GuardPLC Certified Function Blocks -- Basic Suite

GuardPLC Certified Function Blocks -- Basic Suite Catalog Number 753-CFBBASIC Safety Reference 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-. 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. 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 ATTENTION SHOCK HAZARD Identifies information that is critical for successful application and understanding of the product. 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 Labels may be located 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 located on or inside the equipment, for example, a drive or motor, to alert people that surfaces may be dangerous temperatures. The first line of trademarks is an example; the brand or product name changes according to publication but the rest of the line should remain the same. The second line should be used exactly as listed below in any case where it applies. Allen-Bradley, ControlLogix, and RSLinx are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Summary of Changes The information below summarizes the changes to this manual since the last publication. To help you find new and updated information in this release of the manual, we have included change bars as shown to the right of this paragraph. Topic Page Correction to the Diverse Input Wiring Diagram - Automatic Reset 38 Important revised recommendations for setting the Pulse Test 94 Duration of the Redundant Pulst Test Ouput (RPTO) function block 3 Publication 753-RMC-EN-P - May 27

4 Summary of Changes Publication 753-RMC-EN-P - May 27

Table of Contents Preface Introduction..................................... 9 Understanding Terminology......................... 9 Additional Resources.............................. Redundant Input Function Block (RIN) Emergency Stop Function Block (ESTOP) Chapter Overview...................................... Operation...................................... Normal Operation............................. Operation with Inconsistent Inputs................. 2 Operation with Circuit Reset Held On - Manual Reset Only....................................... 2 Cycle Inputs Operation......................... 3 Function Block Description......................... 4 Relationship of I/O Wiring to Function Block Parameters... 6 Redundant Input with Manual Reset Wiring and Programming................................. 6 Redundant Input with Automatic Reset Wiring and Programming................................. 8 Chapter 2 Overview...................................... 2 Operation...................................... 2 Normal Operation............................. 2 Operation with Inconsistent Inputs................. 22 Operation with Circuit Reset Held On - Manual Reset Only....................................... 22 Cycle Inputs Operation......................... 23 Function Block Description......................... 24 Relationship of I/O Wiring to Function Block Parameters... 26 Emergency Stop with Manual Reset Wiring and Programming................................. 26 Emergency Stop with Automatic Reset Wiring and Programming................................. 28 Chapter 3 Diverse Input Function Block (DIN) Overview...................................... 3 Operation...................................... 3 Normal Operation............................. 3 Operation with Inconsistent Inputs................. 32 Operation with Circuit Reset Held On - Manual Reset Only....................................... 32 Cycle Inputs Operation......................... 33 5 Publication 753-RMC-EN-P - May 27

6 Table of Contents Function Block Description......................... 34 Relationship of I/O Wiring to Function Block Parameters... 36 Diverse Input with Manual Reset Wiring and Programming................................. 36 Diverse Input with Automatic Reset Wiring and Programming................................. 38 Enable Pendant Function Block (ENPEN) Chapter 4 Overview...................................... 4 Operation...................................... 4 Normal Operation............................. 4 Operation with Inconsistent Inputs................. 42 Operation with Circuit Reset Held On - Manual Reset Only....................................... 42 Cycle Inputs Operation......................... 43 Function Block Description......................... 44 Relationship of I/O Wiring to Function Block Parameters... 46 Enable Pendant with Manual Reset Wiring and Programming................................. 46 Enable Pendant with Automatic Reset Wiring and Programming................................. 48 Chapter 5 Light Curtain Function Block (LC) Overview...................................... 5 Operation...................................... 52 Normal Operation............................. 52 Light Curtain Muting Operation................... 53 Inputs Inconsistent Operation..................... 55 Circuit Reset Held On Operation (Manual Reset Mode Only)...................................... 56 Cycle Inputs Operation......................... 56 Input Filter Time.............................. 57 Function Block Description......................... 58 Relationship of I/O Wiring to Function Block Parameters... 6 Light Curtain with Manual Reset Wiring and Programming................................. 6 Light Curtain with Automatic Reset Wiring and Programming................................. 62 Publication 753-RMC-EN-P - May 27

Table of Contents 7 Redundant Output with Continuous Feedback Monitoring Function Block (ROUT) Five-Position Mode Selector Function Block (FPMS) Two-Hand Run Station Function Block (THRS) Redundant Pulse Test Output Function Block (RPTO) Chapter 6 Overview...................................... 65 Operation...................................... 65 Function Block Description......................... 68 Relationship of I/O Wiring to Function Block Parameters... 69 Redundant Output with Negative Feedback Wiring and Programming................................. 69 Redundant Output with Positive Feedback Wiring and Programming................................. 7 Chapter 7 Overview...................................... 73 Operation...................................... 73 Function Block Description......................... 74 Relationship of I/O Wiring to Function Block Parameters... 75 Five-Position Mode Selector Wiring and Programming... 75 Chapter 8 Overview...................................... 77 Operation...................................... 77 Normal Operation............................. 77 Button Tie-Down Operation...................... 78 Cycle Buttons Operation........................ 79 Button Fault Operation......................... 8 Function Block Description......................... 8 Relationship of I/O Wiring to Function Block Parameters... 83 Two-Hand Run Station with Active Pin Disabled Wiring and Programming........................ 83 Two-Hand Run Station with Active Pin Enabled Wiring and Programming........................ 84 Chapter 9 Overview...................................... 87 Operation...................................... 88 Normal Operation............................. 88 Cross-wiring Fault............................. 89 Automatic Fault Clearing........................ 9 Generate Pulse Test............................ 92 Pulse Test on Input Transition.................... 92 Function Block Description......................... 94 Relationship of I/O Wiring to Function Block Parameters... 95 Redundant Pulse Test Output..................... 95 Publication 753-RMC-EN-P - May 27

