CC-QS015 - Rockwell Automation
Contents
1. Ctirl U CEO Ser A Reu Hin id Su v2 02 The Device number is printed an the MSR42 product label Enter the Device number Found on the label here To identify this configuration you have to enter a configuration designation e g AB B013 This designation will be printed an the configuration contral document and Default 3 Field must be Filled out cs come Y Advanced settings 21 Chapter1 Product Integration Confirm the Configuration 1 On the Configuration control document dialog box review the configuration t Configuration control document Configuration irmati Remarks and check the confir ation box Safety light curtain Start Mode manual Stop Delay No Double scan2 GPIO1 2 Mone 4 sensor T type muting Muting lamp monitored 74 Muted light curtain GuardShield Safe4 LC interruption monitored t espe 3 000 s 2 Click Continue t sens 10 00 s E mute 2 00 min E msdel 50 00 ms Active E mdo 60 00 s Not connected 5 When prompted to p rint the document OSSD ChA and relay outputs ChB click No GuardShield Micro 400 light curtain Lockout Start release The software saves a copy that can be i 1 I confirm that the configuration is correct printed later from the File menu 4 On the Attach Safety Configurator Label dialog box click OK Attach Safety Configurator Label Attention important information Th e M SR 4 i S NOW fully CO n2. t msdeb s w Light curtain interruption monitored Check whether the muting times are permitted far the application OK Cancel Help Publication CC OS015A EN P November 2009 17 Chapter 1 13 18 Product Integration Time settings are intended to help make sure that only valid objects of the right size moving at the right speed can initiate and maintain a muting sequence You may want to add a few seconds to some of your calculations to allow for variations Time Setting t sens t espe t mute t mdo t msdel Description since both 1 and S2 or both S3 and 4 sensors must be broken simultaneously to initiate a muting sequence these sensors should be spaced no further apart than the length of the smallest typical load Calculate how long a load takes from the time it first reaches S1 until it reaches S2 or S3 until it reaches 4 based on the speed of the conveyor This is the t sens time for your system The t espe field is disabled until you check the Light curtain interruption monitored checkbox under Additional Settings The t espe of your system is the time from the moment a load reaches the second sensor S2 from the right or S3 from the left until it enters the light curtain sensing field Once the light curtain is muted the load must interrupt the light curtain within 3 seconds Therefore the second sensor must be placed within 3 seconds travel time from the light curtain t espe sho
3. Description Provides information on how to select products and gain access to panel and wiring Information Provides files for the Connected Components Building Blocks Provides information installing and setting up the PowerFlex 40P drive parameters with the pre configured RSLogix 500 program that controls you base system including application tips as well as implementing the drive parameter backup and restore functionality Provides information on using the MicroLogix 1100 Programmable Controller Provides information wiring and operating the MSR42 safety controller Provides information on using the MSR45E expander module Provides information on mounting wiring and using safety light curtains Provides information on configuring and programming an MSR42 safety controller with Configuration Tool software Provides access to the Allen Bradley website Provides access to self service support Provides access to the Connected Components website Publication CC OS015A EN P November 2009 Chapter 1 Product Integration introduction A bidirectional four sensor T type muting system lets valid loads or objects pass through its light curtains in either direction without shutting down the machine or process but will stop the machine or process if anything or anyone attempts to move past the light curtain in any other manner This type of system is often used to guard the access point at a hazardous portion of a machine or process where
4. a Go to Related Links on the right side of the page and choose Safety Software ZIP b Save the zip file to your personal computer c Unzip the file d Run the SetupDiagnosticAndConfiguration_Vxxx exe file to install the software Start the Configuration and Diagnostic software Click MSRA2 and then OK Configuration And Diagnostic Software Properties the Configuration and Diagnostic uei software register the software Company a From the Options menu choose A Firstname Em i User Registration Address rats b Type in your information and ai yp 2 click OK Phone E Mail Required Informations Cancel It is not necessary to change the password for this building block The default password is ABGM Publication CC OS015A EN P November 2009 Product Integration Chapter 1 Configure the MSR42 Safety Relay 1 On the Configuration t MSR42 Configuration And Diagnostic Software Configuration1 dialog box select Micro File Options Help 400 Light Curtain from the serene Micr O 400 Inputs Inputs Design Output pull down menu Micro 400 None tdt Edit the settings as shown d b C d e Nome GPIO Micro 400 Light Curtain Ed INI None vj IN2 None v Outputs Info safety Outputs E Info2 Lockout Y Safety safety Outputs OSSD Edit System information Design error messages Design OK ET MSR42 Configurati
