Allen-Bradley Guardmaster 440C-CR30 Quick start guide

Brand: Allen-Bradley

Model: Guardmaster 440C-CR30

Type: Quick start guide

Guardmaster 440C-CR30 Configurable Safety Relay Building

Block

Connected Components Accelerator Toolkit

Quick Start

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to

familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,

and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required

to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be

impaired.

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.

Labels may also be on or inside the equipment to provide specific precautions.

Allen-Bradley, CompactLogix, Connected Components Workbench, Guardmaster, Micro800, Micro820, Micro830, Micro850, PanelView, PowerFlex, ProposalWorks, PS/2, Rockwell Automation, Rockwell Software, and

Stratix 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.

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.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

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.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication CC-QS038A-EN-P - August 2015 3

Where to Start

To complete your building block project, follow this path.

Chapter 1 - Guardmaster 440C-CR30 Configurable Safety Relay Setup

Chapter 2 - System Validation

Read the Getting Started CCAT with

System Design Assistant Quick

Start, publication CC-QS035

4 Rockwell Automation Publication CC-QS038A-EN-P - August 2015

Where to Start

Notes:

Rockwell Automation Publication CC-QS038A-EN-P - August 2015 5

Table of Contents

Preface

About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Available Connected Components Accelerator Toolkit

Building Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1

Guardmaster 440C-CR30

Configurable Safety Relay Setup

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Connect the USB Cable to the Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . 13

Configure the Communication Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Review the 440C-CR30 Software Configurable Safety Relay

Quick Start Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chapter 2

System Validation

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Review the System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Configure the Controller Communication Ports . . . . . . . . . . . . . . . . . . . 19

Configure the PanelView 800 Terminal Communication Settings. . . . 20

Connect Your Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Download Your Program to the Controller . . . . . . . . . . . . . . . . . . . . . . . . 22

Configure the IP Address of Your PanelView 800 Terminal . . . . . . . . . 26

Transfer Your HMI Application to the PanelView 800 Terminal . . . . 26

Validate Your System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Understand the Machine Functions Screen . . . . . . . . . . . . . . . . . . . . . 28

Set Up the Configuration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Understand the Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Understand the Fault Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Verify the Configuration Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Verify the Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshoot a Wiring Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Appendix A

440C-CR30 Configurable Safety Relay

User-defined Function Block

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Appendix B

Global Variables

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6 Rockwell Automation Publication CC-QS038A-EN-P - August 2015

Table of Contents

Notes:

Rockwell Automation Publication CC-QS038A-EN-P - August 2015 7

Preface

About This Publication

The Guardmaster® 440C-CR30 configurable safety relay building block monitors the status of the 440C-CR30 safety relay

through a Modbus RS-232C interface. This quick start provides instructions for how to connect the Micro800®

programmable logic controller (PLC) with the safety relay for status updates. Use this quick start to configure a monitoring

system for your 440C-CR30 safety relay.

To help with the design and installation of your system, application files and other information are provided on the

Connected Components Accelerator Toolkit (CCAT). The CCAT provides bills of materials (BOM), CAD drawings for

panel layout and wiring, control programs, human machine interface (HMI) screens, and more. With these tools and the

built-in best-practices design, you are free to focus on the design of your machine control and not on design overhead tasks.

The CCAT is available on the Connected Components Accelerator Toolkit DVD, publication CC-QR002, or through

the Rockwell Automation Software Download and Registration System (SDRS) site at

http://www.rockwellautomation.com/rockwellautomation/products-technologies/connected-components/tools/

accelerator-toolkit.page.

The beginning of each chapter contains the following information. Read these sections carefully before you begin work in

each chapter:

• Before You Begin - The chapters in this quick start do not have to be completed in the order in which they appear.

However, this section defines the minimum amount of preparation that is required before completing the current

chapter.

• What You Need - This section lists the tools that are required to complete the steps in the current chapter,

including, but not limited to, hardware and software.

• Follow These Steps - This section illustrates the steps in the current chapter and identifies the steps that are required

to complete the examples.

