CC-QS016 - Rockwell Automation
Contents
1. Reset that neither of the two final switching devices FSD normally open NO outputs are shorted that is closed In this application the Start Release circuit goes from 24V through one auxiliary normally closed NC contact of each 100S contactor to the MSR42 relay Similar to EDM if either or both of these NC contacts are open the MSR42 relay cannot be started or reset Publication CC OS016A EN P December 2009 t MSR42 Configuration And Diagnostic Software Configuration1 File Options Help Design Diagnosis Application info Configuration Basic configuration Inputs Design Output Micro 400 Micro 400 Light Curtain v Edit GPIO None v E None x Outputs Infol safety Outputs Info2 Lockout hd Safety safety Outputs OSSD Edit System information Design error messages Design OK Configuration Control aro v1 00 19 12 2008 t MSR42 Configuration And Diagnostic Software Configuration1 File Options Help Design Diagnosis Application info Configuration Basic configuration Inputs Design Output Micro 400 Micro 400 Light Curtain M Edt aio none a dt Start v Start Release v Outputs Info1 Safety Outputs x Info2 Lockout Safety Safety Outputs OSSD Edit System information Design error messages Design OK Configuration Control aro v1 00 19 12 2008 09 25 09 PM 03 42 16 15 Chapter1 Product Integratio2. SAFETY OUTPUT OFF MUTING ERROR MORE INFO 34 Publication CC OS016A EN P December 2009 system Validation and Application Tips Chapter 2 20 Press MORE INFO 21 Press RETURN EJ The Safety Output is off Light Curtain was interrupted during a Muting Error Check to make sure the system is clear and safe Press and release the Start Reset button 22 Press START RESET for 3 seconds and B SAFETY SYSTEM STATUS Mute Enable SAFETY OUTPUT OFF MUTING ERROR MORE INFO The Safety Output turns on The load is still interrupting the light curtain SAFETY SYSTEM STATUS Pressing and releasing START RESET initiated a Mute Dependent Override m t mdo The system switches to muted operation Muting ends as soon as the load clears the light curtain or when the configured t mdo expires SAFETY OUTPUT OFF MUTING ERROR MORE INFO Publication CC OS016A EN P December 2009 35 Chapter2 System Validation and Application Tips 23 Move the dummy load through and out of the system TIP When the START RESET button is green it may be used in place of the Start Reset push button If requirements dictate that remote reset must not be used do not use It If the operator stationed at the PanelView terminal s location cannot see the guarded area well enough to be certain that no one is in the guarded area you must not use the START RESET button The START RESET button can be disabled by removing three wires fro
3. Click Device Manager Taskbar a General Computer Name Hardware Advanced Device Manager z The Device Manager lists all the hardware devices installed on your computer Use the Device Manager to change the properties of any device Expand Ports COM amp LPT R Drivers h Driver Signing lets you make sure that installed drivers are Plug the USB connector of ee ee ee the Optical Interface into P an available USB port on eae your personal computer D w ED Gifsenthardnareconiguolons a r Sa Note the new COM port that appears in the list This is the port assigned to the Optical Interface which you will need to select in the Configuration and Diagnostic software as part of the download procedure Close the Control Panel T MSR42 Configuration And Diagnos File emim USB Com port settings In the Configuration and Diagnostic software choose Conf User registration Options gt USB Comport settings Inp g Change password ic Controller description If USB Comport settings Is not available check Advanced Options 7 support Mode active and choose Language Options gt USB Comport settings Publication CC OS016A EN P December 2009 21 Chapter 1 Product Integration 13 14 15 16 On the OptiLink Communication dialog box select Compatibility mode Choose the Comport assigned by Windows Device Manager Click OK From the File menu choose PC gt MSR42 Dow
4. 11 While avoiding the sensors interrupt the light curtain and keep it interrupted 12 Press MORE INFO 13 Press RETURN 14 Remove the object interrupting the light curtain Once the light curtain is no longer interrupted the display returns to the Ready for START RESET screen 15 Press START RESET for 3 seconds and release Publication CC OS016A EN P December 2009 system Validation and Application Tips Chapter 2 SAFETY SYSTEM STATUS Bem H SAFETY OUTPUT OFF LIGHT CURTAIN INTERRUPTED MORE INFO Something has interrupted the Light Curtain The object may or may not be present Check to make certain that no people or objects other than a load are in the guarded area Press and release the Start Reset Button SAFETY SYSTEM STATUS Mute Enable SAFETY OUTPUT OFF SYSTEM READY FOR START RESET MORE INFO 33 Chapter2 System Validation and Application Tips 16 Move a dummy load such as a large empty carton in front of S1 The muting lamp begins to blink The screen reflects a muting error SAFETY SYSTEM STATUS B E SYSTEM RUNNING MUTING ERROR MORE INFO 17 Press MORE INFO 18 Press RETURN The System is running There has been a muting sequence error The Safety Output will turn off if anything interrupts The light curtain during muting sequence error 19 With S1 still blocked move the dummy load until it interrupts the light curtain as well SAFETY SYSTEM STATUS Be
