User Manual Compact GuardLogix Controllers Catalog Numbers 1768-L43S, 1768-L45S
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://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
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 included change bars as shown to the right of this paragraph. Topic Page Specifications and certifications are in the CompactLogix Controller Specifications Technical Data, publication 1769-TD005.
Summary of Changes Notes: 4 Rockwell Automation Publication 1768-UM002C-EN-P - April 2012
Table of Contents Preface Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Understanding Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Chapter 1 System Overview Safety Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Network Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Task Signature . . . . . . . . .
Table of Contents Chapter 3 Configure the Controller Create a Controller Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set Passwords for Safety-locking and -unlocking . . . . . . . . . . . . . . . . . . . . Protecting the Safety Task Signature in Run Mode . . . . . . . . . . . . . . . . . . Handling I/O Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enable Time Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Replacement with ‘Configure Only When No Safety Signature Exists’ Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Replacement with ‘Configure Always’ Enabled. . . . . . . . . . . . . . . . . . 70 Chapter 6 Develop Safety Applications The Safety Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Task Period Specification . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Chapter 8 Monitor Status and Handle Faults Viewing Status via the Online Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring Status Flags. . . . . . . .
Preface Topic Page Additional Resources 9 Understanding Terminology 10 This manual is a guide for using Compact GuardLogix™ controllers. It describes the Compact GuardLogix-specific procedures you use to configure, operate, and troubleshoot your controller. Use this manual if you are responsible for designing, installing, programming, or troubleshooting control systems that use Compact GuardLogix controllers.
Preface Resource Description Logix5000 Controllers Execution Time and Memory Use Reference Manual, publication 1756-RM087 Provides information on estimating the execution time and memory use for instructions Logix5000 Controllers Import Export Reference Manual, publication 1756-RM084 Provides information on using RSLogix™ 5000 Import/Export utility PhaseManager User Manual, publication LOGIX-UM001 Provides information on programming the controller to use equipment phases in a standard application S
Chapter 1 System Overview Topic Safety Application Requirements Page Safety Application Requirements 11 Distinguishing Between Standard and Safety Components 12 Controller Data Flow Capabilities 13 Selecting System Hardware 14 Selecting Safety I/O Modules 14 Selecting Communication Networks 14 Programming Requirements 15 The Compact GuardLogix controller system is certified for use in safety applications up to and including Safety Integrity Level (SIL) 3 and Performance Level (e) in whic
Chapter 1 System Overview For information on assigning the SNN, see Managing the Safety Network Number (SNN) on page 39. Safety Task Signature The safety task signature consists of an ID number, date, and time that uniquely identifies the safety portion of a project. This includes safety logic, data, and configuration. The Compact GuardLogix system uses the safety task signature to determine the project’s integrity and to let you verify that the correct project is downloaded to the target controller.
System Overview Controller Data Flow Capabilities Chapter 1 This illustration explains the standard and safety data-flow capabilities of the Compact GuardLogix controller. Figure 1 - Data Flow Capabilities Compact GuardLogix Controller Standard Safety Safety Task Standard Tasks Safety Programs Standard Programs Safety Routines Standard Routines Program Safety Data Program Data Controller Standard Tags Controller Safety Tags No.
Chapter 1 System Overview Selecting System Hardware The Compact GuardLogix system supports SIL 3 and PLe safety applications. Controller 1768-L43S and 1768-L45S controllers feature one built-in serial port. A keyswitch on the front panel lets you change controller modes: RUN, PROGram and REMote. The 1768 Compact GuardLogix controllers combine a 1768 backplane with a 1769 backplane.
System Overview Chapter 1 Use these communication modules to provide an interface between Compact GuardLogix controllers and network devices. Use this module To interface between 1768-ENBT, series A, revision 3 (1) The Compact GuardLogix controller and EtherNet/IP devices 1768-CNB, series A, revision 3(1) Controllers on the ControlNet network (1) This or later.
Chapter 1 System Overview Table 3 - Supported Features by RSLogix 5000 Software Version Version 18 Feature Safety Task Add-On instructions X Alarms and events Version 19 Standard Task Safety Task X X X Constant value tags X Equipment phase routines X X Event tasks X X X X X X X X X X X X X X X X X Standard Task X X X Firmware Supervisor Standard Task Safety Task X X External Access Version 20 X X X X Function block diagrams (FBD) X X X Integrated motion X
Chapter 2 Install the Controller Topic Precautions Page Precautions 17 Required System Components 20 Clearance Requirements 20 Module Placement 20 Mount the Controller 22 Insert or Remove a Memory Card 26 Make Communication Connections 26 Update the Controller 28 Remove a 1768 or 1769 Module from the DIN Rail 30 Read and follow these precautions for use.
Chapter 2 Install the Controller Programmable Electronic Systems (PES) ATTENTION: Personnel responsible for the application of safety-related Programmable Electronic Systems (PES) shall be aware of the safety requirements in the application of the system and shall be trained in using the system.
Install the Controller Chapter 2 European Hazardous Location Approval The following applies when the product bears the Ex Marking. This equipment is intended for use in potentially explosive atmospheres as defined by European Union Directive 94/9/EC and has been found to comply with the Essential Health and Safety Requirements relating to the design and construction of Category 3 equipment intended for use in Zone 2 potentially explosive atmospheres, given in Annex II to this Directive.
Chapter 2 Install the Controller Required System Components You need these parts when installing your controller: • 1768-L43S or 1768-L45S Compact GuardLogix controller • 1768-PA3 or 1768-PB3 power supply • 1769-ECR end cap • Mounting screws (M4 or #8 panhead) or one of these EN 50 022 DIN rails: – 35 x 7.5 mm (1.38 x 0.30 in.) – 35 x 15 mm (1.38 x 0.59 in.
Install the Controller IMPORTANT Chapter 2 CompactLogix System Distance Ratings Because the 1768 CompactLogix power supply works with the controller to power a 1768 system, the distance rating in a 1768 CompactLogix system differs from that in a 1769 CompactLogix system. In the 1768 system, the distance rating is the distance between 1769 I/O modules and the controller. In the 1769 system, the distance rating is the distance between 1769 I/O modules and the power supply.
