Muting Controller Box Installation and Operating Instructions
Contents
1. Guard maste Muting Controller Box Installation and Operating Instructions Reset The reset function switches on the OSSD safety outputs consider the safety light curtain is uninterrupted 24V Start OV gt 0 15s 24V OSSD oV Figure 16 Reset function Mute Dependent Override An error in the muting signal sequence will discontinue the muting condition If the safety light curtain is then interrupted the OSSD outputs will switch off This normally leads to a stoppage of the movement of the material The muting lamp will flash For moving the material out of the protective field area in this situation protective field interrupted the start signal triggers the mute dependant override function ATTENTION The maximum activation time t mdo for this override function is set to one minute by default This time has to be considered on risk analysis of the application The Reset Override switch has to be mounted at a location where the dangerous area can be overseen The mute dependant override function is automatically terminated after the mute dependant override time t mdo has elapsed or when the safety light curtain is no longer interrupted a Mute dependent override time Start OV gt 0 15 OSSD 24V Light Curtain WV L max t m do 24V E a OSSD OV anp Figure I7 Mute dependent override function Lockout and Restart The following fault conditions will lead to a lockout e The connec2. OR Safe 4 Reflector Cantilever 445L AMSTDMUT Floor Mounting Plate Muting Sensor included with mounting stand Figure 19 Muting System Allen Bradley Original instructions 7 A Guard maste Muting Controller Box Installation and Operating Instructions Muting Types The international standard IEC 62046 describes two and four sensor T and L type muting The sensor positions recommended below are taken from IEC62046 and IEC61496 A 7 The light curtain should detect the material not the carrier pallet T Type 2 Sensor Figure 20 The distance d5 should be as short as practicable in order to avoid persons entering the hazardous zone without being detected when following immediately after the pallet or the transport system The muting beam cross point has to be in the hazardous zone h1 Lower height of safety protective field h2 Muting sensor height h2 gt h1 d1 d2 Distance light curtain muting sensor d3 d4 Muting sensor reflectors T Type 4 Sensor The distances d1 d2 d3 and d4 has to be selected that the difference in timing is gt 50 ms h2 gt h1 d5 distance from the safety light curtain to the muting sensor crossing point h1 Lowest beam of safety light curtain Recommended mounting position according to IEC 62046 F 2 h2 Muting sensor height d1 lt 200mm d1 Distance light curtain muting sensor d3 lt 200 mm d3 Distance light curtain muting sensor d2 gt 2
3. 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 10000127397 Ver 01 July 2011 Copyright 2011 Rockwell Automation Inc All rights reserved 28 Original instructions Allen Bradley n Guard Imaste
4. according to desired muting type Attach bars e g two sensor muting Step 3 Attaching light curtain brackets GuardShield Safe 2 Safe 4 T slot nut and screws are included with the floor mounting column The mounting brackets are included with the safety light curtain Premount the mounting kits on the T slot Before mounting the light curtain check for height position and cable exit bottom or top Allen Bradley Original instructions i A Guard maste Muting Controller Box Installation and Operating Instructions Step 4 GuardShield Micro 400 The Micro 400 light curtain is supplied with 180 adjustable mounting brackets The flat mounting bracket kit 445L AF6145 is sold separately Before mounting check for height and cable exit position bottom or top The 180 adjustable mounting brackets are included with the safety light curtain T slot M4 nut and screws are included with the floor mounting column Premount the brackets to the Micro 400 profile Attach Micro 400 brackets to the post slots using T nuts provided GuardShield Micro 400 Profile Reinforced specialty light curtains The GuardShield Micro 400 reinforced profile uses the same mounting brackets 445L AF6140 as the GuardShield Safe 4 They are supplied with the light curtain T slot nuts and screws are included with the floor mounting column Before mounting check for height and cable exit position botto