5. Press Click the left mouse button once while the cursor is positioned on ae Click Browse object or selection to initiate an action Double click the application icon Click the to the left of a given item folder to show its contents Expand 1768 Bus under I O Configuration Click the right mouse button once while the cursor Is positioned on Right click the 1768 Bus icon object or selection Select the New Module folder Pressing a specific key on the keyboard or button on a touchscreen Press Enter gt Use this symbol to indicate the sub menu name Choose File gt Menu gt Options Project Additional Resources Resource Connected Components Building Blocks Quick Start publication CC OS001 Connected Components Building Blocks Overview CD publication CC QR001 Position Control Connected Components Building Block Quick Start publication CC OS003 MicroLogix 1100 Controller User Manual publication 1763 UM001 MSR42 Safety Base Module Operating Manual publication 440R IN017 MSR45E Safety Expander Module Operation Manual publication 440R IN018 Guardshield Micro 400 Safety Light Curtain Operation Manual publication 445L IN001 Configuration Tool for MSR42 GuardShield Micro 400 and Safe 2 4 Light Curtains Software Description http http http www rockwellautomation com components connected blocks html www ab com www rockwellautomation com knowledgebase Refers to the applica
6. area you must not use the START RESET button The START RESET button can be disabled by removing three wires from the MicroLogix controller 0 e Wire 6041 e Wire 10231 e Wire 10071 Publication CC OS016A EN P December 2009 11 Chapter1 Product Integration Safety Systems Diagram PanelView Component Terminal MicroLogix 1100 o00F Personal Start yf Stratix Computer 2000 Reset IT MSR42 MSR45E Multi Expansion Controller RightSight gt Rightsight function sensors sensors Safety Relay GuardShield Micro 400 800FP Light Curtains Set Up the Configuration and Diagnostic Software Follow these steps to install and set up the Configuration and Diagnostic software 1 If you do not have the Configuration and Diagnostic software go to http www ab com safety logic relays msr4x to download the Configuration Tool for MSR42 relay GuardShield Micro 400 and Safe2 4 Light Curtains a Go to Related Links on the right side of the page and choose Safety Software ZIP b Save the zip file to your personal computer c Unzip the file d Run the SetupDiagnosticAndConfiguration_Vxxx exe file to install the software 2 Start the Configuration and Diagnostic software 12 Publication CC OS016A EN P December 2009 Product Integration Chapter 1 3 Click MSR42 and then OK 4 If this is the first time you have used Configuration And Diagnostic Software Properties the Co
7. system 5 Confirm that S1 switches as the load passes and the muting lamp turns on or blinks 6 When the load breaks the light curtain sensing field check that e The two 100S contactors de energize e Guarded motion stops e The red stacklight is on 7 Press and release the Start Release button to initiate Mute Dependent Override 28 Publication CC OS016A EN P December 2009 system Validation and Application Tips Chapter 2 8 Check the following e The muting lamp stays on not blinking e The 100S contactors energize e Guarded motion starts e The green stacklight is on 9 As the load clears the light curtain confirm that the muting lamp starts blinking 10 Deactivate the Mute Enable S3 11 Confirm that the muting lamp turns off Muting Error 1 Do not activate the Mute Enable signal S3 2 Block the S1 sensor and keep it blocked 3 Wait the configured tCespe delay approximately 3 seconds for the muting lamp to start blinking signalling a muting error Lockout 1 Carefully disconnect and reconnect one of the light curtain RJ45 connectors at the MSR42 relay 2 Make sure the safety output triggers the instant the light curtain is disconnected 3 Cycle power to the system This completes the validation of the safety systems Publication CC OS016A EN P December 2009 29 Chapter2 System Validation and Application Tips Validate Proper Operation of the PanelView Screens Most of the buttons ar
8. to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication CC OS016A EN P December 2009 Copyright 2009 Rockwell Automation Inc All rights reserved Printed in the U S A
9. 0S contactors energize e Guarded motion starts e The green stacklight is on Light Curtain Function 1 Activate the Mute Enable S3 by pressing the push button and leave it active during steps Zi O 2 Break the light curtain beam and keep it broken taking care not to block any sensors 3 Check the following e The two 100S contactors de energize e Guarded motion stops e The red stacklight is on 4 While the light curtain beam remains broken press the Start Reset button Publication CC OS016A EN P December 2009 27 Chapter2 System Validation and Application Tips 5 Check the following e The two 1005 contactors remain de energized e Guarded motion does not start e The red stacklight remains on 6 Restore the light curtain sensing field 7 Press and release the Start Reset button 8 Check the following e The 100S contactors energize e Guarded motion starts e The green stacklight is on Muting Function Mute Dependent Override 1 Activate the Mute Enable S3 by pressing the push button and leave it active during steps 2 de 2 Send a load through the muting system 3 Check the following e S1 switches as the load passes and the muting lamp turns on e The load passes through the light curtain without the system shutting off e S2 switches as the load passes e S1 switches as the load leaves e S2 switches and the muting lamp turns off as the load leaves 4 Send another load through the muting
10. Bidirectional 2 sensor T type Muting With Enable Using MSR42 Relay Connected Components Building Block Allen Bradley Catalog Numbers MSR42 MicroLogix 1100 GuardShield Micro 400 Light Curtains Quick Start LEER ER EEI a dl D G Pi A ava y We z ES j 4 id of a tf ase S N ee ee Rockwell Allen Bradley Rockwell Software Automation 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 htto Awww rockwellautomation com literature 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 Automati