Chapter 2 Install the Controller • Up to eight 1769 Compact I/O modules can reside on each side of a 1769 power supply in a remote bank. Consult the module’s specifications for its distance rating. IMPORTANT 1769 power supplies must be separated from the 1768 series processor by a bus extension cable. Never put a 1769 power supply in the 1768 backplane or the controller will generate a major fault that cannot be cleared until you remove the 1769 power supply.
Install the Controller Chapter 2 Mount the Controller on a DIN Rail ATTENTION: This product is grounded through the DIN rail to chassis ground. Use zinc plated yellow-chromate steel DIN rail to assure proper grounding. The use of other DIN rail materials (for example, aluminum and plastic) that can corrode, oxidize, or are poor conductors, can result in improper or intermittent grounding. Secure DIN rail to the mounting surface approximately every 200 mm (7.87 in.) and use end anchors appropriately.
Chapter 2 Install the Controller 3. Mount the 1768 power supply and other 1768 modules. 31599-M Mount 1769 I/O Modules Follow these steps to mount 1769 I/O modules to the right of the controller. 1. Align the upper and lower tongue-and-groove slots and slide the module back toward the DIN rail until the bus levers line up. 2. Close the DIN rail latches.
Install the Controller Chapter 2 3. Slide the bus lever to the left to lock the modules together. ATTENTION: When attaching I/O modules, it is very important that the bus connectors are securely locked together for proper electrical connection. 4. Attach the end cap by using the tongue and groove slots (a) and locking the bus lever (b). a. b. a. Confirm the Installation After you have installed the controller and applied power, check that the PWR and I/O PWR status indicators are solid green.
Chapter 2 Install the Controller Insert or Remove a Memory Card WARNING: When you insert or remove the memory card when power is on, an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding. Follow these steps to insert or remove a CompactFlash card. 1. Press the memory-card door latch on the controller front panel and pivot the door down toward you. 2.
Install the Controller Chapter 2 Use RSLinx software to configure the driver for serial communication. 1. From the Communications menu, choose Configure Drivers. 2. From the Available Driver Types pull-down menu, choose the RS-232 DF1 devices driver. 3. Click Add New. 4. Type a name for the driver and click OK. 5. From the Comm Port pull-down menu on the Configure Devices dialog box, choose the serial port on the workstation to which your cable is connected. 6.
Chapter 2 Install the Controller Update the Controller The controllers ship without firmware. Controller firmware is packaged with RSLogix 5000 programming software. In addition, controller firmware is also available for download from the Rockwell Automation Technical Support website at: http://www.rockwellautomation.com/support/. IMPORTANT When installing or updating controller firmware, do not interrupt the update process in any way.
Install the Controller Chapter 2 Install Firmware via AutoFlash Software 1. Make sure the network is connected. 2. Using RSLogix 5000 software, attempt a download to a controller project. 3. AutoFlash software launches if the required firmware is not loaded on the controller. 4. Select the catalog number of the controller and click Next. 5. Expand the network until you see the controller. TIP If the required network is not shown, first configure a driver for that network in RSLinx software. 6.
Chapter 2 Install the Controller Remove a 1768 or 1769 Module from the DIN Rail If you need to remove a module from the DIN rail, follow these steps. 1. Remove power from the controller and wait for all status indicators on the power supply and controller to turn off. Off Power OUT L1 L2/N IMPORTANT If you disconnect any part of the system while the controller is still writing its program to memory, you will lose your program. 2. Remove the 1768 module. b. a. Power OUT L1 L2/N a. c. d.
Install the Controller Chapter 2 3. Remove the 1769 module by unlocking the bus lever (a) and DIN rail latches (b). b. a. Power OUT L1 L2/N b. 4. Slide the module away from the DIN rail along the tongue and groove slots.
Chapter 2 32 Install the Controller Rockwell Automation Publication 1768-UM002C-EN-P - April 2012
Chapter 3 Configure the Controller Topic Create a Controller Project Page Create a Controller Project 33 Set Passwords for Safety-locking and -unlocking 35 Handling I/O Module Replacement 37 Enable Time Synchronization 37 Configure a Peer Safety Controller 38 To configure and program your controller, use RSLogix 5000 software to create and manage a project for the controller. 1. Create a project in RSLogix 5000 software by clicking the New button on the main toolbar. 2.
Chapter 3 Configure the Controller 5. Specify the folder in which to store the safety controller project. 6. For RSLogix 5000, version 20 or later, choose a Security Authority option. For detailed information on security, refer to the Logix5000 Controllers Security Programming Manual, publication 1756-PM016. 7. Click OK. RSLogix 5000 software automatically creates a safety task and a safety program. A main ladder logic safety routine called MainRoutine is also created within the safety program.
Configure the Controller Chapter 3 Figure 3 - Safety Network Number TIP You can use the Controller Properties dialog box to change the controller from standard to safety or vice versa by clicking Change Controller. However, standard and safety projects are substantially affected. See Appendix B, Change Controller Type in RSLogix 5000 Projects, for details on the ramifications of changing controllers.
Chapter 3 Configure the Controller Follow these steps to set passwords. 1. Choose Tools > Safety > Change Password. 2. From the What Password pull-down menu, choose either Safety Lock or Safety Unlock. 3. Type the old password, if one exists. 4. Type and confirm the new password. 5. Click OK. Passwords may be from 1…40 characters in length and are not casesensitive. Letters, numerals, and the following symbols may be used: ‘ ~ ! @#$%^&*()_+,-={}|[]\:;?/.
Configure the Controller Handling I/O Module Replacement Chapter 3 The Safety tab of the Controller Properties dialog box lets you define how the controller handles the replacement of an I/O module in the system. This option determines whether the controller sets the safety network number (SNN) of an I/O module to which it has a connection and for which it has configuration data when a safety task signature(1) exists.
