GuardPLC Certified
Function Blocks -Basic Suite
Catalog Number 1753-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-1.1
available from your local Rockwell Automation sales office or online at
http://literature.rockwellautomation.com) describes some important
differences between solid state equipment and hard-wired electromechanical
devices. Because of this difference, and also because of the wide variety of
uses for solid state equipment, all persons responsible for applying this
equipment must satisfy themselves that each intended application of this
equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for
indirect or consequential damages resulting from the use or application of
this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with
any particular installation, Rockwell Automation, Inc. cannot assume
responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to
use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without
written permission of Rockwell Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware
of safety considerations.
WARNING
IMPORTANT
ATTENTION
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.
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
SHOCK HAZARD
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
3
Page
Correction to the Diverse Input Wiring Diagram - Automatic Reset
38
Important revised recommendations for setting the Pulse Test
Duration of the Redundant Pulst Test Ouput (RPTO) function block
94
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Summary of Changes
Publication 1753-RM001C-EN-P - May 2007
Table of Contents
Preface
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Understanding Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 1
Redundant Input Function Block
(RIN)
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation with Inconsistent Inputs . . . . . . . . . . . . . . .
Operation with Circuit Reset Held On - Manual Reset
Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cycle Inputs Operation . . . . . . . . . . . . . . . . . . . . . . .
Function Block Description . . . . . . . . . . . . . . . . . . . . . . .
Relationship of I/O Wiring to Function Block Parameters .
Redundant Input with Manual Reset Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant Input with Automatic Reset Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 2
Emergency Stop Function Block
(ESTOP)
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation with Inconsistent Inputs . . . . . . . . . . . . . . .
Operation with Circuit Reset Held On - Manual Reset
Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cycle Inputs Operation . . . . . . . . . . . . . . . . . . . . . . .
Function Block Description . . . . . . . . . . . . . . . . . . . . . . .
Relationship of I/O Wiring to Function Block Parameters .
Emergency Stop with Manual Reset Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop with Automatic Reset Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 3
Diverse Input Function Block (DIN) Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation with Inconsistent Inputs . . . . . . . . . . . . . .
Operation with Circuit Reset Held On - Manual Reset
Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cycle Inputs Operation . . . . . . . . . . . . . . . . . . . . . .
5
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Table of Contents
Function Block Description . . . . . . . . . . . . . . . . . . . . . . .
Relationship of I/O Wiring to Function Block Parameters .
Diverse Input with Manual Reset Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diverse Input with Automatic Reset Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Chapter 4
Enable Pendant Function Block
(ENPEN)
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation with Inconsistent Inputs . . . . . . . . . . . . . . .
Operation with Circuit Reset Held On - Manual Reset
Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cycle Inputs Operation . . . . . . . . . . . . . . . . . . . . . . .
Function Block Description . . . . . . . . . . . . . . . . . . . . . . .
Relationship of I/O Wiring to Function Block Parameters .
Enable Pendant with Manual Reset Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enable Pendant with Automatic Reset Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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46
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Chapter 5
Light Curtain Function Block (LC)
Publication 1753-RM001C-EN-P - May 2007
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light Curtain Muting Operation . . . . . . . . . . . . . . . . .
Inputs Inconsistent Operation. . . . . . . . . . . . . . . . . . .
Circuit Reset Held On Operation (Manual Reset Mode
Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cycle Inputs Operation . . . . . . . . . . . . . . . . . . . . . . .
Input Filter Time . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Block Description . . . . . . . . . . . . . . . . . . . . . . .
Relationship of I/O Wiring to Function Block Parameters .
Light Curtain with Manual Reset Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light Curtain with Automatic Reset Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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60
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Table of Contents
7
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Block Description . . . . . . . . . . . . . . . . . . . . . . . . .
Relationship of I/O Wiring to Function Block Parameters . . .
Redundant Output with Negative Feedback Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant Output with Positive Feedback Wiring and
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
65
65
68
69
Chapter 6
Redundant Output with
Continuous Feedback Monitoring
Function Block (ROUT)
69
71
Chapter 7
Five-Position Mode Selector
Function Block (FPMS)
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Block Description . . . . . . . . . . . . . . . . . . . . . . .
Relationship of I/O Wiring to Function Block Parameters .
Five-Position Mode Selector Wiring and Programming .
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80
81
83
Chapter 8
Two-Hand Run Station Function
Block (THRS)
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Button Tie-Down Operation. . . . . . . . . . . . . . . . . . . .
Cycle Buttons Operation . . . . . . . . . . . . . . . . . . . . . .
Button Fault Operation . . . . . . . . . . . . . . . . . . . . . . .
Function Block Description . . . . . . . . . . . . . . . . . . . . . . .
Relationship of I/O Wiring to Function Block Parameters .
Two-Hand Run Station with Active Pin Disabled
Wiring and Programming . . . . . . . . . . . . . . . . . . . . . .
Two-Hand Run Station with Active Pin Enabled
Wiring and Programming . . . . . . . . . . . . . . . . . . . . . .
. . 83
. . 84
Chapter 9
Redundant Pulse Test Output
Function Block (RPTO)
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross-wiring Fault . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Fault Clearing . . . . . . . . . . . . . . . . . . . . . .
Generate Pulse Test . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulse Test on Input Transition . . . . . . . . . . . . . . . . . .
Function Block Description . . . . . . . . . . . . . . . . . . . . . . .
Relationship of I/O Wiring to Function Block Parameters .
Redundant Pulse Test Output . . . . . . . . . . . . . . . . . . .
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Table of Contents
Chapter 10
Single Pulse Test Output Function Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Block (SPTO)
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . .
Relationship of I/O Wiring to Function Block Parameters .
Single Pulse Test Output Wiring and Programming . . .
Index
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102
103
103
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.
9
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
FB1
Input
Feedback 1
FB2
Input
Feedback 2
FP
Output
Fault Present
FR
Input
Fault Reset
IFT
Input
Input Filter Time
II
Output
Inputs Inconsistent
IN1 to IN5
Input
Input 1 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
O1 to O5
Output
Output 1 to Output 5
O1FF
Output
Output 1 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
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Preface
Additional Resources
The following table lists documents that contain additional
information concerning Rockwell Automation GuardPLC products.
Resource
Description
GuardPLC Controller Systems Safety Reference Manual,
publication 1755-RM001
Provides in-depth information on the safety concept of GuardPLC controller
systems
GuardPLC 1600 Controllers Installation Instructions,
publication 1753-IN001
Provides information on installing GuardPLC 1600 controllers
GuardPLC 1800 Controllers Installation Instructions,
publication 1753-IN002
Provides information on installing GuardPLC 1800 controllers
GuardPLC 1753-IB20XOB8 I/O Module Installation
Instructions, publication 1753-IN003
Provides information on installing GuardPLC 1753-IB20XOB8 I/O module
GuardPLC 1753-IB16 Input Module Installation
Instructions, publication 1753-IN004
Provides information on installing GuardPLC 1753-IB16 Input Module
GuardPLC 1753-OB16 Output Module Installation
Instructions, publication 1753-IN005
Provides information on installing GuardPLC 1753-OB16 Output Module
RSLogix Guard PLUS! Programming Software Installation
Instructions, publication 1753-IN006
Provides information on installing RSLogix Guard PLUS! programming
software
GuardPLC OPC Server Installation Instructions, publication Provides information on installing GuardPLC OPC server
1753-IN007
Allen-Bradley Programmable Controller Grounding and
Wiring Guidelines, publication 1770-4.1
Provides in-depth information on grounding and wiring Allen-Bradley
programmable controllers
Application Considerations for Solid-State Controls,
publication SGI-1.1
A description of important differences between solid-state programmable
controller products and hard-wired electromechanical devices
National Electrical Code - Published by the National Fire
Protection Association of Boston, MA.
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 1753-RM001C-EN-P - May 2007
Chapter
1
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 1 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 50 ms.
This Function Block turns Output 1 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
1
1
Channel A
Channel A
0
0
1
1
Channel B
Channel B
0
0
1
1
50 ms
Circuit Reset
0
Output 1
0
1
Output 1
0
11
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12
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 500 ms.
This fault condition is enunciated via the Inputs Inconsistent and the
Fault Present outputs. Output 1 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
1
Channel A
0
1
Channel B
0
1
Output 1
0
500 ms
1
Inputs
Inconsistent 0
1
Fault Present
0
1
Fault Reset
0
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 (1) when the input channels transition
to the Active state.
These state changes are shown in the following timing diagram.
Publication 1753-RM001C-EN-P - May 2007
Redundant Input Function Block (RIN)
13
Circuit Reset and Circuit Reset Held On Operation
1
Channel A
0
1
Channel B
0
1
Circuit Reset
0
1
Output 1
0
Circuit Reset 1
Held On
0
Cycle Inputs Operation
If, while Output 1 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 1 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
1
Channel A
0
1
Channel B
0
1
Output 1
0
1
Cycle Inputs
0
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14
Redundant Input Function Block (RIN)
Function Block Description
RIN_RA
RIN_AUTO_RA
Redundant Input Manual Reset
Redundant Input Automatic Reset
Channel A
Output 1
Channel A
Channel B
Cycle Inputs
Channel B
Circuit Reset Held On
Circuit Reset
Fault Reset
Inputs Inconsistent
Fault Present
Fault Reset
Output 1
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 = 0, Active = 1
Channel B
—
Input
Boolean
Channel B Input (Normally Open)
Safe = 0, Active = 1
Circuit Reset
—
Input
Boolean
Circuit Reset Input
Initial = 0, Reset = 1
Manual Reset - Sets Output 1 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.
Initial = 0, Reset = 1
Output 1
O1
Output
Boolean
Output 1 is set to the Active state when input
conditions are met.
Safe = 0, Active = 1
Cycle Inputs
CI
Prompt
Output
Boolean
Cycle Inputs prompts for action. Before Output 1 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 = 0, Prompt = 1
This prompt is cleared when Channel A and Channel
B transition to the Safe state.
Publication 1753-RM001C-EN-P - May 2007
Redundant Input Function Block (RIN)
15
Redundant Inputs (RIN) Function Block Parameters
Parameter
Short
Name
Type
Data Type
Description
Safe, Active and
Initial Values
Circuit Reset Held
On
CRHO
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 = 0, Prompt = 1
The Circuit Reset Held On prompt is cleared when
the Circuit Reset input is turned off.
Inputs Inconsistent
II
Fault
Output
Boolean
Initial = 0, Fault = 1
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.
Inconsistent Time Period: 500 ms
Fault Present
FP
Fault
Output
Boolean
This is set whenever a fault is present in the
function block. Output 1 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 = 0, Fault = 1
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16
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 EN954-1 Category 4.
Redundant Input Wiring Diagram - Manual Reset
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
E1
L+
DI 1
DI 2
DI 3
L-
DO 1
DO 2
LS+
DI 4
DI 5
GuardPLC
S2
E1 - 24V Power Supply
S1 - Redundant Input Switch
S2 - Circuit Reset Switch
S3 - Fault Reset Switch
S4 - Generate Pulse Test Switch
S3
S4
S1
S1 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 16.
Publication 1753-RM001C-EN-P - May 2007
Redundant Input Function Block (RIN)
17
Redundant Input Programming Example - Manual Reset
Guard PLC
User Program
RPTO_RA
Redundant Pulse Test Output
T#2 to 60 sec
T#10 - 500 msec
DI 5
DI 1
DI 2
Pulse Test Interval
Pulse Test Duration
Generate Pulse Test
Pulse Test Source A
Pulse Test Source B
Pulse Test Fault A
DO 1
DO 2
To User Logic
Pulse Test Fault B
To User Logic
Output 1 A
Output 1 B
Input 1 A
Input 1 B
RIN_RA
Redundant Input Manual Reset
Channel A
DI 3
Channel B
Circuit Reset
DI 4
Fault Reset
Output 1
To User Logic
Cycle Inputs
Circuit Reset Held On
To User Logic
To User Logic
Inputs Inconsistent
Fault Present
To User Logic
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
Publication 1753-RM001C-EN-P - May 2007
18
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 EN954-1 Category 4.