11. Click Close to return to the Muting dialog box 18 Publication CC OS016A EN P December 2009 Product Integration Chapter 1 12 Type the timing values or use the slider to edit the default values 2 sensor T type 4 sensor T type 2 sensor L type 2 sensor T type with enable Bidirectional muting application Connecting diagram Object Muting lamp Muting Settings Time Settings Additional Settings t sens s 4 000 V Muting Lamp monitored t espe s V Mute dependant override active t mute min 5 000 t mdo s 5 000 DE ma light curtain s Gg 0 050 OO salen Light curtain interruption monitored Check whether the muting times are permitted for the application f erei Help Time settings are intended to help make sure that only valid objects of the right size moving at the right speed can initiate and maintain a muting sequence You may want to add a few seconds to some of your calculations to allow for variations Time Setting t sens t espe t mute t mdo t msdel Publication CC QS016A EN P Description Since both S1 and S2 sensors must be broken simultaneously to initiate a muting sequence these sensors should be spaced no further apart than the length of the smallest typical load Calculate how long a load takes from the time it first reaches S1 until it reaches S2 based on the speed of the conveyor This is the t sens time for your system The t espe of your syste
12. Reset button Calculate the time it takes the load to travel from the point where it first reaches the S2 until the trailing edge of the load leaves the light curtain sensing field based on the speed of the conveyor In some instances loads may have gaps that the S1 and S2 sensors might sense through as the load passes This could lead to a muting error One method to avoid such errors is to delay the sensors response to allow for seeing through gaps The t msdel configures that delay time Unless the gap is very long or the load is moving very slowly the gap is present for only a short time In most instances the default 0 050 is suitable Leave this value set at 0 050 December 2009 19 Chapter1 Product Integration Notice that the Connecting diagram shows a lamp connected to the lamp output as well as muting sensors S1 S2 and S3 enable connected to GPIO1 GPIO2 and GPIO3 The switch connected to IN1 is labeled Start Mute override In this application a Muting Lamp is required for safety purposes to warn personnel in the area when the light curtain is muted 13 Review the Additional Settings a Make sure that the Muting Lamp monitored box is checked Muting lamp monitoring means that should the muting lamp fail short or open the MSR42 controller will sense it and not initiate or maintain muting In applications where a muting lamp is required generally the muting lamp is required to be monitored b Because you e
13. Ting diagram 2 sensor T type muting with enable signal initiated by the 3 enable signal Once the enable signal is present a load can pass in either direction in the required enable sensor light curtain sensor enable sequence Muting is ended when a load clears the last sensor of the sequence The Muting Help dialog box also provides definitions for the t sens d d Muting time explanation for more details see Safety Configurator MSR42 manual 104 720 t e spe 9 t mute 9 t m O 9 an t sens Sensor activation time Max time between the activation of the muting sensors t ms del time S which you can tlespe Light curtain activation time Max time between the activation of the muting sensors to the activation interruption of the light curtain Only active if the Light curtain interruption monitored Function is active C onfi gure on the 2 Sensor T typ e t mute Muting time Max time for muting dialog box A oa d that Bees ds any t mdo Mute dependant override time Max time for mute dependant override Function of these configured times as it moves across the conveyor causes a muting error which results in the light curtain not being muted A load entering the light curtain sensing field during a muting error triggers a safe stop timsdel Mute sensor delay time Max time for acceptable interruption of the mute signals and or the light curtain ESPE signal without having an effect on the muting sequence 11
14. a Start Reset It is no longer green once the system is running The Mute Enable signal is active As the load passes S1 muting is initiated The muting lamp turns on The load has not yet interrupted the light curtain sensing held HE H SYSTEM RUNNING MUTED SAFETY SYSTEM STATUS As the load enters the light curtain sensing field the LC light curtain button turns red to indicate that the light curtain has been interrupted The Safety Output button remains on FR FR tc B SAFETY SYSTEM STATUS SYSTEM RUNNING MUTED Publication CC OS016A EN P December 2009 31 Chapter2 System Validation and Application Tips As the load leaves S2 muting ends SAFETY SYSTEM STATUS SYSTEM RUNNING NOT MUTED 5 Release the Mute Enable button 6 Press the E stop SAFETY SYSTEM STATUS Mute Enable The screen updates in response SAFETY OUTPUT OFF E STOP HAS BEEN PRESSED MORE INFO 7 Press MORE INFO 8 Press RETURN 9 Twist and release the E stop The Safety Output is off The E Stop has been pressed 10 Press START RESET for 3 seconds and Twist and release the E Stop release Make sure the system is clear and Safe Press and release the Start Reset Button The Safety Output turns on The system is ready to run It will not run unless Mute Enable is pressed We do not need to run the system to validate the rest of the PanelView screens 32 Publication CC OS016A EN P December 2009
