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.

3Publication 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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4Table of Contents
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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Table of Contents 5
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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6Table of Contents
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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Table of Contents 7
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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8Table of Contents
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