Chapter 3 Configure the Controller Figure 5 - Date/Time Tab For more information on Time Synchronization, refer to the Integrated Architecture™ and CIP Sync Configuration Application Solution, publication IA-AT003. Configure a Peer Safety Controller You can add a remote peer safety controller to the I/O configuration folder of your safety project to allow standard or safety tags to be consumed. To share safety data between peer controllers, you produce and consume controller-scoped safety tags.
Chapter 4 Communicate over Networks Topic The Safety Network Page The Safety Network 39 EtherNet/IP Communication 45 ControlNet Communication 48 Standard DeviceNet Communication 51 Serial Communication 52 Additional Resources 53 The CIP Safety protocol is an end-node to end-node safety protocol that allows routing of CIP Safety messages to and from CIP Safety devices through bridges, switches, and routers.
Chapter 4 Communicate over Networks Time-based Safety Network Number If the time-based format is selected, the SNN value that is generated represents the date and time at which the number was generated, according to the personal computer running the configuration software. Figure 6 - Time-based Format Manual Safety Network Number If the manual format is selected, the SNN represents entered values from 1…9999 decimal.
Communicate over Networks Chapter 4 Assigning the Safety Network Number (SNN) You can allow RSLogix 5000 software to automatically assign an SNN, or you can assign the SNN manually. Automatic Assignment When a new controller or module is created, a time-based SNN is automatically assigned via the configuration software. Subsequent new safety-module additions to the same CIP Safety network are assigned the same SNN defined within the lowest address on that CIP Safety network.
Chapter 4 Communicate over Networks Change the Safety Network Number (SNN) of the Controller 1. In the Controller Organizer, right-click the controller and choose Properties. 2. On the General tab of the Controller Properties dialog box, click the right of the safety network number to open the Safety Network Number dialog box. to 3. Click Time-based and then Generate. 4. Click OK.
Communicate over Networks Chapter 4 3. Double-click the first safety I/O module to view the General tab. 4. Click to the right of the safety network number to open the Safety Network Number dialog box. 5. Choose Time-based and click Generate to generate a new SNN for that EtherNet/IP network. 6. Click OK. 7. Click Copy to copy the new SNN to the Windows Clipboard. 8. Open the General Tab of the Module Properties dialog box of the next safety I/O module under that EtherNet/IP module. 9.
Chapter 4 Communicate over Networks Copy and Paste a Safety Network Number (SNN) If the module’s configuration is owned by another controller, you may need to copy and paste the SNN from the configuration owner into the module in your I/O configuration tree. 1. In the software configuration tool of the module’s configuration owner, open the Safety Network Number dialog box for the module. 2. Click Copy. 3.
Communicate over Networks EtherNet/IP Communication Chapter 4 For CIP Safety communication, including Safety I/O module control, choose a 1768-ENBT module, series A, revision 3 or later. For standard EtherNet/IP communication, choose a 1768-ENBT or 1768-EWEB communication module, series A, revision 3 or later. EtherNet/IP communication modules provide the following features: • Support for messaging, produced/consumed tags, HMI, and distributed I/O.
Chapter 4 Communicate over Networks EtherNet/IP connections are unscheduled. An unscheduled connection is triggered by the requested packet interval (RPI) for I/O control or the program (such as a MSG instruction). Unscheduled messaging lets you send and receive data when needed. The EtherNet/IP communication modules support 64 Common Industrial Protocol (CIP) connections over an EtherNet/IP network.
Communicate over Networks Chapter 4 EtherNet/IP Connections for CIP Safety I/O Modules CIP Safety I/O modules on EtherNet/IP networks are added to the project under the EtherNet/IP communication module as described in Chapter 5, Add, Configure, Monitor, and Replace CIP Safety I/O. When you add a CIP Safety I/O module, RSLogix 5000 software automatically creates controller-scoped safety data tags for that module.
Chapter 4 Communicate over Networks ControlNet Communication For ControlNet communication, choose a 1768-CNB module, series A, revision 3 or later. These software products are available for ControlNet networks. Table 6 - Software for ControlNet Modules Software Purpose Required RSLogix 5000 programming software This software is required to configure the GuardLogix project and define ControlNet communication.
Communicate over Networks Chapter 4 ControlNet connections can be scheduled or unscheduled. Table 7 - ControlNet Connections Connection Type Description Scheduled (unique to the ControlNet network) A scheduled connection is unique to ControlNet communication. A scheduled connection lets you send and receive data repeatedly at a predetermined interval, which is the requested packet interval (RPI).
Chapter 4 Communicate over Networks Figure 10 - ControlNet Communication Example ControlLogix Controller Workstation with 1784-PCIC or 1784-PCICS ControlNet Communication Card Compact GuardLogix Controller with 1768-CNB Module A B PowerFlex 70 Drive with 20-COMM-C ControlNet Adapter Distributed 1734 POINT I/O Modules with 1734-ACR ControlNet Adapter 1794-ACN15 Adapter with 1794 I/O Modules PanelView Plus Terminal with ControlNet Communication Adapter ControlNet Connections for Distributed I/O To
Communicate over Networks Standard DeviceNet Communication Chapter 4 The DeviceNet network uses the Common Industrial Protocol (CIP) to provide the control, configuration, and data collection capabilities for industrial devices. A DeviceNet network lets you connect devices directly to plant-floor controllers without having to hardwire each device to an I/O module.
Chapter 4 Communicate over Networks Figure 11 - Standard DeviceNet Communication Example Compact GuardLogix Controller with 1769-SDN Scanner Distributed 1734 POINT I/O Modules with 1734-ADN Adapter PowerFlex 70 Drive with 20-COMM-D Adapter PowerFlex 40 Drive with 22-COMM-D Adapter Workstation with 1784-PCID, 1784-PCIDS, and 1770-KFD DeviceNet Communication Cards Standard DeviceNet Network with KwikLink™ and Flat Cable Micro Connectors 1606-XL POWER SUPPLY AC 120V AC 240V Output Input AC 100-120/20
Communicate over Networks Chapter 4 Table 11 - DF1 Modes for Logix5000 Controllers Mode Functions DF1 Point-to-Point Communication between a controller and one other DF1-protocol-compatible device. This is the Default System mode. These are the default parameters: • Communication Rate: 19,200 bps • Data Bits: 8 • Parity: None • Stop Bits: 1 • Control Line: No Handshake • RTS send Delay: 0 • RTS Off Delay: 0 This mode is typically used to program a controller through its serial port.
