Rockwell-automation 440C Guardmaster 440C-CR30 Configurable Safety Rel User Manual

Guardmaster® 440C-CR30 Configurable Safety RelayCatalog Number 440C-CR30-22BBBUser Manual — Original Language

10 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Table of ContentsNotes:

100 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 14 Modbus Communication• LocalAddr - The results are placed in LocalAddr.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 101Modbus Communication Chapter 14You should configure a second set of local variable

102 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 14 Modbus CommunicationNotes:

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 103Chapter 15TroubleshootingFaults fall into two categories:• Recoverable• Nonrecover

104 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 15 TroubleshootingNonrecoverable FaultsNonrecoverable faults and failures

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 105Troubleshooting Chapter 15Figure 123 - Mouse Over to Show Error Message (in Yellow

106 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 15 TroubleshootingFigure 125 - Recent Fault ListTroubleshooting with Modbu

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 107Troubleshooting Chapter 15Tab l e 18 shows the 'fault bit' message for

108 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 15 TroubleshootingRemove the fault• The Modbus address 000505 goes LO imme

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 109Chapter 16Security and PasswordGuardmaster 440C safety relay security has two comp

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 11Chapter 1OverviewIntended UseThe Cat. No. 440C-CR30-22BBB (CR30) relay is a softwar

110 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 16 Security and PasswordCompatibilityThe Safety Relay Password feature is

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 111Security and Password Chapter 16Configure PasswordSet, change, and clear the passw

112 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 16 Security and Password5. Click OK.Once a password is created, any new se

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 113Security and Password Chapter 162. Enter the Old Password, New Password and confir

114 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 16 Security and PasswordLost PasswordIf the safety relay is secured with a

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 115Chapter 17Using the Memory ModuleOverviewGuardmaster 440C safety relays support th

116 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 17 Using the Memory ModuleBackup and restore can only occur when the Cat.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 117Using the Memory Module Chapter 175. Using a small flathead screwdriver press the

118 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 17 Using the Memory ModuleThe behavior of the IN and OUT LEDs depends on w

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 119Chapter 18ReportsThe Connected Components Workbench™ (CCW) allows you to generate

12 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 1 OverviewCR30 Hardware DetailsFigure 2 - Hardware DetailsMax Number of Inp

120 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 18 ReportsSelect the desired output type, orientation, image options, head

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 121Appendix ASpecificationsSIL RatingThe CR30 meets the requirements of SIL CL 3 in a

122 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix A SpecificationsGeneral➊ Power has to be supplied by a power supply that

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 123Specifications Appendix AInputsOutputsReaction TimesNumber of Inputs Up to 18 embe

124 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix A SpecificationsRecovery TimesResponse TimesSystem Response Time Calculat

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 125Specifications Appendix AResponse Time - Demand of the Safety FunctionThe safety r

126 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix A SpecificationsFigure 132 - ExampleTable 23 - For SMF1 - E-stop:A demand

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 127Specifications Appendix ATable 24 - For SMF2 - Safety MatA demand of the Safety Ma

128 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix A SpecificationsThe evaluation method of the input or output signal depen

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 129Specifications Appendix AMuting: Synchronization time Synch Time: 0.05…10 sThe max

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 13Overview Chapter 1SoftwareThe CR30 is software configurable using the Rockwell Auto

130 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix A SpecificationsTest Pulse EvaluationIntegral test pulses are applied to

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 131Specifications Appendix AThe overall monitoring time to evaluate a fault and initi

132 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix A SpecificationsFigure 133 - ExampleTable 28 - Consideration for Recovera

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 133Specifications Appendix AReaction TimeThe reaction time is the time to enable the

134 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix A SpecificationsTable 30 - For SMF1 - E-stop:It takes 360 ms to enable th

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 135Specifications Appendix AFigure 135 - Example 2: Same as Figure 134 on page 133 bu

136 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix A SpecificationsTable 33 - For SMF2 - Safety Mat:It takes a minimum of 10

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 137Appendix BRegulatory ApprovalsAgency Certifications• UL Listed Industrial Control

138 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix B Regulatory ApprovalsNotes:

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 139Appendix CConfiguration Reference DocumentThe Configuration Reference Document mus

14 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 1 OverviewNotes:

140 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix C Configuration Reference DocumentConguration Reference DocumentDevice I

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 141Appendix DControlFLASH Firmware UpgradeUpgrade the FirmwareThis appendix shows how

142 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix D ControlFLASH Firmware Upgrade4. Click Next5. Select the catalog number

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 143ControlFLASH Firmware Upgrade Appendix D6. Expand the AB_VBP-1, 1789-A17/A Virtual

144 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix D ControlFLASH Firmware Upgrade9. Click Finish.10. Click Ye s to initiat

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 145ControlFLASH Firmware Upgrade Appendix D12. The “Welcome to ControlFlash” window a

146 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix D ControlFLASH Firmware Upgrade3. Click Next.4. Click Next.5. Click Next.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 147ControlFLASH Firmware Upgrade Appendix D6. Click Next.7. Click Finish.