15. afety risk assessment must be completed to make sure that all tasks and hazards are considered and to confirm that the example circuit provides adequate risk reduction for your specific application Publication CC OS016A EN P December 2009 9 Chapter1 Product Integration What You Need e Personal computer e Connected Components Building Blocks Overview CD publication CC QROO1 e MicroLogix 1100 controller catalog number 1763 L16BBB e PanelView Component C600 terminal catalog number 2711C T6C e Stratix 2000 Ethernet switch catalog number 1783 USO5T or equivalent to connect the MicroLogix controller to the PanelView terminal e Ethernet cables catalog number 1585J M8TBJM 2 or equivalent e MSR127 safety relay catalog number 440R N231132 e MSR42 safety relay catalog number 440R P226AGS NNR e MSR45E expander module catalog number 440R P4NANS e Optical Interface Tool catalog number 445L AF6150 which includes the Optical Interface Tool MSR42 Configuration and Diagnostic Software e Optical Interface Tool Fastener to attach the Optical Interface securely to the MSR42 relay e 24V DC power supply catalog number 1606 XL120D e Safety components such as E stops GuardShield Micro 400 light curtains as listed in the bill of material on the Connected Components Building Blocks Overview CD publication CC QRO01 Follow These Steps Understand the Safety Function on page 11 set Up the Configuration and Diagnostic So
16. design and installation of your system application files and other information are provided on the Connected Components Building Blocks Overview CD publication CC QROO1 The CD provides bills of materials BOM CAD drawings for panel layout and wiring control programs Human Machine Interface HMI screens and more With these tools and the built in best practices design the system designer is free to focus on the design of their machine control and not on design overhead tasks Read these sections carefully before beginning work in each chapter The beginning of each chapter contains the following information e Before You Begin This section lists the steps that must be completed and decisions that must be made before starting that chapter e What You Need This section lists the tools that are required to complete the steps in the current chapter This includes but is not limited to hardware and software e Follow These Steps This illustrates the steps in the current chapter and identifies which steps are required to complete the examples Publication CC OS016A EN P December 2009 7 Preface Conventions Convention Example Check or uncheck To activate or deactivate a checkbox Check Disable Keying Click Br Click the left mouse button twice in quick succession while the cursor Is positioned on object or selection to initiate an action Expand Right click Select Using the mouse to highlight a specific option
17. e real time signals from the MSR42 or MSR127 relays driven via the MicroLogix 1100 controller to the PanelView terminal The buttons change in appearance as the signals driving them change This button Indicates There is no load in front of the sensor A load is in front of the sensor The light curtain sensing field is not interrupted The light curtain sensing field is interrupted The E stop has been pressed The following pages illustrate a typical sequence of PanelView screens Confirm that the system and PanelView screens operate as expected by following this sequence When you apply power to the system the Safety System Status screen appears SAFETY SYSTEM STATUS Mute Enable SAFETY OUTPUT OFF SYSTEM IN LOCKOUT MORE INFO 30 Publication CC OS016A EN P December 2009 system Validation and Application Tips Chapter 2 1 Press MORE INFO for two seconds Whenever an action may be appropriate for an operator to perform MORE INFO is displayed on the screen Pressing MORE INFO calls the related The System is ready for Start Reset Make sure the system is clear and safe message screen Press and release the Start Reset Button 2 Press RETURN for about five seconds to return to the previous screen 3 Press START RESET for 3 seconds and release 4 Press and hold the Mute Enable button The system should start running Note that the START RESET button is green only when the system is ready for
18. enable Bidirectional muting application Connecting diagram JE AIN MMN Muting Settings Time Settings Additional Settings t sens s R V Muting Lamp monitored t espe s V Mute dependant override active A t mute min i k t mdo s i Muted light curtain F 0 050 asila Light curtain interruption monitored Check whether the muting times are permitted for the application Tega Help This dialog box helps you configure your muting system properly The Muting dialog box shows that a load on the conveyor can travel from the right passing into the hazard machine area or from the left passing out of the hazard area As long as the Enable signal S3 is active an object passing in the proper sensor light curtain sequence within the configured time constraints may move past the light curtains without initiating a safe stop The light curtains are ignored by the safety system until the object has passed through the muting system As soon as the object passes the last sensor in the sequence the muting ends The enable button must be released before it can be pressed again to initiate another muting sequence Publication CC OS016A EN P December 2009 17 Chapter1 Product Integration 10 Click Help in the lower right corner of the Muting dialog box The Muting Help dialog box shows the proper timing sequence for two sensor T type muting with an Muting Help enable A muting sequence is