Chapter 4 Communicate over Networks Notes: 54 Rockwell Automation Publication 1768-UM002C-EN-P - April 2012
Chapter 5 Add, Configure, Monitor, and Replace CIP Safety I/O Topic Page Adding CIP Safety I/O Modules 55 Configure CIP Safety I/O Modules via RSLogix 5000 Software 56 Setting the Safety Network Number (SNN) 57 Using Unicast Connections on EtherNet/IP Networks 57 Setting the Connection Reaction Time Limit 57 Understanding the Configuration Signature 61 Reset Safety I/O Module Ownership 62 Addressing Safety I/O Data 62 Monitor Safety I/O Module Status 63 Resetting a Module to Out-of-bo
Chapter 5 Add, Configure, Monitor, and Replace CIP Safety I/O • Configuration signature See page 61 for information on when the configuration signature is set automatically and when you need to set it. • Reaction time limit See page 57 for information on setting the reaction time limit. • Safety input, output, and test parameters You can configure CIP Safety I/O modules via the Compact GuardLogix controller by using RSLogix 5000 software.
Add, Configure, Monitor, and Replace CIP Safety I/O Chapter 5 e. Set module configuration parameters by using the Input Configuration, Test Output, and Output Configuration tabs. Refer to RSLogix 5000 online help for more information on CIP Safety I/O module configuration. f. Set the Connection Reaction Time Limit by using the Safety tab. See page 57 for details. Setting the Safety Network Number (SNN) The assignment of a time-based SNN is automatic when adding new Safety I/O modules.
Chapter 5 Add, Configure, Monitor, and Replace CIP Safety I/O Specify the Requested Packet Interval (RPI) The RPI specifies the period at which data updates over a connection. For example, an input module produces data at the RPI that you assign. For safety input connections, you can set the RPI on the Safety tab of the Module Properties dialog box. The RPI is entered in 1 ms increments, with a range of 1…100 ms. The default is 10 ms.
Add, Configure, Monitor, and Replace CIP Safety I/O Chapter 5 Figure 14 - Resetting the Max Observed Network Delay IMPORTANT The actual Maximum Network Delay time from the producer to the consumer is less than the value displayed in the Maximum Network Delay field on the Safety tab. In general, the actual maximum message delay is approximately one-half the Maximum Network Delay value that is displayed.
Chapter 5 Add, Configure, Monitor, and Replace CIP Safety I/O Network Delay Multiplier The Network Delay Multiplier defines the message transport time that is enforced by the CIP Safety protocol. The Network Delay Multiplier specifies the round-trip delay from the producer to the consumer and the acknowledge back to the producer.
Add, Configure, Monitor, and Replace CIP Safety I/O Chapter 5 The Network Delay Multiplier can be approximated by the following equation: [Maximum Observed Network Delay + Margin_Factor] ÷ RPI EXAMPLE Calculate the Network Delay Multiplier from Maximum Observed Network Delay If: RPI = 50 ms Maximum Observed Network Delay = 20 ms Margin_Factor = 10 Then, the Network Delay Multiplier equals: [20 + 10] ÷ 50 = 60% Table 12 - Additional Resources Resource Description GuardLogix Controllers Systems Safety
Chapter 5 Add, Configure, Monitor, and Replace CIP Safety I/O Different Configuration Owner (listen only connection) When the I/O module configuration is owned by another controller, you need to copy the module configuration signature from its owner’s project and paste it into the Safety tab of the Module Properties dialog box. TIP Reset Safety I/O Module Ownership If the module is configured for inputs only, you can copy and paste the configuration signature.
Add, Configure, Monitor, and Replace CIP Safety I/O Chapter 5 A CIP Safety I/O device address follows this format: Modulename:Type.Member Table 13 - CIP Safety I/O Module Address Format Where Is Modulename The name of the CIP Safety I/O module Type Type of data Input: I Output: O Member Specific data from the I/O module Input-only Module: Modulename:I.RunMode Modulename:I.ConnectionFaulted Modulename:I.Input Members Output-only Module: Modulename:I.RunMode Modulename:I.
Chapter 5 Add, Configure, Monitor, and Replace CIP Safety I/O Table 15 - Status Indicator Operation Indicator Status Description EtherNet/IP Modules Module Status (MS) Network Status (NS) Input Points (INx) Output Points (Ox) IN PWR OUT PWR Off No power. Green, On Operating under normal conditions. Green, Flashing Device is idle. Red, Flashing A recoverable fault exists or a firmware update is in progress. Red, On An unrecoverable fault exists.
Add, Configure, Monitor, and Replace CIP Safety I/O Resetting a Module to Outof-box Condition Chapter 5 If a Guard I/O module was used previously, clear the existing configuration before installing it on a safety network by resetting the module to its out-of-box condition. When RSLogix 5000 software is online, the Safety tab of the Module Properties dialog box displays the current configuration ownership. When the opened project owns the configuration, Local is displayed.
Chapter 5 Add, Configure, Monitor, and Replace CIP Safety I/O Figure 17 - Safety I/O Module Replacement Replacement with ‘Configure Only When No Safety Signature Exists’ Enabled When a module is replaced, the configuration will be downloaded from the safety controller if the DeviceID of the new module matches the original. The DeviceID is a combination of the node/IP address and the Safety Network Number (SNN) and is updated whenever the SNN is set.
Add, Configure, Monitor, and Replace CIP Safety I/O Chapter 5 Scenario 1 - Replacement Module is Out-of-box and Safety Signature Exists 1. Remove the old I/O module and install the new module. 2. Right-click the replacement POINT Guard I/O module and choose Properties. 3. Click to the right of the safety network number to open the Safety Network Number dialog box. 4. Click Set. 5.