ATTENTION
Various safety standards (EN 60204, 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.
Redundant Input Wiring Diagram - Automatic Reset
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
E1
L+
DI 1
DI 2
DI 3
L-
DO 1
DO 2
LS+
DI 4
GuardPLC
S2
E1 - 24V Power Supply
S1 - Redundant Input Switch
S2 - Fault Reset Switch
S3 - Generate Pulse Test Switch
S1
S1 as shown is in the Active state.
Publication 1753-RM001C-EN-P - May 2007
S3
Redundant Input Function Block (RIN)
19
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 18.
Redundant Input Programming Example - Automatic Reset
Guard PLC
User Program
RPTO_RA
Redundant Pulse Test Output
T#2 to 60 sec
T#10 - 500 msec
Pulse Test Interval
Pulse Test Duration
Pulse Test Source A
Pulse Test Source B
DO 1
DO 2
Pulse Test Fault A
Pulse Test Fault B
To User Logic
To User Logic
DI 4
Generate Pulse Test
DI 1
Input 1 A
Output 1 A
DI 2
Input 1 B
Output 1 B
RIN_AUTO_RA
Redundant Input Automatic Reset
DI 3
Channel A
Channel B
Fault Reset
Output 1
Cycle Inputs
Inputs Inconsistent
To User Logic
To User Logic
To User Logic
Fault Present
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
Publication 1753-RM001C-EN-P - May 2007
20
Redundant Input Function Block (RIN)
Publication 1753-RM001C-EN-P - May 2007
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 1 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 50 ms.
This function block turns Output 1 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
1
1
Channel A
Channel A
0
0
1
1
Channel B
Channel B
0
0
1
1
50 ms
Circuit Reset
0
Output 1
0
1
Output 1
0
21
Publication 1753-RM001C-EN-P - May 2007
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 500 ms.
This fault condition is enunciated via the Inputs Inconsistent and the
Fault Present outputs. Output 1 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
1
Channel A
0
1
Channel B
0
1
Output 1
0
500 ms
1
Inputs
Inconsistent 0
1
Fault Present
0
1
Fault Reset
0
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 (1) when the input channels transition
to the Active state.
These state changes are shown in the following timing diagram.
Publication 1753-RM001C-EN-P - May 2007
Emergency Stop Function Block (ESTOP)
23
Circuit Reset and Circuit Reset Held On Operation
1
Channel A
0
1
Channel B
0
1
Circuit Reset
0
1
Output 1
0
Circuit Reset 1
Held On
0
Cycle Inputs Operation
If, while Output 1 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 1 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
1
Channel A
0
1
Channel B
0
1
Output 1
0
1
Cycle Inputs
0
Publication 1753-RM001C-EN-P - May 2007
24
Emergency Stop Function Block (ESTOP)
Function Block Description
ESTOP_AUTO_RA
ESTOP_RA
Emergency Stop Manual Reset
Output 1
Channel A
Output 1
Cycle Inputs
Circuit Reset Held On
Channel B
Cycle Inputs
Channel A
Channel B
Emergency Stop Automatic Reset
Circuit Reset
Fault Reset
Inputs Inconsistent
Fault Present
Fault Reset
Inputs Inconsistent
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 = 0, Active = 1
Channel B
—
Input
Boolean
Channel B Input (Normally Open)
Safe = 0, Active = 1
Circuit Reset
—
Input
Boolean
Circuit Reset Input
Initial = 0, Reset = 1
Manual Reset - Sets Output 1 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.
Initial = 0, Reset = 1
Output 1
O1
Output
Boolean
Output 1 is set to the Active state when input
conditions are met.
Safe = 0, Active = 1
Cycle Inputs
CI
Prompt
Output
Boolean
Cycle Inputs prompts for action. Before Output 1 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 = 0, Prompt = 1
This prompt is cleared when Channel A and Channel
B transition to the Safe state.
Publication 1753-RM001C-EN-P - May 2007
Emergency Stop Function Block (ESTOP)
25
Emergency Stop Function Block Parameters
Parameter
Short
Name
Type
Data Type
Description
Safe, Active and
Initial Values
Circuit Reset Held
On
CRHO
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 = 0, Prompt = 1
The Circuit Reset Held On prompt is cleared when
the Circuit Reset input is turned off.
Inputs Inconsistent
II
Fault
Output
Boolean
Initial = 0, Fault = 1
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.
Inconsistent Time Period: 500 ms
Fault Present
FP
Fault
Output
Boolean
This is set whenever a fault is present in the
function block. Output 1 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 = 0, Fault = 1
Publication 1753-RM001C-EN-P - May 2007
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 EN954-1 Category 4.
Emergency Stop Wiring Diagram - Manual Reset
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
E1
L+
DI 1
DI 2
DI 3
L-
DO 1
DO 2
LS+
DI 4
DI 5
GuardPLC
S2
E1 - 24V Power Supply
S1 - Emergency Stop Switch
S2 - Circuit Reset Switch
S3 - Fault Reset Switch
S4 - Generate Pulse Test Switch
S1
S1 as shown is in the Active state.
Publication 1753-RM001C-EN-P - May 2007
S3
S4
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 60 sec
T#10 - 500 msec
DI 5
DI 1
DI 2
Pulse Test Interval
Pulse Test Duration
Generate Pulse Test
Pulse Test Source A
Pulse Test Source B
Pulse Test Fault A
DO 1
DO 2
To User Logic
Pulse Test Fault B
To User Logic
Output 1 A
Output 1 B
Input 1 A
Input 1 B
ESTOP_RA
Emergency Stop Manual Reset
Channel A
Channel B
DI 3
DI 4
Circuit Reset
Fault Reset
Output 1
Cycle Inputs
Circuit Reset Held On
Inputs Inconsistent
To User Logic
To User Logic
To User Logic
To User Logic
Fault Present
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
Publication 1753-RM001C-EN-P - May 2007
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 EN954-1 Category 4.
ATTENTION
Various safety standards (EN 60204, 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.
Emergency Stop Wiring Diagram - Automatic Reset
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
E1
L+
DI 1
DI 2
DI 3
L-
DO 1
DO 2
LS+
DI 4
GuardPLC
S2
E1 - 24V Power Supply
S1 - Emergency Stop Switch
S2 - Fault Reset Switch
S3 - Generate Pulse Test Switch
S1
S1 as shown is in the Active state.
Publication 1753-RM001C-EN-P - May 2007
S3
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 60 sec
T#10 - 500 msec
DI 4
DI 1
DI 2
Pulse Test Interval
Pulse Test Duration
Generate Pulse Test
Pulse Test Source A
Pulse Test Source B
Pulse Test Fault A
DO 1
DO 2
To User Logic
Pulse Test Fault B
To User Logic
Output 1 A
Output 1 B
Input 1 A
Input 1 B
ESTOP_AUTO_RA
Emergency Stop Automatic Reset
Channel A
Channel B
DI 3
Fault Reset
Output 1
Cycle Inputs
Inputs Inconsistent
Fault Present
To User Logic
To User Logic
To User Logic
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
Publication 1753-RM001C-EN-P - May 2007
30
Emergency Stop Function Block (ESTOP)
Publication 1753-RM001C-EN-P - May 2007
Chapter
3
Diverse Input Function Block (DIN)
Overview
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.
Operation
Normal Operation
This function block monitors the states of two input channels and
turns on Output 1 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 50 ms.
This function block turns Output 1 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
1
1
Channel A
Channel A
0
0
1
1
Channel B
Channel B
0
0
1
1
50 ms
Circuit Reset
0
Output 1
0
1
Output 1
0
31
Publication 1753-RM001C-EN-P - May 2007
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 500 ms.
This fault condition is enunciated via the Inputs Inconsistent and the
Fault Present outputs. Output 1 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
1
Channel A
0
1
Channel B
0
1
Output 1
0
500 ms
Inputs
Inconsistent
1
0
1
Fault Present
0
1
Fault Reset
0
Diverse Input Instruction
t1 - 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 (1) when the input channels transition
to the Active state.
These state changes are shown in the following timing diagram.
Publication 1753-RM001C-EN-P - May 2007
Diverse Input Function Block (DIN)
33
Circuit Reset and Circuit Reset Held On Operation
1
Channel A
0
1
Channel B
0
1
Circuit Reset
0
1
Output 1
0
Circuit Reset 1
Held On
0
Cycle Inputs Operation
If, while Output 1 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 1 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
1
Channel A
0
1
Channel B
0
1
Output 1
0
1
Cycle Inputs
0
Publication 1753-RM001C-EN-P - May 2007
34
Diverse Input Function Block (DIN)
Function Block Description
DIN_AUTO_RA
DIN_RA
Diverse Input Manual Reset
Diverse Input with Automatic Reset
Channel A
Output 1
Channel A
Output 1
Channel B
Cycle Inputs
Circuit Reset Held On
Channel B
Cycle Inputs
Inputs Inconsistent
Circuit Reset
Fault Reset
Inputs Inconsistent
Fault Present
Fault Reset
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 = 0, Active = 1
Channel B
—
Input
Boolean
Channel B Input (Normally Closed)
Safe = 1, Active = 0
Circuit Reset
—
Input
Boolean
Circuit Reset Input
Initial = 0, Reset = 1
Manual Reset - Sets Output 1 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.
Initial = 0, Reset = 1
Output 1
O1
Output
Boolean
Output 1 is set to the Active state when input
conditions are met.
Safe = 0, Active = 1
Cycle Inputs
CI
Prompt
Output
Boolean
Cycle Inputs prompts for action. Before Output 1 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 = 0, Prompt = 1
This prompt is cleared when Channel A and Channel
B transition to the Safe state.
Publication 1753-RM001C-EN-P - May 2007
Diverse Input Function Block (DIN)
35
Diverse Input (DIN) Function Block Parameters
Parameter
Short
Name
Type
Data Type
Description
Safe, Active and
Initial Values
Circuit Reset Held
On
CRHO
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 = 0, Prompt = 1
The Circuit Reset Held On prompt is cleared when
the Circuit Reset input is turned off.
Inputs Inconsistent
II
Fault
Output
Boolean
Initial = 0, Fault = 1
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.
Inconsistent Time Period: 500 ms
Fault Present
FP
Fault
Output
Boolean
This is set whenever a fault is present in the
function block. Output 1 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 = 0, Fault = 1
Publication 1753-RM001C-EN-P - May 2007
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 EN954-1 Category 4.
Diverse Input Wiring Diagram - Manual Reset
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
E1
L+
DI 1
DI 2
L-
DO 1
LS+
DI 3
DI 4
DI 5
GuardPLC
S2
S3
S4
S1
E1 - 24V Power Supply
S1 - Diverse Input Switch
S2 - Circuit Reset Switch
S3 - Fault Reset Switch
S4 - Generate Pulse Test Switch
Publication 1753-RM001C-EN-P - May 2007
S1 as shown is in the Active state. IN0 - Normally Open, IN1 - Normally Closed.