19. f Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Where to Start Connected Components Building Block Outline Follow the path below to complete your connected components building block Connected Components Building Blocks publication CC OS001 Q Chapter 1 Product Integration FPanlview CODD Chapter 2 System Validation and Application SAFETY SYSTEM STATUS X Tips Been H VETER MURG TART TED ae Publication CC OS016A EN P December 2009 3 Where to Start 4 Publication CC OS016A EN P December 2009 Product Integration System Validation and Application Tips Publication CC OS016A EN P December 2009 Table of Contents Preface About This Publication 2 5 i464944484 686 e4 Oe PRESS 7 CONVENU ONS aaa eee caer r r a b a Se 8 Additional Resources 4 65 eeunee Rade ethane eee aes 8 Chapter 1 MM OCU CHO ss ot hae Bt See Ce kes ee eS ee RS ee Ge 9 1550 bi 2 R 9 NPAT OUN E ek paea ane e a Va kana ee eee 10 Follow Dese oee 66 4 4 459 064n 53655 bG CRA Rte ee SS 10 Understand the Safety Function 2 2 we 11 Set Up the Configuration and Diagnostic Software 12 Configure the MSR42 Safety Relay 2 2 13 Download the Configuration 2 0 000 000 00 uk ua u 21 Confirm the Configuration i s siis iss suku oo 23 Chapter 2 TM 01616 618 eue r heee n ea a ie eae or 25 BE 016 YOU Be Ol
20. ftware on page 12 Configure the MSR42 Safety Relay on page 13 Download the Configuration on page 21 Confirm the Configuration on page 23 Publication CC OS016A EN P December 2009 Product Integration Chapter 1 Understand the Safety Function This application provides these two separate safety functions e The GuardShield Micro 400 light curtains and MSR42 safety relay provide a bidirectional two sensor T type muting with an enable function e The E stop and MSR127 safety relay provide an E stop function These two safety functions are independent of one another When set up properly either safety system is capable of stopping dangerous motion The MicroLogix 1100 controller monitors the safety systems and via the PanelView terminal provides a simple graphical representation of the operation and status of the safety systems and recommends corrective actions in response to system faults The controller and the terminal perform no safety or control functions If the PanelView terminal is mounted so that it provides the operator a clear and complete view of the hazard area and local safety regulations permit the PanelView START RESET button may be used to start or reset the safety systems just like the Start Reset push button mi the operator stationed at the PanelView terminal s location cannot see the guarded area well enough to be certain that no one Is in the guarded
21. he best use of these tools Foranadditionallevel oftechnical phone supportfor installation configuration andtroubleshooting we offerTechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience an anomoly within the first 24 hours of installation review the information that s contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Use the Worldwide Locator at http Awww rockwellautomation com support americas phone_en html Canada or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its 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 follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how
22. le sou oon 5 vea gees ee ns de ee ae aes l 25 Whar YOU NECU vs 04 aie whe hee skaka gt Follow These Steps i i sisisiiss es Ee ee 26 Validate Proper Operation of the Safety Systems 26 Validate Proper Operation of the PanelView Screens 30 Table of Contents 6 Publication CC OS016A EN P December 2009 Preface About This Publication This quick start illustrates one way of combining a set of Micro 400 Light Curtains an MSR42 safety relay an MSR45E expansion module an MSR127 safety relay an E stop and two contactors into an integrated safety system providing both a bidirectional two sensor T type muting with enable function and an E stop function A MicroLogix 1100 controller and a Panel View HMI are included to provide a convenient and graphical way to monitor the operation of the safety systems and provide basic diagnostic information and corrective action suggestions when appropriate The MicroLogix controller and PanelView terminal only monitor the safety systems They are not safety components and they have no safety control or function The safety systems operate independently from the MicroLogix controller and PanelView terminal Use this Simple Machine Safety Connected Components Building Block Quick Start in conjunction with the Connected Components Building Blocks Quick Start publication CC OS001 Refer to Additional Resources on page 8 for a listing of quick starts To assist in the
23. llow These Steps Validate Proper Operation of the safety Systems on page 26 Validate Proper Operation of the PanelView Screens on page 30 Validate Proper Operation of the Safety Systems To confirm that the system is operating properly you need to perform a series of tests With the Mute Enable S3 integrated into the system to provide a conveyor run signal guarded motion occurs only when the Mute Enable S3 is activated Start Up 1 Apply power to the system 2 Check the following e The 100S contactors do not energize e Guarded motion does not start e The red stacklight is on 3 Press and release the Start Reset button 4 Check the following e The 100S contactors energize e Guarded motions starts e The green stacklight is on 26 Publication CC OS016A EN P December 2009 system Validation and Application Tips Chapter 2 E stop Function 1 Activate the Mute Enable S3 by pressing the push button and leave it active during steps 2 ra i 2 Press the E stop 3 Check the following e The two 100S contactors de energize e Guarded motion stops e The red stacklight is on 4 Press and release the Start Reset button 5 Check the following e The two 100S contactors remain de energized e Guarded motion does not start e The red stacklight remains on 6 Twist and release the E stop button 7 Press and release the Start Reset button 8 Check the following e The 10