5. 4 000 f j JZ Muting Lamp monitored t espe s 0 000 A Mute dependant override active IN t mute min 5 000 j Muted light curtain 5 000 AB Hees tel Safes Safes All en B r adi ey etp oomo J J Light curtain interruption monitored Check whether the muting times ar M Muting Settings Time Settings Additional Settings t sens s 4 000 mz j IZ Muting Lamp monitored t espe s ooo S o I Mute dependant override active N t mute min soo ff Muted light curtain t mdo 5 000 L ga Safe400 Safet susina ooo J T Light curtain interruption monitored Check whether the muting times are permitted for the application fe permitted for the application Konfigurations und Ci Muting ioj x O Muting i l x Diag nose Softwa re 2 sensor T type 4 sensor T type 2 sensor L type 2 sensor T type with enable 2 sensor T type 4 sensor T type 2 sensor L type 2 sensor T type with enable Unidirectional muting application Connecting diagram M Bidirectional muting application Connecting diagram A Warnung Lese Sicherheitshi Mating Settings j Muting Settings MSR 42 Time Settings Additional Settings Time Settings Additional Settings t sens s 2 000 P a Muting Lamp monitored t sens s 4 00 P Muting Lamp
6. Installation and Operating Instructions Two Sensor Muting with GuardShield 440L GuardShield 440L Rx Rx Micro 400 Tx Micro 400 Ea fE GuardShield 440L Tx 7 Control z Z Cabinet Rx GS_ _ _ Tx GS Tx ee be S4 A D G Muting si s z s 0 Lamp re Muting sensors with reflectors Figure 4 Wiring two sensor muting T Type or L Type with GuardShield 440L ATTENTION When using other safety devices in a muting system the configuration of the MSR42 must be changed according to the Software and Optical Interface section on page 14 Muting of Laser Scanners or Other Safety Sensors Laser Scanner or other Safety Sensor a a Ax Micro 400 _ Tx Micro 400 ees Cabinet Ree EGES RSA 2 PinS Earth Muting sergore with reflectors ac Figure 5 Two sensor muting of a laser scanner or other safety devices with PNP output Allen Bradley Original instructions j A Guard maste Muting Controller Box Installation and Operating Instructions ATTENTION system the MSR42 configuration must be changed according to the Software and Optical Interface section on page 14 Pin Assignment When using other safety devices in a muting 8 pin Cordset Assignment MSR42 Signal 889D F8AB x fat fo Info1 White Output Pin2 24V Brown 24V Pin3 Earth Green Pin4 Status Lockout Info2 Yellow Pin5 OSSD1 OSSD1 Grey Pin6 OSSD2 OSSD2 Pink
7. beam light curtain pair Muting Box 1X Muting Controller Box MSR42 Light Curtain Patchcord 1x Transmitter patchcord 1 m Straight DC Micro M12 4 conductor Light Curtain Patchcord 1x Receiver patchcord 5 m Straight DC Micro M12 5 conductor Muting sensor 20 4 al saccobea belo Hoaraelaear yar iveaseac aie Muting sensor patchcord 2x or 4x 4 conductor M8 patchcord x 1 2 3 or 5 meter Muting sensor bracket 2x or 4x Swivel Tilt Bracket for RightSight sensors muting sensor patchcord Muting sensor reflector 2x or 4x Reflector 76 mm Bracket included in 445L AMSTDMUT If external mute lamp is desired one mute lamp option with right angle bracket is below 855E 24TL7 855E BVMC Muting lamp patchcord 889P M4AB 5 4 conductor M8 Pico patchcord 5 meters Muting stand 2x 445L AMSTD2M Muting cantilever 2x or 4x 445L AMSTDMUT Muting lamp with bracket Muting lamp with right angle bracket Micro 400 Light Curtain Example Light Curtain 1x 440L P4E1200FP 30 mm Micro 400 light curtain pair 1200 mm Muting Box 1x 445L AMUTBOX1 Muting Controller Box MSR42 Micro 400 patchcords 2x 445L AC8PC1 8 pin M12 patchcord with filter 1 meter also offered in 3 meter and 5 meter lengths RightSight Polarized Retro Red DC 2 Complementary LO DO Outputs PNP 4 pin aS EKOT TAER PANPRNIA Pico QD on 152 mm 6 in pigtail 2 or 4 sensors required muting sensor patchcord Muting sensor patchcord 2xor4x 889P F4ABPM x 4 conductor M8 patchcord x 1 2 3
8. or 5 meter Muting sensor bracket 2x or 4x 60 2649 Swivel Tilt Bracket for RightSight sensors muting sensor patchcord Muting sensor reflector 2x or 4x 92 39 Reflector 76 mm Bracket included in 445L AMSTDMUT Allen Bradley Original instructions 17 A Guard maste Muting Controller Box Installation and Operating Instructions Muting System Examples continued Product Part Number Description If external mute lamp is desired one mute lamp option with right angle bracket is below 855E 24TL7 he Muting lamp with bracket 1x 855E BVMC Muting lamp with right angle bracket Muting lamp patchcord 1x 889P M4AB 5 4 conductor M8 Pico patchcord 5 meters Optical interface 1x 445L AF6150 Optical interface can be reused for further configuration Installation If mounting the Rockwell Automation Guardmaster muting box as a standalone muting box it is best to locate this muting box adjacent to the muting sensors and safety light curtain The enclosure may be mounted to a smooth flat surface by using the brackets supplied with the muting box It is also possible to mount the enclosure to the Rockwell Automation floor mounting stand 445L AMSTD2M This two meter stand kit comes with a aluminum floor plate hardware and Installation instructions Depending upon the muting system design it may be necessary to purchase one or two 500 mm aluminum post kits 445L AMSTDMUT that are designed to be cantilevered from the side of the vertically mount
