Light Curtain Muting Safety Function
Contents
1. Release the E stop The OUT status indicator should blink requiring a reset UY 4 Press and release the reset Button The OUT status indicator should turn steady green indicating that the GSR SI relay has reset The PWR Fault status indicator should blink red green twice then blink only green and then repeat The conveyor must start 5 Set the rotary switch back to MM The PWR Fault status indicator should turn steady green MSR42 MSR45E Tests Test Step Validation Pass Fail Changes Modifications 1 While the conveyor is running remove the start release wire from terminal IN2 of the MSR 42 relay The MSR42 relay should not respond 2 Interrupt the light curtain s sensing plane The MSR42 relay and MSR45E module must immediately de energize its safety contacts The conveyor must stop 3 Restore the light curtain s sensing plane Press and release the MSR42 relay and MSR45E module start button The MSR42 relay and MSR45E module must not respond The conveyor must not start 5 Reconnect the start release wire to terminal IN2 The MSR42 relay and MSR45E module must not respond 6 Press and release the MSR42 start button The MSR42 relay and MSR45E module must energize their safety outputs The conveyor must start NETT C MM 440L P4KL1280YD Tests While the conveyor is running remove the light curtain s OSSD1 wire from terminal GPIO4 of the MSR42 relay The MSR42 relay and MSR45E module must immediately de energiz2. c 11 Briefly short the light curtain s OSSD1 input on terminal GPIO4 to the OSSD2 input on terminal GPIO3 The MSR42 relay and MSR45E module de energize their safety outputs immediately and the conveyor stops The OSSD OFF status indicator on the light curtain receiver flashes red P messmieenetnptbesemenmemp Press and release the MSR42 start button The system must not respond 13 Cycle power to the light curtain s receiver The OSSD OFF status indicator no longer flashes red 14 Press and release the MSR42 start button The MSR42 relay and MSR45E module energize their safety outputs The conveyor starts Additional Resources For more information about the products used in this example refer to these resources Document Pub No GuardShield Type 4 User Manual 440L UM003 How to install operate and maintain the 440L Safety Light Curtains Guardmaster Safety Relay SI Installation Instructions 440R IN042 Howto install configure commission operate and maintain GSR SI Safety Relays MSR42 User Manual Configuration Tool and Software Description SAFETY UM001 How to configure an MSR42 and download the configuration to an MSR42 User Manual E MSR45E Safety Relay Expansion Module User Manual How to install commission operate and maintain the MSR45E Expansion Module MSR42 Control Module User Manual How to install commission operate and maintain MSR42 Systems RightSight Photoelectric Sensor Installation Instructions H
3. GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Verification and Validation Checklist GENERAL MACHINERY INFORMATION Machine Name Model Number Machine Serial Number Customer Name Test Date Tester Name s Schematic Drawing Number Light Curtain Pair 440L P4KL1280YD Specialty Safety Relay 440R P226AGS NNR Specialty Expansion Relay 440R P4ANS Guardmaster Safety Relay Model 440R S12R2 Safety Wiring and Relay Configuration Verification Test Step Verification Pass Fail Changes Modifications 1 Visually inspect and verify that the safety relay circuit is wired as documented in the schematics 2 Visually inspect the safety relay s configuration switch settings are correct as documented Normal Operation Verification The Safety System Performs as Intended in Response to Normal Intended Non faulted Input Test Step Verification Pass Fail Changes Modifications Verify that no one is in the hazard area N Apply power to the safety system Verify that the motor is stopped EN Ww Verify that nothing is on the conveyor 5 Verify that the E stop is released Verify that the four GPIO status indicators of the MSR42 relay are green Verify that the OSSD1 and OSSD2 status 6 indicators of the MSR42 relay are red Verify that the IN1 and IN2 status indicators of the MSR42 relay are green Verify that the FSD status indicator of the MSR45E module is red P
4. T MSR42 Configuration And Diagnostic Software Configuration NHP Safety Reference Guide gt Safety Function Documents GSR 6B 111 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Configure the MSR42 Relay cont 7 IntheTime Settings area set the following t sens s to 3 6 seconds t espe s to 3 seconds t mute min to 3 minutes t mdo s to 30 seconds Leave t msdel s set at 0 050 8 Click OK to save your changes and return to the MSR42 configuration screen NHP Safety Reference Guide gt Safety Function Documents GSR 6B 112 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Configure the MSR42 Relay cont 9 On the Configuration tab set the following From the IN1 pull down menu choose Start From the IN2 pull down menu choose Start Release Notice that the design error messages data field now says Design OK Configuration control document gn Print configuration control document Ctrl P NHP Safety Reference Guide gt Safety Function Documents GSR 6B 113 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Configure the MSR42 Relay cont Notice that t