24. m is the time from the moment a load reaches S2 until it enters the light curtain sensing field Once the light curtain is muted the load must interrupt the light curtain within 3 seconds Therefore sensor 2 must be placed within 3 seconds travel time from the light curtain t espe should be no longer than 3 seconds except in extraordinary circumstances supported by the risk assessment This setting establishes the maximum length of time the light curtain remains muted Calculate the length of time it takes the load to travel from the point where it first reaches the S2 until the trailing edge of the load leaves the light curtain based on the speed of the conveyor This is the minimum t mute for your system which is entered in minutes This setting establishes the maximum length of a Mute Dependent Override Occasionally a load may stop within the light curtain sensing field It may be difficult to move the load past the light curtain sensing field with a safe stop in effect Mute Dependent Override is a function that lets a safety stop be paused and muting to be re initiated for the duration of the t mdo setting which lets the load move beyond the light curtain sensing field As soon as the load moves past the light curtain sensing field muting ceases If the hazardous area Is In clear view of the operator and no personnel or objects are in the hazard area Mute Dependent Override can be initiated in this case by pressing and releasing the Start
25. m the MicroLogix controller 0 e Wire 6041 e Wire 10231 e Wire 10071 24 Carefully disconnect then reconnect one of the light curtain cables from the MSR42 relay at its RJ45 socket 25 Press MORE INFO 26 Press RETURN 36 SAFETY SYSTEM STATUS Hag E SSE SAFETY OUTPUT OFF START MORE INFO SYSTEM IN LOCKOUT RESET The system is in Lockout Check the system components and wiring Press and hold the Start Reset button for 10 seconds then release Press and release the Start Reset button normally If the system fails to start there is an internal error Replace the MSR42 Publication CC OS016A EN P December 2009 system Validation and Application Tips Chapter 2 27 Press and hold START RESET for 10 seconds SAFETY SYSTEM STATUS 28 Cycle power to the system This 7 completes validation of the PanelView J uc ESTOP screens SAFETY OUTPUT OFF SYSTEM READY FOR START RESET MORE INFO Publication CC OS016A EN P December 2009 37 Chapter 2 38 system Validation and Application Tips Publication CC OS016A EN P December 2009 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and applicationnotes samplecodeandlinkstosoftwareservice packs andaMySupportfeaturethatyoucancustomizetomaket
26. machine A conveyor run signal can be used to enable the muting system as well as start the conveyor This signal can be remotely generated by a host controller or as in this Connected Components Building Block by a local push button The enable signal must begin before a load enters the muting system and be maintained until the load has cleared the muting system The system lets just one load through the muting system per enable signal A typical application for such a system might be a pick up and drop off P amp D station for an automatic storage and retrieval system ASRS A forklift places its load for transfer into the system on a section of conveyor at the P amp D station at a guarded access point to the ASRS system The forklift operator then presses and holds a push button which both starts the conveyor and enables the two sensor muting system that guards the access point Muting lets the load on the conveyor pass into the ASRS without the light curtain stopping the conveyor as the load passes The operator releases the push button once the load clears the muting system into the ASRS system This Connected Components Building Block is intended to ease the installation configuration and implementation of such a system Before You Begin Review the Connected Components Building Blocks Quick Start publication CC QS001 verifying that you have completed the hardware design and installation as well as software installation Tii S
27. n 16 6 8 Click OK on the safety notice dialog box From the Outputs Infol pull down menu choose Micro 400 Light Curtain Status Micro 400 Light Curtain is shown connected to Infol This output switches High or Low depending on whether the light curtain beam is broken or complete This is independent of the safety output and can be considered an auxiliary output From the Inputs GPIO pull down menu choose Muting Micro 400 R MSR42 Configuration And Diagnostic Software Configuration1 File Options Help Design Diagnosis Application info Configuration Basic configuration Inputs Design Output Micro 400 Micro 400 Light Curtain v Edit GPIO None v Start None Outputs Infol Micro 400 Light Curtain Info2 Lockout x safety Safety Outputs OSSD Edit System information Design error messages Design OK J OV ae i MSR42 Configuration Control 1 00 19 12 2008 qh o 09 25 09 PM 03 48 01 Important safety notice To use the muting function an analysis of the system is necessary The muting Function by passes the safety light curtain Please check the conditions For a correct application of the muting Function according IEC 62046 Publication CC OS016A EN P December 2009 Product Integration Chapter 1 9 On the Muting dialog box click 2 sensor T type with enable 2 sensor T type 4 sensor T type 2 sensor L type 2 sensor T type with