8 Table of Contents Single Pulse Test Output Function Block (SPTO) Chapter Overview...................................... 97 Operation...................................... 98 Normal Operation............................. 98 Function Block Diagram.......................... 2 Relationship of I/O Wiring to Function Block Parameters.. 3 Single Pulse Test Output Wiring and Programming.... 3 Index Publication 753-RMC-EN-P - May 27

Preface Introduction This reference manual is intended to describe Rockwell Automation s GuardPLC Safety Application Function Block Set for Safety Integrity Level (SIL) 3, Category (CAT) 4 applications. Understanding Terminology The following table defines abbreviations used in this manual. Abbreviation Type Description AP Input Active Pin BP Output Buttons Pressed BT Output Button Tiedown CB Output Cycle Buttons CHA Input Channel A CHB Input Channel B CI Output Cycle Inputs CR Input Circuit Reset CRHO Output Circuit Reset Held On EN Input Enable FB Input Feedback FB2 Input Feedback 2 FP Output Fault Present FR Input Fault Reset IFT Input Input Filter Time II Output Inputs Inconsistent IN to IN5 Input Input to Input 5 LBF Output Left Button Failure LBNC Input Left Button Normally Closed LBNO Input Left Button Normally Opened LCB Output Light Curtain Blocked LCM Output Light Curtain Muted MLC Input Mute Light Curtain MMS Output Multiple Modes Selected NM Output No Mode O to O5 Output Output to Output 5 OFF Output Output Feedback Failure O2FF Output Output 2 Feedback Failure RBF Output Right Button Failure RBNC Input Right Button Normally Closed RBNO Input Right Button Normally Opened SA Output Station Active SAF Output Station Active Failure 9 Publication 753-RMC-EN-P - May 27

Preface Additional Resources The following table lists documents that contain additional information concerning Rockwell Automation GuardPLC products. Resource GuardPLC Controller Systems Safety Reference Manual, publication 755-RM GuardPLC 6 Controllers Installation Instructions, publication 753-IN GuardPLC 8 Controllers Installation Instructions, publication 753-IN2 GuardPLC 753-IB2XOB8 I/O Module Installation Instructions, publication 753-IN3 GuardPLC 753-IB6 Input Module Installation Instructions, publication 753-IN4 GuardPLC 753-OB6 Output Module Installation Instructions, publication 753-IN5 RSLogix Guard PLUS! Programming Software Installation Instructions, publication 753-IN6 GuardPLC OPC Server Installation Instructions, publication 753-IN7 Allen-Bradley Programmable Controller Grounding and Wiring Guidelines, publication 77-4. Application Considerations for Solid-State Controls, publication SGI-. National Electrical Code - Published by the National Fire Protection Association of Boston, MA. Description Provides in-depth information on the safety concept of GuardPLC controller systems Provides information on installing GuardPLC 6 controllers Provides information on installing GuardPLC 8 controllers Provides information on installing GuardPLC 753-IB2XOB8 I/O module Provides information on installing GuardPLC 753-IB6 Input Module Provides information on installing GuardPLC 753-OB6 Output Module Provides information on installing RSLogix Guard PLUS! programming software Provides information on installing GuardPLC OPC server Provides in-depth information on grounding and wiring Allen-Bradley programmable controllers A description of important differences between solid-state programmable controller products and hard-wired electromechanical devices An article on wire sizes and types for grounding electrical equipment 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. Publication 753-RMC-EN-P - May 27

Chapter Redundant Input Function Block (RIN) Overview The basic purpose of the Redundant Input Function Block is to emulate the input functionality of a safety relay in a software programmable environment which is intended for use in SIL3/CAT4 safety applications. Operation Normal Operation This function block monitors the states of two input channels and turns on Output when the following conditions are met: When using Manual Reset: both inputs are in the Active state and the Circuit Reset input is transitioned from a zero to a one. When using Automatic Reset: both inputs are in the Active state for 5 ms. This Function Block turns Output off when either one or both of the input channels returns to the Safe state. Both input channels for the Redundant Input Function Block (RIN) are normally open. This means zeros on both channels represent the Safe state, and ones on both channels represent the Active state. These normal operation state changes are shown in the following timing diagrams. Normal Operation Manual Reset Automatic Reset Channel A Channel A Channel B Circuit Reset Channel B Output 5 ms Output Publication 753-RMC-EN-P - May 27

2 Redundant Input Function Block (RIN) Operation with Inconsistent Inputs This function block generates a fault if the input channels are in inconsistent states (one Safe and one Active) for more than the specified period of time. The inconsistent time period is 5 ms. This fault condition is enunciated via the Inputs Inconsistent and the Fault Present outputs. Output cannot enter the Active state while the Fault Present output is active. The fault indication is cleared when the offending condition is remedied and the Fault Reset input is transitioned from zero to one. These state changes are shown in the following timing diagram. Inputs Inconsistent, Fault Present, and Fault Reset Operation Channel A Channel B Output Inputs Inconsistent Fault Present Fault Reset 5 ms Operation with Circuit Reset Held On - Manual Reset Only This function block also sets the Circuit Reset Held On output prompt if the Circuit Reset input is set () when the input channels transition to the Active state. These state changes are shown in the following timing diagram. Publication 753-RMC-EN-P - May 27

Redundant Input Function Block (RIN) 3 Circuit Reset and Circuit Reset Held On Operation Channel A Channel B Circuit Reset Output Circuit Reset Held On Cycle Inputs Operation If, while Output is active, one of the input channels transitions from the Active state to the Safe state and back to the Active state before the other input channel transitions to the Safe state, the Cycle Inputs output prompt is set, and Output cannot enter the Active state again until both input channels cycle through their Safe states. These state changes are shown in the following timing diagram. Cycle Inputs Operation Channel A Channel B Output Cycle Inputs Publication 753-RMC-EN-P - May 27