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 60 sec
T#10 - 500 msec
DI 5
DI 1
DI 2
Pulse Test Interval
Pulse Test Duration
Generate Pulse Test
Pulse Test Source A
DO 1
Pulse Test Fault A
To User Logic
Input 1 A
Input 1
Output 1 A
Output 1
DIN_RA
Diverse Input Manual Reset
Channel A
Channel B
DI 3
DI 4
Circuit Reset
Fault Reset
Output 1
Cycle Inputs
Circuit Reset Held On
Inputs Inconsistent
Fault Present
To User Logic
To User Logic
To User Logic
To User Logic
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
Publication 1753-RM001C-EN-P - May 2007
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 EN954-1 Category 4.
ATTENTION
Various safety standards (EN 60204, 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.
Diverse Input Wiring Diagram - Automatic Reset
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
E1
L+
DI 1
L-
DO 1
DI 2
DI 3
DI 4
LS+
1753 GuardPLC
S2
S3
S1
E1 - 24V Power Supply
S1 as shown is in the Active state. CHA/DI 1 - Normally Open, CHB/DI 2 - Normally Closed
S1 - Diverse Input Switch
S2 - Fault Reset Switch
S3 - Generate Pulse Test Switch
Publication 1753-RM001C-EN-P - May 2007
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 60 sec
Pulse Test Interval
T#10 - 500 msec
DI 4
Pulse Test Duration
Generate Pulse Test
DI 1
DI 2
Pulse Test Source A
DO 1
Pulse Test Fault A
To User Logic
Input 1 A
Input 1
Output 1 A
Output 1
DIN_AUTO_RA
Diverse Input Automatic Reset
Channel A
Channel B
DI 3
Fault Reset
Output 1
Cycle Inputs
Inputs Inconsistent
Fault Present
To User Logic
To User Logic
To User Logic
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
Publication 1753-RM001C-EN-P - May 2007
40
Diverse Input Function Block (DIN)
Publication 1753-RM001C-EN-P - May 2007
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 1 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 50 ms.
This function block turns Output 1 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
1
1
Channel A
Channel A
0
0
1
1
Channel B
Channel B
0
0
1
1
50 ms
Circuit Reset
0
Output 1
0
1
Output 1
0
41
Publication 1753-RM001C-EN-P - May 2007
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 1 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
1
Channel A
0
1
Channel B
0
1
Output 1
0
3 sec
1
Inputs
Inconsistent 0
1
Fault Present
0
1
Fault Reset
0
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 (1) when the input channels transition
to the Active state.
These state changes are shown in the following timing diagram.
Publication 1753-RM001C-EN-P - May 2007
Enable Pendant Function Block (ENPEN)
43
Circuit Reset and Circuit Reset Held On Operation
1
Channel A
0
1
Channel B
0
1
Circuit Reset
0
1
Output 1
0
Circuit Reset 1
Held On
0
Cycle Inputs Operation
If, while Output 1 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 1 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
1
Channel A
0
1
Channel B
0
1
Output 1
0
1
Cycle Inputs
0
Publication 1753-RM001C-EN-P - May 2007
44
Enable Pendant Function Block (ENPEN)
Function Block Description
ENPEN_RA
ENPEN_AUTO_RA
Enable Pendant Manual Reset
Enable Pendant Automatic Reset
Channel A
Output 1
Channel A
Output 1
Channel B
Cycle Inputs
Channel B
Cycle Inputs
Inputs Inconsistent
Fault Present
Circuit Reset
Fault Reset
Circuit Reset Held On
Inputs Inconsistent
Fault Present
Fault Reset
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 = 0, Active = 1
Channel B
—
Input
Boolean
Channel B Input (Normally Open)
Safe = 0, Active = 1
Circuit Reset
—
Input
Boolean
Circuit Reset Input
Initial = 0, Reset = 1
Manual Reset - Sets Output 1 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.
Initial = 0, Reset = 1
Output 1
O1
Output
Boolean
Output 1 is set to the Active state when input
conditions are met.
Safe = 0, Active = 1
Cycle Inputs
CI
Prompt
Output
Boolean
Cycle Inputs prompts for action. Before Output 1 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 = 0, Prompt = 1
This prompt is cleared when Channel A and Channel
B transition to the Safe state.
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Enable Pendant Function Block (ENPEN)
45
Enable Pendant Function Block Parameters
Parameter
Short
Name
Type
Data Type
Description
Safe, Active and
Initial Values
Circuit Reset Held
On
CRHO
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 = 0, Prompt = 1
The Circuit Reset Held On prompt is cleared when
the Circuit Reset input is turned off.
Automatic Reset - Visible, but not used.
Inputs Inconsistent
II
Fault
Output
Boolean
Initial = 0, Fault = 1
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.
Inconsistent Time Period: 3 s
Fault Present
FP
Fault
Output
Boolean
This is set whenever a fault is present in the
function block. Output 1 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 = 0, Fault = 1
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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 EN954-1 Category 4.
Enable Pendant Wiring Diagram - Manual Reset
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
E1
L+
DI 1
DI 2
DI 3
L-
DO 1
DO 2
LS+
DI 4
DI 5
GuardPLC
S2
E1 - 24V Power Supply
S1 - Enable Pendant Switch
S2 - Circuit Reset Switch
S3 - Fault Reset Switch
S4 - Generate Pulse Test Switch
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S1
S3
S4
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 60 sec
T#10 - 500 msec
DI 5
DI 1
DI 2
Pulse Test Interval
Pulse Test Duration
Generate Pulse Test
Pulse Test Source A
Pulse Test Source B
Pulse Test Fault A
DO 1
DO 2
To User Logic
Pulse Test Fault B
To User Logic
Output 1 A
Output 1 B
Input 1 A
Input 1 B
ESTOP_RA
Emergency Stop Manual Reset
Channel A
Channel B
DI 3
DI 4
Circuit Reset
Fault Reset
Output 1
Cycle Inputs
Circuit Reset Held On
Inputs Inconsistent
To User Logic
To User Logic
To User Logic
To User Logic
Fault Present
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
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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 EN954-1 Category 4.
Various safety standards (EN 60204, 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.
ATTENTION
Enable Pendant Wiring Diagram - Automatic Reset
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
E1
L+
DI 1
DI 2
DI 3
L-
DO 1
DO 2
LS+
DI 4
GuardPLC
S2
E1 - 24V Power Supply
S1 - Enable Pendant Switch
S2 - Fault Reset Switch
S3 - Generate Pulse Test Switch
Publication 1753-RM001C-EN-P - May 2007
S1
S3
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 60 sec
T#10 - 500 msec
DI 4
DI 1
DI 2
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
Input 1 A
Input 1 B
DO 1
DO 2
To User Logic
To User Logic
Output 1 A
Output 1 B
ENPEN_AUTO_RA
Enable Pendant Automatic Reset
Channel A
Channel B
DI 3
Fault Reset
Output 1
Cycle Inputs
Inputs Inconsistent
Fault Present
To User Logic
To User Logic
To User Logic
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
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Enable Pendant Function Block (ENPEN)
Publication 1753-RM001C-EN-P - May 2007
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; OSSD1 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
OSSD1 and OSSD2. If using these devices, then OSSD1 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 100 µs during a pulse test, then
the hardware must filter out LO signals that are 100 µs or longer. Note
that the Safety DeviceNet I/O modules have a configurable filter of 0
to 126 ms. The safety I/O modules have a fixed filter time of 100 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 OSSD1, 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 OSSD1 multiple times before the filter times
out, and OSSD1 is set logically LO.
51
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52
Light Curtain Function Block (LC)
The following chart shows how many times OSSD1 must be scanned
LO before the timer times out. It assumes a scan time of 25 ms.
Filter Time
Consecutive Scans
OSSD1 LO
0
1
1-25
2
26-50
3
51-75
4
76-100
5
…
…
The downside of using a longer hardware or software filter is that this
filter time must be directly added to the calculation of the light curtain
safety reaction time.
Operation
Normal Operation
This function block monitors the states of two input channels and
turns on output 1 when the following conditions are met:
• When using Manual Reset: both inputs are in the Active state
when the Circuit Reset input is transitioned from a zero to a one.
• When using Automatic Reset: both inputs are in their Active state
for 50 ms.
The function block turns output 1 off when either one or both of the
input channels return to the Safe state.
These normal operation state changes are shown in the following
timing diagrams.
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Light Curtain Function Block (LC)
53
Normal Operation
Manual Reset
Automatic Reset
1
1
Channel A
Channel A
0
0
1
1
Channel B
Channel B
0
0
1
1
Output 1
Circuit Reset
Output 1
50 ms
0
0
1
Light Curtain 1
Blocked
0
0
1
Light Curtain
Blocked
0
Light Curtain Muting Operation
The one exception to the normal Output 1 control is Light Curtain
Muting which, when enabled, permits the inputs to leave the Active
state and output 1 to remain on. The Light Curtain Muted output
represents the value of the Mute Light Curtain input and indicates that
the light curtain is not being used.
This function block also has a Light Curtain Blocked output which
indicates when the input channels are NOT in the Active state (ones).
These state changes are shown in the following timing diagrams.
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54
Light Curtain Function Block (LC)
Light Curtain Muting Operation - Example 1
1
Channel A
0
1
Channel B
0
1
Output 1
0
1
Mute Light
Curtain
Light Curtain
Muted
Light Curtain
Blocked
0
1
0
1
0
If the Mute Light Curtain input is not set, or the light curtain is blocked
after the muting period is finished, the behavior of this function block
reverts back to the behavior defined earlier when no muting is
present.
Light Curtain Muting Operation - Example 2
1
Channel A
0
1
Channel B
0
1
Output 1
0
1
Mute Light
Curtain
Light Curtain
Muted
0
1
0
1
Light Curtain
Blocked
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0
Light Curtain Function Block (LC)
55
Inputs Inconsistent Operation
This function block generates a fault if the input channels are in
inconsistent states (one Safe and one Active) for more than 500 ms.
This fault condition is enunciated via the Inputs Inconsistent and the
Fault Present outputs. Output 1 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 Operation
1
Channel A
0
1
Channel B
0
Output 1
1
0
500 ms
Inputs
Inconsistent
Fault
Present
1
0
1
0
1
Fault Reset
0
Light Curtain
Blocked
1
0
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56
Light Curtain Function Block (LC)
Circuit Reset Held On Operation (Manual Reset Mode Only)
This function block also sets the Circuit Reset Held On output prompt
if the Circuit Reset input is set (1) when the input channels transition
to the Active state.
These state changes are shown in the following timing diagram.
Circuit Reset Held On Operation
1
Channel A
0
1
Channel B
0
1
Circuit Reset
0
1
Output 1
0
Circuit Reset
Held On
1
0
Cycle Inputs Operation
If, while Output 1 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, this function block
sets the Cycle Inputs output prompt, and Output 1 cannot enter the
Active state again until both input channels cycle through their Safe
states. If the inputs were in inconsistent states for more than 500 ms,
the Inputs Inconsistent and Fault Present outputs are also set to 1.
If the Light Curtain Muted input is active and one of the input
channels transitions from the Active state to the Safe state and back to
the Active state, Output 1 remains active and the Cycle Inputs prompt
is set to one.
IMPORTANT
Publication 1753-RM001C-EN-P - May 2007
In version 1.0 of the Light Curtain instructions, if the Light
Curtain Muted input is active and one of the input channels
transitions from the Active state to the Safe state and back to
the Active state, Output 1 turns off immediately and the Cycle
Inputs prompt is set to one.
Light Curtain Function Block (LC)
57
These state changes are shown in the following timing diagram.
Cycle Inputs Operation
1
Channel A
0
1
Channel B
0
1
Output 1
0
1
Cycle Inputs
0
Input Filter Time
When an input filter time is specified, then, for that length of time, an
input channel is allowed to go to the Safe state while the other
channel is in the Active state without Output 1 going to its Safe state.
However, Output 1 will go to the Safe state when both input channels
are in the Safe state at the same time.