5. injury or death property damage or economic loss Identifies information that is critical for successful application and under standing 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 typically found on or inside equipment for example a drive or motor to alert people that dangerous voltage can be present BURN HAZARD Labels typically found on or inside equipment for example a drive or motor to alert people that surfaces can reach dangerous temperatures Contact Rockwell Automation to find out more about our safety risk assessment services This application example is for advanced users and assumes that you are trained and experienced in safety system requirements ATTENTION Perform a risk assessment to verify that all task and hazard con ditions have been identified and addressed The risk assessment can require additional circuitry to reduce the risk to a tolerable level Safety circuits must consider safety distance calculations that are not part of the scope of this document NHP Safety Reference Guide gt Safety Function Documents GSR 6B 105 Safety Function Documents GSR Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Functional Safety Description W
6. Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Verification and Validation Plan Verification and validation play an important role in avoiding faults throughout the safety system design and development process ISO EN 13849 2 sets the requirements for verification and validation which calls for a documented plan to confirm all safety functional requirements are met Verification is an analysis of the resulting safety control system The Performance Level PL of the safety control system is calculated to confirm it meets the Required Performance Level PLr specified The SISTEMA software tool is typically used to perform the calculations and assist with satisfying ISO 13849 1 requirements Validation is a functional test of the safety control system to demonstrate that it meets the specified requirements of the safety function The safety control system is tested to confirm all safety related outputs respond appropriately to their corresponding safety related inputs The functional test should include normal operating conditions and potential fault inject of failure modes A checklist is typically used to document the validation of the safety control system Prior to validating the GSR Safety Relay system it is necessary to confirm the GSR Relay has been wired and configured in accordance with the Installation Instructions NHP Safety Reference Guide gt Safety Function Documents GSR 6B 121 Safety Function Documents
7. their safety outputs The conveyor must not start Press and release the MSR42 start button The MSR42 relay and MSR45E module safety outputs must energize and the conveyor must start 18 Place a typical unit on the conveyor moving toward the muting system Observe that the muting sensors indicators respond as the unit passes between them and their reflectors Verify that the muting lamp turns on 19 The unit must pass through the light curtain s sensing plane without the MSR42 relay and MSR45E module responding Verify that the muting lamp turns off as the unit clears the light curtain s sensing plane NHP Safety Reference Guide gt Safety Function Documents GSR 6B 122 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Verification and Validation Checklist cont Normal Operation Verification continued The Safety System Performs as Intended in Response to Normal Intended Non faulted Input continued 20 Place a typical unit on the conveyor moving toward the muting system Block muting sensor 2 before the unit reaches muting sensor 1 Observe whether the muting lamp starts flashing after three seconds Keep it blocked until the unit passes in front of it Observe that when the unit reaches the light curtain sensing plane the MSR42 relay and MSR45E module de energize their safety outputs and the conveyor stops Leave the uni
8. 12 Press and release the E stop The IN status indicator must be on and Un the OUT status indicator must be blinking Press and release the reset button The OUT status indicator must be on steady The conveyor must start Repeat steps 1 through 7 to test E stop Channel 2 Use terminal S21 in place of terminal S11 and terminal S22 in place of terminal 12 co 9 Briefly short the E stop input wire at terminal S12 of the GSR SI relay to 24V DC The GSR SI relay must trip immediately The conveyor must stop The PWR Fault status indicator is steady red All other status indicators are off B presara esetere aon TeS eyso OOOO O Press and release the reset button The GSR SI relay must not respond 11 Cycle power to the DSR SI relay Verify that the PWR Fault and IN status indicators of the GSR SI are green Verify that the OUT status indicator blinks green Press and release the reset button The OUT status indicator must turn steady green The conveyor must start NHP Safety Reference Guide gt Safety Function Documents GSR 6B 123 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Verification and Validation Checklist cont E stop Input Tests GSR DI continued 12 Briefly short the E stop input wire at terminal S12 of the GSR DI relay to 0V DC The GSR SI relay must trip immediately The PWR Fault status indicator is st
9. Conditions of Sale a copy of which is available on application NHP Safety Reference Guide gt Safety Function Documents GSR 6B 126