28. n 6 Disconnect the Optical Interface tool Publication CC OS016A EN P December 2009 Chapter 2 System Validation and Application Tips Introduction In this chapter you validate the operation of the two safety functions as well as the operation of the MicroLogix 1100 controller and PanelView Component 600 terminal Before You Begin e Review the Connected Components Building Blocks Quick Start publication CC QS001 verifying that you have completed all of the steps in Chapter 3 of that publication e Verify that you have completed all of the steps in Chapter 1 of this document e Verify that all components of the system are assembled and wired per the Bill of Materials Assembly Diagrams and Wiring Diagrams provided for this Connected Components Building Block and as required for your application e Verify that the MicroLogix controller and the PanelView Component terminal have power applied to them What You Need e Personal computer e Connected Components Building Blocks Overview CD publication CC QROO1 e MicroLogix 1100 controller catalog number 1763 L16BBB e PanelView Component C600 terminal catalog number 2711C T6C e Stratix 2000 Ethernet switch catalog number 1783 USO5T or equivalent to connect the MicroLogix controller to the PanelView terminal e Ethernet cables catalog number 1585J M8TBJM 2 or equivalent Publication CC OS016A EN P December 2009 25 Chapter2 System Validation and Application Tips Fo
29. n The software automatically lb a ee A end a Disturbences displays 48 as the Total beam Resolution 30mm number of system n Total beam number of system n Protective height coca e Leave Double Scan set to Yes 3 Click OK Notice that Micro 400 Light i S t MSR42 Configuration And Diagnostic Software Configuration1 Curtains have been added fe opte Hep t O th e D es i g n Out put Application Configuration Basic configuration dia gr am Inputs Design Output Micro 400 Micro 400 Light Curtain z i GPIO None T None v None w Outputs Infol Safety Outputs 25 Info2 Lockout ind Safety Safety Outputs OSSD Edit System information Design error messages One or more component has manual start vam but no start is connected V MSR42 Configuration Control v1 00 19 12 2008 Ib o 09 28 09 PM 04 41 58 14 Publication CC OS016A EN P December 2009 Product Integration Chapter 1 4 On the Configuration dialog box select Start from the IN1 Inputs pull down menu In addition to the Micro 400 Light Curtains a NO momentary push button connected to IN1 appears on the Design Output diagram The red error message disappears replaced by Design OK 5 From the IN2 pull down menu choose Start Release Notice that Start Release is shown connected to IN2 Start Release is a feedback circuit that confirms at Start
30. n important information When you have changed the configuration adhere the enclosed label see below to the side of the controller Configuration changed see Configuration Control Document Date Name Configuration Designation Write the current date your name and the configuration designation on this label You have to check the safety functions on the MSR42 23 24 Chapter1 Product Integration 5 Click the Diagnosis tab CJ MSR42 Configuration And Diagnostic Software Configuration File Options das Diagnosis Procedure 1 Connect Optical Interface Reset 2 Options PC settings SW ersion Power on hours No relay switches Reaction time t C t LC Se state 202 1138 2224 9 20 ms 4 08 ms 13 26 ms Ch Off ChB OFF Protective field viewer Service information Muting Time Recorder Error History Operation Receiver Transmitter This screen lets you monitor the status of the light curtain when a computer is attached to the MSR42 relay via the Optical Interface It has other helpful diagnostic features that are described in the MSR42 Safety Base Module Operation Manual publication 440R IN017 and the Configuration Tool for MSR42 GS Micro 400 and Safe 2 4 Light Curtains Software Description document available on the CD that ships with the Optical Interface tool Otherwise a personal computer is neither required nor recommended for normal system operatio
31. nfiguration and Diagnostic rr software register the software Company a From the Options menu choose E TI Sl User Registration Address pastes b Type in your information and l a aS k FT click OK Phone E Mail Required Informations TIP It is not necessary to change the password for this building block The default password Is ABGM Configure the MSR42 Safety Relay 1 On the Configuration 8 V t MSR42 Configuration And Diagnostic Software Configuration1 dialog box select Micro File Options Help 4 0 0 Light Cu rt q i n fr om th e Design Diagnosis Application info Configuration Basic configuration Micr O 400 Inputs Inputs Design Output icro one bi pull down menu piita E None GPIO Micro 400 Light Curtain Et INI None ti tis SY IN2 None o gt Outputs Infol Safety Outputs w Info2 Lockout z Safety Safety Outputs OSSD Edit System information Design error messages Design OK 24 MSR42 Configuration Control 1 00 19 12 2008 qh o 09 25 09 PM 03 32 06 Publication CC OS016A EN P December 2009 13 Chapter1 Product Integration 2 Edit the settings as shown GuardShield Micro 400 a Choose Manual Start Stop Setting syn b Leave Stop Delay set to No R Recelver c Choose Resolution 30 mm nan d From the Protective height EEE pull down menu choose 1200 mm Light curtain parameters optional Double sca