4 Redundant Input Function Block (RIN) Function Block Description RIN_RA Redundant Input Manual Reset RIN_AUTO_RA Redundant Input Automatic Reset Channel A Channel B Circuit Reset Fault Reset Output Cycle Inputs Circuit Reset Held On Inputs Inconsistent Fault Present Channel A Channel B Fault Reset Output Cycle Inputs Inputs Inconsistent Fault Present Redundant Inputs (RIN) Function Block Parameters Parameter Short Name Type Data Type Description Safe, Active and Initial Values Channel A Input Boolean Channel A Input (Normally Open) Safe =, Active = Channel B Input Boolean Channel B Input (Normally Open) Safe =, Active = Circuit Reset Input Boolean Circuit Reset Input Initial =, Reset = Manual Reset - Sets Output after Channel A and Channel B transition from the Safe state to the Active state, and the Circuit Reset input transitions from zero to one. Fault Reset Input Boolean After fault conditions are corrected for the function block, the fault outputs for the function block are cleared when this input transitions from off to on. Output O Output Boolean Output is set to the Active state when input conditions are met. Initial =, Reset = Safe =, Active = Cycle Inputs CI Prompt Output Boolean Cycle Inputs prompts for action. Before Output is turned on, Channel A and Channel B inputs must be cycled through their Safe States at the same time before the circuit can be reset. Initial =, Prompt = This prompt is cleared when Channel A and Channel B transition to the Safe state. Publication 753-RMC-EN-P - May 27

Redundant Input Function Block (RIN) 5 Redundant Inputs (RIN) Function Block Parameters Parameter Circuit Reset Held On Short Name CRHO Type Data Type Description Safe, Active and Initial Values Prompt Output Boolean Manual Reset - The Circuit Reset Held On prompt is set when both input channels transition to the Active states, and the Circuit Reset input is already on. Initial =, Prompt = The Circuit Reset Held On prompt is cleared when the Circuit Reset input is turned off. Inputs Inconsistent II Fault Output Boolean This fault is set when Channel A and Channel B inputs are in inconsistent states (one Safe and one Active) for a period of time greater than the Inconsistent Time Period (listed below). This fault is cleared when Channel A and Channel B inputs return to consistent states (both Safe or both Active) and the Fault Reset input transitions from off to on. Initial =, Fault = Inconsistent Time Period: 5 ms Fault Present FP Fault Output Boolean This is set whenever a fault is present in the function block. Output cannot enter the Active state when Fault Present is set. Fault Present is cleared when all faults are cleared and the Fault Reset input transitions from off to on. Initial =, Fault = Publication 753-RMC-EN-P - May 27

6 Redundant Input Function Block (RIN) Relationship of I/O Wiring to Function Block Parameters Redundant Input with Manual Reset Wiring and Programming Wiring Example The following wiring diagram is one example of how to wire a 2-channel switch having two normally open contacts to a GuardPLC module to comply with EN954- Category 4. The inputs shown on this wiring diagram correspond to the inputs for the function block. Redundant Input Wiring Diagram - Manual Reset L+ DI DI 2 DI 3 DI 4 DI 5 E L- DO DO 2 LS+ GuardPLC S2 S3 S4 E - 24V Power Supply S - Redundant Input Switch S2 - Circuit Reset Switch S3 - Fault Reset Switch S4 - Generate Pulse Test Switch S S as shown is in the Active state. Programming Example The following programming example shows how the Redundant Input Function Block with Manual Reset can be applied to the wiring diagram shown in Redundant Input Wiring Diagram - Manual Reset, on page 6. Publication 753-RMC-EN-P - May 27

Redundant Input Function Block (RIN) 7 Redundant Input Programming Example - Manual Reset Guard PLC User Program RPTO_RA Redundant Pulse Test Output T#2 to 6 sec T# - 5 msec DI 5 Pulse Test Interval Pulse Test Duration Generate Pulse Test Pulse Test Source A Pulse Test Source B Pulse Test Fault A Pulse Test Fault B DO DO 2 DI DI 2 Input A Input B Output A Output B RIN_RA Redundant Input Manual Reset Channel A Output DI 3 DI 4 Channel B Circuit Reset Fault Reset Cycle Inputs Circuit Reset Held On Inputs Inconsistent Fault Present EN954- Category 4 requires that inputs be independently pulse tested. Publication 753-RMC-EN-P - May 27

8 Redundant Input Function Block (RIN) Redundant Input with Automatic Reset Wiring and Programming Wiring Example The following wiring diagram shows one example of how to wire a 2-channel switch having two normally open contacts to a GuardPLC module to comply with EN954- Category 4. ATTENTION Various safety standards (EN 624, EN 954) require that when using the Automatic Circuit Reset feature, other measures must be implemented to ensure that an unexpected (or unintended) startup will not occur in the system or application. The inputs shown on this wiring diagram correspond to the inputs for the function block. Redundant Input Wiring Diagram - Automatic Reset L+ DI DI 2 DI 3 DI 4 E L- DO DO 2 LS+ GuardPLC S2 S3 E - 24V Power Supply S - Redundant Input Switch S2 - Fault Reset Switch S3 - Generate Pulse Test Switch S S as shown is in the Active state. Publication 753-RMC-EN-P - May 27