10. GSR SAFETY FUNCTION DOCUMENTS Light Curtain with Muting Lid 9 Lit VW Lit m a Lit LL LL cc gt Lit LL lt L C QW L Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Table of Contents Introduction nnn OT Important User Information ee OT Safety Function Realization Risk Assessment OB Light Curtain Muting Safety Function 9B Safety Function Requirements 9B General Safety Information D 5 99 Functional Safety Description 6 100 amp Bill of Material nnn 6 101 Setup and Wiring inne 63101 System Overview ne 6 102 Electrical Schematic y s 6 103 Configuration nn 6 104 Configure the GSR SI Safety Relay for Monitored Manual Reset 6 104 Configure the MSR42 Relay yV aaa 6 105 Calculation ofthe Performance Level 5 6 110 Verification and Validation Plan 6115 Additional Resources 6 119 AB Authorised wm Distributor NHP Safety Reference Guide gt Safety Function Documents GSR 6B 102 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Introduction This safety function application technique explains how to wire configure and integrat
11. HP Safety Reference Guide gt Safety Function Documents GSR 6B 103 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Safety Function Realization Risk Assessment The performance level required is the result of a risk assessment and refers to the amount of the risk reduction to be carried out by the safety related parts of the control system Part of the risk reduction process is to determine the safety functions of the machine In this application the performance level required PLr by the risk assessment is Category 3 Performance Level d CAT 3 PLd for each safety function A safety system that achieves CAT 3 PLd or higher can be considered control reliable Each safety product has its own rating and can be combined to create a safety function that meets or exceeds the PLr Light Curtain Muting Safety Function This application includes three safety functions 1 Emergency stop of hazardous motion initiated by a light curtain Muting of a light curtain Emergency stop of hazardous motion initiated by an E stop button This system executes a Stop Category 0 stop The motion is allowed to coast to a stop Safety Function Requirements Interrupting the light curtain stops and prevents hazardous motion by removing power to the motor The motor coasts to a stop Stop Category 0 Upon resetting the light curtain hazardo
12. HP Safety Reference Guide gt Safety Function Documents GSR 6B 106 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Setup and Wiring For detailed information on installing and wiring refer to the product manuals listed in the Additional Resources A safety light curtain provides no physical barrier between a person and the hazardous motion The safety light curtain must be installed at a sufficient distance from the hazardous motion to ensure that someone putting a hand through the light curtain cannot reach the hazard before it has stopped This distance is referred to as the Safety Distance The Safety Distance Ds required varies from installation to installation and therefore must be calculated for each specific application This application technique uses the ANSI formula i Lae ursi at D igre Leu lageemcBus oe i D Total Response Time mas m ai Aqup r Em Lamia ae gat Fam Lee EN m e TE Tzu e m co duxi Minimal Safery Distance mm Reto ee laH cele a rus be eee ee iis aar Rerum rr ir n dis rir dee SE E 588mm Voasflgiaem marne coe be se char Heu S28 72 mm hp eee eel heirs see Foe aF osabretg eed riaan agha eee ugue cm Hear yy mama z li mir uires mim mam ram nimm rimi E MEYS mma arr C eee a 1 Fu Hrs Ds K x Ts Tc Tr Tom D
13. K 1600 mm per second T 559 ms Machine Stopping Time 500 ms 20 ms LC 18 ms MSR42 6 ms MSR45E 15 ms K1 K2 C 8 d 14 but not less than O where d is the resolution of the LC S 1600 x 559 8 14 14 The LC must not be mounted closer than 895 mm 35 24 in from the guarded hazard NHP Safety Reference Guide gt Safety Function Documents GSR 6B 107 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 The MSR42 Configuration Software can also be used to calculate safety distances System Overview A 2 Sensor L type muting single direction muting system allows loads or objects to pass through its light curtains in one direction without shutting down the protected machine or process but will stop the protected machine or process if anything or anyone attempts to move past the light curtains in the other direction The system will also shut down the protected machine when an object fails to satisfy the requirements for muting 2 Sensor L type muting is often used to guard the output area of a machine or process Typical places where this form of muting would be typical are the exit of an automatic palletizing system or an automatic assembly machine To initiate muting an object must pass in sequence sensor 1 then sensor 2 and finally the light curtain The time between the beam breaks is monitored a
