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.

3 Publication 1752-UM001A-EN-P - October 2006

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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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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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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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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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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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

11 Publication 1752-UM001A-EN-P - October 2006

Preface

Read this preface to familiarize yourself with the rest of the manual. It

provides information concerning:

• who should use this manual.

• the purpose of this manual.

• related documentation.

• conventions used in this manual.

• terminology used in this manual.

Who Should Use This

Manual

Use this manual if you are responsible for designing, installing,

programming, or troubleshooting control systems that use

SmartGuard 600 controllers.

You must have a basic understanding of electrical circuitry and

familiarity with relay logic. You must also be trained and experienced

in the creation, operation, and maintenance of safety systems.

Purpose of This Manual

This manual is a guide for using SmartGuard 600 controllers. It

describes the specific procedures you use to configure, operate, and

troubleshoot your SmartGuard 600 controller.

Additional Resources

The table below provides a listing of publications that contain

important information about SmartGuard 600 controller systems.

If you would like a manual, you can:

• download a free electronic version from the Internet at

http://literature.rockwellautomation.com

.

• purchase a printed manual by contacting your local

Allen-Bradley distributor or Rockwell Automation sales office.

For Read This Document Publication

Information on installing the SmartGuard 600 controller SmartGuard 600 Controller Installation Instructions 1752-IN001

Detailed requirements for achieving and maintaining SIL 3

with the SmartGuard controller system

SmartGuard Controllers Systems Safety Reference

Manual

1752-RM001

Information on installing Guard I/O DeviceNet Safety modules DeviceNet Safety I/O Installation Instructions 1791DS-IN001

Information on using Guard I/O DeviceNet Safety modules Guard I/O DeviceNet Safety Modules User Manual 1791DS-UM001

Publication 1752-UM001A-EN-P - October 2006

12 Preface

Common Techniques Used

in This Manual

The following conventions are used throughout this manual:

• Bulleted lists, such as this one, provide information, not

procedural steps.

• Numbered lists provide sequential steps or hierarchical

information.

• Italic type is used for emphasis.

Understanding Terminology

The following table defines terms used in this manual.

Terms and Definitions

Abbreviation Full Term Definition

1oo2 One out of two Refers to the behavioral design of a multi-processor safety system.

CIP Common industrial protocol A communications protocol designed for industrial automation applications.

PC Personal computer Computer used to interface with a control system via programming software.

PFD Probability of failure on demand The average probability of an operational system to fail to perform its design

function on demand.

PFH Probability of failure per hour The probability of an operational system to have a dangerous failure occur per

hour.

RPI Requested packet interval When communicating over a network, this is the expected rate in time for

production of data.

SNN Safety network number A unique number that identifies a safety network or safety subnet across all

routable networks in the safety system.

— Standard Any object, task, tag, program, or component in your project that is not a

safety-related item.

13 Publication 1752-UM001A-EN-P - October 2006

Chapter

1

Overview

Introduction

About the SmartGuard 600

Controller

The SmartGuard 600 controller is a programmable electronic system

featuring 16 digital inputs, 8 digital outputs, 4 test pulse sources, and

connections for USB and DeviceNet communications. The

SmartGuard 600 controller supports both standard and CIP Safety

communications over DeviceNet networks. The SmartGuard 600

controller is certified for use in safety applications up to and including

Safety Integrity Level (SIL) 3, according to IEC 61508, and Category

(CAT) 4, according to EN 954-1.

SmartGuard 600 Controller Safety Control System Example

Topic Page

About the SmartGuard 600 Controller 13

Safety Concept of the Controller 17

Additional Resources 17

1 The SmartGuard 600 controller executes safety logic operations and controls local

safety I/O.

2 As a DeviceNet safety master, the controller also controls remote CIP Safety I/O

slaves on the DeviceNet network.

As a DeviceNet safety slave, the controller can perform safety interlocking with

another CIP Safety master.

3 As a DeviceNet standard slave, the SmartGuard 600 controller communicates with a

DeviceNet standard master.