9. 50 mm d2 Distance muting curtain muting sensor 12 Original instructions Allen Bradley n Guard Imaste Muting Controller Box Installation and Operating Instructions L Type 2 Sensor h1 Lowest beam of safety light curtain Recommended mounting position according to IEC 62046 F 2 h2 Muting sensor height d1 lt 200mm d1 Distance light curtain muting sensor d2 gt 250 mm d2 Distance muting sensor muting sensor h2 gt h1 Muting Function Moving goods e g pallet through the muting station leads to the timing diagram of the left picture below During the mute time t mute the muting lamp is lit Muting sensor S1 and muting sensor S2 must have a timing delay of at least gt 50 ms ESPE f o 1 1 1 1 1 Muting Sensor S1 D Muting Sensor S2 I i t t SEN9 ESPE ESPE t SEN t MUTE Timing for 2 Sensor T type standard factory supplied configuration Mute M2222 ag2aoee Allen Bradley Original instructions 1 A Guard maste Muting Controller Box Installation and Operating Instructions Configuration and Diagnostic Tool Software and Optical Interface The default configuration is set for two beam T Type muting of a GuardShield Safe 2 or Safe 4 445L or a GuardShield 440L safety light curtain Other muting types can be selected with the configuration and diagnostic tool software and downloaded with the optical interface 445L AF6150 The software and manual are supplied wit
10. Muting Controller Box Installation and Operating Instructions Allen Bradley A Guard maste Original instructions Muting Controller Box Installation and Operating Instructions Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in the guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Rockwell Automation does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Rockwell Automation publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Rockwell Automation sales office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or part without wr
11. Pin7 GND GND Blue Pin8 Start In1 Start Red Table 1 Connector power PWR IO Patchcord 889D M5AC x MSR42 Signal Pin Pin2 Pin3 Pin4 Pin5 Assignment MSR42 Signal 24V Earth Earth Table 5 Connect GuardShield 440L or Safe 2 or Safe 4 transmitter Tx GS Tx S4 Assignment MSR42 Signal Pin1 24V Pin2 GPIO 4 Pin3 GND Pin4 GPIO 3 Pin5 Earth Table 6 Connector GuardShield Safe 2 or Safe 4 receiver Rx S4 Assignment MSR42 Signal Pin1 NC NC Pin2 24V 24V Pin3 Earth Earth Pin5 OSSD 1 GPIO 3 Pin6 OSSD 2 GPIO 4 Pin7 GND GND Pin8 NC NC Table 7 Connector GuardShield 440L receiver Rx GS Assignment MSR42 Signal Pin 3 Tx 3 Pin 5 Tx 5 Pin 6 Tx 6 Pin 7 Tx 7 Pin 8 Tx 8 Table 8 Connector GuardShield Micro 400 transmitter Tx Micro 400 MSR42 Signal Pin 1 24V Pin 2 NC Pin 3 GND Pin 4 GPIO1 GPIO2 GPIO3 GPIO4 Table 4 Connector muting sensor S1 S2 3 and S4 8 Original instructions Assignment MSR42 Signal Pin 3 Rx 3 Table 9 Connector GuardShield Micro 400 receiver Rx Micro 400 Allen Bradley n Guard Imaste Muting Controller Box Installation and Operating Instructions Muting Lamp The muting lamp warns an operator in the event that the light curtain is muted Depending on the risk analysis often a muting lamp monitored by the MSR42 control unit controller box signals the muting procedure The size and t
12. d on one mounting bar and the reflectors on the other side Allen Bradley Original instructions A Guard maste Muting Controller Box Installation and Operating Instructions Trouble Shooting When the LED Status Output and Status Error are lit the muting system is operating A simple functionality test can be performed interrupting each sensor for its own Supposing that power is on light curtain muting sensors and the muting lamp are connected The function of each sensor can be checked with the sensor LED indicator When considering correct operation of the light curtain and muting sensors the muting lamp will flash when interrupting one muting sensor for a few seconds Check for the muting sequence according to Figure 3 Time for two sensor T type Muting Lamp Ez Possible Reason Possible Solution off on Operating safety light curtain active on on on Operating safety light curtain muted Reset X off on Operating OSSD output off Make sure that the safety light curtain and muting senors are operating and uninterrupted Reset for ten seconds X X off Lockout Check cables and connections of the light curtains See the Lockout and Restart in the Operating section on page 10 on Error Indications Make sure that the muting sensor and the safety light curtain are uninterruupted Check alignment of the safety light curtain and muting sensors Clean the muting sensors and safety light curtain fla