14. K2 Status to PLC MSR42 440R P226AGS NNR Ribbon Cable connector MSR42 to MSR 45E 440R ACABL1 MSR45E 440R P4NANS SI 440R S12R2 L1 L2 L3 LIT us L 3 External Switched 1 Stop Start Circuit I I NHP Safety Reference Guide gt Safety Function Documents GSR 6B 109 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Configuration The 440L light curtain features DIP switches to configure it for different applications This application uses the default settings so no DIP switch changes are necessary Receiver Factory Settings MN Mode Activation Combination activates one of the EECKE following modes Guard Only Start Interlock Guard Only E MPCE Monitoring Disable BEEN Disabled Fixed Blanking Activate Disabled Floating Blanking Activate Single Beam Switches 5 amp 6 cannot be activated On at the same time NEN Floating Blanking Activate Two Beams og s qem 000 e Transmitter Factory Settings Switch Switch Function Default Setting Description 1 Set Beam Coding OFF Disabled Machine Test Signal OFF OFF Signal High Active No connection or connect normally open ON Signal Low Active Connect N C Configure the GSR SI Safety Relay for Monitored Manual Reset The following procedure sets the function of the drive AM 1 Start configuration overwrite With pow
15. WG IEC Color Coded No Connector 2 m 6 56 ft length PHOTOSWITCH Photoelectric Sensor RightSight Polarized Retroflective Red DC 2 Complementary 889D FAAC2 889D F8AB 2 42EF P2MPB F4 LO DO Outputs Source PNP 4 pin DC Micro QD on 152 mm 6 in pigtail DC Micro M12 Female Straight 4 pin PVC Cable Yellow Unshielded 22 AWG IEC Color Coded No Connector 2 m 6 56 ft length 60 2649 60 2649 Swivel Tilt Mounting Bracket 889D F4AC2 2 92 89 92 89 Reflector 440R P226AGS NNR MSR42 Multi function Controller for GuardShield Light Curtains Control Tower Stack Light Pre assembled 10 cm Pole Mount with Cap Gray Housing 24V AC DC Full 855EP G24L5 l Voltage Amber Flashing LED 445 AF6150 Optical Interface Tool required to configure the MSR42 1 440R ACABL1 Ribbon cable 10 pin for 1 extension 1 MSRA5E Relay Extension ribbon cables for 1 2 or 3 MSR45 extension are ordered separately from the MSR45 2 1 440R P4NANS 800F 1YP3 800F 1 hole Enclosure E stop Station Plastic PG Twist to release 40 mm Non illuminated 2 N C 800F BX10 N O Status Contact add to 800F 1YP3 1 440R S12R2 Guardmaster Safety Relay 1 Dual Channel Universal Input 1 N C Solid State Auxiliary Outputs 1 800F Push Button Metal Guarded Blue R Metal Latch Mount 1 N O Contact s 0 N C Contact s standard standard pack qty 1 100S C09EJ23C MCS 100S C Safety Contactor 9 A 24V DC 2 800FM G611MX10 N
16. e Stet functor i Do lyfi mm ELLE LII ET w OF bee Ligh Corte blues Burnia eS Dipi ar spied Die banc ben nnoaeesd Sy rane imd In this system the PL achieved by each safety function is higher than the PLr required PLd per EN ISO 13849 1 2008 by the risk assessment Electromechanical devices like E stop buttons and safety contactors have limited operational lives directly related to how often they are operated In the following calculations it is presumed that The E stop button is operated 730 365 X 2 times a year Safety contactors operate a total of 8 760 24 X 365 times a year 1 All other components are electronic and thus have an essentially infinite operational life The emergency stop of hazardous motion initiated by a light curtain s safety function can be modeled as below LOGIC Light Curtain Safety Function Light Curtain MSR45E Subsystem 1 Subsystem 2 Subsystem 3 Subsystem 4 Applies to safety contactors where their operation can be the result of power up reset an E St6 paaifiejerence Guide gt Safety Function Documents GSR 6B 116 pressed the light curtain s field of view being interrupted or an error in the muting process Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Calculation of the Performance Level cont The functional safety data for the emerge
17. e an MSR42 safety relay and an MSR45E expansion module with a GSR SI safety relay to monitor a 440L GuardShield light curtain to create a 2 Sensor L type muting single direction muting system with an additional E stop function When an object interrupts the light curtain field of view when it is not muted or a fault is detected in the monitoring circuit the MSR42 relay and MSR45E module de energizes the redundant pair of 100S contactors stopping the motion Whenever the E stop is pressed the GSR SI relay de energizes the contactors stopping the motion When an object of the specified size passes the muting sensors in the proper sequence within the configured time interval the light curtain is muted The object is allowed to continue passing through the light curtain without the motion being stopped Muting is terminated as soon as the object leaves the light curtain s field of view A mute dependant override capability is provided to clear objects stranded in the monitored area When an object interrupts the light curtain s field of view from the non muted direction the MSR42 relay and MSR45E module de energize the contactors When an object approaches from the muted direction and does not pass the muting sensors in the proper sequence or within the configured time interval muting is not activated In this case the contactors are de energized as soon as the object interrupts the light curtain s field of view Important Us