1

3

2

SmartGuard

Controller

Standard Slave

Non-safety Control

Safety Control

Standard Controller

DeviceNet Safety I/O

Safety Slave

DeviceNet

Network

RSNetWorx for DeviceNet

Software

MS

NS

LOCK

COMM

NODE ADR

x10 x1

USB

SERVICE

BAUD RATE

24VDC

V0V0 G0 G0

00

O

N

1

2

3

4

OUT

IN

24VDC

V1 G1 T0 T2

V2 G2 T1 T3

0246

1357

8101214

9111315

024 6

135 7

0246

1357

0246

1357

8101214

9111315

Smart

600

Publication 1752-UM001A-EN-P - October 2006

14 Overview

Hardware

The SmartGuard 600 controller features 16 digital inputs, 8 digital

outputs, 4 pulse test sources, and connections for USB and DeviceNet

Safety protocol.

SmartGuard 600 Controller Features

Number Feature

1 Module LED Indicators

2 Alphanumeric display

3 Node address switches

4 Baud rate switches

5 USB port

6 DeviceNet communications connector

7 Terminal connectors

8 Input LED indicators

9 Output LED indicators

10 Service switch

1

3

4

6

10

5

2

7

8

9

7

Publication 1752-UM001A-EN-P - October 2006

Overview 15

Safety Inputs

The controller has 16 local safety inputs, which support the features

described below.

• Input circuit diagnosis — Test pulse sources can be used to

monitor internal circuits, external devices, and external wiring.

• Input on- and off-delays — You can set input time filters of

0…126 ms in multiples of the controller cycle time. Setting input

on- and off-delays helps reduce the influence of chattering and

external noise.

• Dual Channel mode — You can set Dual Channel mode for pairs

of related local inputs. When Dual Channel mode is set, time

discrepancies in changes in data or input signals between two

paired, local inputs can be evaluated.

Safety Outputs

The controller has eight local safety outputs, which support the

features described below.

• Output circuit diagnosis — Test pulses can be used to diagnose

the controller’s internal circuits, external devices, and external

wiring.

• Overcurrent detection and protection — To protect the circuit,

an output is blocked when an overcurrent is detected.

• Dual Channel mode — Both of two paired outputs can be set

into a safety state without depending on the user program when

an error occurs in either of the two paired local outputs.

Test Pulse Sources

Four independent test outputs are normally used in combination with

safety inputs. They can also be set for use as standard signal output

terminals. The test pulse outputs support the following features.

• Overcurrent detection and protection — To protect the circuit,

an output is blocked when an overcurrent is detected.

• Current monitoring for muting lamp — Disconnection can be

detected for the T3 terminal only.

Communications

The controller can act as a DeviceNet safety master or slave, as a

DeviceNet standard slave, or as a standalone controller when

DeviceNet communications are disabled. A single controller can

Publication 1752-UM001A-EN-P - October 2006

16 Overview

function simultaneously as a safety master, safety slave, and standard

slave.

Explicit messages can be used to read controller status information.

Explicit messages set from the configuration software can be sent from

the user program.

The USB port can be used to program the SmartGuard controller and

to configure devices on the DeviceNet network. The SmartGuard

provides some limited pass-through capability from USB to DeviceNet,

for programming and configuration purposes. When used in

Standalone mode, the controller communicates with the configuration

software via USB communications.

Configuration and Programming

Use RSNetWorx for DeviceNet software to configure, program, and

monitor the status of the controller. With RSNetWorx for DeviceNet

software, you can configure the controller using the SmartGuard

controller’s USB port or via the DeviceNet network.

The logic editor is launched from within RSNetWorx for DeviceNet

software. Basic logic operations, such as AND and OR, and function

blocks, such as ESTOP and light curtain, are supported. A maximum

of 256 logic functions and function blocks can be used in a maximum

of 32 programming pages. You can password-protect both

configuration data and project files.

Status and Error Monitoring

The controller’s internal status information and I/O data can be

monitored online using RSNetWorx for DeviceNet software with either

a USB or DeviceNet network connection.

The LED indicators and alphanumeric display on the controller

provide status and error information. When the service switch on the

front of the controller is pressed, the alphanumeric display shows the

controller’s safety configuration signature two digits at a time for a

total of ten pairs of numbers.

Errors detected by the controller are recorded in an error history log,

along with the total operating time at the time the error was detected.

Publication 1752-UM001A-EN-P - October 2006

Overview 17

Safety Concept of the

Controller

The SmartGuard 600 controller is certified for use in safety

applications up to and including Safety Integrity Level (SIL) 3,

according to IEC 61508, and Category (CAT) 4, according to EN 954-1,

in which the de-energized state is the safety state. Safety application

requirements include evaluating the probability of failure rates (PFD

and PFH), system reaction-time calculations, and functional

verification tests that fulfill SIL 3 criteria. You must read, understand,

and fulfill these requirements prior to operating a SmartGuard 600

controller-based SIL 3 or CAT 4 safety system.