Redundant Input Function Block (RIN) 9 Programming Example The following programming example shows how the Redundant Input Function Block with Automatic Reset can be applied to the wiring diagram shown in Redundant Input Wiring Diagram - Automatic Reset, on page 8. Redundant Input Programming Example - Automatic Reset Guard PLC User Program RPTO_RA Redundant Pulse Test Output T#2 to 6 sec T# - 5 msec Pulse Test Interval Pulse Test Duration Pulse Test Source A Pulse Test Source B DO DO 2 DI 4 Generate Pulse Test Pulse Test Fault A Pulse Test Fault B DI Input A Output A DI 2 Input B Output B RIN_AUTO_RA Redundant Input Automatic Reset DI 3 Channel A Channel B Fault Reset Output Cycle Inputs Inputs Inconsistent Fault Present EN954- Category 4 requires that inputs be independently pulse tested. Publication 753-RMC-EN-P - May 27

2 Redundant Input Function Block (RIN) Publication 753-RMC-EN-P - May 27

Chapter 2 Emergency Stop Function Block (ESTOP) Overview The basic purpose of the Emergency Stop Function Block is to emulate the input functionality of a safety relay in a software programmable environment which is intended for use in SIL3/CAT4 safety applications. Operation Normal Operation This function block monitors the states of two input channels and turns on Output when the following conditions are met: When using Manual Reset: both inputs are in the Active state and the Circuit Reset input is transitioned from a zero to a one. When using Automatic Reset: both inputs are in the Active state for 5 ms. This function block turns Output off when either one or both of the input channels returns to the Safe state. Both input channels for the Emergency Stop Function Blocks are normally open. This means zeros on both channels represent the Safe state, and ones on both channels represent the Active state. These normal operation state changes are shown in the following timing diagrams. Normal Operation Manual Reset Automatic Reset Channel A Channel A Channel B Circuit Reset Channel B Output 5 ms Output 2 Publication 753-RMC-EN-P - May 27

22 Emergency Stop Function Block (ESTOP) Operation with Inconsistent Inputs This function block generates a fault if the input channels are in inconsistent states (one Safe and one Active) for more than the specified period of time. The inconsistent time period is 5 ms. This fault condition is enunciated via the Inputs Inconsistent and the Fault Present outputs. Output cannot enter the Active state while the Fault Present output is active. The fault indication is cleared when the offending condition is remedied and the Fault Reset input is transitioned from zero to one. These state changes are shown in the following timing diagram. Inputs Inconsistent, Fault Present, and Fault Reset Operation Channel A Channel B Output Inputs Inconsistent Fault Present Fault Reset 5 ms Operation with Circuit Reset Held On - Manual Reset Only This function block also sets the Circuit Reset Held On output prompt if the Circuit Reset input is set () when the input channels transition to the Active state. These state changes are shown in the following timing diagram. Publication 753-RMC-EN-P - May 27

Emergency Stop Function Block (ESTOP) 23 Circuit Reset and Circuit Reset Held On Operation Channel A Channel B Circuit Reset Output Circuit Reset Held On Cycle Inputs Operation If, while Output is active, one of the input channels transitions from the Active state to the Safe state and back to the Active state before the other input channel transitions to the Safe state, the Cycle Inputs output prompt is set, and Output cannot enter the Active state again until both input channels cycle through their Safe states. These state changes are shown in the following timing diagram. Cycle Inputs Operation Channel A Channel B Output Cycle Inputs Publication 753-RMC-EN-P - May 27

24 Emergency Stop Function Block (ESTOP) Function Block Description ESTOP_RA Emergency Stop Manual Reset ESTOP_AUTO_RA Emergency Stop Automatic Reset Channel A Channel B Circuit Reset Output Cycle Inputs Circuit Reset Held On Inputs Inconsistent Channel A Channel B Fault Reset Output Cycle Inputs Inputs Inconsistent Fault Present Fault Reset Fault Present Emergency Stop Function Block Parameters Parameter Short Name Type Data Type Description Safe, Active and Initial Values Channel A Input Boolean Channel A Input (Normally Open) Safe =, Active = Channel B Input Boolean Channel B Input (Normally Open) Safe =, Active = Circuit Reset Input Boolean Circuit Reset Input Initial =, Reset = Manual Reset - Sets Output after Channel A and Channel B transition from the Safe state to the Active state, and the Circuit Reset input transitions from zero to one. Fault Reset Input Boolean After fault conditions are corrected for the function block, the fault outputs for the function block are cleared when this input transitions from off to on. Output O Output Boolean Output is set to the Active state when input conditions are met. Initial =, Reset = Safe =, Active = Cycle Inputs CI Prompt Output Boolean Cycle Inputs prompts for action. Before Output is turned on, Channel A and Channel B inputs must be cycled through their Safe States at the same time before the circuit can be reset. Initial =, Prompt = This prompt is cleared when Channel A and Channel B transition to the Safe state. Publication 753-RMC-EN-P - May 27

Emergency Stop Function Block (ESTOP) 25 Emergency Stop Function Block Parameters Parameter Circuit Reset Held On Short Name CRHO Type Data Type Description Safe, Active and Initial Values Prompt Output Boolean Manual Reset - The Circuit Reset Held On prompt is set when both input channels transition to the Active states, and the Circuit Reset input is already on. Initial =, Prompt = The Circuit Reset Held On prompt is cleared when the Circuit Reset input is turned off. Inputs Inconsistent II Fault Output Boolean This fault is set when Channel A and Channel B inputs are in inconsistent states (one Safe and one Active) for a period of time greater than the Inconsistent Time Period (listed below). This fault is cleared when Channel A and Channel B inputs return to consistent states (both Safe or both Active) and the Fault Reset input transitions from off to on. Initial =, Fault = Inconsistent Time Period: 5 ms Fault Present FP Fault Output Boolean This is set whenever a fault is present in the function block. Output cannot enter the Active state when Fault Present is set. Fault Present is cleared when all faults are cleared and the Fault Reset input transitions from off to on. Initial =, Fault = Publication 753-RMC-EN-P - May 27