18. e their safety outputs The conveyor must stop 1 2 Reconnect the OSSD1 wire to terminal GPIOA Press and release the MSR42 start button The MSR42 relay and MSR45E module must not respond 3 Interrupt the light curtain s sensing plane and then restore it 4 Press and release the MSR42 start button The MSR42 relay and MSR45E module must energize their safety outputs The conveyor must start 5 Repeat steps 1 to 4 with the light curtain s OSSD2 wire from terminal GPIO3 of the MSR42 relay NHP Safety Reference Guide gt Safety Function Documents GSR 6B 124 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Verification and Validation Checklist cont 440L P4KL1280YD Tests continued 6 Briefly short the light curtain s OSSD1 input on terminal GPIO4 to 24V The MSR42 relay and MSR45E module de energize their safety outputs immediately and the conveyor stops The OSSD OFF status indicator on the light curtain receiver flashes red 7 Press and release the MSR42 start button The system must not respond DS 8 Cycle power to the light curtain s receiver The OSSD OFF status indicator no longer flashes red BEEN 9 Press and release the MSR42 start button MSR42 relay and MSR45E module energize their safety outputs The conveyor starts Repeat steps 6 to 9 with the OSSD2 input on terminal GPIO3 rather than the OSSD1 input
19. eady red All other status indicators are off WwW Press and release the reset button The GSR SI relay must not respond 14 Cycle power to the GSR SI relay Verify that the PWR Fault and IN status indicators of the GSR SI relay are green Confirm that the OUT status indicator blinks green Press and release the reset button The OUT status indicator must turn steady green The conveyor must start 15 Briefly short the E stop terminal 12 to terminal 22 of the GSR SI relay The GSR SI relay must trip immediately The conveyor must stop The PWR Fault status indicator is steady red All other status indicators are off Press and release the reset button The GSR SI relay must not respond ony 17 Cycle power to the DSR SI relay Verify that the PWR Fault and IN status indicators of the GSR SI relay are green Confirm that the OUT status indicator blinks green Press and release the reset button The OUT status indicator must turn steady green The conveyor must start Logic Switch Setting Tests GSR SI 1 While running turn the logic rotary switch on the safety relay from the proper MM to AM The conveyor should keep running The PWR Fault status indicator should blink red green twice then blink only green and then repeat 2 Press the E stop The GSR SI relay must de energize its safety outputs The conveyor must stop The PWR Fault status indicator should blink red green twice then blink only green and then repeat
20. er Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices 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 is Rockwell Automation Inc 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 N
21. er off turn the rotary switch to position 0 and unit is powered up After power up test the PWR status indicator flashes red MM 2 Set configuration Turn the rotary switch to the desired position The IN1 status indicator blinks the new setting NOTE Position is set when PWR status indicator is solid green e 3 Lockin configuration by cycling unit power AM Configuration must be confirmed before operation A white space on the face of the device is provided to record unit setting MM NHP Safety Reference Guide gt Safety Function Documents GSR 6B 110 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Configure the MSR42 Relay 4 From the GPIO pull down menu choose Muting other device OSSDs Follow these steps to configure the MSR42 relay L pen Huet configuration software T MSR4 Configuration And Diagnostic Software Configuration Refer to Configuring GSR SI Safety Relay for Monitored Manual a Reset publication SAFETY UMOO 1 ti E nesliguralisn Aad Diapers tee Sel are Configuration And Diagnostic Software aadh in Ficed Blankang To use the muting Function an analysis of the system is The muting f by the safety light curt 2 Onthe software home screen click MSR42 Pinan check Hui condiiohs for a cormict ago 3 On the MSR42 configuration screen click the Configuration tab
22. he document includes the times set in step 7 and response times used in the Safety Distance calculation on page 7 t Configuration control document Start Mode manus Stop Delay No Guarditveld Safed LC interruption mantored Hespek 3 000 s beens 3 600 i timrutek 3 00 min t edixdel 50 Q0 mi Actree E emda S 000 s iot connected os en Gria venei cec peter enr rer arme ie 18 00 ms amp t SCmdt Marinum ialay extension module resporae tre for safety component on Geis Sa er category DIISO 13047 PLe Cat 4 eve EHEC 61508 3 Fes thoat 300 ms Mena ee E a 11 Click Print to include this information as part of the system documentation Refer to Configuring GSR SI Safety Relay for Monitored Manual Reset publication SAFETY UM001 for how to connect the optical interface between your personal computer PC and the MSR42 relay so you can download the created configuration to the MSR42 relay 12 The download sequence requires you to enter the MSR device number The serial number can be found on the side of the MSR42 Gummer MSR42 mies BASE MODULE The Device number is printed on the A here x NHP Safety Reference Guide gt Safety Function Documents GSR 6B 114 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Configure the MSR42 Relay cont 13 When communication is established choo