The controller uses the following mechanisms to support the integrity

of safety data.

• Safety network number (SNN) — A unique number that

identifies the safety network. Each DeviceNet sub-network that

contains safety nodes must have one unique SNN.

• Configuration signature — The combination of an ID number,

date, and time that uniquely identifies a specific configuration

for a safety device.

• Configuration lock (or safety-lock) — After the configuration

data has been downloaded and verified, you can lock the

controller’s configuration to prevent it from being modified.

• Password protection — The controller’s configuration can be

protected by the use of an optional password. If you set a

password, download, locking, unlocking, resetting, and

changing the status of the controller requires a password to

perform.

Additional Resources

Refer to the SmartGuard Controllers Safety Reference Manual,

publication 1752-RM001, for information on SIL 3 and CAT 4 safety

system requirements, including functional verification test intervals,

system reaction time, and PFD/PFH values.

Publication 1752-UM001A-EN-P - October 2006

18 Overview

19 Publication 1752-UM001A-EN-P - October 2006

Chapter

2

Installing and Wiring the SmartGuard 600

Controller

Introduction

General Safety Information

Topic Page

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

Wiring the SmartGuard 600 Controller 28

ATTENTION

Environment and Enclosure

This equipment is intended for use in 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 Publication 11.

Without appropriate precautions, there may be potential difficulties ensuring electromagnetic compatibility

in other environments due to conducted as well as radiated disturbance.

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 flame spread rating or

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, Alllen-Bradley publication 1770-4.1.

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

degrees of protection provided by different types of enclosure.

Publication 1752-UM001A-EN-P - October 2006

20 Installing and Wiring the SmartGuard 600 Controller

North American Hazardous Location Approval

The following information applies when operating this

equipment in hazardous locations

Informations sur l’utilisation de cet équipement en

environnements dangereux

Products marked CL I, DIV 2, GP A, B, C, D are suitable for use in

Class I Division 2 Groups A, B, C, D, Hazardous Locations and

nonhazardous locations only. Each product is supplied with

markings on the rating nameplate indicating the hazardous location

temperature code. When combining products within a system, the

most adverse temperature code (lowest T number) may be used to

help determine the overall temperature code of the system.

Combinations of equipment in your system are subject to

investigation by the local Authority Having Jurisdiction at the time

of installation.

Les produits marqués CL I, DIV 2, GP A, B, C, D ne conviennent qu’à une

utilisation en environnements de Classe I Division 2 Groupes A, B, C, D

dangereux et non dangereux. Chaque produit est livré avec des

marquages sur sa plaque d’identification qui indiquent le code de

température pour les environnements dangereux. Lorsque plusieurs

produits sont combinés dans un système, le code de température le

plus défavorable (code de température le plus faible) peut être utilisé

pour déterminer le code de température global du système. Les

combinaisons d’équipements dans le système sont sujettes à

inspection par les autorités locales qualifiées au moment de

l’installation.

WARNING

EXPLOSION HAZARD

• Do not disconnect equipment unless power

has been removed or the area is known to

be nonhazardous.

• Do not disconnect connections to this

equipment unless power has been removed

or the area is known to be nonhazardous.

Secure any external connections that mate

to this equipment by using screws, sliding

latches, threaded connectors, or other

means provided with this product.

• Substitution of components may impair

suitability for Class I, Division 2.

• If this product contains batteries, they must

only be changed in an area known to be

nonhazardous.

AVERTISSEMENT

RISQUE D’EXPLOSION

• Couper le courant ou s’assurer que

l’environnement est classé non dangereux

avant de débrancher l'équipement.

• Couper le courant ou s'assurer que

l’environnement est classé non dangereux

avant de débrancher les connecteurs. Fixer

tous les connecteurs externes reliés à cet

équipement à l'aide de vis, loquets

coulissants, connecteurs filetés ou autres

moyens fournis avec ce produit.

• La substitution de composants peut rendre cet

équipement inadapté à une utilisation en

environnement de Classe I, Division 2.

• S’assurer que l’environnement est classé non

dangereux avant de changer les piles.

ATTENTION

Safety Programmable Electronic Systems (PES)

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.

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