KEYENCE GC-1000 Safety Controller Manual

Unlock enabling conditions (all must be met):

The speed of dangerous moving parts has been reduced to a sufficiently low-risk level;

Or the driving torque has dropped sufficiently low;

Or if the driver has been turned off, the delay parameter should consider individual differences and aging of the machine.

4.7 Bypass

This function block is used to temporarily pause security functions (not for regular blocking). When using a bypass, a safety level signal must be used as the bypass input (such as a confirmation signal from a safety PLC or output through a manual mode control block). Using only non safety signals to trigger the bypass will lower the overall safety level of the machine to the level of that signal.

Time limit: The duration of the bypass should be as short as possible. If it takes more than 1 hour, the "bypass enable" function or safety device signal (such as light curtain obstruction confirmation) must be used.

Important warning: The bypass function block is not used for masking. When materials automatically pass through the light curtain, a dedicated Muting function block should be used.

Response time calculation and safety distance verification

When calculating the safe distance (such as the minimum distance from the light curtain to the hazard source), the total response time of the entire system from sensor triggering to actuator stopping must be considered. The response time of GC series is calculated according to the following formula:

5.1 Basic Formula

Ttotal

=Tfoundation

+TEnter additional

+TOutput additional

+T Function block attachment

T total=T foundation

+T Enter additional

+T Output additional

+T Function block attachment

5.2 Parameter Values

Basic response time: 4.8 ms (from input signal change to logic processing completion)

Input OFF → ON or ON → OFF: both are 4.8 ms

Additional time (input side):

Input on the main controller (GC Link or terminal block):+0 ms

Input on expansion unit or remote I/O module:+1.7 ms

Input filtering time: For example, if the filtering is set to 0.5 ms, then+0.7 ms+filtering time (i.e. 0.5 ms)=+1.2 ms

Additional time (output side):

Safety output on the main controller (semiconductor):+0 ms

Safe output on expansion unit:+2.4 ms

GC-1000R relay output:+10 ms

Function block attachment:

Use the OFF delay or ON delay function block: add the set delay time.

Connect registers (Store/Load) in series: add 2 ms to each pair of registers.

5.3 Calculation Example

Assuming system configuration:

The emergency stop button is connected through the main controller's safe input I0 (without filtering).

The program uses an ON delay timer (set to 50 ms) and a register pair.

The safety output drives the contactor from the semiconductor output of the main controller.

T total=four point eight(Basic)+0(Input additional)+0(Additional output)+fifty(ON Delay)+two(Register)=fifty-six point eight ms T total=4.8 (Basic)+0 (Input Additional)+0 (Output Additional)+50 (ON Delay)+2 (Register)=56.8 ms

According to ISO 13855, safe distance S=K×(T total+T braking)+C S=K×(T total+T braking)+C， take K=one thousand and six hundred mm/s K=1600 mm/s， The pre braking distance contributed by the controller alone is 1600 × 0.0568 ≈ 91 mm.

Fault diagnosis and maintenance

6.1 LED Status Indication

Meaning of LED status

POWER green light, normal power supply

Turn off no power supply

ERROR red flashing error occurred (specific error code needs to be checked)

Extinguish without error

LINK (GC-1000 only) green light GC Link established

Green flashing data transmission in progress

Extinguish no connection

When the ERROR LED flashes, it is necessary to connect to the GC Configurator to read detailed diagnostic information. The LCD screen of the controller (on the main controller) will display an error code, such as "Activation CRC Error" indicating that the configuration check has failed and the program needs to be downloaded again.

6.2 Misclassification

Category affects program behavior

Minor abnormal information does not affect the continued operation of security functions

Warning may affect normal operation, but continues to operate safely

Error: Unable to execute relevant security functions properly, related output block OFF continues to run but restricted

Serious error: The controller itself has malfunctioned, and all safety output OFF programs have stopped

6.3 Periodic Inspection

After initial debugging: Check the installation, wiring, and functionality according to the requirements of this manual.

Regular inspection: at least once a year. If local regulations or risk assessments require shorter cycles, comply.

Situations triggering inspection: replacement of equipment, modification of programs or wiring, long-term shutdown, or occurrence of accidents.

The inspection content should include:

Trigger each safety input (emergency stop, light curtain obstruction, door opening, etc.), confirm that the safety output is correctly closed and the actuator stops.

When the safety output self diagnosis is disabled, the measured output voltage after manually triggering the emergency stop should be<5V.