Laser Scanner Protection for Automated Conveyor Car Using
Contents
1. back within a designated aisle While the car is moving forward the scanner in the back is muted While in reverse the scanner in the front is muted The conveyor car moves at two speeds fast and slow The safety zone of the scanner must be adjusted for a longer range when moving fast and can be adjusted for a shorter range when moving at slow speed At preprogrammed locations the conveyor car stops to transport materials to and from one of the fixed conveyor lines Publication SAFETY EN Deor 2007 Laser Stannar Proton fr Atma Comer Using SmartGuard 600 Packapo Satay Cntr Safety Function When an object is detected in the safety zone the conveyor car must stop moving or must remain stopped if not moving When the safety zones are clear the car can move in the direction of an active scanner Stopping Time and Safety Distance Calculate the necessary safety field length using the formula Safety Field Length SA ZG ZR ZF ZB where SA Stopping distance ZG General safety supplement 100 mm 3 94 in ZR Supplement for any measurement error of the SafeZone Multizone safety laser scanner related to reflection ZF Supplement for any lack of ground clearance of the vehicle ZB Supplement for the reduction in the braking performance Of the vehicle as defined in the related vehicle documentation Refer to the SafeZone Multizone Safety Laser Scanner User Manual publication 75046 172. 1 01 4 for details on the safety distance length for mobile applications Example Bill of Materials This safety application example uses these components Cat Wo Description y RULSEUNMZ SafeZone Multae laser sanior 7 MOLCSEZNMZ a Pre varod Cabo with mamory modula Am TSE cable 7 TAE 600 programmana safety contar T WUNMMTM Stop pash btn wis orelease Tigger acto T DORKS Sal monitoring contact Hock T TNE contact Tow camren adC ONNECT T BOUFTEYETTZ Yow aged Omm 235 Energency Sap T esa ato ius Tegend matal body Y E Weal ateh contact w voltage QusdCONNECT Y Lg Tosa equiod pilor Wg Blue round metal operator T tale LED ew 28 dc T MOLGEBMIL TO s Von E Fc SAFETVATIQEA N tbe 2007 Laser Scanner Protection for Automate Conveyor Car Using Smartt 00 Packaged Safety Cortmller 8 Setup and Wiring For detailed information on installing and wiring refer to the product manuals listed in the Additional Resources section on page 13 System Overview Sane Min Sere Mine uorum nn So g p SO Publication SAFETY ATOEA ELP Deor 2007 6 Laser Stannar Potton fr Automat Comer Using Sparta 600 Contr Configure the Laser Scanner baton SAFETY ATOEA eher 2007 The scanners are connected to a SmartG
3. Introduction Safety Application Example Laser Scanner Protection for Automated Conveyor Car Using SmartGuard 600 Packaged Safety Controller Safety Network enabled Example Safety Rating Category 3 according to EN954 1 E E Tespm E taser Cewmwg i This application example describes a safety system applied to the movement of an automated conveyor car Laser scanners are placed in the front and back of the car The scanners detect objects in the car s path and issue a stop command to the drive motors if an object is detected The sensors are connected to SmartGuard 600 programmable safety controller which provides muting logic and sends signals to the control system Features and Benefits A single SmartGuard 600 controller controls both the E Stop and two laser scanners This type of solution is applicable to many industries for example material handling packaging and automotive Rockwell Automation 2 Laser Stannar Potton fr Automat Comer Using Sparta 600 Patagod Safety Contr Important User Information Solid state equipment has operational characteristics differing from those of clectromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local R
4. amage or economie loss IMPORTANT information trat eal Tor successful application and understanding of he product ATTENTION A Tories information about practicas or creumstancos that can lead o personal injury or death property damage or economie os Attontions help you identify a hazard avoid a hazard and recognize the may be onor inside the equipment for example a drive or motor to alert popia that dangerous voltage may be present A A abe may bo ono inside equipment Tor a drive or motor to alert people that surfaces may reach dangerous temperatures PbicaonSAFET ATOEA 24 October 2007 Laver Scanner Protection fo Automate Conveyor Car Using Smarter 00 Package Safety Cortmller 3 General Safety Information This aplication examples for advanced users and assumes that you 2 vine and experiance in safety systern rumen uicsesmar siro aad fant contr hw bmn ried an awed Th ak assassmant may require 48 circuitry to reduce tho risk to a tolerable lvl Safety circuits must taka into consideration safety distance calculations which are not part of the scape of this document Contact Rockwell Automation to find out more about our safety risk assessment services Description m id L lat The automated conveyor car moves forward and