26 Emergency Stop Function Block (ESTOP) Relationship of I/O Wiring to Function Block Parameters Emergency Stop with Manual Reset Wiring and Programming Wiring Example The following wiring diagram shows one example of how to wire a 2-channel Emergency Stop switch having two normally open contacts to a GuardPLC module to comply with EN954- Category 4. The inputs shown on this wiring diagram correspond to the inputs for the function block. Emergency Stop Wiring Diagram - Manual Reset L+ DI DI 2 DI 3 DI 4 DI 5 E L- DO DO 2 LS+ GuardPLC E - 24V Power Supply S - Emergency Stop Switch S2 - Circuit Reset Switch S3 - Fault Reset Switch S4 - Generate Pulse Test Switch S S as shown is in the Active state. S2 S3 S4 Publication 753-RMC-EN-P - May 27

Emergency Stop Function Block (ESTOP) 27 Programming Example The following programming example shows how the Emergency Stop Function Block with Manual Reset can be applied to the wiring diagram shown in Emergency Stop Wiring Diagram - Manual Reset on page 26. Emergency Stop Programming Example - Manual Reset Guard PLC User Program RPTO_RA Redundant Pulse Test Output T#2 to 6 sec T# - 5 msec DI 5 Pulse Test Interval Pulse Test Duration Generate Pulse Test Pulse Test Source A Pulse Test Source B Pulse Test Fault A DO DO 2 Pulse Test Fault B DI DI 2 Input A Input B Output A Output B ESTOP_RA Emergency Stop Manual Reset DI 3 DI 4 Channel A Channel B Circuit Reset Fault Reset Output Cycle Inputs Circuit Reset Held On Inputs Inconsistent Fault Present EN954- Category 4 requires that inputs be independently pulse tested. Publication 753-RMC-EN-P - May 27

28 Emergency Stop Function Block (ESTOP) Emergency Stop with Automatic Reset Wiring and Programming Wiring Example The following wiring diagram shows one example of how to wire a 2-channel Emergency Stop switch having two normally open contacts to a GuardPLC module to comply with EN954- Category 4. ATTENTION Various safety standards (EN 624, EN 954) require that when using the Automatic Circuit Reset feature, other measures must be implemented to ensure that an unexpected (or unintended) startup will not occur in the system or application. The inputs shown on this wiring diagram correspond to the inputs for the function block. Emergency Stop Wiring Diagram - Automatic Reset L+ DI DI 2 DI 3 DI 4 E L- DO DO 2 LS+ GuardPLC S2 S3 E - 24V Power Supply S - Emergency Stop Switch S2 - Fault Reset Switch S3 - Generate Pulse Test Switch S S as shown is in the Active state. Publication 753-RMC-EN-P - May 27

Emergency Stop Function Block (ESTOP) 29 Programming Example The following programming example shows how the Emergency Stop Function Block with Automatic Reset can be applied to the wiring diagram shown in Emergency Stop Wiring Diagram - Automatic Reset, on page 28. Emergency Stop Programming Example - Automatic Reset Guard PLC User Program RPTO_RA Redundant Pulse Test Output T#2 to 6 sec T# - 5 msec DI 4 Pulse Test Interval Pulse Test Duration Generate Pulse Test Pulse Test Source A Pulse Test Source B Pulse Test Fault A DO DO 2 Pulse Test Fault B DI DI 2 Input A Input B Output A Output B ESTOP_AUTO_RA Emergency Stop Automatic Reset DI 3 Channel A Channel B Fault Reset Output Cycle Inputs Inputs Inconsistent Fault Present EN954- Category 4 requires that inputs be independently pulse tested. Publication 753-RMC-EN-P - May 27

3 Emergency Stop Function Block (ESTOP) Publication 753-RMC-EN-P - May 27

Chapter 3 Diverse Input Function Block (DIN) Overview Operation The basic purpose of the Diverse Input Function Block is to emulate the input functionality of a safety relay in a software programmable environment which is intended for use in SIL3/CAT4 safety applications. Normal Operation This function block monitors the states of two input channels and turns on Output when the following conditions are met: When using Manual Reset: both inputs are in the Active state and the Circuit Reset input is transitioned from a zero to a one. When using Automatic Reset: both inputs are in the Active state for 5 ms. This function block turns Output off when either one or both of the input channels returns to the Safe state. The Diverse Input function block has one input channel that is normally open and one that is normally closed. This means that a zero on the normally open channel and a one on the normally closed channel represents the Safe state and vice-versa for the Active state. These normal operation state changes are shown in the following timing diagrams. Normal Operation Manual Reset Automatic Reset Channel A Channel A Channel B Circuit Reset Channel B Output 5 ms Output 3 Publication 753-RMC-EN-P - May 27

32 Diverse Input Function Block (DIN) Operation with Inconsistent Inputs This function block generates a fault if the input channels are in inconsistent states (one Safe and one Active) for more than the specified period of time. The inconsistent time period is 5 ms. This fault condition is enunciated via the Inputs Inconsistent and the Fault Present outputs. Output cannot enter the Active state while the Fault Present output is active. The fault indication is cleared when the offending condition is remedied and the Fault Reset input is transitioned from zero to one. These state changes are shown in the following timing diagram. Inputs Inconsistent, Fault Present, and Fault Reset Operation Channel A Channel B Output Inputs Inconsistent Fault Present Fault Reset 5 ms Diverse Input Instruction t - Inconsistent Time Period Operation with Circuit Reset Held On - Manual Reset Only This function block also sets the Circuit Reset Held On output prompt if the Circuit Reset input is set () when the input channels transition to the Active state. These state changes are shown in the following timing diagram. Publication 753-RMC-EN-P - May 27