8 Rockwell Automation Publication CC-QS038A-EN-P - August 2015

Preface

Terminology

Term (Abbreviation) Definition

Application Sequence Programs User-modified programs that work together with the standard-state machine logic to control what the machine does

while in the abort, clear, reset, run, and stop states.

Auto/manual operation When the PanelView™ 800 terminal is in Auto mode, the controller logic controls the machine and monitors machine

status.

When the PanelView 800 terminal switches to Manual mode, the terminal takes over control. Command buttons and

numeric entry fields are available only when the machine is in Manual mode.

Bill of Materials (BOM) A list of components that are needed for your system.

Building block (BB) Tools to accelerate and simplify the development of a Micro800 controller-based application. A typical building block

includes a starting Bill of Material (BOM), Computer-Aided Design (CAD) drawings, Micro800 controller programs,

PanelView 800 terminal applications, and a quick start document.

Computer-Aided Design (CAD) A computer-based system that is developed to facilitate design of mechanical parts.

Connected Components Accelerator Toolkit (CCAT) Software with application files and other information to speed the design and startup of component-based machines.

CCAT project A project that consists of these items:

• A ProposalWorks™-based bill of materials

• A set of CAD drawings (dimensions and schematics)

• A Connected Components Workbench project

• HMI screens

• A set of Quick Start documents

• A project document with information about the project components and links to reference materials

Connected Components Workbench™ software Software environment for configuring or programming Micro800 controllers, PanelView 800 terminals, PowerFlex® drives,

and other component-level products.

Connected Components Workbench project A project consists of one or more of the following:

• Micro800 controller configuration

• Up to 256 Micro800 programs, each with program local variables

• Micro800 global variables

• PanelView 800 terminal application

• PowerFlex drive parameter lists

Global variables Project variables that any program can access, including all I/O and system variables.

State Machine control code Machine logic for coordinating overall machine operation that is based on states. The state machine broadcasts commands

and receives feedback information from each of the building blocks via user-modified application sequence programs.

Tags A PanelView 800 term for variables.

User-defined Function Blocks (UDFBs) Function block instructions that can be used like standard function block instructions within any Connected Components

Workbench programming language. Anyone that uses Connected Components Workbench software can write these

functions blocks. Many UDFBs are posted on the Rockwell Automation sample code website:

http://samplecode.rockwellautomation.com/idc/groups/public/documents/webassets/sc_home_page.hcst

User-defined Object (UDO) A collection of PanelView 800 terminal screen objects that can be pasted into a new screen.

Rockwell Automation Publication CC-QS038A-EN-P - August 2015 9

Preface

Available Connected Components Accelerator Toolkit Building Blocks

For the most up-to-date listing of available Connected Components Accelerator Toolkits and related quick starts, refer to

these resources:

• Rockwell Automation Connected Components Accelerator Toolkit website at

http://www.rockwellautomation.com/rockwellautomation/products-technologies/connected-components/tools/

accelerator-toolkit.page

• Connected Components Accelerator Toolkit Building Block Project Descriptions Quick Reference,

publication CC-QR003

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

You can view or download publications at http://www.rockwellautomation.com/literature/

. To order paper copies of

technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

Resource Description

Guardmaster 440C-CR30 Software Configurable Safety Relay

Quick Start Guide, publication 440C-QS001

Provides information on how to configure a Guardmaster 440C-CR30 configurable safety relay to communicate

with a PanelView 800 terminal via Modbus communication protocol.

Guardmaster 440C-CR30 Configurable Safety Relay User Manual,

publication 440C-UM001

Provides detailed information on how to install, configure, operate, and troubleshoot a Guardmaster 440C-CR30

configurable safety relay.

Micro830 and Micro850 Programmable Controllers User Manual,

publication 2080-UM002

Provides a reference guide for Micro830® and Micro850® controller systems. This publication also contains

procedures on how to install, wire, and troubleshoot your controller.

Micro800 Digital and Analog Plug-in Modules and Accessories

User Manual, publication 2080-UM004

Provides an overview and procedures for installing, wiring, and troubleshooting Micro800 plug-in modules and

accessories.