5. and released after 1 the E Stop is released 2 the appropriate scanner is active and 3 the EDM feedback signals are satisfied Reset Indicators This indicator blinks to indicate that the SmartGuard 600 controller is ready and waiting for the reset button to be pressed einige cess The portion of sample code above shows function blocks for control Of these inputs and outputs Forward Reverse Direction This takes a diverse input 1 N C 1 N O to determine which scanner is active To avoid a single fault error each contact should come from an independent device for example not from one relay One scanner is active all the time and the other is inactive When the inputs are closed terminal 9 and open on terminal 8 then the forward scanner is active When the inputs are open on terminal 9 and closed on terminal amp then the reverse scanner is active Switching from scanner to the other will not cause the outputs of the SmartGuard 600 controller to momentarily turn off Fasi Slow Speed Selection This takes a diverse input 1 N C 1 NO and creates two diverse inputs one for each scanner This selects the safety and warning fields used by both scanners Both scanners are changed at the same time The fast fields look further out as the stopping time of the car will be longer The slow fields do not look as far out as the fast fields as the stopping time of the car is quicker Publicat
6. cal manuals knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit htp suppor rockwellautomation com Installation Assistance 1f you experience a problem within the first 24 hours of installation please review the information that s contained in this manual You can also contact a special Customer Support number for initial help in getting your product up and running United States KEEN Monday Friday Bam 5 pm EST United States Please contact your local Fackuel Automation representative for any technical support issues New Product Satisfaction Return Rockwell Automation tests all of ts products to ensure that they are fully operational when shipped from the manufacturing facility However f your product is not functioning and needs to he retumed follow these procedures stad States Contact your distributor You must provide a Customer Support casa number so phone number above to obtain on to your distributor in order to complete the retum process Outside United States Please contact your local Fockwal Automation represen
7. ion SAFETY ATOEA Der 2007 42 Laser Seamer rotation for Automated Conor Uing Sara 600 Packaged Safety Contr This fast slow selection does not necessarily have to be processed by the SmartGuard 600 controller Four contacts two for each scanner can supply signals directly to the scanners to select the fields To avoid potential single fault errors each contact should come from an independent device The wiring diagram shows mechanical contacts which are sourced from Test Pulse outputs The test pulses will initiate a stop command if shorts are detected to 24V to ground or between the two channels Performance Data These field sets for the laser scanner are provided as examples The actual field sets depend on the conveyor aisle and the conveyor speed For demonstration purposes the fields are asymmetric and short SAFETY ATOEA 24 eher 2007 Lasar Scanner Protaction fo Automated Cover Car Using SmartGuard 60 Packaged Safety Controlar 13 Additional Resources For more information about the products used in this example refer to these resources Description Safety Laser Scanner User Manual publication 7908171401 Provides tali wing configuration commissioning and rouboshooting SafeZone scanner 600 Controllers User Manual publication 1752 UM0D1 Provides detailed formation on stalling config
8. ockwell Automation sales office or online at rockwellastomsation com describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application ofthis equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or lability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circus equipment or software described in this manual Reproduction of the contents of this manual in whole or in without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations A antes formation about practicos or circumstances Wat can cause an explosion in a hazardous environment which may lead to personal Injury ar death propery d