13. dShield Micro 400 Safe 2 OR Safe 4 Reflector Cantilever 445L AMSTDMUT Floor Mounting Plate Muting Sensor included with mounting stand Figure Muting System Wiring Connect muting components power and output according the corresponding muting type picture below Two Sensor Muting with Safe 4 O E a MA a Control Cabinet Muting sergore with reflectors Figure 2 Wiring two sensor muting T Type or L Type with GuardShield Safe 4 e e e w Allen Bradley Original instructions A Guard maste Muting Controller Box Installation and Operating Instructions Four Sensor Muting with GuardShield Micro 400 Micre 400 Rx Micro 400 Tx Ax Micro 400 y Tx Micro 400 Control Cabinet Ax GS Tx GS Tx 34 Ar 34 Muting sergore with reflectors os es Se es Figure 3 Wiring four sensor muting T Type with GuardShield Micro 400 ATTENTION A ATTENTION A If connecting the Micro 400 to the muting box the configuration of the MSR42 has to be changed according to the Software and Optical Interface section on page 14 It is necessary to use the original shielded Micro 400 patchcords 445L AC8PCX X is 1 2 3 5 or 8 m to connect the Micro 400 transmitter and receiver to the muting controller Not using these cables may cause a safety risk 6 Original instructions Allen Bradley n Guard Imaste Muting Controller Box
14. e connection of the Safe2 Safe4 Micro 400 or GuardShield POC and PAC safety light curtains It also has pre wired quick disconnect connectors to connect up to four Rockwell 42EF 42JS or other Rockwell sensors as well as an M8 quick disconnect connector for a muting lamp The GuardShield Type 2 and Safe 2 light curtains may be used with the muting controller However the use of Type 2 devices with Category 4 devices does not improve the safety level of the safety circuit above a Category 2 Make sure that a risk assessment determines that a Category 2 Type 2 level of safety is sufficient for the application ATTENTION The Rockwell Automation Guardmaster muting box is supplied with flat brackets to mount this enclosure to a solid flat surface or to the Rockwell Automation aluminum two meter floor mounting stand 445L AMSTD2M This floor mounting stand is designed for one or two 500 mm aluminum posts 445L AMSTDMUT to be cantilevered to each side of the vertical floor stand allowing for two or four muting sensors to be connected and positioned along their length This mounting stand with one cantilever post is best for two sensor L type muting applications and a two cantilever post configuration is best suited for two or four sensor T type muting Both L and T configurations are best suited for conveyorized muting applications The MSR42 multi function safety control module allows up to four sensor muting if the Mic
15. ed floor stand Mounting hardware T nuts and screws are included in the two meter stand and 500 mm post kits to mount the muting sensor light curtain and muting box Mounting of the Muting Controller Box Mount the brackets on the muting box Tighten the screws properly Determine where on the mounting stand the muting box will be located Check for height position with respect to the cable wiring of the light curtain muting sensors and muting lamp Connectors should be positioned on the bottom side of the muting box Premount the muting box with the T slot nuts to the mounting column Do not tighten the screws until the box is in right position Tighten the screws alternately 1 T nuts and screws for Safety light curtain Safe4 Safe2 445L AF6145 for Micro 400 GuardShield 440L Muting sensor bracket 60 2649 RightSight and 92 39 Reflector Muting box 18 Original instructions Allen Bradley n Guard Imaste Muting Controller Box Installation and Operating Instructions Mounting Stand Mounting Column basic instructions see installation instructions supplied with 445L AMSTD2M kit Step 1 Assemble floor plate to two meter post Mount the mounting column onto the floor plate See mounting stand installation instruction Check for front side positioning of the column see picture Check the sliding nuts position for light curtain sensor bar and controller box Step 2 Attach muting sensor post s
16. h the optical interface or are available on www ab com Product MSR42 Muting Type Safety Light Curtain Muting Sensor Guard Other Shield Safety 440L Sensor i Comments fv ff fo fe fo fo foontouti wi eee TLE PP YY fee Table 24 Setting for the MSR42 muting controller Outputs Safety External Device Stop delay Monitor EDM Default Start None Safety Output Lockout No No Start EDM See MSR42 Safety See MSR42 Safety EDM See ene aeoeinput Start Release Software Software sae Start Release Table 25 Settings for the muting controller MSR42 Additional Settings Time Settings Light Curtain M Lamp Mute Depend Interrupt Monitored Override Active Muted Light Curtain Monitored t msdel Selectable yes no ann ia See MSR42 configuration manual Table 26 Settings for the MSR42 muting controller 14 Original instructions Allen Bradley n Guard Imaste Muting Controller Box Installation and Operating Instructions E Muting i lol x 2 sensor T type 4 sensor T type 2 sensor L type 2 sensor T type with enable M Bidirectional muting application Connecting diagram E Muting E lol x 2 sensor T type 4 sensor T type 2 sensor L type 2 sensor T type with enable ty Configuration And Diagnostic Software M Bidirectional muting application Connecting diagram M Muting Settings Time Settings Additional Settings t sens s