Diverse Input Function Block (DIN) 33 Circuit Reset and Circuit Reset Held On Operation Channel A Channel B Circuit Reset Output Circuit Reset Held On Cycle Inputs Operation If, while Output is active, one of the input channels transitions from the Active state to the Safe state and back to the Active state before the other input channel transitions to the Safe state, the Cycle Inputs output prompt is set, and Output cannot enter the Active state again until both input channels cycle through their Safe states. These state changes are shown in the following timing diagram. Cycle Inputs Operation Channel A Channel B Output Cycle Inputs Publication 753-RMC-EN-P - May 27

34 Diverse Input Function Block (DIN) Function Block Description DIN_RA Diverse Input Manual Reset DIN_AUTO_RA Diverse Input with Automatic Reset Channel A Channel B Circuit Reset Fault Reset Output Cycle Inputs Circuit Reset Held On Inputs Inconsistent Fault Present Channel A Channel B Fault Reset Output Cycle Inputs Inputs Inconsistent Fault Present Diverse Input (DIN) Function Block Parameters Parameter Short Name Type Data Type Description Safe, Active and Initial Values Channel A Input Boolean Channel A Input (Normally Open) Safe =, Active = Channel B Input Boolean Channel B Input (Normally Closed) Safe =, Active = Circuit Reset Input Boolean Circuit Reset Input Initial =, Reset = Manual Reset - Sets Output after Channel A and Channel B transition from the Safe state to the Active state, and the Circuit Reset input transitions from zero to one. Fault Reset Input Boolean After fault conditions are corrected for the function block, the fault outputs for the function block are cleared when this input transitions from off to on. Output O Output Boolean Output is set to the Active state when input conditions are met. Initial =, Reset = Safe =, Active = Cycle Inputs CI Prompt Output Boolean Cycle Inputs prompts for action. Before Output is turned on, Channel A and Channel B inputs must be cycled through their Safe States at the same time before the circuit can be reset. Initial =, Prompt = This prompt is cleared when Channel A and Channel B transition to the Safe state. Publication 753-RMC-EN-P - May 27

Diverse Input Function Block (DIN) 35 Diverse Input (DIN) Function Block Parameters Parameter Circuit Reset Held On Short Name CRHO Type Data Type Description Safe, Active and Initial Values Prompt Output Boolean Manual Reset - The Circuit Reset Held On prompt is set when both input channels transition to the Active states, and the Circuit Reset input is already on. Initial =, Prompt = The Circuit Reset Held On prompt is cleared when the Circuit Reset input is turned off. Inputs Inconsistent II Fault Output Boolean This fault is set when Channel A and Channel B inputs are in inconsistent states (one Safe and one Active) for a period of time greater than the Inconsistent Time Period (listed below). This fault is cleared when Channel A and Channel B inputs return to consistent states (both Safe or both Active) and the Fault Reset input transitions from off to on. Initial =, Fault = Inconsistent Time Period: 5 ms Fault Present FP Fault Output Boolean This is set whenever a fault is present in the function block. Output cannot enter the Active state when Fault Present is set. Fault Present is cleared when all faults are cleared and the Fault Reset input transitions from off to on. Initial =, Fault = Publication 753-RMC-EN-P - May 27

36 Diverse Input Function Block (DIN) Relationship of I/O Wiring to Function Block Parameters Diverse Input with Manual Reset Wiring and Programming Wiring Example The following wiring diagram is one example of how to wire a 2-channel switch having diverse inputs to a GuardPLC module to comply with EN954- Category 4. Diverse Input Wiring Diagram - Manual Reset The inputs shown on this wiring diagram correspond to the inputs for the function block. L+ DI DI 2 DI 3 DI 4 DI 5 E L- DO LS+ GuardPLC S2 S3 S4 S E - 24V Power Supply S - Diverse Input Switch S2 - Circuit Reset Switch S3 - Fault Reset Switch S4 - Generate Pulse Test Switch S as shown is in the Active state. IN - Normally Open, IN - Normally Closed. Publication 753-RMC-EN-P - May 27

Diverse Input Function Block (DIN) 37 Programming Example The following programming example shows how the Diverse Input Function Block with Manual Reset can be applied to the wiring diagram shown in Diverse Input Wiring Diagram - Manual Reset, on page 36. Diverse Input Programming Example - Manual Reset Guard PLC User Program SPTO_RA Single Pulse Test Output T#2 to 6 sec T# - 5 msec DI 5 Pulse Test Interval Pulse Test Duration Generate Pulse Test Pulse Test Source A Pulse Test Fault A DO DI DI 2 Input A Input Output A Output DIN_RA Diverse Input Manual Reset DI 3 DI 4 Channel A Channel B Circuit Reset Fault Reset Output Cycle Inputs Circuit Reset Held On Inputs Inconsistent Fault Present EN954- Category 4 requires that inputs be independently pulse tested. Publication 753-RMC-EN-P - May 27

38 Diverse Input Function Block (DIN) Diverse Input with Automatic Reset Wiring and Programming Wiring Example The following wiring diagram is one an example of how to wire a 2-channel switch having diverse inputs to a GuardPLC module to comply with EN954- Category 4. ATTENTION Various safety standards (EN 624, EN 954) require that when using the Automatic Circuit Reset feature, other measures must be implemented to ensure that an unexpected (or unintended) startup will not occur in the system or application. The inputs shown on this wiring diagram correspond to the inputs for the function block. Diverse Input Wiring Diagram - Automatic Reset L+ DI DI 2 DI 3 DI 4 E L- DO LS+ 753 GuardPLC S2 S3 S E - 24V Power Supply S - Diverse Input Switch S as shown is in the Active state. CHA/DI - Normally Open, CHB/DI 2 - Normally Closed S2 - Fault Reset Switch S3 - Generate Pulse Test Switch Publication 753-RMC-EN-P - May 27

