Rockwell Automation Allen-Bradley Guardmaster 440G-MZ Original Instructions Manual

Safely-limited speed and guard door unlocking with armor powerflex safety function

Hide thumbs

page of 30

/ 30
Bookmarks

Quick Links

Download this manual

Application Technique

Original Instructions

Safely-limited Speed and Guard Door Unlocking with Armor

PowerFlex Safety Function

Products: Guardmaster 440G-MZ Interlocking Switch, GuardLogix 5580 or Compact GuardLogix 5380 Controller, Armor PowerFlex

35S Integrated Safety, 700S-C Relay

Safety Rating: Cat. 3, PLd to ISO 13849-1: 2023

Topic

Important User Information

General Safety Information

Introduction

Use Sample Project Files

Safety Function Realization: Risk Assessment

Safety Function

Safety Function Requirements

Bill of Materials

Setup and Wiring

Configuration

Programming

Calculation of the Performance Level

Verification and Validation Plan

Additional Resources

Page

Need help?

Do you have a question about the Allen-Bradley Guardmaster 440G-MZ and is the answer not in the manual?

Questions and answers

Summary of Contents for Rockwell Automation Allen-Bradley Guardmaster 440G-MZ

Page 1 Application Technique Original Instructions Safely-limited Speed and Guard Door Unlocking with Armor PowerFlex Safety Function Products: Guardmaster 440G-MZ Interlocking Switch, GuardLogix 5580 or Compact GuardLogix 5380 Controller, Armor PowerFlex 35S Integrated Safety, 700S-C Relay Safety Rating: Cat. 3, PLd to ISO 13849-1: 2023 Topic Page Important User Information...
Page 2 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.
Page 3 Safely-limited Speed and Guard Door Unlocking with Armor PowerFlex Safety Function Application Technique General Safety Information Contact Rockwell Automation to learn more about our safety risk assessment services. IMPORTANT This application example is for advanced users and assumes that you are trained and experienced in safety system requirements.
Page 4 PLr. From: Risk Assessment (ISO 12100) 1. Identification of safety functions 2. Specification of characteristics of each function 3. Determination of required PL (PLr) for each safety function To: Realization and PL Evaluation Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 5 SLS function is reset when the request is removed OFF(0), provided no SLS faults have occurred. Check Delay Speed Active Limit Condition Request for Reset SLS Active SLS Limit Start SLS Begin Speed Initiate STO, SS1, Monitoring SS2, or SOS Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 6 Remove the SLS request. 3. Press the Safety Reset to lock the guard door, and on the falling edge of the reset the STO is removed, which allows the motor to be enabled. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 7 Safety Function: Light Curtain Products: Light Curtain GuardLogix Controller, publication SAFETY-AT191 IMPORTANT A risk assessment may require additional safeguarding methods such as hold-to-run devices and proximity to complementary safety functions such as E-stops and lifelines. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 8 Compact GuardLogix processor, 10.0 MB standard memory, 5.0 MB safety memory 5069-L3100ERMS2 1606-XLP72E Compact power supply, 24…28V DC, 72 W, 120/240V AC input If your PLr is SIL 3/PLe, use a GuardLogix 5580 controller with a safety partner, cat. no. 1756-L8SP. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 9 This example was tested using available components. An induction AC motor with dual-channel incremental encoder feedback that is compatible with the encoder input of the safety Armor PowerFlex AC drive was used for this example. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 10 Power to Sink Out Release Unlock 24V Com Gate +24V Source Out 24V Com 889D-E5NC-xx SFTY IN 2,3 SLS Keyswitch Test Out1 Test Out0 Network Architecture GuardLogix 5580 Controller Compact GuardLogix 5380 Controller Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 11 1756-L8SP Safety Partner to the right of the primary controller. Set the IP address for the controller and the Armor PowerFlex 35S. Armor PowerFlex 35S Configuration - Device Definition Create an Armor PowerFlex Drive via Ethernet to the project I/O Configuration. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 12 0 and 1 is an Output Signal Switching Device (OSSD). Set the Input Delay Time for these inputs to 1 ms. b. Point Mode 2,3 - Single-channel equivalent, which is used with Test Output. Safety input device (SLS Keyswitch) wired to points 2 and 3 is a standard contact device. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 13 Leave all other settings at default values. The Logix safety instructions are used for the SLS and SS1 safety functions. The Effective Resolution (4096 count/rev) is required to configure the GuardLogix SFX instruction. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 14 5. Scaling: For this example, we are not using position feedback, leave values at default. 