Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Monitor I/O Power Supply Input . . . . . . . . . . . . . . . . . . . . 116

Monitor I/O Maintenance Information . . . . . . . . . . . . . . . . 117

Contact Operation Counter Monitoring . . . . . . . . . . . . . 117

Total On-time Monitoring. . . . . . . . . . . . . . . . . . . . . . . 117

Configure a Maintenance Monitoring Mode. . . . . . . . . . 118

Clear the Maintenance Values. . . . . . . . . . . . . . . . . . . . 119

View I/O Status Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

General Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Local Input Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Local Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Test Output or Muting Lamp Status. . . . . . . . . . . . . . . . 122

Controller Connection Status (Safety Slave Function) . . . . . 123

Error Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Error History Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Error History Memory Area. . . . . . . . . . . . . . . . . . . . . . 126

Display the Error History Table . . . . . . . . . . . . . . . . . . 126

Error History Messages and Corrective Actions . . . . . . . . . . 127

Download Errors and Corrective Actions . . . . . . . . . . . . . . 131

Reset Errors and Corrective Actions . . . . . . . . . . . . . . . . . . 133

Mode Change Errors and Corrective Actions. . . . . . . . . . . . 135

Appendix A

Status Indicators

Status LED Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Identifying Errors Using Status Indicators . . . . . . . . . . . . . . 139

Appendix B

Logic Functions Command

Reference

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

NOT Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

NOT Instruction Diagram . . . . . . . . . . . . . . . . . . . . . . . 143

NOT Instruction Truth Table . . . . . . . . . . . . . . . . . . . . 143

AND Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

AND Instruction Diagram . . . . . . . . . . . . . . . . . . . . . . . 144

AND Instruction Truth Tables. . . . . . . . . . . . . . . . . . . . 144

OR Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

OR Instruction Diagram . . . . . . . . . . . . . . . . . . . . . . . . 147

OR Instruction Truth Tables . . . . . . . . . . . . . . . . . . . . . 147

Exclusive OR Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Exclusive OR Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 149

Exclusive OR Truth Table. . . . . . . . . . . . . . . . . . . . . . . 150

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Table of Contents 7

Exclusive NOR Instruction . . . . . . . . . . . . . . . . . . . . . . . . . 150

Exclusive NOR Instruction Diagram . . . . . . . . . . . . . . . 150

Exclusive NOR Instruction Truth Tables . . . . . . . . . . . . 150

Routing Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Routing Instruction Diagram. . . . . . . . . . . . . . . . . . . . . 151

Routing Instruction Truth Table . . . . . . . . . . . . . . . . . . 151

Reset Set Flip-flop (RS-FF) Instruction . . . . . . . . . . . . . . . . 151

Reset Set Flip-flop Instruction Diagram . . . . . . . . . . . . . 152

Reset Set FIip-flop Error Handling. . . . . . . . . . . . . . . . . 152

RS Flip-flop Instruction Timing Chart . . . . . . . . . . . . . . 152

Multi-connector Instruction . . . . . . . . . . . . . . . . . . . . . . . . 152

Multi-connector Instruction Diagram. . . . . . . . . . . . . . . 153

Multi-connector Instruction Truth Table . . . . . . . . . . . . 153

Comparator Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Comparator Instruction Diagram. . . . . . . . . . . . . . . . . . 154

Comparator Instruction Parameters . . . . . . . . . . . . . . . . 154

Comparator Instruction Truth Table . . . . . . . . . . . . . . . 155

Comparator Instruction Timing Chart . . . . . . . . . . . . . . 156

Appendix C

Function Blocks Command

Reference

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Reset Function Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Reset Function Block Parameters . . . . . . . . . . . . . . . . . 158

Reset Function Block Timing Charts . . . . . . . . . . . . . . . 159

Restart Function Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Restart Function Block Parameters . . . . . . . . . . . . . . . . 160

Restart Function Block Timing Charts . . . . . . . . . . . . . . 161

Emergency Stop (ESTOP) . . . . . . . . . . . . . . . . . . . . . . . . . 161

ESTOP Function Block Parameters . . . . . . . . . . . . . . . . 162

ESTOP Function Block Truth Tables . . . . . . . . . . . . . . . 162

ESTOP Function Block Error Handling . . . . . . . . . . . . . 163

ESTOP Function Block Timing Chart. . . . . . . . . . . . . . . 164

Light Curtain (LC) Function Block . . . . . . . . . . . . . . . . . . . 164

Light Curtain Function Block Parameters. . . . . . . . . . . . 165

Light Curtain Function Block Truth Tables . . . . . . . . . . 165

Light Curtain Function Block Error Handling. . . . . . . . . 165

Light Curtain Function Block Timing Chart . . . . . . . . . . 166

Safety Gate Monitoring Function Block . . . . . . . . . . . . . . . 166

Safety Gate Monitoring Function Block Optional

Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Safety Gate Monitoring Function Block Fault Present