Diverse Input Function Block (DIN) 39 Programming Example The following programming example shows how the Diverse Input Function Block with Automatic Reset can be applied to the wiring diagram shown in Diverse Input Wiring Diagram - Automatic Reset, on page 38. Diverse Input Programming Example - Automatic Reset Guard PLC User Program SPTO_RA Single Pulse Test Output T#2 to 6 sec Pulse Test Interval Pulse Test Source A DO T# - 5 msec DI 4 Pulse Test Duration Generate Pulse Test Pulse Test Fault A DI DI 2 Input A Input Output A Output DIN_AUTO_RA Diverse Input Automatic Reset DI 3 Channel A Channel B Fault Reset Output Cycle Inputs Inputs Inconsistent Fault Present EN954- Category 4 requires that inputs be independently pulse tested. Publication 753-RMC-EN-P - May 27

4 Diverse Input Function Block (DIN) Publication 753-RMC-EN-P - May 27

Chapter 4 Enable Pendant Function Block (ENPEN) Overview The basic purpose of the Enable Pendant Function Block is to emulate the input functionality of a safety relay in a software programmable environment which is intended for use in SIL3/CAT4 safety applications. Operation Normal Operation This function block monitors the states of two input channels and turns on Output when the following conditions are met: When using Manual Reset: both inputs are in the Active state and the Circuit Reset input is transitioned from a zero to a one. When using Automatic Reset: both inputs are in the Active state for 5 ms. This function block turns Output off when either one or both of the input channels returns to the Safe state. Both input channels for the Enable Pendant function block are normally open. This means zeros on both channels represent the Safe state, and ones on both channels represent the Active state. These normal operation state changes are shown in the following timing diagrams. Normal Operation Manual Reset Automatic Reset Channel A Channel A Channel B Circuit Reset Channel B Output 5 ms Output 4 Publication 753-RMC-EN-P - May 27

42 Enable Pendant Function Block (ENPEN) Operation with Inconsistent Inputs This function block generates a fault if the input channels are in inconsistent states (one Safe and one Active) for more than the specified period of time. The inconsistent time period is 3 seconds. This fault condition is enunciated via the Inputs Inconsistent and the Fault Present outputs. Output cannot enter the Active state while the Fault Present output is active. The fault indication is cleared when the offending condition is remedied and the Fault Reset input is transitioned from zero to one. These state changes are shown in the following timing diagram. Inputs Inconsistent, Fault Present, and Fault Reset Operation Channel A Channel B Output Inputs Inconsistent Fault Present Fault Reset 3 sec Operation with Circuit Reset Held On - Manual Reset Only This function block also sets the Circuit Reset Held On output prompt if the Circuit Reset input is set () when the input channels transition to the Active state. These state changes are shown in the following timing diagram. Publication 753-RMC-EN-P - May 27

Enable Pendant Function Block (ENPEN) 43 Circuit Reset and Circuit Reset Held On Operation Channel A Channel B Circuit Reset Output Circuit Reset Held On Cycle Inputs Operation If, while Output is active, one of the input channels transitions from the Active state to the Safe state and back to the Active state before the other input channel transitions to the Safe state, the Cycle Inputs output prompt is set, and Output cannot enter the Active state again until both input channels cycle through their Safe states. These state changes are shown in the following timing diagram. Cycle Inputs Operation Channel A Channel B Output Cycle Inputs Publication 753-RMC-EN-P - May 27

44 Enable Pendant Function Block (ENPEN) Function Block Description ENPEN_RA Enable Pendant Manual Reset ENPEN_AUTO_RA Enable Pendant Automatic Reset Channel A Channel B Circuit Reset Fault Reset Output Cycle Inputs Circuit Reset Held On Inputs Inconsistent Fault Present Channel A Channel B Fault Reset Output Cycle Inputs Inputs Inconsistent Fault Present Enable Pendant Function Block Parameters Parameter Short Name Type Data Type Description Safe, Active and Initial Values Channel A Input Boolean Channel A Input (Normally Open) Safe =, Active = Channel B Input Boolean Channel B Input (Normally Open) Safe =, Active = Circuit Reset Input Boolean Circuit Reset Input Initial =, Reset = Manual Reset - Sets Output after Channel A and Channel B transition from the Safe state to the Active state, and the Circuit Reset input transitions from zero to one. Automatic Reset - Visible, but not used. Fault Reset Input Boolean After fault conditions are corrected for the function block, the fault outputs for the function block are cleared when this input transitions from off to on. Output O Output Boolean Output is set to the Active state when input conditions are met. Initial =, Reset = Safe =, Active = Cycle Inputs CI Prompt Output Boolean Cycle Inputs prompts for action. Before Output is turned on, Channel A and Channel B inputs must be cycled through their Safe States at the same time before the circuit can be reset. Initial =, Prompt = This prompt is cleared when Channel A and Channel B transition to the Safe state. Publication 753-RMC-EN-P - May 27

Enable Pendant Function Block (ENPEN) 45 Enable Pendant Function Block Parameters Parameter Circuit Reset Held On Short Name CRHO Type Data Type Description Safe, Active and Initial Values Prompt Output Boolean Manual Reset - The Circuit Reset Held On prompt is set when both input channels transition to the Active states, and the Circuit Reset input is already on. The Circuit Reset Held On prompt is cleared when the Circuit Reset input is turned off. Initial =, Prompt = Automatic Reset - Visible, but not used. Inputs Inconsistent II Fault Output Boolean This fault is set when Channel A and Channel B inputs are in inconsistent states (one Safe and one Active) for a period of time greater than the Inconsistent Time Period (listed below). This fault is cleared when Channel A and Channel B inputs return to consistent states (both Safe or both Active) and the Fault Reset input transitions from off to on. Initial =, Fault = Inconsistent Time Period: 3 s Fault Present FP Fault Output Boolean This is set whenever a fault is present in the function block. Output cannot enter the Active state when Fault Present is set. Fault Present is cleared when all faults are cleared and the Fault Reset input transitions from off to on. Initial =, Fault = Publication 753-RMC-EN-P - May 27