148 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Appendix D ControlFLASH Firmware UpgradeNotes:

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 15Chapter 2InstallationMounting DimensionsDIN Rail MountingMounting dimensions exclud

Publication 440C-UM001C-EN-P - November 2014Supersedes Publication 440C-UM001B-EN-P - September 2014 Copyright © 2014 Rockwell Automation, Inc. All ri

16 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 2 InstallationPanel MountingFigure 4 - Panel Mounting [mm (in.)]The preferr

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 17Installation Chapter 2Enclosure ConsiderationsMost applications require installatio

18 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 2 InstallationNotes:

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 19Chapter 3Power, Ground, and WiringWiring Requirements and Recommendation• Allow for

Important User InformationRead this document and the documents listed in the additional resources section about installation, configuration, and opera

20 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 3 Power, Ground, and WiringWire SizeTable 1 - Wiring RequirementsTerminal A

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 21Power, Ground, and Wiring Chapter 3Grounding the Configurable Safety RelayThis prod

22 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 3 Power, Ground, and WiringWire Input DevicesInput Devices with Mechanical

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 23Power, Ground, and Wiring Chapter 3Wire Output DevicesUse Surge SuppressorsBecause

24 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 3 Power, Ground, and WiringFigure 9 - PinoutsTab l e 3 shows a recommended

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 25Chapter 4Configuring the CR30This manual assumes that the Connected Components Work

26 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 4 Configuring the CR303. Double-click the icon in the Project Organizer to

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 27Configuring the CR30 Chapter 45. Click and drag the Gate Switch function block to t

28 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 4 Configuring the CR30Download the ConfigurationDownload initiates the tran

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 29Configuring the CR30 Chapter 415. File transfer successful or failed.a. File transf

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 3PrefaceRead this preface to familiarize yourself with the rest of the manual. It pro

30 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 4 Configuring the CR30VerificationAfter validation, you can assign a unique

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 31Configuring the CR30 Chapter 421. Click Ye s to change the safety relay back to Run

32 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 4 Configuring the CR30Viewing the Verification ID without CCWDuring machine

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 33Configuring the CR30 Chapter 4Press the Verification button within five seconds.Fig

34 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 4 Configuring the CR30Multiple Block ConnectionsMultiple blocks can be conn

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 35Chapter 5Pulse TestingThe CR30 performs three types of pulse testing functions:• N.

36 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 5 Pulse TestingFigure 18 - Test SequenceNormally Closed Input Pulse Testing

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 37Pulse Testing Chapter 5The purpose of the test pulses is to detect short circuits f

38 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 5 Pulse TestingThen a sequence occurs in which each output is individually

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 39Chapter 6Input FilterInput filtering gives the CR30 the ability to filter out noise

4 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014PrefaceDefinitionsPublication AG-7.1 contains a glossary of terms and abbreviations

40 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 6 Input FilterThe input filtering is set in the Advanced Settings of each s

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 41Chapter 7Discrepancy TimeSafety Monitoring functions using dual inputs have a featu

42 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 7 Discrepancy TimeNotes:

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 43Chapter 8Safety Block RenamingGeneralWith Release 7 of the Connected Components Wor

44 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 8 Safety Block RenamingNaming Error IndicationAfter tabbing off, pressing e

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 45Chapter 9Safety Monitoring FunctionsMany types of safeguarding and safety devices a

46 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsYou can use the default Discrepancy Time and I

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 47Safety Monitoring Functions Chapter 9The available input selections for the Enablin

48 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsFeedback MonitoringThe Feedback function block

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 49Safety Monitoring Functions Chapter 9Figure 37 - Example Feedback Schematic with Tw

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 5Table of ContentsImportant User Information . . . . . . . . . . . . . . . . . . . .