9. r Car Using Smartt 00 Package Safty 7 3 Choose the type of application to indicate whether the SafeZone MultiZone scanner is operated on a stationary machine mobile vehicle e Configure the scanner Choose the OSSD configuration for the scanner Publication SAFETY ATOEA Deor 2007 Laser Seater Protartion far Automated Comer Car Lising SmartGuard 60 Packapo Slt Contar 6 Configure the scanners inputs m ase m Choose the type of restart for the scanner The Configuration Assistant dialog provides information about each type of restart SAFETY ATIEA 24 eer 2007 Laser Scanner Protection for Automate Conveyor Car Using Smarter 00 Packaged Safety Cortmiler S 9 Create two field sets for the scanner created as _ e e a om Em 11 Enter the user name you want to appear in the configuration protocol and diagnostic reports 12 Repeat these configuration steps for the second scanner ross tha PgDn to lat the program download Th Acknowledge hocones ive Pbliaon SAFETY ATDOGAEN P Deor 2007 10 Laser Seamer rotation for Automated Conveyor Uing Sara 600 Padage Safety Conor Programming Use RSNetWorx for DeviceNet software to configure the SmartGuard 600 controller and program your application The Logie Editor la
10. tative for the ratur produ ented orl con Tee ane Satu RS ee Ss ad QuiEDANIT ad t Madea oct hong oc Atoms ae peyote pein compan wwwrreckwellautomation com wer Control and Information Solutions Headquarters uc Rocke Aro tee 14 Core rper 3 100 Cyberpor Red Hong Kong TH N52 208 7 Pa 52 2508 1946 SAFETY ATOGA N P Deer 2007
11. uard 600 safety rated programmable controller The SmartGuard 600 controller performs the muting logic and sends signals to the control system to allow starting of the motor of stop the motor when an object is detected in the safety zone The SmartGuard 600 controller has a DeviceNet connection which allows it to connect to additional safety modules as well as non safety rated devices Each scanner can have two separate selectable field sets with each set consisting of a warning field and a safety field The field sets are selected by inputs 1 and A2 The Al and A2 inputs use a combination of one normally closed and one normally open contact to help reduce the probability of a fault due to shorting The software dialogs on the following pages illustrate the steps and configuration settings needed to configure this application example using the Configuration Assistant in the Safety Configuration and Diagnostic SCD software TE The SafaZane Multizone software cannot run while RSLinx software is nunning In your icon tray the icon and choose Shutdown RS software automatically loads again whan You run RSNetwon for DeviceNat software The default password for the laser scanner is For demonstration purposes log in as an Authorized Client 1 Enter name for your application 2 Enter a unique name for the SafeZone MultiZone scanner Laser Scanner Protection fo Automate Conveyo
12. unched from within RSNetWorx for DeviceNet software lets you program your application using Function Blocks SAFETY ATOEA tober 2007 This portion of sample code shows function blocks for control of these inputs and outputs E Stop The E Stop is setup as a dual channel equivalent input QNO The E Stop is active in all modes of operation forward reverse fast and slow Pressing the E Stop will initiate an immediate stop Resetting the E Stop will not cause the car to The E Stop wiring uses the pulse testing outputs to check shorts to 24V ground and between channels Forward Scanner OSSD Outputs These safety outputs will initiate stop command if the scanner is active Reverse Scanner OSSD Outputs These safety outputs will initiate a stop command if the scanner is active Immediate Output Feedback The SmariGuard 600 controller monitors the output switching device If the device does not activate within the prescribed time selectable between 100 1000 ms the outputs will turn off Delayed Output Feedback The SmartGuard 600 controller monitors the output switching device If the devices does not activate within the prescribed time selectable between 100 1000 ms the outputs will turn off Laser Scanner Potaction fe Automated Conveyor Car Using Smartt 600 Packaged Safty Cortraler 11 Reset To initiate the outputs the reset button must be pressed
13. uring programming and wubloshoting SmartGuard 600 controllers SarGuanl 600 Controls Satay Referenco Manual publication Provides SIL Tand CATE safety system requirements including functional veriication tast intervals system reaction time and PFD PFH vales Automation Safety Products Catalog publication S115 Provides infomation Rockwell Automations safety product offerings Automation Wiingand Grounding Guidelines publication 1770 41 Provides general guidelines for instaling a Rockwell Automation industrial system Produ Corificatons website Mofa con Provides declarations of conformity caricato and othar certification details You can view or download publications at up literature rockwellautomation com To order paper copies of technical documentation contact your local Rockwell Automation distributor or sales representative Publication SAFETY ATI Deer 2007 14 Lasar Seamer Proton for Automated Comer Ling Smartta 600 Packaged Se Controller Notes SAFETY ATOOGAEN P October 2007 Lasar Scanner tocan for Automated Conveyor Car Using Smartuard B00 Packaged Safety Controlar 15 Publication SAFETY EN Deer 2007 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At up supportrockwellautomation com you can find techni
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