32. nload OptiLink Communication IF you use Optical Interfaces with software gt 2 00 the Configurator can find the correct communication port For the Optical Interfaces with software smaller than 2 00 please use the compatibility mode and select the Comport manually C Auto mode Compatibility mode Selected Comport t MSR42 Configuration And Diagnost i Options Help come F Advanced settings D New Ctrl N B Open Ctrl O bel Save Crs De bel Save as Shift Ctrl S 17 When prompted type the password ABGM A Configuration control document amp Print configuration control document Ctrl P MSR42 gt PC Upload Ctrl U i PC gt MSR42 Download Ctrl D Exit 18 On the Controller Description dialog box type the six digit Device number and click OK Controller Description Add controller information Device number mrar MSRAZ pnauctefsumenn BASE MODULE catNo 440 R xxxeeEx EEK Ser AM 107 177 IDM 00004 Reu eT l Hw 1 10 aT Sars 08072600012 Sul v2 02 CEQ 19 Cycle power to the MSR42 relay to allow the download to proceed The Device number is printed on the Device number MSR42 product label Enter the Download PC to MSR42 P x Device number Found on the label here Download Connect ge H H Configuration designation To identify this configuration you have to enter a configuration designation e g AB B013 This designation
33. ntered a t mdo time earlier leave the Mute dependent override box checked c Check the Light curtain interruption monitored box 14 Click OK 9 complete the t MSR42 Configuration And Diagnostic Software Configuration1 configuration Eile Options Help Design Diagnosis Application info Configuration Basic configuration Inputs Design Output 15 Choose File gt Save and save the configuration as 2sensor T type with 1 Star z en abl e Start Release v Outputs Infol Safety Outputs gt Info2 fLockout x 16 Do not exit the MSR42 configuration and Safety Safety Outputs OSSD _ Edi diagnostic software System information Design error messages Design OK Configuration Control v1 00 19 12 2008 aio 11 09 09 PM 03 16 23 20 Publication CC QS016A EN P December 2009 Product Integration Chapter 1 Download the Configuration 1 10 11 12 Write down the device number from the label on the side of the MSR42 relay Apply power to the MSR42 relay Attach the suction cup connector to the interface window on the side of the MSR42 relay In Microsoft Windows be ST open the Control Panel Fie Ede eo Q Bacl 2 po Search Key Folders fi Double click on System control Panel vi Control Panel On the System Properties switch to category view dialog box click See Also Hardware P System Help and Support System Restore Automatic Updates Remote
34. on 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 Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss IMPORTANT Identifies information that Is critical for successful application and understanding of the product ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures o A a A A A Allen Bradley Rockwell Automation TechConnect MicroLogix PanelView Rockwell Software and GuardShield are trademarks o
35. tion on both the controller side and the PanelView component side Description Provides information on how to select products and gain access to panel and wiring Information Provides files for the Connected Components Building Blocks Provides information installing and setting up the PowerFlex 40P drive parameters with the pre configured RSLogix 500 program that controls you base system including application tips as well as implementing the drive parameter backup and restore functionality Provides information on using the MicroLogix 1100 Programmable Controller Provides information wiring and operating the MSR42 safety controller Provides information on using the MSR45E expander module Provides information on mounting wiring and using safety light curtains Provides information on configuring and programming an MSR42 safety controller with Configuration Tool software Provides access to the Allen Bradley website Provides access to self service support Provides access to the Connected Components website Publication CC OS016A EN P December 2009 Chapter 1 Product Integration Introduction In some instances especially those where a conveyor runs only at specific time a bidirectional two sensor T type muting with an enable can provide a good safeguarding solution When enabled this type of muting solution automatically lets a valid load or object pass through the light curtain in either direction without shutting down the
36. will be printed on the configuration control document and Download Messages Start Download Try to connect Designation max 35 digits Default Field must be filled out 7 ance Please connect Optilink and power up MSR42 Once the download is complete the Configuration control document dialog box appears 22 Publication CC OS016A EN P December 2009 Product Integration Chapter 1 Confirm the Configuration 1 On the Configuration control document dialog box review the configuration Configuration t Configuration control document 1 1 onnector Pin emar and check the confirmation box Connector Pn Funct Remarks RJ45 GPIO1 2 2 Click Continue 3 When prompted to print the document click No The software saves a copy that can be printed later from the File menu 4 On the Attach Safety Configurator Label dialog box click OK The MSR42 is now fully configured and ready for operation Publication CC OS016A EN P December 2009 Safety light curtain Start Mode manual Stop Delay No Double scan2 None GPIO1 4 2 sensor T type muting with Muting lamp monitored Muted light curtain GuardShield Safe4 LC interruption monitored t espe 3 000 s tfsens 5 000 s t mute 45 00 s t msdel 50 00 ms Active t mdo 70 00 s Not connected OSSD Ch and relay outputs ChB GuardShield Micro 400 light curtain Lockout Start release Attach Safety Configurator Label Attentio
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