Chapter 5 Add, Configure, Monitor, and Replace CIP Safety I/O Scenario 2 - Replacement Module SNN is Different from Original and Safety Signature Exists 1. Remove the old I/O module and install the new module. 2. Right-click your POINT Guard I/O module and choose Properties. 3. Click the Safety tab. 4. Click Reset Ownership. 5. Click OK. 6. Right-click your controller and choose Properties. 7. Click to the right of the safety network number to open the Safety Network Number dialog box.
Add, Configure, Monitor, and Replace CIP Safety I/O Chapter 5 8. Click Set. 9. Verify that the Network Status (NS) status indicator is alternating red/green on the correct module before clicking Yes on the confirmation dialog box to set the SNN and accept the replacement module. 10. Follow your company-prescribed procedures to functionally test the replaced I/O module and system and to authorize the system for use.
Chapter 5 Add, Configure, Monitor, and Replace CIP Safety I/O Scenario 3 - Replacement Module SNN is Different from Original and No Safety Signature Exists 1. Remove the old I/O module and install the new module. 2. Right-click your POINT Guard I/O module and choose Properties. 3. Click the Safety tab. 4. Click Reset Ownership. 5. Click OK. 6. Follow your company-prescribed procedures to functionally test the replaced I/O module and system and to authorize the system for use.
Add, Configure, Monitor, and Replace CIP Safety I/O Chapter 5 If the project is configured for ‘Configure Always’, follow the appropriate steps to replace a POINT Guard I/O module. 1. Remove the old I/O module and install the new module. a. If the module is in out-of-box condition, go to step 6. No action is needed for the GuardLogix controller to take ownership of the module. b. If an SNN mismatch error occurs, go to the next step to reset the module to out-of-box condition. 2.
Chapter 5 Add, Configure, Monitor, and Replace CIP Safety I/O Notes: 72 Rockwell Automation Publication 1768-UM002C-EN-P - April 2012
Chapter 6 Develop Safety Applications Topic Page The Safety Task 74 Safety Programs 76 Safety Routines 76 Safety Tags 76 Produced/Consumed Safety Tags 81 Safety Tag Mapping 86 Safety Application Protection 88 Software Restrictions 91 This chapter explains the components that make up a safety project and provides information on using features that help protect safety application integrity, such as the safety task signature and safety-locking.
Chapter 6 Develop Safety Applications The Safety Task When you create a safety controller project, RSLogix 5000 software automatically creates a safety task with a safety program and a main (safety) routine. Figure 18 - Safety Task in the Controller Organizer Within the safety task, you can use multiple safety programs, composed of multiple safety routines. The Compact GuardLogix controller supports one safety task. The safety task cannot be deleted.
Develop Safety Applications Chapter 6 The safety task should be a high priority. You specify the safety task period (in ms) and the safety task watchdog (in ms). The safety task period is the period at which the safety task executes. The safety task watchdog is the maximum time allowed from the start of safety task execution to its completion. The safety task period is limited to a maximum of 500 ms and cannot be modified online.
Chapter 6 Develop Safety Applications Safety Programs Safety programs have all the attributes of standard programs, except that they can only be scheduled in the safety task and can only contain safety components. Safety programs can only contain safety routines, one of which must be designated as the main routine, and one of which may be designated as the fault routine. Safety programs cannot contain standard routines or standard tags.
Develop Safety Applications Chapter 6 To create a safety tag, open the New Tag dialog box by right-clicking Controller Tags or Program Tags and choosing New Tag. Figure 20 - Creating a New Tag Tag Type Table 17 defines the four types of tags: base, alias, produced, and consumed. Table 17 - Four Tag Types Tag Type Description Base These tags store values for use by logic within the project. Alias A tag that references another tag. An alias tag can refer to another alias tag or a base tag.
Chapter 6 Develop Safety Applications Data Type The data type defines the type of data that the tag stores, such as bit or integer. Data types can be combined to form structures. A structure provides a unique data type that matches a specific need. Within a structure, each individual data type is called a member. Like tags, members have a name and data type. You can create your own structures, as user-defined data types. Logix controllers contain predefined data types for use with specific instructions.
Develop Safety Applications Chapter 6 Scope A tag’s scope determines where you can access the tag data. When you create a tag, you define it as a controller tag (global data) or a program tag for a specific safety or standard program (local data). Safety tags can be controller-scoped or safety program-scoped. Controller-scoped Tags When safety tags are controller-scoped, all programs have access to the safety data.
Chapter 6 Develop Safety Applications Class Tags can be classified as standard or safety. Tags classified as safety tags must have a data type that is permitted for safety tags. When you create program-scoped tags, the class is automatically specified, depending upon whether the tag was created in a standard or safety program. When you create controller-scoped tags, you must manually select the tag class.
Develop Safety Applications Produced/Consumed Safety Tags Chapter 6 To transfer safety data between GuardLogix controllers, you use produced and consumed safety tags. Produced and consumed tags require connections. The default connection type for produced and consumed tags is unicast in version 19 and later of RSLogix 5000 software.
Chapter 6 Develop Safety Applications Follow these steps to copy and paste the SNN. 1. Add the producer controller to the consumer controller’s I/O tree. 2. In the producer controller’s project, right-click the producer controller and choose Controller Properties. 3. Copy the producer controller’s SNN. TIP An SNN can be copied and pasted by using the buttons on the Safety Network Number dialog box.
Develop Safety Applications Chapter 6 Produce a Safety Tag Follow this procedure to produce a safety tag. 1. In the producing controllers project, create a user-defined data type defining the structure of the data to be produced. Make sure that the first data member is of the CONNECTION_STATUS data type. 2. Right-click Controller Tags and choose New Tag. 3. Set the type as Produced, the class as Safety, and the Data Type to the userdefined type you created in step 1. 4.