46 Enable Pendant Function Block (ENPEN) Relationship of I/O Wiring to Function Block Parameters Enable Pendant with Manual Reset Wiring and Programming Wiring Example The following wiring diagram is one example of how to wire a 2-channel switch having two normally open contacts to a GuardPLC module to comply with EN954- Category 4. The inputs shown on this wiring diagram correspond to the inputs for the function block. Enable Pendant Wiring Diagram - Manual Reset L+ DI DI 2 DI 3 DI 4 DI 5 E L- DO DO 2 LS+ GuardPLC S2 S3 S4 E - 24V Power Supply S - Enable Pendant Switch S2 - Circuit Reset Switch S3 - Fault Reset Switch S4 - Generate Pulse Test Switch S Publication 753-RMC-EN-P - May 27

Enable Pendant Function Block (ENPEN) 47 Programming Example The following programming example shows how the Enable Pendant function block with Manual Reset can be applied to the wiring diagram shown in Enable Pendant Wiring Diagram - Manual Reset, on page 46. Enable Pendant Programming Example - Manual Reset Guard PLC User Program RPTO_RA Redundant Pulse Test Output T#2 to 6 sec T# - 5 msec DI 5 Pulse Test Interval Pulse Test Duration Generate Pulse Test Pulse Test Source A Pulse Test Source B Pulse Test Fault A Pulse Test Fault B DO DO 2 DI DI 2 Input A Input B Output A Output B ESTOP_RA Emergency Stop Manual Reset DI 3 DI 4 Channel A Channel B Circuit Reset Fault Reset Output Cycle Inputs Circuit Reset Held On Inputs Inconsistent Fault Present EN954- Category 4 requires that inputs be independently pulse tested. Publication 753-RMC-EN-P - May 27

48 Enable Pendant Function Block (ENPEN) Enable Pendant with Automatic Reset Wiring and Programming Wiring Example The following wiring diagram is one example of how to wire a 2-channel switch having two normally open contacts to a GuardPLC module to comply with EN954- Category 4. ATTENTION Various safety standards (EN 624, EN 954) require that when using the Automatic Circuit Reset feature, other measures must be implemented to ensure that an unexpected (or unintended) startup will not occur in the system or application. Enable Pendant Wiring Diagram - Automatic Reset The inputs shown on this wiring diagram correspond to the inputs for the function block. L+ DI DI 2 DI 3 DI 4 E L- DO DO 2 LS+ GuardPLC S2 S3 E - 24V Power Supply S - Enable Pendant Switch S2 - Fault Reset Switch S3 - Generate Pulse Test Switch S Publication 753-RMC-EN-P - May 27

Enable Pendant Function Block (ENPEN) 49 Programming Example The following programming example shows how the Enable Pendant Function Block with Automatic Reset can be applied to the wiring diagram shown in Enable Pendant Wiring Diagram - Automatic Reset, on page 48. Enable Pendant Programming Example - Automatic Reset Guard PLC User Program RPTO_RA Redundant Pulse Test Output T#2 to 6 sec T# - 5 msec DI 4 Pulse Test Interval Pulse Test Duration Generate Pulse Test Pulse Test Source A Pulse Test Source B Pulse Test Fault A Pulse Test Fault B DO DO 2 DI DI 2 Input A Input B Output A Output B ENPEN_AUTO_RA Enable Pendant Automatic Reset DI 3 Channel A Channel B Fault Reset Output Cycle Inputs Inputs Inconsistent Fault Present EN954- Category 4 requires that inputs be independently pulse tested. Publication 753-RMC-EN-P - May 27

5 Enable Pendant Function Block (ENPEN) Publication 753-RMC-EN-P - May 27

Chapter 5 Light Curtain Function Block (LC) Overview The basic purpose of the Light Curtain Function Block is to provide a manual and an automatic circuit reset interface from a programmable controller to a light curtain used in SIL3/CAT4 safety applications. Many Light Curtains pulse test their two outputs; OSSD and OSSD2. If these outputs are wired directly into GuardPLC controller inputs, the pulse test needs to be filtered. Otherwise, the GuardPLC controller may mistake the LO pulse test for a light curtain blockage. Note that most light curtains do provide controllers or relays that essentially filter out the pulse test and provide two dry contacts for OSSD and OSSD2. If using these devices, then OSSD and OSSD2 can be wired directly to the GuardPLC controller. If you are NOT using the light curtain controller or relay, then the GuardPLC controller must provide the pulse test filtering. There are two ways for the GuardPLC controller to filter this signal. The first is hardware- based digital input filters on the Safety input modules. The second is a software- based filter in the Light Curtain function block. For information on the software-based filter, see Input Filter Time on page 5-57 of this manual. Of these two methods, the hardware filter is preferred. If the digital input filters the LO signals for longer than the LO pulse test width, then the hardware filter will filter out the pulse test. For example, if the Light Curtain signals pulse LO for µs during a pulse test, then the hardware must filter out LO signals that are µs or longer. Note that the Safety DeviceNet I/O modules have a configurable filter of to 26 ms. The safety I/O modules have a fixed filter time of µs. If the hardware filter cannot filter the pulse test, or you choose not to use the hardware filter, then the filtering must be done in the GuardPLC controller code. Software based filters look at the input once every program cycle. Theoretically, every time the GuardPLC controller looks at OSSD, it may be LO if the pulse test is occurring at that exact time. In other words, you may have to make your software filter long enough to scan OSSD multiple times before the filter times out, and OSSD is set logically LO. 5 Publication 753-RMC-EN-P - May 27