17. he brightness of the connected lamp must also be designed as required by the safety analysis By default the muting lamp is not monitored in the muting controller box However the muting lamp must be used reference the MSR42 user manual for further information To change the muting lamp to monitored reference the Configuration and Diagnostic Tool user manual If an error in the muting sequence has occurred the muting lamp will blink ca 1 Hz indicating that the muting condition has not been initiated or has been discontinued The plug muting lamp offers to connect an additional muting lamp to the controller box Muting Lamp Meaning Off Safety light curtain active On Light curtain muted Flashing Error in muting sequence Table 14 Muting lamp Operating The control of the muting is done with one spring return switch called Reset Override It triggers the start input of the MSR42 controller The control signal on the Quick QD M12 connector PWR I O Pin 8 Start works in parallel to the key switch Key Switch Reset Override Turn right impulse Reset Turn right impulse Mute dependent override Turn right 10 sec Power restart Reset override key switch on muting box is identical with the start signal from connector PWR I O Pin 8 Start Before restarting the muting operation make sure all personnel are out of the hazardous area ATTENTION Allen Bradley e Original instructions 9
18. itten permission of Rockwell Automation is prohibited Throughout this manual 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 Identifies information that is critical for successful application and understanding of aati 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 consequences TV Labels may be on or inside the equipment for example drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example drive or motor to alert people that surfaces may reach dangerous temperatures PEPI gt LIPe It is recommended that you save this user manual for future use 2 Original instructions Allen Bradley n Guard Imaste Muting Controller Box Installation and Operating Instructions Contents Reference DOCUMENTS ssisissssrsssiei ciao sass snc edie a Howe sueae dads ce sae eeeweee sas eewss E ce ween 3 utaere Ue 0 ie ee ee ee re 4 VL i er ee ee ee ee 5 Or a ee ee ee Ter eT ee re ee rer ee eee 9 MUUING Typos 165 ts lt dscs cen cenesevacededecs orsea einer ewnestenduceduss ned e
19. m or top 20 Original instructions Allen Bradley n Guard Imaste GuardShield Type 2 Type 4 440L Step 4 Mounting of the Muting Sensors Step 5 Mounting of the Retroreflectors Muting with GuardShield Micro 400 Muting Controller Box Installation and Operating Instructions The mounting brackets for the GuardShield 440L are supplied with the light curtain T slot nut and screws are included with the floor mounting column Before mounting check for height and cable exit position bottom or top Premount the bracket Premount the light curtain with the supported screws Tighten the screws after aligning Note Only one slot of the GuardShield bracket will fit into the mounting stand channel Before starting to mount the muting sensors check the section for the mounting position with respect to the muting type Mount the muting sensor according its instruction T slot nut and screws for the RightSight bracket 60 2649 are supported with the cantilever Check for good visibility of the sensor indicator LEDs Check the Muting Types section on page 12 for the mounting position for the chosen muting type T slot nut and screws are provided with the cantilever For muting a GuardShield Micro 400 safety light curtain use the safety software to create a configuration and download it to the MSR42 controller Two Beam or Four Beam Muting The MSR42 offers two beam and four beam muting according to