Micro820 20-point Programmable Controllers User Manual,

publication 2080-UM005

Provides a reference guide for Micro820™ controller systems. It also contains procedures on how to install, wire,

and troubleshoot your controller.

PanelView 800 HMI Terminals User Manual, publication

2711R-UM001

Provides information for configuring the PanelView 800 terminal.

PanelView 800 HMI Terminals Installation Instructions,

publication 2711R-IN001

Provides instructions on how to install, wire, ground, and troubleshoot PanelView 800 terminals.

10 Rockwell Automation Publication CC-QS038A-EN-P - August 2015

Preface

Notes:

Rockwell Automation Publication CC-QS038A-EN-P - August 2015 11

Chapter 1

Guardmaster 440C-CR30 Configurable Safety Relay Setup

This chapter provides information for how to configure the hardware for the 440C-CR30 safety relay.

Before You Begin

• Review the Getting Started Connected Components Accelerator Toolkit with System Design Assistant Quick Start,

publication CC-QS035

• Apply power to your 440C-CR30 safety relay.

What You Need

• Personal computer with an available USB port

• 440C-CR30-22BBB safety relay

• USB cable (for programming the safety relay)

• Connected Components Workbench software, version 8.00

12 Rockwell Automation Publication CC-QS038A-EN-P - August 2015

Chapter 1 Guardmaster 440C-CR30 Configurable Safety Relay Setup

Follow These Steps

To configure your 440C-CR30 safety relay, complete these steps.

Start

Connect the USB Cable to the

Safety Relay on page 13

Review the 440C-CR30 Software

Configurable Safety Relay Quick

Start Guide on page 14

Configure the Communication

Settings on page 13

Rockwell Automation Publication CC-QS038A-EN-P - August 2015 13

Guardmaster 440C-CR30 Configurable Safety Relay Setup Chapter 1

Connect the USB Cable to the Safety Relay

Connect a USB cable between the safety relay and your personal computer. The driver for the safety relay is automatically

installed. If the driver did not install, unplug the USB cable and plug it in again.

Figure 1 - Connect the Safety Relay to Your Computer

Configure the Communication Settings

To configure the safety relay communication settings for the Micro800 controller, follow these steps.

1. Launch the Connected Component Workbench version 8 software.

2. To add the 440C-CR30 safety relay to your project, from the Device Tool box open Catalog > Safety and

double-click the 440C-CR30 safety relay.

3. In the project organizer, double-click the safety relay.

14 Rockwell Automation Publication CC-QS038A-EN-P - August 2015

Chapter 1 Guardmaster 440C-CR30 Configurable Safety Relay Setup

4. To configure the communication parameters, select Serial Port.

5. From the Common Settings pull-down menu lists, choose these options:

•Driver: Modbus RTU

• Baud Rate: 19200

•Parity: None

6. Download the configuration to the safety relay.

7. Select the device from the connection browser and click OK to begin download.

Review the 440C-CR30 Software Configurable Safety Relay Quick Start Guide

Follow the instructions in the 440C-CR30 Software Configurable Safety Relay Quick Start Guide,

publication 440C-QS001

, to configure the safety relay.

Rockwell Automation Publication CC-QS038A-EN-P - August 2015 15

Chapter 2

System Validation

This chapter provides information for how to configure the controller and human machine interface (HMI) so the devices

are communicating correctly. After the configuration is complete, you can validate the system for monitoring the status of

the 440C-CR30 safety relay.

Before You Begin

• Complete the steps in Chapter 1.

• Verify that the devices are connected as shown in the wiring diagrams (see Figure 2

, Figure 3, or Figure 4).

• Apply power to the devices.

What You Need

• Micro800 controller

• 440C-CR30-22BBB safety relay

• 4-inch or larger PanelView 800 terminal

• Stratix™ Ethernet switch (if you use a CIP-on-Ethernet connection)

• One pair of 1761-CBL-HM02 cables

• Three pairs of USB programming cables (A to B) or Ethernet cables for personal computer to Micro800 controller

communication

• Personal computer with available USB port and Ethernet connection with Connected Components Workbench

software, version 8.00, installed

16 Rockwell Automation Publication CC-QS038A-EN-P - August 2015

Chapter 2 System Validation

Follow These Steps

To validate your system, complete these steps.

