Rockwell Automation SmartGuard 600 Operation manual

Safety Application Example

Single Safety Gate Protection Using

SmartGuard 600 Packaged Safety Controller

Safety Network-enabled Example

Safety Rating: Category 4, according to EN954-1

Introduction

This example shows how to wire, configure and program a

SmartGuard 600 safety controller to monitor a safety gate using two

safety limit switches.

Features and Benefits

•A single SmartGuard 600 safety controller monitors state of limit

switches.

•The safety system described in this example could be expanded

as needed, by adding additional safety input or outputs.

•This example provides easy integration into Logix or

GuardLogix controllers and HMIs through CIP Safety on

DeviceNet networks.

Topic Page

Introduction 1

Important User Information 2

General Safety Information 3

Description 3

Setup and Wiring 4

Configure the SmartGuard 600 Controller 5

Programming 7

Performance Data 7

Additional Resources 8

Publication SAFETY-AT005A-EN-P - October 2007

2Single Safety Gate Protection Using SmartGuard 600 Packaged Safety Controller

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.

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.

Publication SAFETY-AT005A-EN-P - October 2007

Single Safety Gate Protection Using SmartGuard 600 Packaged Safety Controller 3

General Safety Information

Contact Rockwell Automation to find out more about our safety risk

assessment services.

Description

This application example describes a simple safety system that

monitors a safety gate guarding hazardous machinery. The state of the

gate is monitored by two plunger-style limit switches.

The status of the limit switches is monitored by the SmartGuard 600

safety controller. Two safety output contactors are wired to the

outputs on the SmartGuard 600 controller.

The SmartGuard 600 controller is programmed using RSNetWorx for

DeviceNet software.

Safety Function

The safety components used in this example have dual dry contacts.

Two limit switches are used to monitor the safety gate.

The SmartGuard 600 controller also uses its test pulse outputs (T0, T1,

and so on) to send test pulses over the dual limit switch circuits. This

includes shorts to 24V dc and shorts between channels. The pulse test

feature is configured in RSNetWorx for DeviceNet software.

This example meets the requirements of Category 4, according to

EN954-1.

IMPORTANT This application example is for advanced users and assumes that you

are trained and experienced in safety system requirements.

ATTENTION A risk assessment should be performed to make sure all task and

hazard combinations have been identified and addressed. The risk

assessment may require additional circuitry to reduce the risk to a

tolerable level. Safety circuits must take into consideration safety

distance calculations which are not part of the scope of this

document.

Publication SAFETY-AT005A-EN-P - October 2007

4Single Safety Gate Protection Using SmartGuard 600 Packaged Safety Controller

Example Bill of Material

This application example uses these components.

Setup and Wiring

For detailed information on installing and wiring, refer to the product

manuals listed in the Additional Resources on page 8.

System Overview

Cat. No. Description Quantity

440P-MRPS11E Senator metal roller plunger limit switch (1N.C., 1 N.O.) 2

1752-L24BBB SmartGuard 600 controller 1

100S-C Safety contactors 2

800FM-R611 Reset button, blue, flush operator, “R” legend, metal

body

1606-XL 24V dc power supply 2

SmartGuard 600 Controller

Limit Switches Safety Contactors

Reset Button

Publication SAFETY-AT005A-EN-P - October 2007

Single Safety Gate Protection Using SmartGuard 600 Packaged Safety Controller 5

Wiring

Configure the

SmartGuard 600 Controller

Use RSNetWorx for DeviceNet software, version 8.0 or later, to

configure the SmartGuard 600 controller. Follow these steps to

configure the inputs and outputs used in this application example.

1. In RSNetWorx for DeviceNet software, browse the network.

2. Right-click the SmartGuard controller and choose Properties.

3. Select the Local Input/Test Output tab.

V1 G1 T0

I3 I5

I2 I4 I6

V2 G2 O3 O5

O2 O4 O6

KM1

KM2

KM1

KM2

I11 I13

I10 I12 I14

I15

KM1-NC

KM2-NC

E1 and E2: 24V dc Power Supplies

S1: Limit Switch 1

S2: Limit Switch 2

S3: Reset Switch

KM1 and KM2: Contactors

Connect a 24V dc power supply to terminals V0 and G0, the power supply terminals for internal

circuits.

Publication SAFETY-AT005A-EN-P - October 2007

6Single Safety Gate Protection Using SmartGuard 600 Packaged Safety Controller

4. Configure test pulse outputs for the two limit switches and also

External Device Monitoring (EDM).

The Reset button is used as a standard input, so no test pulse is

required.

5. Select the Local Outputs tab.

6. Configure the safety output contactors as Safety Pulse Test.

7. Click Apply and then OK.

Publication SAFETY-AT005A-EN-P - October 2007

Single Safety Gate Protection Using SmartGuard 600 Packaged Safety Controller 7

Programming

The Logic Editor, launched from within RSNetWorx for DeviceNet

software, lets you program your application using Function Blocks.

Because this application example uses automatic reset, the external

device monitoring (EDM) function block [2] uses the output of the

safety gate monitoring function block [1] directly as its inputs.

Refer to the SmartGuard 600 Controllers User Manual, publication

1752-UM001, for details on using the Logic Editor.

Performance Data

Safety Gate Closed

Idle to Run TEDM TEDM

KM1

KM2

EDM

Feedback

Safety Gate Opened

Timing Diagram

Publication SAFETY-AT005A-EN-P - October 2007 8

Allen-Bradley, Rockwell Automation, SmartGuard, GuardLogix, and RSNetWorx for DeviceNet are trademarks

of Rockwell Automation, Inc.

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

Additional Resources

For more information about the products used in this example, refer

to these resources.

You can view or download publications at

http://literature.rockwellautomation.com. To order paper copies of

technical documentation, contact your local Rockwell Automation

distributor or sales representative.

Resource Description

SmartGuard 600 Controllers User Manual,

publication 1752-UM001

Provides detailed information on installing,

configuring, programming, and

troubleshooting SmartGuard 600

controllers.

SmartGuard 600 Controllers Safety

Reference Manual, publication

1752-RM001

Provides information on SIL 3 and CAT 4

safety system requirements, including

functional verification test intervals, system

reaction time, and PFD/PFH values.

Limit Switches - C115 Catalog Provides general information and product

selection information for 440P limit

switches.

Industrial Automation Wiring and Grounding

Guidelines, publication 1770-4.1

Provides general guidelines for installing a

Rockwell Automation industrial system.

Product Certifications website,

http://ab.com

Provides declarations of conformity,

certificates, and other certification details.

Other manuals for SmartGuard 600

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