50 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsYou can modify the number and types of inputs:

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 51Safety Monitoring Functions Chapter 9Light CurtainThe Light Curtain function block

52 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsMutingMuting is the temporary automatic suspen

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 53Safety Monitoring Functions Chapter 9You can use the default Discrepancy Time and I

54 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsFigure 47 - Example Schematic for 2-Sensor T-T

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 55Safety Monitoring Functions Chapter 9Table 4 - Muting and Synchronization Timing Se

56 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsFigure 50 - Example Schematic for 2-Sensor L-T

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 57Safety Monitoring Functions Chapter 9Tab l e 5 shows the muting and synchronization

58 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsFigure 53 - Example Schematic for 4-Sensor Mut

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 59Safety Monitoring Functions Chapter 9Tab l e 6 shows the muting and synchronization

6 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Table of ContentsChapter 4Configuring the CR30Begin Configuration. . . . . . . . . .

60 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsResetThe reset block is used in safety functio

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 61Safety Monitoring Functions Chapter 9Figure 57 - Wiring Connection for a Reset Sign

62 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsFor a valid Restart operation, according to th

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 63Safety Monitoring Functions Chapter 9Figure 62 - Example Schematic for a Safety Mat

64 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsSingle Wire Safety InputWhen configured for th

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 65Safety Monitoring Functions Chapter 9Two-Hand ControlThe CR30 can be configured to

66 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsType IIIA Two-hand ControlThe Type IIIA uses o

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 67Safety Monitoring Functions Chapter 9Figure 72 - Wiring Connection for a Type IIIC

68 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsAlternate DeviceThe Alternate Device provides

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 69Safety Monitoring Functions Chapter 9Figure 75 - Example Schematic for Single Chann

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 7Table of ContentsAlternate Device . . . . . . . . . . . . . . . . . . . . . . . . .

70 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsPulse testing can be set to 1 Source, 2 Source

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 71Safety Monitoring Functions Chapter 9Figure 80 - Example Schematic for Two OSSDDual

72 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsIf a short circuit occurs on terminal 12 to gr

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 73Safety Monitoring Functions Chapter 9Figure 86 - Example Schematic for Three N.C. w

74 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 9 Safety Monitoring FunctionsNotes:

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 75Chapter 10Logic Levels A and BThe Connected Components Workbench (CCW) has two leve

76 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 10 Logic Levels A and BTable 8 - AND Logic Table for Two InputsORThe OR blo

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 77Logic Levels A and B Chapter 10NANDThe NAND block accepts 2…24 inputs. The NAND per

78 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 10 Logic Levels A and BTable 13 - NOT Logic Table for Two InputsAND with Re

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 79Logic Levels A and B Chapter 10Figure 97 - AND with Restart Timing DiagramOR with R

8 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Table of ContentsChapter 15TroubleshootingRecoverable Faults. . . . . . . . . . . .

80 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 10 Logic Levels A and BFigure 99 - Logic of the Restart Function with Two I

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 81Chapter 11Safety OutputsThe safety output blocks are the fourth stage of the config

82 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 11 Safety OutputsImmediate OFFThe Immediate OFF block is used to turn off o

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 83Safety Outputs Chapter 11ON DelayThe ON Delay block turns on the output after the s

84 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 11 Safety OutputsOFF DelayThe OFF Delay block turns off the output after th

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 85Safety Outputs Chapter 11JogThe Jog block turns on the output for a specified durat

86 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 11 Safety OutputsNotes:

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 87Chapter 12Plug-in ModulesThe CR30 accepts up to two plug-in I/O modules. Ta b l e 1

88 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 12 Plug-in Modules2080-IQ4OB4The 2080-IQ4OB4 has four sinking inputs and fo

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 89Plug-in Modules Chapter 122080-IQ4The 2080-IQ4 has four sinking inputs. The four CO

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 9Table of ContentsAppendix ASpecificationsSIL Rating. . . . . . . . . . . . . . . . .

90 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 12 Plug-in Modules2080-OW4IThe 2080-OW4I has four electromechanical relays

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 91Chapter 13LEDsThe CR30 has 21 LEDs on the upper left front of the module. These 21

92 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 13 LEDsInput and Output LEDsTo access and configure the LEDs in the CCW, 1.

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 93LEDs Chapter 13In the previous example:a. Input LED 1 is monitoring a terminal stat

94 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 13 LEDsNotes:

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 95Chapter 14Modbus CommunicationThe CR30 uses Modbus RTU communications to transfer s

96 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 14 Modbus CommunicationFigure 113 - (Non-)Readable Pass-through Blocks00037

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 97Modbus Communication Chapter 14Example ArchitecturesSome examples of how the CR30 i

98 Rockwell Automation Publication 440C-UM001C-EN-P - November 2014Chapter 14 Modbus CommunicationFigure 116 - Modbus RTU Communication — PanelView C6

Rockwell Automation Publication 440C-UM001C-EN-P - November 2014 99Modbus Communication Chapter 14Reading CR30 StatusIn the Micro800 family, the Msg_M