Chapter 6 Develop Safety Applications Consume Safety Tag Data Follow these steps to consume data produced by another controller. 1. In the consumer controller’s project, create a user-defined data type identical to the one created in the producer project. TIP The user-defined type can be copied from the producer project and pasted into the consumer project. 2. Right-click Controller Tags and choose New Tag. 3.
Develop Safety Applications Chapter 6 8. Enter the requested packet interval (RPI) for the connection in 1 ms increments. The default is 20 ms. Consumer’s Project Producer’s Project The RPI specifies the period at which data updates over a connection. The RPI of the consumed safety tag must match the safety task period of the producing safety project. The Connection Reaction Time Limit is the maximum age of safety packets on the associated connection.
Chapter 6 Develop Safety Applications Table 22 - Additional Resources Safety Tag Mapping Resource Description Pages 57…61 Provides more information on setting the RPI and understanding how the Max.
Develop Safety Applications Chapter 6 Create Tag Mapping Pairs 1. Choose Map Safety Tags from the Logic menu to open the Safety Tag Mapping dialog box. 2. Add an existing tag to the Standard Tag Name or Safety Tag Name column by typing the tag name into the cell or choosing a tag from the pull-down menu. Click the arrow to display a filtered tag browser dialog box. If you are in the Standard Tag Name column, the browser shows only controller-scoped standard tags.
Chapter 6 Develop Safety Applications Monitor Tag Mapping Status The leftmost column of the Safety Tag Mapping dialog box indicates the status of the mapped pair. Table 23 - Tag Mapping Status Icons Cell Contents Description Empty Tag mapping is valid. When offline, the X icon indicates that tag mapping is invalid. You can move to another row or close the Safety Tag Mapping dialog box.(1) When online, an invalid tag map results in an error message explaining why the mapping is invalid.
Develop Safety Applications TIP Chapter 6 The text of the online bar’s safety status button indicates the safety-lock status. Safety Status Button The application tray also displays the following icons to indicate the safety controller’s safety-lock status. • = controller safety-locked • = controller safety-unlocked You can safety-lock the controller project regardless of whether you are online or offline and regardless of whether you have the original source of the program.
Chapter 6 Develop Safety Applications Generate a Safety Task Signature Before verification testing, you must generate the safety task signature. You can generate the safety task signature only when online with the safety-unlocked Compact GuardLogix controller in Program mode, and with no safety forces, pending online safety edits, or safety faults. The safety status must be Safety Task OK.
Develop Safety Applications Chapter 6 Delete the Safety Task Signature Click Delete to delete the safety task signature. The safety task signature cannot be deleted when the following is true: • The controller is safety-locked. • The controller is in Run mode with the keyswitch in RUN. • The controller is in Run or Remote Run mode with run mode protection enabled. ATTENTION: If you delete the safety task signature, you must retest and revalidate your system to meet SIL 3/PLe.
Chapter 6 Develop Safety Applications Notes: 92 Rockwell Automation Publication 1768-UM002C-EN-P - April 2012
Chapter 7 Go Online with the Controller Topic Connecting the Controller to the Network Page Connecting the Controller to the Network 93 Configuring the Network Driver 94 Understanding the Factors that Affect Going Online 95 Download 98 Upload 100 Go Online 101 If you have not done so, connect the controller to the network.
Chapter 7 Go Online with the Controller TIP If you make your own cable, do the following: • Limit the length to 15.2 m (50 ft). • Wire the connectors as shown below. • Attach the shield to both connectors. Workstation Controller 1 DCD 1 DCD 2 RDX 2 RDX 3 TXD 3 TXD 4 DTR 4 DTR COMMON COMMON 6 DSR 6 DSR 7 RTS 7 RTS 8 CTS 8 CTS 9 9 Connect Your EtherNet/IP Device and Computer Connect your EtherNet/IP device and computer by using an Ethernet cable.
Go Online with the Controller Chapter 7 Configure a Serial Communication Driver 1. Start RSLinx software. 2. From the Communication menu, choose Configure Drivers. 3. From the Available Driver Types pull-down menu, choose the driver. 4. Click Add New. 5. Click OK to accept the default name for the driver. 6. From the Comm Port pull-down menu, choose the serial port (on the workstation) to which the cable is connected. 7. From the Device pull-down menu, choose CompactLogix Serial Port. 8.
Chapter 7 Go Online with the Controller Project to Controller Matching The Project to Controller Match feature affects the download, upload, and go online processes of standard and safety projects. If the Project to Controller Match feature is enabled in the offline project, RSLogix 5000 software compares the serial number of the controller in the offline project to that of the connected controller.
Go Online with the Controller Chapter 7 Safety Task Signature and Safety-locked and -unlocked Status The existence of a safety task signature and the safety-locked or -unlocked status of the controller affect both the upload and download processes. On Upload If the controller has a safety task signature, the safety task signature and the safety task lock status are uploaded with the project.
Chapter 7 Go Online with the Controller Download Follow these steps to transfer your project from your computer to your controller. Download Project Controller 1. Turn the keyswitch of the controller to REM. 2. Open the RSLogix 5000 project that you want to download. 3. Define the path to the controller. a. Click Who Active . b. Select the controller. To open a level, click the + sign. If a controller is already selected, make sure that it is the correct controller. 4. Click Download.
Go Online with the Controller Chapter 7 5. Follow the directions in this table to complete the download based on the software’s response. If the software indicates Then Download to the controller. Choose Download. The project downloads to the controller and RSLogix 5000 software goes online. Unable to download to the controller. Mismatch between the offline project and the controller serial number. Selected controller may be the wrong controller.
Chapter 7 Upload Go Online with the Controller Follow these steps to transfer a project from the controller to your computer. Upload Project Controller 1. Define the path to the controller. a. Click Who Active . b. Select the controller. To expand a level, click the + sign. If a controller is already selected, make sure that it is the correct controller. 2. Click Upload. 3. If the project file does not exist, choose File>Select>Yes. 4. If the project file exists, select it.