Input Filter Time
1
Channel A
0
t1
1
Channel B
0
t1
1
Output 1
0
t1 ≤ input filter time
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58
Light Curtain Function Block (LC)
Function Block Description
LC_RA
LC_AUTO_RA
Light Curtain Manual Reset
Channel A
Output 1
Cycle Inputs
Channel B
Input Filter Time
Mute Light Curtain
Circuit Reset
Fault Reset
Light Curtain Automatic Reset
Channel A
Channel B
Light Curtain Blocked
Input Filter Time
Light Curtain Muted
Circuit Reset Held On
Mute Light Curtain
Inputs Inconsistent
Fault Reset
Output 1
Cycle Inputs
Light Curtain Blocked
Light Curtain Muted
Inputs Inconsistent
Fault Present
Fault Present
Light Curtain Function Block Parameters
Parameter
Short Name
Type
Data Type
Description
Safe, Active and Initial Values
Channel A
—
Input
Boolean
Channel A Input
Safe = 0, Active = 1
Channel B
—
Input
Boolean
Channel B Input
Safe = 0, Active = 1
Input Filter Time
—
Input
Time
This is a selectable time, from 0 to
250 ms, used for filtering of the
output pulse testing by the light
curtain.
Initial = 0 ms
Mute Light Curtain
—
Input
Boolean
Permits muting of the light curtain
when it is not being used.
Initial = 0, Mute Light Curtain = 1
Circuit Reset
—
Input
Boolean
Circuit Reset Input
Initial = 0, Reset = 1
Manual Reset - Sets Output 1 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.
Initial = 0, Reset = 1
Output 1
O1
Output
Boolean
Output 1 is set to the Active state
when input conditions are met.
Safe = 0, Active = 1
Cycle Inputs
CI
Prompt
Output
Boolean
Cycle Inputs prompts for action.
Before Output 1 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 = 0, Prompt = 1
This prompt is cleared when
Channel A and Channel B transition
to the Safe state.
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Light Curtain Function Block (LC)
59
Light Curtain Function Block Parameters
Parameter
Short Name
Type
Data Type
Description
Safe, Active and Initial Values
Circuit Reset Held
On
CRHO
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 = 0, Prompt = 1
The Circuit Reset Held On prompt is
cleared when the Circuit Reset input
is turned off.
Light Curtain
Blocked
LCB
Indicator
Output
Boolean
This is indicates that the light
curtain is blocked or has lost power.
Initial = 0, Blocked = 1
Light Curtain
Muted
LCM
Indicator
Output
Boolean
This indicates that the light curtain
is muted (not being used).
Initial = 0, Muted = 1
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 500 ms. 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 = 0, Fault = 1
Fault Present
FP
Fault
Output
Boolean
Initial = 0, Fault = 1
This is on whenever a fault is
present in the function block. Output
1 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.
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60
Light Curtain Function Block (LC)
Relationship of I/O Wiring
to Function Block
Parameters
Light Curtain with Manual Reset Wiring and Programming
Wiring Example
The following wiring diagram is one example of how to wire a light
curtain’s two normally open outputs and two inputs required for
muting to a GuardPLC module to comply with EN954-1 Category 4.
Light Curtain Wiring Diagram - Manual Reset
OSSD2
OSSD1
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
LCA
E1
LCB
L+
DI 1
DI 2
L-
DO 1
DI 3
DI 4
DO 2
DI 5
DI 6
DI 7
LS+
GuardPLC
Dual Input
Muting Device
MDA
E1 - 24V Power Supply
LCA - Light Curtain Output A
LCB - Light Curtain Output B
MDA - Dual Input Muting Device Channel A
MDB - Dual Input Muting Device Channel B
S1 - Circuit Reset Switch
S2 - Fault Reset Switch
S3 - Generate Pulse Test Switch
Publication 1753-RM001C-EN-P - May 2007
S1
MDB
S2
S3
Light Curtain Function Block (LC)
61
Programming Example
The following programming example shows how the Light Curtain
Function Block with Manual Reset can be applied to the wiring
diagram shown in Light Curtain Wiring Diagram - Manual Reset, on
page 60.
Light Curtain Programming Example - Manual Reset
Guard PLC
User Program
RPTO_RA
Redundant Pulse Test Output
T#2 to 60 sec
Pulse Test Interval
Pulse Test Source A
T#10 - 500 msec
Pulse Test Duration
Pulse Test Source B
DO 2
Pulse Test Fault A
To User Logic
Pulse Test Fault B
To User Logic
DI 7
Generate Pulse Test
DI 3
Input 1 A
Output 1 A
DI 4
Input 1 B
Output 1 B
DO 1
RIN_RA
Redundant Input Manual Reset
Channel A
Output 1
Channel B
Cycle Inputs
To User Logic
Circuit Reset Held On
To User Logic
Inputs Inconsistent
To User Logic
Fault Present
To User Logic
DI 5
Circuit Reset
DI 6
Fault Reset
LC_RA
Light Curtain Manual Reset
DI 1
Channel A
Output 1
To User Logic
DI 2
Channel B
Cycle Inputs
To User Logic
Light Curtain Blocked
To User Logic
Light Curtain Muted
To User Logic
Circuit Reset Held On
To User Logic
Inputs Inconsistent
To User Logic
Fault Present
To User Logic
T#0 to 250msec
Input Filter Time
Mute Light Curtain
Circuit Reset
Fault Reset
EN954-1 Category 4 requires that inputs be independently pulse
tested.
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Light Curtain Function Block (LC)
Light Curtain with Automatic Reset Wiring and Programming
Wiring Example
The following wiring diagram is one example of how to wire a light
curtain’s two normally open outputs and two inputs required for
muting to a GuardPLC module to comply with EN954-1 Category 4.
ATTENTION
Various safety standards (EN 60204, 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.
Light Curtain Wiring Diagram - Automatic Reset
OSSD2
OSSD1
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
LCA
E1
LCB
L+
DI 1
DI 2
L-
DO 1
DI 3
DI 4
DO 2
DI 5
DI 6
LS+
GuardPLC
Dual Input
Muting Device
MDA
E1 - 24V Power Supply
LCA - Light Curtain Output A
LCB - Light Curtain Output B
MDA - Dual Input Muting Device Channel A
MDB - Dual Input Muting Device Channel B
S1 - Fault Reset Switch
S2 - Generate Pulse Test Switch
Publication 1753-RM001C-EN-P - May 2007
S1
MDB
S2
Light Curtain Function Block (LC)
63
Programming Example
The following programming example shows how the Light Curtain
Function Block with Automatic Reset can be applied to the wiring
diagram shown in Light Curtain Wiring Diagram - Automatic Reset,
page 62.
Light Curtain Programming Example - Automatic Reset
Guard PLC
User Program
RPTO_RA
Redundant Pulse Test Output
Version X
T#2 to 60 sec
Pulse Test Interval
Pulse Test Source A
T#10 - 500 msec
Pulse Test Duration
Pulse Test Source B
DO 2
Pulse Test Fault A
To User Logic
Pulse Test Fault B
To User Logic
DI 6
Generate Pulse Test
DI 3
Input 1 A
Output 1 A
DI 4
Input 1 B
Output 1 B
DO 1
RIN_AUTO_RA
Redundant Input Automatic Reset
DI 5
Channel A
Output 1
Channel B
Cycle Inputs
To User Logic
Inputs Inconsistent
Fault Present
To User Logic
To User Logic
Fault Reset
LC_AUTO_RA
Light Curtain Automatic Reset
DI 1
DI 2
T#0 to 250msec
Channel A
Channel B
Input Filter Time
Mute Light Curtain
Fault Reset
Output 1
Cycle Inputs
To User Logic
To User Logic
Light Curtain Blocked
To User Logic
Light Curtain Muted
To User Logic
Inputs Inconsistent
To User Logic
Fault Present
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
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64
Light Curtain Function Block (LC)
Publication 1753-RM001C-EN-P - May 2007
Chapter
6
Redundant Output with Continuous Feedback
Monitoring Function Block (ROUT)
Overview
The basic purpose of the Redundant Output with Continuous
Feedback Monitoring Function Block is to emulate the output
functionality of a safety relay in a software programmable
environment which is intended for use in SIL3/CAT4 safety
applications.
The Redundant Output with Continuous Feedback Monitoring
Function Block can be used in two ways:
• Redundant Output with Negative Feedback (RONF)
• Redundant Output with Positive Feedback (ROPF)
Operation
This function block monitors a single logical input and activates two
field outputs when the logical input goes Active.
1
Enable
0
1
Output 1
0
1
Output 2
0
It also monitors a feedback channel for each field output and
generates a fault if both channels do not, within a time limit, indicate
the desired state of the associated outputs.
Function block operation is illustrated in the following timing
diagrams.
65
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66
Redundant Output with Continuous Feedback Monitoring Function Block (ROUT)
Negative Feedback Examples
1
1
Enable
Enable
0
Output 1
0
1
Output 2
0
1
0
1
1
Feedback 1
Feedback 2
0
0
250 ms
Output 1
Feedback
Failure
250 ms
1
Output 2
Feedback
Failure
0
1
0
1
Fault Reset
Fault Reset
0
0
1
1
Enable
Enable
0
Output 1
1
1
Output 2
0
0
1
0
1
1
Feedback 1
Feedback 2
0
0
250 ms
Output 1
Feedback
Failure
1
0
250 ms
Output 2
Feedback
Failure
1
Fault Reset
0
Publication 1753-RM001C-EN-P - May 2007
1
0
1
Fault Reset
0
Redundant Output with Continuous Feedback Monitoring Function Block (ROUT)
67
Positive Feedback Examples
1
1
Enable
Enable
0
Output 1
0
1
Output 2
0
0
1
Feedback 1
Feedback 2
0
Output 1
Feedback
Failure
1
0
250 ms
Output 2
Feedback
Failure
0
1
0
1
Fault Reset
0
0
1
1
Enable
Enable
0
Output 1
1
250 ms
1
Fault Reset
1
0
1
Output 2
0
1
0
1
1
Feedback 1
Feedback 2
0
0
250 ms
Output 1
Feedback
Failure
1
0
250 ms
Output 2
Feedback
Failure
1
Fault Reset
0
1
0
1
Fault Reset
0
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68
Redundant Output with Continuous Feedback Monitoring Function Block (ROUT)
Function Block Description
ROPF_RA
RONF_RA
Redundant Output Negative Feedback
Output 1
Enable
Redundant Output Positive Feedback
Output 1
Enable
Feedback 1
Feedback 2
Output 2
Output 1 Feedback Failure
Feedback 2
Output 2
Output 1 Feedback Failure
Fault Reset
Output 2 Feedback Failure
Fault Present
Fault Reset
Output 2 Feedback Failure
Fault Present
Feedback 1
Redundant Output with Continuous Feedback Function Block Parameters
Parameter
Short
Name
Type
Data Type
Description
Safe, Active and Initial
Values
Enable
—
Input
Boolean
Input to Enable the Redundant Outputs
Safe = 0, Active = 1
Feedback 1
—
Input
Boolean
Feedback from a device either directly or
indirectly controlled by Output 1.
RONF: Off = 1, On = 0
ROPF: Off = 0, On = 1
Feedback 2
—
Input
Boolean
Feedback from a device either directly or
indirectly controlled by Output 2.
RONF: Off = 1, On = 0
ROPF: Off = 0, On = 1
Fault Reset
—
Input
Boolean
After fault conditions are corrected for the
function block, the Fault Present output for
the function block is cleared when this
input transitions from off to on.
Initial = 0, Reset = 1
Output 1
O1
Output
Boolean
Output 1 of the redundant outputs.