23. henever the E stop is actuated the GSR SI opens its safety contacts and the hazardous motion is stopped When all safety input signals are correct no faults are detected and the reset push button is pressed for 0 25 to 3 0 seconds and then released the GSR SI re energizes its safety contacts to provide power to the contactor coils In summary when the un muted light curtain is blocked the contactors drop out When the light curtain is unblocked and the appropriate reset button is pressed and released the contacts the hazardous motion is stopped When all safety contactors are energized input signals are correct no faults are detected and the reset When properly muted the light curtain s field of view can push button is pressed the MSR42 energizes its safety contacts be interrupted without dropping out the safety contactors to provide power to the contactor coils via the GSR SI Whenever the light curtain is muted the muting lamp is energized The E stop is connected to the GSR SI which uses pulse checking to monitor the E stop for actuation and faults Bill of Material Cat No Description Qty 440L P4KL1280YD GuardShield Safety Light Curtain Res 30 mm Pt Ht 1280 mm 64 Beams Integrated Laser Alignment DC Micro M12 Female Straight 4 pin PVC Cable Yellow Unshielded 22 AWG IEC Color Coded No Connector 2 m 6 56 ft length DC Micro M12 Female Straight 8 pin PVC Cable Yellow Unshielded 24 A
24. ncy stop of hazardous motion initiated by a light curtain s safety function is as follows The functional safety data for the light curtain s subsystem is as follows The functional safety data for the MSR45E relay s logic subsystem is as follows EE Monitoring Salety Relay MSRASE MITES KM pU NHP Safety Reference Guide gt Safety Function Documents GSR 6B 117 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Calculation of the Performance Level cont The muting of a LC s safety function can be modeled as follows LOGIC Sensor Block Light E Curtain i Block Muted Light Curtain MSR45E Safety Function NHP Safety Reference Guide gt Safety Function Documents GSR 6B 118 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Calculation of the Performance Level cont The functional safety data for the MSR45E relay s logic subsystem is as follows 5E Monitoring Safety Relay MSR45E iu E Stop Safety Function The functional safety data for the emergency stop of hazardous motion initiated by an E stop button safety function is as follows E Stop 1 NHP Safety Reference Guide gt Safety Function Documents GSR 6B 119 Safet
25. nd must not exceed the specified times The overall time that the system is muted is likewise monitored The protected system shuts down if any specified time is exceeded The sensors and light curtain must be positioned so that all three are broken simultaneously at one point in the process The sensors and light curtain must be restored in the same sequence as they were passed to initiate the muting sequence A new object cannot start the process break sensor 1 until the previous object has moved beyond the light curtain The protected system shuts down if either sensor is broken before the previous object has moved beyond the light curtain Muting is suspended as the object passes out of the light curtain field of view The 440L light curtain monitors itself and its outputs for faults and responds to any fault by turning off both of its outputs The MSR42 relay monitors the light curtain outputs and the sensor outputs The MSR42 relay verifies that it receives the sensors and light curtain signals in the proper sequence within the specified times When the MSR42 relay detects any fault at its inputs or an internal fault it de energizes the MSR45E safety contacts shutting down the protected system The MSR42 relay monitors the 100S contactors via NC contacts from each contactor connected in series to provide a Start Release function The MSR42 relay does not respond to its Start button and energize the MSR45E safety contacts when the light cu
26. ow to install commission operate and maintain 42EF Photoelectric Sensors Industrial Automation Wiring and Grounding Guidelines General guidelines for installing a Rockwell Automation industrial automation system Safety Products Catalog 117 CA001 Overview of safety products product specifications and application examples You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative NHP Safety Reference Guide gt Safety Function Documents GSR 6B 125 Safety Function Document Disclaimer The information contained in this and any related publications is intended as a guide only Every care has been taken to ensure that the information given is accurate at time of publication Neither NHP nor any of the manufacturers portrayed in this and any related publications accept responsibility for any errors or omissions contained therein nor any misapplications resulting from such errors or omissions Risk assessments should be conducted by authorized persons The purchaser and installer are responsible for ensuring the safety system s incorporating these products complies with all current regulations and applicable standards Products are subject to change without notice and may differ from any illustration s provided All products offered for sale are subject to NHP standard