20. ment of the safety light curtain GuardShield Safe 4 GuardShield Safe 2 or GuardShield Type 2 or Bulletin 440L GuardShield d a 4 GG F Use the integrated laser alignment system ILAS for easy verification Touching the symbol turns the laser on or off Z The green indicator on the receiver light curtain confirms the oa correct allignment Step 8 Adjustment of the Light Curtain GuardShield Micro 400 The Micro 400 light curtain is best aligned by LED indicators A green LED indicator on either the emitter or receiver light curtain confirms the correct alignment Adjustment of the Muting Sensors and Retroreflectors For the corresponding muting type check the Muting Types section on page 12 for sensor positions Tighten the cantilever screw when positioned at the correct height and the muting sensors are at the proper distance to the light curtain see the Muting Types section on page 12 Adjust the reflectors and muting sensors to each other Check the status LEDs on the opto retroreflective sensor for correct operation ATTENTION e A pallet should not interrupt the light curtain nor the muting sensors The light curtain and the muting sensors should be interrupted by the transported goods only e Fora correct muting sequence the muting sensors must be interrupted from the goods with a time difference of gt 50 ms Note The image shows the RightSight with reflector Normally the muting sensor gets mounte
21. monitored t espe s 2 000 z Mute dependant override active iN t espe s 0 000 OOOO Mute dependant override active N t mnute min 5 000 ff T Muting disable signals connected umem e0 Pf T Muting disable signals connected _ Mehr Informationen www ab com safety tmt foo sf Muted light curtain E ff Muted light curtain h Safe400 C Safe4 Safe400 C Safe4 AB Allen Br adley msde s Ghee J 7 Light curtain interruption monitored tmsdel s oomo J JT Light curtain interruption monitored Check whether the muting times are permitted for the application Check whether the muting times are permitted for the application Ss mate Table 27 MSR42 configuration and diagnostic software Download with Optical Interface In case the default configuration see above will not be used the created configuration has to be downloaded with the optical interface 445L AF6150 connected to the MSR42 control module Clip the suction head cap into the black fastener Connect the USB plug into your computer Start the configuration software Create the desired configuration Reference the Configuration and Diagnostic Tool user manual Download the configuration Menu File download Allen Bradley Original instructions 15 A Guard maste Muting Controller Box Installation and Operating Instructions Indication Safety Light Curtain The green LED on the receiver light curtain i
22. naaeeeeduxee esis deacsatawse tases 12 Configuration and Diagnostic lOO 6 ivissseseastewsesicvuiadsawiecswwiesewiesen seas ewes sew swarweesuteeseees 14 ee ee ee ee ee ee er eer ee 16 Et ee ee ee ee ee ee ee ee 18 Mounting Stand 26606 050000set tuned euias sees ieeniecewe sauce diene tetadeewihownevesaretadeabeeuuseeeseuses 19 BOI i ee ee ee eee ee ee ee ee ee ee re ee ee 22 TROUDIC SNOGUNG reee roc ceca ene h sates ctw E EE eine T eee ee EA teeeeeaens 24 Application Restriction S i400 2beoscaeasieiantsse sia eeew due ene E E ENEE iewerawense eeu sea eines 24 edhe a ee ee ee ee ee ee 25 Certifications and Conformity 4 6606654 00500neaesseese sures wiooress ess enon eine ees ENEAN PEN EEEREN EREE 26 Reference Documents GuardShield User Manual MSR42 Control Module User Manual GuardShield Safe 4 Safety Light Curtains User Manual GuardShield Micro 400 Safety Light Curtains User Manual MSR42 Configuration and Diagnostic Tool User Manual Installation Instruction Mounting Column User manual for any other safety device being connected to the muting controller box Allen Bradley Original instructions 3 A Guard maste Muting Controller Box Installation and Operating Instructions Introduction The Rockwell Automation Guardmaster muting controller box is a pre wired enclosure using an MSR42 multi function control module as the muting control module This muting enclosure has pre wired M12 quick disconnect connectors to accommodate th
23. nd 2 The meaning of the indication can be changed according to the configuration downloaded for the MSR42 see Software and Optical Interface section 16 Original instructions Allen Bradley n Guard Imaste Muting Controller Box Installation and Operating Instructions Muting System Examples Product Part Number Description Safe 4 PAC Light Curtain Example Light Curtain 1x 445L P4S3400YD Safe 4 PAC 3 beam light curtain pair Muting Box 1X 445L AMUTBOX1_ Muting Controller Box MSR42 Light Curtain Patchcord 2x 889D F5ACDM 1 5 conductor M12 patchcord 1 meter also offered in 5 and 10 meter lengths 2 required RightSight Polarized Retro Red DC 2 Complementary LO DO Outputs PNP 4 pin muting sengor exora TEER AER Pico QD on 152 mm 6 in pigtail 2 or 4 sensors required muting sensor patchcord Muting sensor patchcord 2xor4x 889P F4ABPM x 4 conductor M8 patchcord x 1 2 3 or 5 meter Muting sensor bracket 2x or 4x 60 2649 Swivel Tilt Bracket for RightSight sensors 2x or 4x 889P F4ABPM 1 Muting sensor reflector 2x or 4x 92 39 Reflector 76 mm Bracket included in 445L AMSTDMUT If external mute lamp is desired a mute lamp option with right angle bracket is below Muting lamp with bracket 1x Muting lamp with right angle bracket Muting lamp patchcord 1x 4 conductor M8 Pico patchcord 5 meters Connection cable outputs 1x x 2 5 or 10 meter GuardShield PAC Light Curtain Example Light Curtain 1x GuardShield PAC 3