Safe = 0, Active = 1
Output 2
O2
Output
Boolean
Output 2 of the redundant outputs.
Safe = 0, Active = 1
Output 1 Feedback
Failure
O1FF
Fault
Boolean
Output 1 Feedback is not indicating the
correct state of Output 1 within 250 ms
Initial = 0, Fault = 1
Output 2 Feedback
Failure
O2FF
Fault
Boolean
Output 2 Feedback is not indicating the
correct state of Output 2 within 250 ms
Initial = 0, Fault = 1
Fault Present
FP
Fault
Boolean
Initial = 0, Fault = 1
This is set whenever a fault is present in
the function block. Outputs 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.
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Redundant Output with Continuous Feedback Monitoring Function Block (ROUT)
Relationship of I/O Wiring
to Function Block
Parameters
69
Redundant Output with Negative Feedback Wiring and
Programming
Wiring Example
The following wiring diagram is one example of how to wire two
contactors and normally open auxiliary contacts to a GuardPLC
module to comply with EN954-1 Category 4.
Redundant Output with Negative Feedback Wiring Diagram
The inputs shown on this
wiring diagram correspond
to the inputs for the function
block.
L1
GuardPLC
E1
L+
DI 1
DI 2
DI 3
L-
DO 1
DO 2
LS+
L2
L3
K1
K1a
K2
K2a
DI 4
DO 3
DO 4
M
K1a
K2a
S1
S2
K1
K2
PS
E1 - 24V Power Supply
PS - Power Source (application specific)
K1 - Power Contact 1
K2 - Power Contact 2
K1a - Auxilary Contact 1
K2a - Auxilary Contact 2
S1 - Fault Reset Switch
S2 - Generate Pulse Test Switch
Programming Example
The following programming example shows how the Redundant
Output function block with negative feedback can be applied to the
wiring diagram shown in Figure Redundant Output with Negative
Feedback Wiring Diagram, Redundant Output with Negative Feedback
Wiring Diagram.
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Redundant Output with Continuous Feedback Monitoring Function Block (ROUT)
Redundant Output with Negative Feedback Programming Example
Guard PLC
User Program
RPTO_RA
Redundant Pulse Test Output
T#2 to 60 sec
Pulse Test Interval
Pulse Test Source A
DO 1
T#10 - 500 msec
DI 4
Pulse Test Duration
Generate Pulse Test
Pulse Test Source B
Pulse Test Fault A
DO 2
To User Logic
Pulse Test Fault B
To User Logic
DI 1
Input 1 A
Output 1 A
DI 2
Input 1 B
Output 1 B
RONF_RA
Redundant Output Negative Feedback
Input from another Safety
Instruction Output
DI 3
Enable
DO 3
Output 1
Feedback 1
Feedback 2
Output 2
Output 1 Feedback Fault
To User Logic
DO 4
Fault Reset
Output 2 Feedback Fault
To User Logic
Fault Present
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
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Redundant Output with Continuous Feedback Monitoring Function Block (ROUT)
71
Redundant Output with Positive Feedback Wiring and
Programming
Wiring Example
The following wiring diagram is one example of how to wire two
contactors and normally open auxiliary contacts to a GuardPLC
module to comply with EN954-1 Category 4.
Redundant Output with Positive Feedback Wiring Diagram
The inputs shown on this
wiring diagram correspond
to the inputs for the function
block.
L1
GuardPLC
E1
L+
DI 1
DI 2
DI 3
L-
DO 1
DO 2
LS+
L2
L3
K1
K1a
K2
K2a
DI 4
DO 3
DO 4
M
K1a
K2a
S1
S2
K1
K2
PS
E1 - 24V Power Supply
PS - Power Source (application specific)
K1 - Power Contact 1
K2 - Power Contact 2
K1a - Auxilary Contact 1
K2a - Auxilary Contact 2
S1 - Fault Reset Switch
S2 - Generate Pulse Test Switch
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72
Redundant Output with Continuous Feedback Monitoring Function Block (ROUT)
Programming Example
The following programming example shows how the Redundant
Output function block with positive feedback can be applied to the
wiring diagram shown in Redundant Output with Positive Feedback
Wiring Diagram, on page 71.
Redundant Output with Positive Feedback Programming Example
Guard PLC
User Program
RPTO_RA
Redundant Pulse Test Output
T#2 to 60 sec
Pulse Test Interval
Pulse Test Source A
DO 1
T#10 - 500 msec
DI 4
Pulse Test Duration
Generate Pulse Test
Pulse Test Source B
Pulse Test Fault A
Pulse Test Fault B
DO 2
To User Logic
To User Logic
DI 1
DI 2
Input 1 A
Input 1 B
Output 1 A
Output 1 B
ROPF_RA
Redundant Output Positive Feedback
Input from another Safety
Instruction Output
DI 3
Enable
Feedback 1
Feedback 2
Output 1
Output 2
Output 1 Feedback Fault
DO 3
DO 4
To User Logic
Fault Reset
Output 2 Feedback Fault
Fault Present
To User Logic
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
Publication 1753-RM001C-EN-P - May 2007
Chapter
7
Five-Position Mode Selector Function Block
(FPMS)
Overview
The basic purpose of the Five-Position Mode Selector Function Block
is to provide an interface from a programmable controller to a
three-to-five-position selector switch used in SIL3/CAT4 safety
applications.
Operation
The Five-Position Mode Selector Function Block has five outputs that
are associated with five inputs. Its main job is to enable one of the five
outputs when its associated input goes active.
It has two faults; one for more than one input active, and the other for
no inputs active. These faults occur when the associated input
conditions exist for more than 250 ms.
During this 250 ms, if one of the fault conditions is detected, the
outputs temporarily remain in their last state. If the fault condition is
still present after the 250 ms, the Fault Present bit is set to one and the
instruction's outputs are set to zero.
IMPORTANT
In version 1.0 of the FPMS instruction, all outputs are
immediately set to zero upon detection of either input fault
condition.
Faults may be cleared by the rising edge of the Fault Reset signal, but
only after the input fault condition has been cleared.
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74
Five-Position Mode Selector Function Block (FPMS)
Function Block Description
FPMS_RA
Five Position Mode Selector
Output 1
Input 1
Input 2
Output 2
Input 3
Output 3
Input 4
Output 4
Input 5
Output 5
No Mode
Fault Reset
Multiple Modes Selected
Fault Present
Five-Position Mode Selector Switch Function Block Parameters
Parameter
Short Name
Type
Data Type
Description
Safe, Active and Initial
Values
Input 1
—
Input
Boolean
Mode 1 Selected Input
Safe = 0, Active = 1
Input 2
—
Input
Boolean
Mode 2 Selected Input
Safe = 0, Active = 1
Input 3
—
Input
Boolean
Mode 3 Selected Input
Safe = 0, Active = 1
Input 4
—
Input
Boolean
Mode 4 Selected Input
Safe = 0, Active = 1
Input 5
—
Input
Boolean
Mode 5 Selected Input
Safe = 0, Active = 1
Fault Reset
—
Input
Boolean
After fault conditions are corrected for the
function block, the Fault Present output for
the function block is cleared when this
input transitions from off to on.
Initial = 0, Reset = 1
Output 1
O1
Output
Boolean
Output associated with Input 1
Safe = 0, Active = 1
Output 2
O2
Output
Boolean
Output associated with Input 2
Safe = 0, Active = 1
Output 3
O3
Output
Boolean
Output associated with Input 3
Safe = 0, Active = 1
Output 4
O4
Output
Boolean
Output associated with Input 4
Safe = 0, Active = 1
Output 5
O5
Output
Boolean
Output associated with Input 5
Safe = 0, Active = 1
No Mode
NM
Fault
Boolean
No Mode Selected Fault
Initial = 0, Fault = 1
Multiple Modes
Selected
MMS
Fault
Boolean
More than One Mode Selected Fault
Initial = 0, Fault = 1
Fault Present
FP
Fault
Boolean
This is set whenever a fault is present in
the function block. An 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 = 0, Fault = 1
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Five-Position Mode Selector Function Block (FPMS)
Relationship of I/O Wiring
to Function Block
Parameters
75
Five-Position Mode Selector Wiring and Programming
Wiring Example
The following wiring diagram is one example of how to wire a
five-position selector switch to a GuardPLC module to comply with
EN954-1 Category 4.
Five-Position Selector Switch Wiring Diagram
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
E1
L+
DI 1
L-
LS+
DI 2
DI 3
DI 4
DI 5
DI 6
GuardPLC
S2
1
2
3
4
5
S1
E1 - 24V Power Supply
S1 - Five Position Selector Switch (Shown with Position 1 selected)
S2 - Fault Reset Switch
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Five-Position Mode Selector Function Block (FPMS)
Programming Example
The following programming example shows how the Five-Position
Mode Selector function block can be applied to the wiring diagram
shown in Five-Position Selector Switch Wiring Diagram, on page 75.
Five-Position Mode Selector Programming Example
Guard PLC
User Program
FPMS_RA
Five Position Mode Selector
Publication 1753-RM001C-EN-P - May 2007
DI 1
DI 2
Input 1
Input 2
Output 1
Output 2
To User Logic
To User Logic
DI 3
DI 4
DI 5
Input 3
Input 4
Input 5
Output 3
Output 4
Output 5
To User Logic
To User Logic
To User Logic
DI 6
Fault Reset
No Mode
Multiple Modes Selected
To User Logic
To User Logic
Fault Present
To User Logic
Chapter
8
Two-Hand Run Station Function Block (THRS)
Overview
The basic purpose of the Two-Hand Run Station function block is to
provide a method to incorporate two diverse input buttons used as a
single operation start button into a software programmable
environment which is intended for use in SIL3/CAT4 safety
applications.
A run station can also be inserted or removed from controlling the
process by using an Active Pin input in this function block. The
Two-Hand Run Station with Active Pin Function Block takes the four
inputs (two from each button) and turns them into one signal for the
rest of the application.
Operation
Normal Operation
The Two-Hand Run Station function block takes the four inputs (two
from each button) and turns them into one signal for the rest of the
application.
These normal operation state changes are shown in the following
timing diagram.
Normal Operation
Right Button
Normally Open
Right Button
Normally Closed
Left Button
Normally Open
1
0
1
0
1
0
1
Left Button
Normally Closed 0
1
Buttons Pressed
0
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78
Two-Hand Run Station Function Block (THRS)
Button Tie-Down Operation
The Two-Hand Run Station function block also monitors the four
inputs to make sure none of them fail or are intentionally defeated. If
the buttons are not pressed within 500 ms (t1) of each other, this
function block generates a Button Tie-Down condition and prevents
the Buttons Pressed output from entering the Active state.
These state changes are shown in the following timing diagram.
Button Tie-Down Operation
Right Button
Normally Open
Right Button
Normally Closed
1
0
1
0
500 ms
Left Button
Normally Open
Left Button
Normally Closed
1
0
1
0
1
Button Tie-Down
0
1
Buttons Pressed
0
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Two-Hand Run Station Function Block (THRS)
79
Cycle Buttons Operation
If, while Buttons Pressed is active, one of the buttons transitions from
the Active state to the Safe state and back to the Active state before
the other button transitions to the Safe state, this function block sets
the Cycle Buttons output prompt, and prevents the Buttons Pressed
output from entering the Active state again until both buttons cycle
through their Safe states.
These state changes are shown in the following timing diagram.