27. pf K Ts Tc Tr Tbm Dpf the standard hand speed of 63 inches per second the stop time of the machine the response time of the safety system the MSR42 relay MSR45E module and K1 K2 contactors the response time of the presence sensing device the light curtain LC additional time allowed for the brake monitor if any to compensate for variations in normal stopping time the distance that a standard hand could possibly move through the LC before it is detected This is a fixed value based on the light curtain resolution In this application technique the values are K Ts TC Tr Tbm Dpf 63 inches per second 500 ms 0 5 sec is only for purposes of this application note The stop time for a specific application must be measured 39 ms 18 ms MSR42 6 ms MSR45E 15 ms K1 K2 20 ms LC Tr Tc 20 39 59 ms 0 059 sec 0 none used in this application 78 7 mm 3 1 inches DS 63 x 0 5 0 059 3 1 38 3 inches The LC must not be mounted closer than 895 mm 35 24 in from the guarded hazard The following is the same calculation using 13855 S KxT C S minimum distance in millimeters mm K is a parameter in millimeters per second mm s derived from data on approach speeds of the body or parts of the body T is the overall stopping performance in seconds C is the intrusion distance in mm In this application technique the values are
28. ress and release the MSR42 start button Verify that the OSSD1 and OSSD2 status indicators turn green Verify that 7 the MSR45E module energizes its safety contacts Verify that the FSD status indicator of the MSR45E module turns green 8 Verify that the motor does not start on power up 9 Verify that the PWR Fault and IN status indicators of the GSR SI relay are green 10 Verify that the OUT status indicator of the GSR SI relay blinks green Press and release the GSR SI reset button The OUT status indicator of the GSR SI must turn on steady green The GSR SI relay energizes its safety outputs The conveyor starts Press the E stop The IN and OUT status indicators of the GSR SI relay must turn off The GSR SI safety output must de energize The conveyor must stop The MSR42 relay and MSR45E module must not respond Release the E stop The IN status indicator turns green The OUT status indicator blinks green The GSR SI safety output must NOT energize The conveyor must NOT start 14 Press and release the GSR SI reset button The OUT status indicator must turn steady green The GSR SI safety output must energize and the conveyor must start 15 Move an object directly into the light curtain s sensing plane The MSR42 relay and MSR45E module must immediately de energize their safety outputs The conveyor must stop The GSR SI must not respond Remove the object from the sensing plane The MSR42 relay and MSR45E module must not energize
29. rtain is interrupted there is a fault detected or when the 100S contactors are not in the proper off state The MSR42 runs and monitors a muting lamp Should the lamp burn out or be removed the MSR42 relay does not mute the light curtain The GSR SI relay monitors the state of the E stop push button It checks for faults by connecting its pulse test outputs though the E stop contacts and monitoring its inputs The GSR SI relay monitors itself for internal faults A fault in the E stop circuit an internal fault or pressing the E stop causes the GSR SI relay to open its safety contacts shutting down the protected system The GSR relay monitors the 100S contactors via NC contacts from each contactor connected in series as part of its reset circuit The GSR SI relay does not respond to its reset button and energize its safety contacts when the E stop button has not been released a fault is detected or when the 100S contactors are not in the proper off state NHP Safety Reference Guide gt Safety Function Documents GSR 6B 108 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Electrical Schematic 24V ove Class 2 Source required 440L P4KL1280YD Brn 42EF P2MPB F4 S1 EE lt a Wht Status Wht Status to PLC to PLC Brn Brn Blu Blk K1 K2 Start K1 Status to PLC K2 Status to PLC Reset K1
30. se File gt PC gt MSR42 Download ME MSR42 Configuration And Diagnostic Softw Ciro Chri 5 Shft Ctrie 5 ga Print configuration control document Ctrl P B MRAZ gt PC Upload Y 14 For the password type ABGM all CAPITAL letters and click OK Password dialog e ml opty maenol loeis pier cine eoa hs Lm DAP Mem ped FH Ste eor PT bahet pers iR wooed irira tan Fie rfr an 5b FEET mote caue fn ined rater ies Wi nf ies Ta E Prosperi wed cant Ou neges cu The download proceeds ta Download PC ta MSR4 2 Shas t D m i ion m Try bo cer wert t aA Please connect Opbical Inter ace and power up MSRA NHP Safety Reference Guide gt Safety Function Documents GSR 6B 115 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Calculation of the Performance Level The project s functional safety specifications call for a structure of Cat 3 minimum and a PLr of PLd minimum A PFHd of less than 1 0 E 06 for the overall safety function is required for PLd This SISTEMA project includes three safety functions 1 Emergency stop of hazardous motion initiated by a light curtain 2 Muting of a light curtain 3 Emergency stop of hazardous motion initiated by an E stop button The individual safety function s achieved performance level PL values are shown below Project IFA Dexxsmeria o