Output Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Safety Gate Monitoring Function Block Function Tests . 167

Safety Gate Monitoring Function Block Parameters . . . . 168

Safety Gate Monitoring Function Block Truth Tables . . . 169

Safety Gate Monitoring Function Block Error Handling . 170

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8Table of Contents

Safety Gate Monitoring Function Block Timing Charts . . 171

Two-hand Control Function Block . . . . . . . . . . . . . . . . . . . 172

Two-hand Control Function Block Optional Outputs. . . 172

Two-hand Control Function Block Fault Present Output

Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Two-hand Control Function Block Parameters. . . . . . . . 173

Two-hand Control Function Block Truth Table . . . . . . . 173

Two-hand Control Function Block Error Handling. . . . . 174

Two-hand Control Function Block Timing Chart . . . . . . 174

OFF-delay Timer Function Block . . . . . . . . . . . . . . . . . . . . 175

OFF-delay Timer Function Block Timing Chart . . . . . . . 175

ON-delay Timer Function Block . . . . . . . . . . . . . . . . . . . . 175

ON-Delay Timer Function Block Timing Chart . . . . . . . 176

User Mode Switch Function Block . . . . . . . . . . . . . . . . . . . 176

User Mode Switch Function Block Optional Outputs . . . 176

User Mode Switch Function Block Fault Present Output

Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

User Mode Switch Function Block Truth Table . . . . . . . 177

User Mode Switch Function Block Error Handling . . . . . 177

User Mode Switch Function Block Timing Chart . . . . . . 178

External Device Monitoring (EDM) . . . . . . . . . . . . . . . . . . 178

EDM Function Block Optional Outputs. . . . . . . . . . . . . 179

EDM Function Block Fault Present Output Setting . . . . . 179

EDM Function Block Parameter . . . . . . . . . . . . . . . . . . 179

EDM Function Block Error Handling. . . . . . . . . . . . . . . 179

EDM Function Block Timing Chart . . . . . . . . . . . . . . . . 180

Muting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Muting Function Block Parameters . . . . . . . . . . . . . . . . 181

Muting Function Block Optional Outputs . . . . . . . . . . . 182

Muting Function Block Fault Present Output Setting . . . 182

Muting Function Block Error Handling . . . . . . . . . . . . . 182

Muting Function Details . . . . . . . . . . . . . . . . . . . . . . . . 183

Example: Parallel Muting With 2 Sensors. . . . . . . . . . . . 184

Example: Position Detection. . . . . . . . . . . . . . . . . . . . . 193

Example: Override Function. . . . . . . . . . . . . . . . . . . . . 195

Enable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Enable Switch Function Block Parameters. . . . . . . . . . . 199

Optional Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Fault Present Output Setting . . . . . . . . . . . . . . . . . . . . . 199

Enable Switch Function Block Error Handling . . . . . . . . 200

Enable Switch Function Block Timing Charts . . . . . . . . 200

Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Pulse Generator Function Block Parameters . . . . . . . . . 201

Pulse Generator Function Block Timing Chart. . . . . . . . 202

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Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Counter Function Block Parameters . . . . . . . . . . . . . . . 202

Reset Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Count Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Counter Function Block Timing Charts . . . . . . . . . . . . . 204

Appendix D

Explicit Messages

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Receiving Explicit Messages. . . . . . . . . . . . . . . . . . . . . . . . 207

Command Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Response Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Error Response Format. . . . . . . . . . . . . . . . . . . . . . . . . 209

Example Read Message from a GuardLogix Controller. . 210

Sending Explicit Messages . . . . . . . . . . . . . . . . . . . . . . . . . 210

Restrictions on Sending Explicit Messages . . . . . . . . . . . 211

Access Controller Parameters Using DeviceNet Explicit

Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Appendix E

Application and Configuration

Examples

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Emergency Stop Application . . . . . . . . . . . . . . . . . . . . . . . 219

Safety Gate Application with Automatic Reset. . . . . . . . . . . 221

Dual Zone Safety Gate Application Using Emergency

Stop Switch with Manual Reset . . . . . . . . . . . . . . . . . . . . . 222

Safety Mat Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Light Curtain Application. . . . . . . . . . . . . . . . . . . . . . . . . . 227

Glossary

Index

Publication 1752-UM001A-EN-P - October 2006

10 Table of Contents

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