Cycle Buttons Operation
Right Button
Normally Open
1
0
1
Right Button
Normally Closed 0
Left Button
Normally Open
1
0
1
Left Button
Normally Closed 0
1
Cycle Buttons
0
1
Buttons Pressed
0
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80
Two-Hand Run Station Function Block (THRS)
Button Fault Operation
This function block also monitors the individual inputs from each
button. If the two contacts for one of the buttons are in opposite
safety states for more than 250 ms (t1), the appropriate fault is set (Left
Button Fault or Right Button Fault). The Fault Present output is also
set.
The Buttons Pressed output is set to the Safe state whenever one of
these faults exists.
These state changes are shown in the following timing diagrams.
Left Button Fault Operation
Left Button
Normally Open
Left Button
Normally Closed
1
1
0
0
1
1
0
0
t1
Left Button
Fault
t1
1
1
0
0
1
1
0
0
Fault Reset
Right Button Fault Operation
1
1
0
0
1
Right Button
Normally Closed 0
1
Right Button
Normally Open
0
t1
Right Button
Fault
t1
1
1
0
0
1
1
0
0
Fault Reset
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Two-Hand Run Station Function Block (THRS)
81
Function Block Description
THRS_AP_RA
THRS_RA
Two Hand Run Station Active Pin
Two Hand Run Station
Right Button Normally Open
Right Button Normally Closed
Left Button Normally Open
Left Button Normally Closed
Buttons Pressed
Button Tiedown
Cycle Buttons
Right Button Fault
Left Button Fault
Fault Present
Fault Reset
Active Pin
Right Button Normally Open
Right Button Normally Closed
Left Button Normally Open
Left Button Normally Closed
Buttons Pressed
Station Active
Button Tiedown
Cycle Buttons
Station Active Fault
Right Button Fault
Left Button Fault
Fault Present
Fault Reset
Two-Hand Run Station Function Block Parameters
Parameter
Short
Name
Type
Data Type
Description
Safe, Active and
Initial Values
Active Pin
—
Input
Boolean
Active Pin for run station
Initial = 0, Set = 1
When set, the Buttons Pressed output can enter
the Active state. When clear, the Buttons
Pressed output remains off.
Right Button
Normally Open
—
Input
Boolean
Right Button N.O. Contact Input
Safe = 0, Active = 1
Right Button
Normally Closed
—
Input
Boolean
Right Button N.C. Contact Input
Safe = 1, Active = 0
Left Button
Normally Open
—
Input
Boolean
Left Button N.O. Contact Input
Safe = 0, Active = 1
Left Button
Normally Closed
—
Input
Boolean
Left Button N.C. Contact Input
Safe = 1, Active = 0
Fault Reset
—
Input
Boolean
Fault Reset Input
Initial = 0, Reset = 1
Active Pin Enabled - When transitioned from off
to on, and the fault cause has been cleared, the
Right Button Fault, Left Button Fault and Station
Active Fault outputs are cleared.
Active Pin Disabled - When transitioned from off
to on, and the fault cause has been cleared, the
Right Button Fault and Left Button Fault outputs
are cleared.
Buttons Pressed
BP
Output
Boolean
Output is enabled when the run station buttons
are pressed and no faults are present.
Safe = 0, Active = 1
Station Active
SA
Indicator
Output
Boolean
Output is enabled when the run station is active. Initial = 0, Active = 1
Button Tiedown
BT
Indicator
Output
Boolean
Indicates that both buttons were not pressed
within 500 ms of each other.
Initial = 0, Active = 1
Cleared when both buttons are released.
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Two-Hand Run Station Function Block (THRS)
Two-Hand Run Station Function Block Parameters
Parameter
Short
Name
Type
Data Type
Description
Safe, Active and
Initial Values
Cycle Buttons
CB
Prompt
Output
Boolean
Set when the Button Tiedown indicator is set.
Cleared when the Button Tiedown indicator is
cleared.
Initial = 0, Active = 1
Station Active Fault SAF
Fault
Output
Boolean
Fault is set when the station is inactive.
Initial = 0, Active = 1
Right Button Fault
Fault
Output
Boolean
There is a right button fault.
Initial = 0, Active = 1
RBF
Set when the Right Button Normally Closed and
the Right Button Normally Open inputs are not
both energized or not both de-energized within
250 ms.
Left Button Fault
LBF
Fault
Output
Boolean
There is a left button fault.
Initial = 0, Active = 1
Set when the Left Button Normally Closed and
the Left Button Normally Open inputs are not
both energized or not both de-energized within
250 ms.
Fault Present
FP
Fault
Output
Boolean
One or more of the faults are present.
Active Pin Enabled - Set when the Station Active
Fault, Right Button Fault or Left Button Fault
outputs are set. Cleared when the Station Active
Fault, Right Button Fault and Left Button Fault
outputs are cleared.
Active Pin Disabled - Set when the Station Right
Button Fault or Left Button Fault outputs are set.
Cleared when the Right Button Fault and Left
Button Fault outputs are cleared and the Fault
Reset input transitions from off to on.
Publication 1753-RM001C-EN-P - May 2007
Initial = 0, Active = 1
Two-Hand Run Station Function Block (THRS)
Relationship of I/O Wiring
to Function Block
Parameters
83
Two-Hand Run Station with Active Pin Disabled Wiring and
Programming
Wiring Example
The Two-Hand Run Station is wired properly when the four run
button inputs are in the safe state when the run buttons are
released.
IMPORTANT
The following wiring diagram is one example of how to wire Right
and Left push buttons to a GuardPLC module to comply with EN954-1
Category 4. Each Push Button has 2 diverse input channels.
Two-Hand Run Station with Active Pin Disabled Control Wiring Diagram
The inputs shown on this
wiring diagram correspond
to the inputs for the function
block.
E1
L+
DI 1
DI 2
L-
LS +
DO 1
DI 3
DI 4
DI 5
DI 6
GuardPLC
S1
RB
S2
LB
E1 - 24V Power Supply
RB - Right Button
LB - Left Button
S1 - Fault Reset Switch
S2 - Generate Pulse Test Switch
Programming Example
The following programming examples show how the Two-Hand Run
Station without Active Pin function block can be applied to the wiring
diagram shown in Two-Hand Run Station with Active Pin Disabled
Control Wiring Diagram, on page 83. One example shows Active Pin
disabled, and the other shows Active Pin enabled.
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Two-Hand Run Station Function Block (THRS)
Two-Hand Run Station Programming Example - Active Pin Disabled
Guard PLC
User Program
SPTO_RA
Single Pulse Test Output
T#2 to 60 sec
Pulse Test Interval
T#10 - 500 msec
Pulse Test Duration
DI 6
Generate Pulse Test
DI 1
Input 1 A
DI 2
Input 1
DI 3
Input 2 A
DI 4
Input 2
Pulse Test Source A
DO 1
Pulse Test Fault A
To User Logic
Output 1 A
Output 1
Output 2 A
Output 2
THRS_RA
Two Hand Run Station
Right Button Normally Open
Buttons Pressed
To User Logic
Right Button Normally Closed
Button Tiedown
To User Logic
Left Button Normally Open
DI 5
Left Button Normally Closed
Fault Reset
Cycle Buttons
To User Logic
Right Button Fault
Left Button Fault
To User Logic
To User Logic
Fault Present
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
Two-Hand Run Station with Active Pin Enabled Wiring and
Programming
Wiring Examples
IMPORTANT
The Two-Hand Run Station is wired properly when the four run
button inputs are in the safe state when the run buttons are
released.
The following wiring diagram is one example of how to wire Right
and Left push buttons to a GuardPLC module to comply with EN954-1
Category 4. Each Push Button has 2 diverse input channels.
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Two-Hand Run Station Function Block (THRS)
85
Two-Hand Run Station with Active Pin Enabled Control Wiring Diagram
(Active Pin High - Run Station Connected to System)
The inputs shown on this
wiring diagram correspond
to the inputs for the function
block.
E1
L+
DI 1
DI 2
L-
LS +
DO 1
DI 3
DI 4
DI 5
DI 7
DI 6
GuardPLC
S1
RB
S2
LB
E1 - 24V Power Supply
RB - Right Button
LB - Left Button
S1 - Fault Reset Switch
S2 - Generate Pulse Test Switch
The following wiring diagram is one example of how to wire a
Dummy Plug to a GuardPLC module to comply with EN954-1
Category 4. Each Push Button has 2 diverse input channels.
Two-Hand Run Station with Active Pin Enabled Control Wiring Diagram
(Active Pin Low - Run Station Not Connected to System)
The inputs shown on this
wiring diagram correspond
to the inputs for the function
block.
E1
L+
DI 1
DI 2
L-
LS +
DO 1
DI 3
DI 4
DI 6
DI 5
DI 7
GuardPLC
Dummy Plug
S1
S2
E1 - 24V Power Supply
S1 - Fault Reset Switch
S2 - Generate Pulse Test Switch
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Two-Hand Run Station Function Block (THRS)
Programming Example
The following programming examples show how the Two-Hand Run
Station with Active Pin function block can be applied to the wiring
diagram shown in Two-Hand Run Station with Active Pin Enabled
Control Wiring Diagram (Active Pin High - Run Station Connected to
System), on page 85. One example shows Active Pin disabled, and the
other shows Active Pin enabled.
Two-Hand Run Station Programming Example - Active Pin Enabled
Guard PLC
User Program
SPTO_RA
Single Pulse Test Output
T#2 to 60 sec
Pulse Test Interval
Pulse Test Source A
T#10 - 500 msec
Pulse Test Duration
Pulse Test Source B
DO 2
Pulse Test Fault A
To User Logic
Pulse Test Fault B
To User Logic
DI 7
DI 1
Generate Pulse Test
Input 1 A
DI 2
Input 1
DI 3
Input 2 A
DI 4
Input 2
DO 1
Output 1 A
Output 1
Output 2 A
Output 2
THRS_AP
Two Hand Run Station Active Pin
DI 6
Active Pin
Right Button Normally Open
Right Button Normally Closed
Left Button Normally Open
Left Button Normally Closed
DI 5
Fault Reset
Buttons Pressed
To User Logic
Station Active
To User Logic
Button Tiedown
To User Logic
Cycle Buttons
Station Active Fault
To User Logic
To User Logic
Right Button Fault
Left Button Fault
To User Logic
To User Logic
Fault Present
To User Logic
EN954-1 Category 4 requires that inputs be independently pulse
tested.
Publication 1753-RM001C-EN-P - May 2007
Chapter
9
Redundant Pulse Test Output Function Block
(RPTO)
Overview
The Redundant Pulse Test Output function block is designed for
SIL3/CAT4 safety applications which require a pulse test for the input
device.
There are two ways to generate a pulse test in the GuardPLC family of
products:
• Using the RPTO and SPTO function blocks in the application
program
• Using the services built into the GuardPLC 1600 controller’s
operating system
Users can choose between the two methods for pulse testing the
GuardPLC 1600 and DIO blocks controlled by the GuardPLC 1600
(IB16, IB8XOB8, IB16XOB8, IB20XOB8).
Refer to the following table for pulse test methods available for your
product.
Product
RPTO/SPTO
OS Configurable
1200
yes
no
1600
optional
yes
1800
yes
no
2000
yes
no
Consider the following when choosing a method of pulse testing.
• Function block allows the pulse test source (output) and safety
input to be on different physical nodes. The OS configured
pulse test assumes that the source and input are local to the
same physical controller or I/O block.
• The function block has a pulse test fault output that can be used
for status inside the user program. The OS configured pulse test
has an error code that can be monitored for pulse test status.
87
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88
Redundant Pulse Test Output Function Block (RPTO)
• The OS configured pulse test occurs each GuardPLC cycle. The
pulse test function blocks allow the user to configure the pulse
test interval.
• The duration of the pulse test is configurable when using the
function blocks.
• The pulse test could be disabled if necessary when using the
function blocks.