6. Motor Encoder Feedback: Set to match encoder specifications. These settings must match the Safety Feedback configuration (step Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 15 Logix SS1 instruction. This setting is the action that the drive takes when a communication loss or communication timeout occurs. Safe Brake Control (SBC) is not used. The communication connection loss and connection idle action is set to drive based SS1. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 16 3. The Reset and Safe Stop 1 (SS1) signals for safety logic are mapped from the standard logic with the mapped alias. Figure 1 - Standard Program, Any Routine Figure 2 - Safety Program, I00_MappedTags Routine Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 17 The optional raC_Dvc_DCS Add-On Instruction (AOI) connects DCS to the HMI faceplate. (ME, SE, PV5000) raC_Dvc_DCS To find this information, go to the Product Compatibility Download Center website, and search for Safety Device Library. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 18 Position Scaling: Counts/rev Safe Feedback Interface Monitors safety position, velocity, and feedback status Scales position and velocity to proper units. SFX.ActualSpeed is used by the SLS and SS1 instructions to monitor actual motor velocity. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 19 Safely-limited Speed instruction Velocity Active Limit is the maximum velocity. Can be programmatically changed. Feedback SFX is the SFX being monitored. SLS Active, Limit, Fault values sent to the drive for pass through standard tags. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 20 Armor PowerFlex tag SO.SLSActive goes false and the speed resumes to normal running speed. A trend can be used to verify the timing of the safety functions. Understanding sequential logic timing is important to allow time for a system to respond and help prevent nuisance tripping. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 21 SS1_Req Safe Speed 1 (SS1) request mapped from standard. SLS.StopReq SLS malfunction or velocity over limit removes run permissive. SAF_RunPerm On loss of safe run permissive, a Safe Stop 1 (SS1) is executed Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 22 Provides continuous monitoring of locked feedback relationship to commanded unlock output. The optional raC_Dvc_CROUT AOI connects CROUT to the HMI faceplate. (ME, SE, PV5000) raC_Dvc_CROUT To find this information, go to the Product Compatibility Download Center website, and search for Safety Device Library. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 23 Status of guard door lock for other safety task routines. Output SS1 — Safety Routine O10_Ax1_SS1 The Output SS1 routine performs the Safe Stop 1 (SS1) safety function. SS1 Request on loss of run permissive and no SS1 fault. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 24 Not valid for overdriving loads or gravitational loads that can move after motor torque has been removed. For these applications, use other forms of stop monitoring such as Safe Operating Stop. STO_Req This bit is used to have the SS1 instruction initiate the drive STO. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 25 The output STO routine contains drive safety reset logic, device status summary, and the main run permissive. Table 9 - Drive Safety Reset Request Description STOOutput Must be on to reset drive safety Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 26 Depending on the devices you choose, the overall safety rating of your system is different. The SISTEMA file that is referenced in this safety function application technique is attached to this publication. For instructions on how to access the attachments, see Use Sample Project Files on page Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 27 PLd. Guard Door Unlock at Zero Speed (SS1 and Standstill Monitoring) Assuming the use of the following subsystem choices, the overall Performance Level that is achieved is shown in the graphic. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 28 Subsystem 1 Subsystem 2 Subsystem 3 Subsystem 4 IMPORTANT The PFH for this complete safety function, with the sensor, logic, and actuator subsystems, is 1.3E-8. The PL for the complete safety function is PLd. Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023...
Page 29 For a validation checklist, see the attached spreadsheet. For instructions on how to access the attachments, see Use Sample Project Files on page Additional Resources These documents contain additional information about related products from Rockwell Automation. Resource Description Describes the GuardLogix 5580 and Compact GuardLogix 5380 controller system.
Page 30 Safety Functions. Allen-Bradley, Armor, CompactLogix, ControlLogix, expanding human possibility, Factory Talk, GuardLogix, Guardmaster, PowerFlex, Rockwell Automation, RSLinx, SensaGuard, Studio 5000, and Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

This manual is also suitable for:

Allen-bradley guardlogix 5580 Allen-bradley guardlogix 5380 Allen-bradley powerflex 35s Allen-bradley 700s-c