Go Online with the Controller Chapter 7 6. The software checks for changes in the offline project. a. If there are no changes in the offline project, you can go online without uploading. Click Go Online. b. If there are changes in the open project that are not present in the controller, you can choose to upload the project, cancel the upload, or select another file. If you choose Upload, the standard and safety applications are uploaded. If a safety task signature exists, it is also uploaded.
Chapter 7 Go Online with the Controller 3. Follow the directions in the table below to connect to the controller. Table 28 - Connect to the Controller If the software indicates Then Unable to connect to controller. Mismatch between the offline project and the controller serial number. Selected controller may be the wrong controller.
Chapter 8 Monitor Status and Handle Faults Topic Page Viewing Status via the Online Bar 103 Monitoring Connections 104 Monitoring Safety Status 106 Controller Faults 106 Developing a Fault Routine 108 See Appendix B, Status Indicators for information on interpreting the controller’s status indicators. Viewing Status via the Online Bar The online bar displays project and controller information, including the controller’s status, force status, online edit status, and safety status.
Chapter 8 Monitor Status and Handle Faults The Safety Status button itself indicates whether the controller is safety-locked or -unlocked, or faulted. It also displays an icon that shows the safety status. Table 29 - Safety Status Icon If the safety status is This icon is displayed Safety Task OK Safety Task Inoperable Safety Unavailable Offline Icons are green when the controller is safety-locked, yellow when the controller is safety-unlocked, and red when the controller has a safety fault.
Monitor Status and Handle Faults Chapter 8 Safety Connections For tags associated with produced or consumed safety data, you can monitor the status of safety connections by using the CONNECTION_STATUS member. For monitoring input and output connections, Safety I/O tags have a connection status member called SafetyStatus. Both data types contain two bits: RunMode and ConnectionFaulted.
Chapter 8 Monitor Status and Handle Faults Monitoring Safety Status View controller safety status information on the safety status button on the online bar and on the Safety tab of the Controller Properties dialog box. Figure 26 - Safety Task Status These are the possible values for safety status: • • • • Safety partner is unavailable. Safety firmware is incompatible. Safety task inoperable. Safety task OK.
Monitor Status and Handle Faults Chapter 8 When the safety task encounters a nonrecoverable safety fault that is cleared programmatically in the Controller Fault Handler, the standard application continues to execute. ATTENTION: Overriding the safety fault does not clear it! If you override the safety fault, it is your responsibility to prove that doing so maintains safe operation.
Chapter 8 Monitor Status and Handle Faults Fault Codes Table 31 shows the fault codes specific to Compact GuardLogix controllers. The type and code correspond to the type and code displayed on the Major Faults tab of the Controller Properties dialog box and in the PROGRAM object, MAJORFAULTRECORD (or MINORFAULTRECORD) attribute. Table 31 - Major Safety Faults (Type 14) Code Cause Task watchdog expired. User task has not completed in a specified period of time.
Monitor Status and Handle Faults Chapter 8 Controller Fault Handler The controller fault handler is an optional component that executes when the program fault routine could not clear the fault or does not exist. You can create only one program for the controller fault handler. After you create that program, you must configure a routine as the main routine. The Logix5000 Controllers Major and Minor Faults Programming Manual, publication 1756-PM014, provides details on creating and testing a fault routine.
Chapter 8 Monitor Status and Handle Faults Table 32 - GSV/SSV Accessibility Safety Object Safety Task Safety Program Safety Routine Safety Controller AOI (Safety) (1) (2) (3) (4) 110 Attribute Name Data Type Attribute Description Accessible from the Safety Task GSV SSV ✓ Accessible from Standard Tasks GSV(4) SSV ✓ Instance DINT Provides instance number of this task object. Valid values are 0…31. MaximumInterval DINT[2] The max time interval between successive executions of this task.
Monitor Status and Handle Faults Chapter 8 Access FaultRecord Attributes Create a user-defined structure to simplify access to the MajorFaultRecord and SafetyTaskFaultRecord attributes.
Chapter 8 Monitor Status and Handle Faults Notes: 112 Rockwell Automation Publication 1768-UM002C-EN-P - April 2012
Chapter 9 Store and Load Projects Using Nonvolatile Memory Using Memory Cards for Nonvolatile Memory Topic Page Using Memory Cards for Nonvolatile Memory 113 Storing a Safety Project 115 Loading a Safety Project 115 Manage Firmware with Firmware Supervisor 116 Compact GuardLogix controllers, revision 18 or later, support a 1784-CF128 CompactFlash card for nonvolatile memory. Nonvolatile memory lets you keep a copy of your project on the controller.
Chapter 9 Store and Load Projects Using Nonvolatile Memory ATTENTION: Do not remove the memory card while the controller is reading from or writing to the card, as indicated by a flashing green CF status indicator. This could corrupt the data on the card or in the controller, as well as corrupt the latest firmware in the controller. Leave the card in the controller until the CF status indicator turns solid green.
Store and Load Projects Using Nonvolatile Memory Chapter 9 You cannot store a safety project if the safety task status is Safety Task Inoperable. When you store a safety project, controller firmware is saved to the memory card. Storing a Safety Project If no application exists in the controller, you can save just the firmware of the safety controller only if valid partnership exists. A firmware-only load will not clear a Safety Task Inoperable condition.
Chapter 9 Store and Load Projects Using Nonvolatile Memory Manage Firmware with Firmware Supervisor Beginning with RSLogix 5000 software, version 18, you can use the Firmware Supervisor feature to manage firmware on Compact GuardLogix controllers. Firmware Supervisor lets controllers automatically update devices: • Local and remote modules can be updated while in Program or Run modes. • Electronic keying must be configured for Exact Match.
Appendix A Status Indicators Topic Page Compact GuardLogix Controller Status Indicators 117 Clear a Major Fault 118 Clear a Nonrecoverable Fault 119 Troubleshoot a Nonresponsive Module 119 Troubleshoot System Power 120 This table describes the controller’s status indicators. Compact GuardLogix Controller Status Indicators Table 35 - Status Indicator Descriptions Indicator Status Description PWR Green The controller is providing power to 1768 modules in the system.