For more information on OS configuration for pulse testing see the
GuardPLC User Manual, 1753-UM001.
Operation
Normal Operation
The Redundant Pulse Test Output function block provides the ability
to select from 1 to 16 input pairs.
Pulse Test Source A
Input 1 A
Pulse Test Source B
Input 1 B
.
.
.
Input 16 A
Input 16 B
The Redundant Pulse Test Output provides two alternating pulsed
outputs Pulse Test Source A and Pulse Test Source B whose waveform
is specified by Pulse Test Interval and Pulse Test Duration. The Pulse
Test Outputs are used to source the inputs of a external device, an
Emergency Stop switch for example. The external device outputs are
then directed to a pair of function block inputs Input x A and Input x
B which are pulse tested by the function block. The corresponding
outputs, Output x A and Output x B are then used to source the
Channel A and Channel B inputs of an ESTOP safety relay function
block (x can have the value of 1 through 16).
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Redundant Pulse Test Output Function Block (RPTO)
89
Normal Operation
1
Pulse Test Source A
D
D
0
I
I
1
Pulse Test Source B
D
0
1
Input x A
0
1
Input x B
0
1
Output x A
0
1
Output x B
0
Cross-wiring Fault
This function block will generate a fault when Input x A is cross-wired
with Input x B, when the inputs are shorted to VCC, or when Input x
A is shorted to Input x B. The fault condition is enunciated via the
Pulse Test Fault A and Pulse Test Fault B outputs.
TIP
Input B goes to LO when Source A is pulsed LO, a likely
indication of cross-wiring
Cross Wiring Fault Example
1
Pulse Test Source A
D
0
I
I
1
D
Pulse Test Source B
0
1
Input x A
0
1
Input x B
0
1
Output x A
0
1
Output x B
0
1
Pulse Test Fault A
0
1
Pulse Test Fault B
0
TIP
Input A is consistently HI indicating it is likely shorted to VCC.
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Redundant Pulse Test Output Function Block (RPTO)
Input x A Fault Example
1
Pulse Test Source A
D
D
0
I
I
1
Pulse Test Source B
D
0
1
Input x A
0
1
Input x B
0
1
Output x A
0
1
Output x B
0
1
Pulse Test Fault A
0
1
Pulse Test Fault B
0
TIP
Both Input A and Input B are HI during the pulse test. Both have
another source of VCC; likely a short between the two
channels.
Input x A to Input x B Fault Example
1
D
Pulse Test Source A
0
I
I
1
Pulse Test Source B
D
0
1
Input x A
0
1
Input x B
0
1
Output x A
0
1
Output x B
0
1
Pulse Test Fault A
0
1
Pulse Test Fault B
0
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Redundant Pulse Test Output Function Block (RPTO)
91
Automatic Fault Clearing
Once the wiring problem causing the fault condition has been
corrected, the fault condition will be cleared at the next pulse test
sequence. A pulse test can be forced by setting the Generate Pulse
Test input.
Automatic Fault Clearing Example
1
Pulse Test Source A
D
0
I
I
1
Pulse Test Source B
D
0
1
Input x A
0
1
Input x B
0
1
Output x A
0
1
Output x B
0
1
Pulse Test Fault A
0
1
Pulse Test Fault B
0
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92
Redundant Pulse Test Output Function Block (RPTO)
Generate Pulse Test
Generate Pulse Test forces a pulse test on Channel A followed in
100 ms by a pulse test of Channel B.
Fault Clearing via Generate Pulse Test Example
1
Pulse Test Source A
D
0
100msec
100msec
1
Pulse Test Source B
D
0
1
Input x A
0
1
Input x B
0
1
Generate Pulse Test
0
1
Output x A
0
1
Output x B
0
1
Pulse Test Fault A
0
1
Pulse Test Fault B
0
Pulse Test on Input Transition
The pulse test sequence will also be started when a low to high
transition is detected on Input x A and Input x B during the pulse test
interval timing period.
The purpose of the Pulse Test on a low to high transition is to prevent
the user from masking a fault by
• putting faulted input into the safe state,
• putting some other "good" input into the active state which will
pass the next pulse test.
This would allow the machine to restart and run until the next pulse
test captures the fault again. If the interval between pulse tests is long,
this could be a safety issue.
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Redundant Pulse Test Output Function Block (RPTO)
93
Pulse Test on Input Transition Example
1
D
Pulse Test Source A
0
100msec
100msec
1
D
Pulse Test Source B
0
1
Input x A
0
1
Input x B
0
1
Output x A
0
1
Output x B
0
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94
Redundant Pulse Test Output Function Block (RPTO)
Function Block Description
RPTO_RA
Redundant Pulse Test Output
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
Input 1 A
Output 1 A
Input 1 B
Output 1 B
Input 16 A
Output 16 A
Input 16 B
Output 16 B
Redundant Pulse Test Output Function Block Parameters
Parameter
Short
Name
Type
Data Type
Description
Safe, Active and
Initial Values
Generate Pulse Test
GPT
Input
Boolean
Sets the Start Pulse Test output.
Initial = 0, Test = 1
Input x A
IxA
Input
Boolean
1 of 16 pulse tested Channel A inputs. x = 1 to n. (1)
Safe = 0, Active = 1
Input x B
IxB
Input
Boolean
1 of 16 pulse tested Channel B inputs. x = 1 to n. (1)
Safe = 0, Active = 1
Output x A
OxA
Output
Boolean
1 of 16 Channel A outputs corresponding to one of
the Input x A inputs. x = 1 to n.(1)
Safe = 0, Active = 1
Output x B
OxB
Output
Boolean
1 of 16 Channel B outputs corresponding to one of
the Input x B inputs. x = 1 to n.(1)
Safe = 0, Active = 1
Pulse Test Duration
PTD
Input
Time
User settable pulse width from 10 to 500 ms. This is
the maximum amount of time to wait for an input
being pulse tested to go low.
Initial = 10 ms
IMPORTANT: Set the pulse test duration to at least
2 times the maximum scan time of the GuardPLC
controller. We recommend a pulse test duration of 5
times the maximum scan time.
Pulse Test Interval
PTI
Input
Time
User settable from 2 to 60 seconds to set the time
between test pulses. This is defined as the time that
the Channel A pulse ends and the Channel B pulse
starts and vice versa.
Initial = 2 seconds
Pulse Test Fault A
PTFA
Output
Boolean
This is a Fault.
Initial = 0, Fault = 1
Pulse Test Fault B
PTFB
Output
Boolean
This is a Fault.
Initial = 0, Fault = 1
Pulse Test Source A
PTSA
Output
Boolean
This is the Channel A pulse test source derived from
the Pulse Test Interval and Duration.
Safe = 0, Active = 1
Pulse Test Source B
PTSB
Output
Boolean
This is the Channel B pulse test source derived from
the Pulse Test Interval and Duration.
Safe = 0, Active = 1
(1)
A number of Timer Expired and Timer Start/Stop signals exist in the model. Each is scoped to its timer transformation.
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Redundant Pulse Test Output Function Block (RPTO)
Relationship of I/O Wiring
to Function Block
Parameters
95
Redundant Pulse Test Output
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 EN954-1 Category 4.
Redundant Pulse Test Output Wiring Diagram
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
E1
L+
DI 1
DI 2
L-
DO 1
DO 2
DI 3
DI 4
DI 5
LS+
S3
S1
DI 6
DI 7
Guard PLC
S4
S5
S2
E1 - 24V Power Supply
S1 - Emergency Stop Switch #1
S2 - Emergency Stop Switch #2
S3 - Circuit Reset Switch
S4 - Fault Reset Switch
S5 - Generate Pulse Test Switch
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96
Redundant Pulse Test Output Function Block (RPTO)
Programming Example
The following programming example shows how the Redundant
Pulse Test Output function block can be applied to the wiring diagram
shown in Redundant Pulse Test Output Wiring Diagram, on page 95.
Redundant Pulse Test Output Programming Example
Guard PLC
User Program
RPTO_RA
Redundant Pulse Test Output
T#2 to 60 sec
T#10 - 500 msec
DI 7
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
DI 1
Input 1 A
Output 1 A
DI 2
DI 3
DI 4
Input 1 B
Input 2 A
Input 2 B
Output 1 B
Output 2 A
Output 2 B
DO 1
DO 2
To User Logic
To User Logic
ESTOP_RA
Emergency Stop Manual Reset
DI 5
DI 6
Channel A
Channel B
Circuit Reset
Fault Reset
Output 1
Cycle Inputs
Circuit Reset Held On
Inputs Inconsistent
To User Logic
To User Logic
To User Logic
To User Logic
Fault Present
To User Logic
ESTOP_RA
Emergency Stop Manual Reset
Channel A
Channel B
Circuit Reset
Fault Reset
Publication 1753-RM001C-EN-P - May 2007
Output 1
Cycle Inputs
Circuit Reset Held On
Inputs Inconsistent
To User Logic
To User Logic
To User Logic
To User Logic
Fault Present
To User Logic
Chapter
10
Single Pulse Test Output Function Block
(SPTO)
Overview
The Single Pulse Test Output function block is designed for SIL3/CAT4
safety applications which require a pulse test for the input device.
There are two ways to generate a pulse test in the GuardPLC family of
products:
• Using the RPTO and SPTO function blocks in the application
program
• Using the services built into the GuardPLC 1600 controller’s
operating system
Users can choose between the two methods for pulse testing the
GuardPLC 1600 and DIO blocks controlled by the GuardPLC 1600
(IB16, IB8XOB8, IB16XOB8, IB20XOB8).
Refer to the following table for pulse test methods available for your
product.
Product
RPTO/SPTO
OS Configurable
1200
yes
no
1600
optional
yes
1800
yes
no
2000
yes
no
Consider the following when choosing a method of pulse testing.
• Function block allows the pulse test source (output) and safety
input to be on different physical nodes. The OS configured
pulse test assumes that the source and input are local to the
same physical controller or I/O block.
• The function block has a pulse test fault output that can be used
for status inside the user program. The OS configured pulse test
has an error code that can be monitored for pulse test status.
97
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98
Single Pulse Test Output Function Block (SPTO)
• The OS configured pulse test occurs each GuardPLC cycle. The
pulse test function blocks allow the user to configure the pulse
test interval.
• The duration of the pulse test is configurable when using the
function blocks.
• The pulse test could be disabled if necessary when using the
function blocks.
For more information on OS configuration for pulse testing see the
GuardPLC User Manual, 1753-UM001.
Operation
Normal Operation
The Single Pulse Test Output function block provides the ability to
select from 1 to 16 input pairs.
Pulse Test Source A
24Vdc
Input 1 A
Input 1
.
.
.
Input 16 A
Input 16
The Single Pulse Test Output function block provides a single Pulse
Test Source A whose waveform is specified by Pulse Test Interval and
Pulse Test Duration. The Pulse Test Output is used to source one
input of an external device, an Emergency Stop switch for example.
The other input is not pulse tested and is sourced by Vcc. The
external device outputs are then directed to a pair of function block
inputs Input x A and Input x where only Input x A input is pulse
tested by the function block. The corresponding outputs, Output x A
and Output x are then used to source the Channel A and Channel B
inputs of an ESTOP safety relay function block. (x can have the value
of 1 through 16)
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Single Pulse Test Output Function Block (SPTO)
99
Normal Operation
1
D
Pulse Test Source A
I
D
0
1
Input x A
0
1
Input x
0
1
Output x A
0
1
Output x
0
This function block will generate a fault when the Input x A is shorted
to VCC, when Input x A is shorted to Input x, or if the Input is
cross-wired.
TIP
All three faults exhibit the same reaction of Input x A remains
HI during a pulse test.