Review the System

Overview on page 17

Validate Your System on page 28

Configure the Controller

Communication Ports on page 19

Configure the PanelView 800

Terminal Communication Settings

on page 20

Connect Your Devices on page 22

Download Your Program to the

Controller on page 22

Transfer Your HMI Application

to the PanelView 800 Terminal

on page 26

Start

Configure the IP Address of Your

PanelView 800 Terminal on page 26

Rockwell Automation Publication CC-QS038A-EN-P - August 2015 17

System Validation Chapter 2

Review the System Overview

The PanelView 800 Graphic Terminal can be connected to the Micro800 controller with a CIP serial or CIP-on-Ethernet

connection:

• For a CIP serial connection, use a 1761-CBL-PM02 cable to connect the PanelView 800 terminal to the embedded

serial port of the Micro800 controller.

• For a CIP-on-Ethernet connection, connect the PanelView 800 terminal to the Stratix Ethernet switch. Then use the

Ethernet patch cords to connect the Stratix Ethernet switch to the embedded Ethernet port of the Micro800

controller.

• For a CIP-on-Ethernet connection to a Micro850 controller, you can connect the terminal directly to the Ethernet

port on the Micro850 controller by using an Ethernet cable.

All connection methods are explained in this manual, but choose only one method for your project.

The 440C-CR30 safety relay can be connected directly to the embedded serial port of the Micro800. The safety relay can

also be connected to a serial plug-in module when the embedded serial port is already configured to communicate with a

PanelView 800 terminal.

Figure 2 - Connection for Micro820 and 440C-CR30 Safety Relay With a Modified 1761-CBL-HM02 Cable

To modify the 1761-CBL-HM02 cable, follow these steps.

1. Cut the 1761-CBL-HM02 cable to the required length.

2. Identify the wire that is connected to pins 2, 4, and 7 of the PS/2™ connector.

3. Connect the wire to the respective terminal according to this table.

IP Address: 192.168.1.2

Modified 1761-CBL-HM02

Micro820

IP Address: 192.168.1.3

440C-CR30 Safety Relay

Ethernet

Cable

18 Rockwell Automation Publication CC-QS038A-EN-P - August 2015

Chapter 2 System Validation

Figure 3 - Connection for Micro850 and 440C-CR30 Safety Relay

Figure 4 - Connection for Micro830 and 440C-CR30 Safety Relay

440C-CR30 Safety Relay Connector Micro800 Controller Terminal

Pin 7 Rx

Pin 4 Tx

Pin 2 G

IP Address: 192.168.1.2

1761-CBL-HM02

440C-CR30 Safety Relay

Ethernet

Cable

Micro850

IP Address: 192.168.1.3

440C-CR30 Safety Relay

Modified 1761-CBL-HM02

1761-CBL-PM02

Micro830

Rockwell Automation Publication CC-QS038A-EN-P - August 2015 19

System Validation Chapter 2

Configure the Controller Communication Ports

By default, the 440C-CR30 safety relay serial communication port has these communication settings.

Figure 5 - Default Communication Configuration for the 440C-CR30 Safety Relay

To communicate with the 440C-CR30 safety relay, you must configure the embedded serial port or serial plug-in module

of the Micro800 controller with these configuration settings.

Figure 6 - Embedded Serial Port Settings for the Micro800 Controller

20 Rockwell Automation Publication CC-QS038A-EN-P - August 2015

Chapter 2 System Validation

Configure the PanelView 800 Terminal Communication Settings

To modify these settings in the default Connected Components Workbench project, follow these steps.

1. To open the PanelView 800 application editor, in the Project Organizer double-click the PanelView 800 device icon.

The PanelView 800 Communication Settings pane appears in the main project window.

2. Configure the appropriate communication settings:

For CIP Serial communication, configure the settings that are shown here.

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Allen-Bradley Guardmaster 440C-CR30 Quick start guide

Allen-Bradley Guardmaster 440C-CR30 Quick start guide

Allen-Bradley Guardmaster 440C-CR30 Quick start guide

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