Appendix A Status Indicators Table 35 - Status Indicator Descriptions Indicator Status Description OK Off No power is applied. If MEM SAVE indicator is green, the user program and configuration data are being saved to nonvolatile memory. Flashing Red The controller requires a firmware update or a firmware update is in progress. A recoverable major fault occurred on the controller. A non-recoverable major fault occurred on the controller. See Clear a Major Fault on page 118.
Status Indicators Appendix A If the OK status indicator is flashing red because of a nonrecoverable major fault, the controller: • initially displayed a solid red OK indicator. • reset itself. • cleared the project from its memory. • set the OK indicator to flashing red. • produced a major recoverable fault and generated a corresponding fault code in the RSLogix 5000 project. – Fault code 60 means the CompactFlash card is not installed. – Fault code 61 means the CompactFlash card is installed.
Appendix A Status Indicators Troubleshoot System Power The CompactLogix power supply works with the CompactLogix controller to provide power to the system. You must consider both when attempting to troubleshoot system power. IMPORTANT Before you disconnect, reconnect, or replace any component, make sure you have turned off power and allowed all system status indicators to turn off.
Status Indicators Appendix A Examine the Controller PWR Indicator This task assumes that the power supply PWR indicator is green. Controller PWR Indicator Status Recommended Action Off Make sure all of the modules in the system are installed properly and are fully engaged with one another. If the indicator remains off, follow the corrective action below. Green The controller is providing power to 1768 modules in the system.
Appendix A Status Indicators 1. If there is a 1769 power supply installed in the local bank, remove it and reapply power. If the I/O PWR indicator remains red, go to the next step. 2. Remove power and wait for all status indicators to turn off. 3. Disconnect the 1769 I/O modules from the system. 4. Reapply power. 5. Check the controller I/O PWR indicator. a. If the indicator is red, replace the controller. b. If the indicator is green, one of the 1769 I/O modules is causing the red indicator.
Appendix B Change Controller Type in RSLogix 5000 Projects Topic Page Changing from a Standard to a Safety Controller 123 Changing from a Safety to a Standard Controller 124 Changing from a 1756 GuardLogix Controller to a 1768 Compact GuardLogix Controller or Vice Versa 125 Changing from a 1756-L7xS Controller to a 1756-L6xS or 1768-L4xS Controller 125 Additional Resources 125 Because safety controllers have special requirements and do not support certain standard features, you must understan
Appendix B Change Controller Type in RSLogix 5000 Projects Changing from a Safety to a Standard Controller Upon confirmation of a change from a safety controller project to a standard controller, some components are changed and others are deleted, as described below: • Safety I/O modules and their tags are deleted. • The safety task, programs, and routines are changed to a standard task, programs, and routines. • All safety tags, except safety consume tags, are changed to standard tags.
Change Controller Type in RSLogix 5000 Projects Changing from a 1756 GuardLogix Controller to a 1768 Compact GuardLogix Controller or Vice Versa Appendix B When you change from one safety controller type to another, the class of tags, routines, and programs remains unaltered. Any I/O modules that are no longer compatible with the target controller are deleted.
Appendix B Change Controller Type in RSLogix 5000 Projects Notes: 126 Rockwell Automation Publication 1768-UM002C-EN-P - April 2012
Appendix C History of Changes With the availability of new controllers, modules, applications, and RSLogix 5000 software features, this manual has been revised to include updated information. This appendix briefly summarizes changes that have been made with each revision of this manual. Reference this appendix if you need to determine what changes have been made across multiple revisions.
Appendix C History of Changes Notes: 128 Rockwell Automation Publication 1768-UM002C-EN-P - April 2012
Index Numerics 1747-CP3 cable 93 1756-CP3 20, 26 1756-CP3 cable 93 1768 Compact GuardLogix controller 125 1768-PA3 20 1768-PB3 20 1769-ECR 20 A Add-On Instructions 124 address CIP Safety I/O module 63 advanced connection reaction time 59 alert symbol 104 alias tags 77 attributes safety object 109 AutoFlash software 28, 29 automatic firmware updates 116 B bank local 21, 22 remote 21, 22 base tags 77 bus extension cable 22 C cable serial 26 cable length 26 Change Controller button 35 changing controllers 1
Index F create a project 33 fault D data types CONNECTION_STATUS 81 delete safety task signature 91 DeviceNet network 51 communication 51 module capability 51 required interfaces 51 required software for communication 51 DeviceNet network example 52 diagnostic coverage 10 DIN rail 22, 30 distance rating 21 download effect of controller match 96 effect of firmware revision match 96 effect of safety status 96 effect of safety task signature 97 effect of safety-lock 97 process 98-99 driver ControlNet 95 Eth
Index M major fault clear 118 major faults tab 107, 108 major safety faults 108 MajorFaultRecord 111 maximum observed network delay 58 reset 85 memory card 113, 114, 116 installation 26 removal 26 minor faults tab 108 module properties connection tab 62 module placement 20 monitor connections 104 status 63 morphing See changing controllers.
Index RSLogix 5000 software reset module 65 restrictions 91 versions 15 RSLogix Security 89 run mode protection 90, 91 RunMode bit 105 S safe state 11 safety network number 39 assignment 39 automatic assignment 41 changing controller SNN 42 changing I/O SNN 42 copy 44 copy and paste 44 definition 10 description 11 formats 39 managing 39 manual 40 manual assignment 41 modification 41 paste 44 set 57 time-based 40 view 34 safety object attributes 109 safety programs 76 safety projects features not supported
Index T tags alias 77 base 77 class 80 constant value 80 consumed 77, 81 controller-scoped 79 data type 78 external access 76, 80 naming 62 overview 76 produced 77, 81 produced/consumed safety data 78, 79 program-scoped 79 safety I/O 78, 79 scope 79 See also, safety tags.
Index 134 Rockwell Automation Publication 1768-UM002C-EN-P - April 2012
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