24. ndicates under normal operation if the protective field is uninterrupted See corresponding light curtain manual GuardShield Safe 4 GuardShield Safe 2 Emitter Receiver Emitter LED green on Normal operation Power on Power on i orange orange Receiver LED green on Protective field is uninterrupted normal operation s Orai LED red on Protective field is interrupted green green Test input Output inactive red red OptiLink OptiLink IR light IR light GuardShield Micro 400 LED green on Protective field is uninterrupted LED red on Protective field is interrupted LED Flashing red Lock out condition LED Flashing green Low light intensity Note Ifthe LED is flashing green optimal alignment has not been attained Continue adjusting the Micro 400 until a solid green LED is visible Muting Sensor Check the sensor manual for LED indication The yellow LED on the RightSight sensor indicates correct alignment of an uninterrupted beam If the orange LED is off the intensity is too low and the beam should be readjusted Muting Box Three indicators showing the condition of the muting box Muting lamp off Safety light curtain is active white on Safety light curtain is muted white flashing Muting sequence error Output status off OSSD output off green on OSSD output on Error status off Lockout green on ok ara The status output are driven from the MSR42 output info 1 a
25. ounting stand 5 7 kg Housing dimensions 111 x 22 5 x 125 mm incl plugs Certifications According MSR42 Interfaces Optical Interface Weight and packaging Dispatch packaging MSR42 280x 200 x 70 mm Muting box 300x 200x 200 mm Cantilever floor mounting stand Dispatch weight MSR42 350g Muting box 2 3 kg Cantilever floor mounting stand 6 5 kg OSSD semi conductor outputs PNP Voltage Un 2V Current Max 400 mA short circuit protected and with cross fault detection Leakage current Max response time t C with Uy protective mode Output S1 S4 MSR42 GPIO1 GPIO4 Nominal voltage IMAX off S 0 1 MA CioaD lt 3 3 uF lt 17 3 ms Un 2V coded Short circuit protected Current max 100 mA short circuit protected Leakage current Status Outputs PNP MSR42 Info 1 Info 2 IMAX Off lt 0 05 mA Croap lt 100 nF Voltage Current max Un 2V 100 mA short circuit protected Leakage current Inputs MSR42 Power supply Uj IMAX off lt 0 05 mA CLoAD lt 4 7 uF 24V DC EN 60204 1 at 5 residual ripple Current consumption Max power consumption at max supply voltage Controller protection external 0 85 1 15 Un Nominal 70 mA Rush In current max 1 7 A 2 1 W semiconductor outputs unloaded 5 Aslow Control current into IN 1 IN 2 Minimum voltage at IN 1 IN 2 2 mA each min in accordance with EN 61131 2 11V DC at activa
26. ro 400 safety light curtain is used Or for two sensor muting if the Safe 2 Safe 4 or GuardShield safety light curtains are used The Rockwell Automation muting control box is designed in accordance with the technical specification TS IEC 62046 The Rockwell Automation muting control box is factory configured for two sensor muting using a Safe 2 Safe 4 or GuardShield safety light curtain Other muting configurations or safety light curtains will require the reprogramming of the MSR42 muting control module using the optical interface 445L AF6150 The factory default configuration of the MSR42 muting control module is as follows e Two sensor T type muting e Without monitored muting lamp e With manual start mode e Without EDM Mute dependant override is active and configured as follows T mdo is 60 seconds Configured muting times t sens IS 4 seconds tmute is 5 minutes Umsdel is 50 ms The response time of the factory configured muting box is 17 30 ms Muting is indicated by the illumination of a white lamp on the front cover of the muting box or an external muting lamp may be connected to an M8 pico quick disconnect connector located on the bottom of the muting box 4 Original instructions Allen Bradley n Guard Imaste Muting Controller Box Installation and Operating Instructions Muting Controller Box MSR42 445L AMUTBOX1 Mounting Stand 445L AMSTD2M Light Curtains POC or PAC Guar