The fault condition is enunciated via the Pulse Test Fault A output.
Input x A Fault Example
1
Pulse Test Source A
D
I
0
1
Input x A
0
1
Input x
0
1
Output x A
0
1
Output x
0
1
Pulse Test Fault A
0
Once the wiring problem causing the fault condition has been
corrected, the fault condition will be cleared at the next pulse test
sequence. A pulse test can be forced by setting the Generate Pulse Test
input.
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100
Single Pulse Test Output Function Block (SPTO)
Automatic Fault Clearing
1
D
Pulse Test Source A
I
0
1
Input x A
0
1
Input x
0
1
Output x A
0
1
Output x
0
1
Pulse Test Fault A
0
Fault Clearing via Generate Pulse Test Example
1
Pulse Test Source A
D
I
0
1
Input x A
0
1
Input x
0
1
Generate Pulse Test
0
1
Output x A
0
1
Output x
0
1
Pulse Test Fault A
0
The pulse test sequence will also be started when a low to high
transition is detected on Input x A during the pulse test Interval timing
period.
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Single Pulse Test Output Function Block (SPTO)
101
Pulse Test on Input Transition Example
1
D
Pulse Test Source A
I
0
1
Input x A
0
1
Input x
0
1
Output x A
0
1
Output x
0
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102
Single Pulse Test Output Function Block (SPTO)
Function Block Diagram
SPTO_RA
Single Pulse Test Output
Pulse Test Interval
Pulse Test Duration
Generate Pulse Test
Pulse Test Source A
Input 1 A
Pulse Test Fault A
Output 1 A
Input 1
Output 1
Input 16 A
Output 16 A
Input 16
Output 16
Single Pulse Test Output Parameters
Parameter
Short Scope
Name
Data Type
Description
Safe, Active and
Initial Values
Generate Pulse Test
GPT
Input
Boolean
Sets the Start Pulse Test output.
Initial = 0, Active = 1
Input x A
IxA
Input
Boolean
1 of 16 pulse tested Channel A inputs. x = 1 to n.(1) Safe = 0, Active = 1
Input x
Ix
Input
Boolean
1 of 16 non pulse tested inputs. x = 1 to n.(1)
Safe = 0, Active = 1
Output x A
OxA
Output
Boolean
1 of 16 Channel A outputs corresponding to one of
the Input x A inputs. x = 1 to n.(1)
Safe = 0, Active = 1
Output x
Ox
Output
Boolean
1 of 16 outputs corresponding to one of the non
pulse tested Input x inputs. x = 1 to n.(1)
Safe = 0, Active = 1
Pulse Test Duration
PTD
Input
Time
User settable pulse width from 10 to 500 ms. This
is the maximum amount of time to wait for an
input being tested to go low.
Initial = 10 ms
Pulse Test Interval
PTI
Input
Time
User settable from 2 to 60 seconds to set the time
between test pulses. This is defined as the time
that the Channel A pulse ends and the Channel B
pulse starts and vice versa.
Initial = 2 seconds
Pulse Test Fault A
PTFA
Output
Boolean
This is a Fault.
Initial = 0, Fault = 1
Pulse Test Source A
PTSA
Output
Boolean
This is the Channel A pulse test source derived
from the Pulse Test Interval and Duration.
Safe = 0, Active = 1
(1)
x ranges from 1 to 16 depending on the number of input pairs selected.
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Single Pulse Test Output Function Block (SPTO)
Relationship of I/O Wiring
to Function Block
Parameters
103
Single Pulse Test Output 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 EN954-1 Category 4.
SPTO Wiring Diagram
The inputs shown on this wiring
diagram correspond to the inputs
for the function block.
E1
L+
DI 1
DI 2
L-
DO 1
LS+
DI 3
DI 4
DI 5
Guard PLC
S2
S3
S4
S1
E1 - 24V Power Supply
S1 - Emergency Stop Switch
S2 - Circuit Reset Switch
S3 - Fault Reset Switch
S4 - Generate Pulse Test Switch
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104
Single Pulse Test Output Function Block (SPTO)
Programming Example
The following programming example shows how the Single Pulse Test
Output function block can be applied to the wiring diagram shown in
SPTO Wiring Diagram, on page 103.
SPTO Programming Example
Guard PLC
User Program
SPTO_RA
Single Pulse Test Output
T#2 - 60 sec
T#10 - 500 msec
DI 5
DI 1
DI 2
Pulse Test Interval
Pulse Test Duration
Generate Pulse Test
Pulse Test Source A
Pulse Test Fault A
Input 1 A
Input 1
DO 1
To User Logic
Output 1 A
Output 1
ESTOP_RA
Emergency Stop Manual Reset
Channel A
DI 3
DI 4
Publication 1753-RM001C-EN-P - May 2007
Channel B
Circuit Reset
Fault Reset
Output 1
To User Logic
Cycle Inputs
Circuit Reset Held On
Inputs Inconsistent
Fault Present
To User Logic
To User Logic
To User Logic
To User Logic
Index
D
DIN
Automatic Reset 38
Cycle Inputs Operation 33
Function Block Parameters 34
Manual Reset 36
Normal Operation 31
Operation with Circuit Reset Held On Manual Reset Only 32
Programming Example 37, 39
Wiring Example 36, 38
Diverse Input Function Block (DIN) 31
Diverse Input with Automatic Reset
Wiring and Programming 38
Diverse Input with Manual Reset Wiring
and Programming 36
Dummy Plug 85
F
Five-Position Mode Selector Function
Block (FPMS) 73
Five-Position Mode Selector Wiring and
Programming 75
FPMS
Function Block Parameters 74
Programming Example 76
Wiring Example 75
G
Generate Pulse Test
RPTO 92
generate pulse test
SPTO 99
I
E
Emergency Stop Function Block (ESTOP)
21
Emergency Stop with Automatic Reset
Wiring and Programming 28
Enable Pendant Function Block (ENPEN)
41
Enable Pendant with Automatic Reset
Wiring and Programming 48
Enable Pendant with Manual Reset
Wiring and Programming 46
ENPEN
Automatic Reset 48
Cycle Inputs Operation 43
Manual Reset 46
Normal Operation 41
Operation with Circuit Reset Held On Manual Reset Only 42
Operation with Inconsistent Inputs 42
Programming Example 47, 49
Wiring Example 46, 48
ESTOP
Automatic Reset 28
Cycle Inputs Operation 23
Manual Reset 26
Normal Operation 21, 88, 98
Operation with Circuit Reset Held On Manual Reset Only 22
Operation with Inconsistent Inputs 22
Programming Example 27, 29, 96
Wiring Example 26, 28
Installation Assistance 109
L
LC
Automatic Reset 62
Circuit Reset Held On Operation (Manual
Reset Mode Only) 56
Cycle Inputs Operation 56
Input Filter Time 57
Inputs Inconsistent Operation 55
Light Curtain Muting Operation 53
Manual Reset 60
Normal Operation 52
Programming Example 61, 63
Wiring Example 60, 62
Light Curtain Function Block (LC) 51
Light Curtain Muting Operation 53
Light Curtain with Automatic Reset
Wiring and Programming 62
Light Curtain with Manual Reset Wiring
and Programming 60
N
New Product Satisfaction Return 109
P
Programming Example
DIN 37, 39
ENPEN 47, 49
ESTOP 27, 29, 96
FPMS 76
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106
Index
LC 61, 63
RIN 16, 19
ROUT 69, 72
THRS 83, 86
Pulse Test
Diverse Input 37, 39, 70, 72, 84, 86
Emergency Stop 27, 29
Enable Pendant 49
Light Curtain 61, 63
Redundant Input 17, 19
pulse test duration
RPTO 88, 94
SPTO 98
pulse test interval
RPTO 88, 94
SPTO 98
R
Redundant Input Function Block(RIN) 11
Redundant Input with Automatic Reset
Wiring and Programming 18
Redundant Input with Manual Reset
Wiring and Programming 16
Redundant Output with Continuous
Feedback Monitoring Function
Block (ROUT) 65
Redundant Output with Negative
Feedback (RONF) 65
Redundant Output with Positive
Feedback (ROPF) 65
Redundant Output with Positive
Feedback Wiring and
Programming 71
Redundant Pulse Test Output (RPTO) 87
RIN
Automatic Reset 18
Cycle Inputs Operation 13
Function Block Parameters 14
Manual Reset 16
Normal Operation 11
Operation with Circuit Reset Held On Manual Reset Only 12
Operation with Inconsistent Inputs 12
Programming Example 16, 19
Wiring Example 16, 18
Rockwell Automation Support 109
RONF 67, 69
ROPF 66, 71
ROUT
Function Block Parameters 68
Negative Feedback 69
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Negative Feedback Examples 66
Positive Feedback 71
Positive Feedback Examples 67
Programming Example 69, 72
Wiring Example 69, 71
RPTO
automatic fault clearing 91
cross-wiring fault 89
function block description 94
generate pulse test 92
normal operation 88
Overview 87
parameters 94
programming example 96
pulse test duration 88
pulse test interval 88
wiring diagram 95
S
Single Pulse Test Output (SPTO)
overview 97
SPTO
automatic fault clearing 100
generate pulse test 99, 100
normal operation 98
parameters 102
programming example 104
pulse test duration 98, 102
pulse test interval 98, 102
wiring diagram 103
T
terminology
used throughout manual 9
THRS
Active Pin Disabled 83
Active Pin Enabled 84
Button Fault Operation 80
Button Tie-Down Operation 78
Cycle Buttons Operation 79
Dummy Plug 85
Normal Operation 77
Programming Example 83, 86
Wiring Example 83
Wiring Examples 84
Two-Hand Run Station Function Block
(THRS) 77
Two-Hand Run Station with Active Pin
Disabled Wiring and
Programming 83
Index
Two-Hand Run Station with Active Pin
Enabled Wiring and
Programming 84
W
Wiring Example
DIN 36, 38
ENPEN 46, 48
ESTOP 26, 28
FPMS 75
LC 60, 62
107
RIN 16, 18
ROUT 69, 71
THRS 83, 84
Z
Emergency Stop with Manual Reset
Wiring and Programming 26
Redundant Output with Negative
Feedback Wiring and
Programming 69
Publication 1753-RM001C-EN-P - May 2007
108
Index
Publication 1753-RM001C-EN-P - May 2007
Rockwell Automation
Support
Rockwell Automation provides technical information on the web to assist you
in using our products. At http://support.rockwellautomation.com, you can
find technical manuals, a knowledge base of FAQs, technical and application
notes, sample code and links to software service packs, and a MySupport
feature that you can customize to make the best use of these tools.
For an additional level of technical phone support for installation,
configuration and troubleshooting, we offer TechConnect Support programs.
For more information, contact your local distributor or Rockwell Automation
representative, or visit http://support.rockwellautomation.com.
Installation Assistance
If you experience a problem with a hardware module within the first 24
hours of installation, please review the information that's contained in this
manual. You can also contact a special Customer Support number for initial
help in getting your module up and running:
United States
1.440.646.3223
Monday – Friday, 8am – 5pm EST
Outside United
States
Please contact your local Rockwell Automation representative for any
technical support issues.
New Product Satisfaction Return
Rockwell tests all of our products to ensure that they are fully operational
when shipped from the manufacturing facility. However, if your product is
not functioning and needs to be returned:
United States
Contact your distributor. You must provide a Customer Support case
number (see phone number above to obtain one) to your distributor in
order to complete the return process.
Outside United
States
Please contact your local Rockwell Automation representative for
return procedure.
Publication 1753-RM001C-EN-P - May 2007 109
Supersedes Publication 1753-RM001B-EN-P - September 2005
Copyright © 2007 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.