31. t where it stopped 21 Make certain no one is in the hazard area Press and release the MSR42 start button The conveyor starts The muting lamp turns on steady Verify that as the unit moves out of the light curtain s sensing plane the muting lamp turns off 22 Place a typical unit on the conveyor moving toward the muting system Let the unit pass in front of muting sensor 1 and muting sensor 2 The muting lamp turns on steady Hold the unit in place before it reaches the light curtain s sensing plane Observe if the muting lamp starts flashing after three seconds Release the unit to continue along the conveyor The MSR42 relay and MSR45E module de energize their safety outputs immediately when the unit enters the light curtain s sensing plane Leave the unit where it stopped 23 Make certain no one is in the hazard area Press and release the MSR42 start button The conveyor starts The muting lamp turns on steady As the unit moves out of the light curtain s sensing plane verify that the muting lamp turns off 24 Place a typical unit on the conveyor moving toward the muting system Let the unit pass in front of muting sensor 1 and muting sensor 2 The muting lamp turns on steady Let the unit enter the light curtain s sensing plane which is now muted Hold the unit in place part way through the light curtain s sensing plane Observe if the muting lamp starts flashing after three seconds The MSR42 relay and MSR45E module de energize their safety ou
32. tputs and the conveyor stops 25 Make certain no one is in the hazard area Press and release the MSR42 start button The conveyor starts The muting lamp turns on steady As the unit moves out of the light curtain s sensing plane verify that the muting lamp turns off Abnormal Operation Verification The Safety Relay System Properly Responds to All Foreseeable Faults with Corresponding Diagnostics E stop Input Tests GSR DI 1 While the motor is running remove the E stop input wire at terminal 12 of the GSR SI relay The GSR SI relay must trip immediately and de energize its safety contactors The conveyor must stop The IN and OUT status indicators must be off Reconnect the wire to terminal S12 The GSR SI relay must NOT respond Press and release the reset button The GSR SI relay must not respond N 3 Cycle the E stop button The IN status indicator must be on and the OUT status indicator must be blinking Press and release the reset button The OUT status indicator must be on steady The conveyor must start 4 While the conveyor is running jump the E stop input wire at terminal S11 to terminal S12 of the GSR SI relay The GSR SI relay should not trip Press the E stop The GSR SI relay must trip immediately The IN and OUT status indicators must turn off The conveyor must stop 6 Release the E stop Press and release the reset button The GSR SI relay must not respond 7 Remove the jumper from terminal 11 to terminal S
33. us motion and power to the motor does not resume until a secondary action start button depressed occurs Muting the light curtain is done to allow automatically fed material to enter the area Multiple sensors are configured to detect the incoming material and initiate and monitor the muting function per IEC TS 62046 Faults at the light curtain muting sensors wiring terminals or safety controller are detected before the next safety demand The safe distance from the location of the light curtain to the hazard must be established per ISO 13855 so the hazardous motion is stopped before the user can reach the hazard The safety function in this example is capable of connecting and interrupting power to motors rated up to 9 A 600V AC The safety function in this application technique meets or exceeds the requirements for Category 3 Performance Level d CAT 3 PLd per EN ISO 13849 1 and control reliable operation per ANSI B11 19 Throughout this manual when necessary we use notes to make you aware of safety considerations NHP Safety Reference Guide gt Safety Function Documents GSR 6B 104 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 General Safety Information IMPORTANT WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which can lead to personal
34. y Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function Safety Rating PLe Cat 4 to EN ISO 13849 1 2008 Calculation of the Performance Level cont The functional safety data for the E stop button s input subsystem is as follows E Stop 1 5B 1005 Safety Contactor The E stop and safety contactors data includes MTTFd DCavg and CCF data because they are electromechanical devices Electromechanical device functional safety evaluations include how frequently they are operated whether they are effectively monitored for faults and properly specified and installed SISTEMA calculates the MTTFd by using B10d data provided for the contactors with the estimated frequency of use entered during the creation of the SISTEMA project The DCavg 99 for the contactors was selected from the Output Device table of EN ISO 13849 1 Annex E Direct Monitoring The DCavg 99 for the E stop was selected from the Input Device table of EN ISO 13849 1 Annex E Cross Monitoring The CCF value is generated using the scoring process outlined in Annex F of ISO 13849 1 The complete CCF scoring process must be done when actually implementing an application A minimum score of 65 points must be achieved NHP Safety Reference Guide gt Safety Function Documents GSR 6B 120 Safety Function Documents GSR GuardMaster Safety Relay Light Curtain Muting Safety Function
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