27. shing on Mute Sequence Error Error in Sequence If an error in the muting sequence has occurred the muting lamp will blink ca 1 Hz indicating that the muting condition will not be initiated or has been discontinued Make sure that the muting sensor and the safety light curtain are uninterrupted Check alignment of the safety light curtain and muting sensors Eventually the muting sensors and safety light curtain have to be cleaned Lockout A non illuminated LED error status indicates a lockout as described in the Software and Optical Interface section on page 14 The reason for the lockout can be analyzed with the optical interface 445L AF6150 and the safety software see page 14 Application Restrictions The application is not intended for the following usage e In an explosive environment EX e In radioactive areas or e Outside of a temperature range of 0 55 C e Operating range lt 2 5 m depending on muting sensors and light curtain For further restrictions see technical specification of the safety light curtain and MSR42 Safety Controller 24 Original instructions Allen Bradley n Guard Imaste Technical Data General data Temperature range Enclosure rating according EN 60529 Net weight Muting Controller Box Installation and Operating Instructions Environment temp 0 55 C 32 131 F Stock temp 25 70 C 13 158 F IP65 MSR42 130g Muting box 1 7 kg Cantilever floor m
28. ted controller EN 61131 2 Start pulse duration Min 50 ms Max 5s Mute sensor time delay gt 50 ms Test pulse duration min Control current into GPIO1 GPIO4 Safety Prevention Lamp Minimum current at Lamp Safety Related Parameter Probability of a dangerous failure per hour PFH Allen Bradley 6 A Guard maste Response time x 2 7 MA 8 mA with lamp switched on 0 9 A with lamp switched on 9 0 E 10 1 h MSR42 Main M 3 0 E 10 1 h MSR45E 4 0 E 9 1 h GuardShield Micro 400 Original instructions 25 Muting Controller Box Installation and Operating Instructions Certifications and Conformity The Muting Station is based on the MSR42 Safety Controller Relevant safety conformity and certifications may be found on the MSR42 and safety light curtain documentation Please contact us for Technical Assistance In the U S 1 440 646 5800 Outside U S 001 440 646 5800 Visit our website www ab com safety 26 Original instructions Allen Bradley n Guard Imaste Muting Controller Box Installation and Operating Instructions Allen Bradley Original instructions a A Guard maste Muting Controller Box Installation and Operating Instructions 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
29. the Muting Types section page 12 The controller box is delivered by default with the two beam T type muting Other muting configurations can be selected with the safety software and downloaded with the optical interface Note Four beam muting is only possible if the Micro 400 safety light curtain is used Allen Bradley A Guard maste Original instructions 21 Muting Controller Box Installation and Operating Instructions Adjustment Step 6 Adjustment of the Safety Light Curtain Position the emitter and receiver light curtain at the same height on the mounting column Fully tighten the light curtain mounting screws General First adjust the horizontal angle of the floor mounting plate Second adjust the light curtain vertical axis left right and vertical front back axis of the stand However the lighting of the green LED on the light curtain indicates that the protective field is uninterrupted and the light curtain aligned Premount the column with the floor mounting plate on the floor Adjust with the floor plate adjustment screws the position of the mounting column after mounting a light curtain When the light curtain indicates uninterrupted protective field mount the mounting screws on the floor plate 22 Original instructions Allen Bradley n Guard Imaste Muting Controller Box Installation and Operating Instructions Adjustment of GuardShield Safe 4 Safe 2 or 440L GuardShield Adjust
30. tion to the Micro 400 safety light curtain emitter or receiver is interrupted e Defect in the electronics of Micro 400 light curtain or the MSR42 controller e Supply over or undervoltage e Error in EDM A lockout is indicated with LED Error Status off and with the output signal Lockout of connector PWR IO Pin 4 On the Micro 400 light curtain it is indicated with the red blinking LED emitter and receiver 10 Original instructions Allen Bradley n Guard Imaste Muting Controller Box Installation and Operating Instructions 24V Output Status OV 24V Error Status OV 24V Start OV gt 10sec gt 0 15 24V OSSD OV Figure 18 Power up function The lockout mode may be reset by one of two methods e Power down then Power up If the fault is still present the module will lockout again e Astart signal on switch Reset Override e A start signal on connector PWR I O Pin 4 Assuming the cause of the lockout has been eliminated from activating the Reset Override switch for ten seconds the controller starts up If the safety light curtain is interrupted e g due a pallet the controller goes into a safe off mode The Reset Override switch has to be reactivated again to start the mute dependent override function see Figure 18 Muting Controller Box MSR42 445L AMUTBOX1 Mounting Stand 445L AMSTD2M Light Curtains POC or PAC GuardShield Micro 400 Safe 2
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