5. information are provided on the Connected Components Building Blocks Overview CD publication CC QROO1 The CD provides bills of materials BOM CAD drawings for panel layout and wiring control programs Human Machine Interface HMI screens and more With these tools and the built in best practices design the system designer is free to focus on the design of their machine control and not on design overhead tasks Read these sections carefully before beginning work in each chapter The beginning of each chapter contains the following information e Before You Begin This section lists the steps that must be completed and decisions that must be made before starting that chapter e What You Need This section lists the tools that are required to complete the steps in the current chapter This includes but is not limited to hardware and software e Follow These Steps This illustrates the steps in the current chapter and identifies which steps are required to complete the examples Publication CC OS015A EN P November 2009 7 Preface Conventions Convention Example Check or uncheck To activate or deactivate a checkbox Check Disable Keying Click Bones Click the left mouse button twice in quick succession while the cursor is positioned on object or selection to initiate an action Expand Right click Select Using the mouse to highlight a specific option Press Click the left mouse button once while the cursor i
6. is permitted to pass though the light curtains without triggering a safe stop The light curtains are ignored by the safety system until the object passes completely through clearing the light curtain sensing field and passing the third sensor ending the muting period As soon as the third sensor is cleared the safety system will again trigger a safe stop if anything breaks the sensing field without first passing S1 and S2 in the proper order and within the configured time constraints 10 Click Help in the lower right corner of the Muting dialog box 16 Publication CC OS015A EN P November 2009 Product Integration Chapter 1 The Muting Help dialog box shows Muting Help the proper timing sequence for 4 Timing diagram 4 sensor T type muting sensor T type muting An object must not only pass the sensors and EE Q M the light curtain in the proper sequence To initiate muting an object moving right to left in the diagram must be in front of both S1 and S2 for an instant When moving left to right an object must be in front of both S3 and S4 for an instant Take this timing and the S i Ze of the loa d into cons ideration Muting time explanation For more details see Safety Configurator MSR42 manual 104 720 t sens Sensor activation time Max time between the activation of the muting sensors when mounting the Sensors The t espe Light curtain activation time Max time between the activation of the muting sensors
7. safety or control functions If the PanelView terminal is mounted so that it provides the operator a clear and complete view of the hazard area and local safety regulations permit the PanelView START RESET button may be used to start or reset the safety systems just like the Start Reset push button Motel tae the operator stationed at the PanelView terminals location cannot see the guarded area well enough to be certain that no one is in the guarded area you must not use the START RESET button The START RESET button can be disabled by removing three wires from the MicroLogix controller 0 e Wire 6041 e Wire 10231 e Wire 10071 Safety Systems Diagram PanelView Component Terminal MicroLogix 1100 800F Personal Start Do Stratix Computer Reset e 2000 me MSR42 MSR45E DM Multi Expansion TEST me Rightsight function Controller Sensors sensors Safety Relay GuardShield Micro 400 800FP Light Curtains Publication CC OS015A EN P November 2009 11 Chapter1 Product Integration set Up the Configuration and Diagnostic Software Follow these steps to install and set up the Configuration and Diagnostic software If this is the first time you have used 1 If you do not have the Configuration and Diagnostic software go to http www ab com safety logic relays msr4x to download the Configuration Tool for MSR42 relay GuardShield Micro 400 and Safe2 4 Light Curtains
8. to the activation interruption of D the light curtain Only active if the Light curtain interruption monitored Function is active minimum load must be long t mute Muting time Max time For muting enou gh tO be in fro nt O f both S 1 t mdo Mute dependant override time Max time For mute dependant override Function t msdel Mute sensor delay time Max time For acceptable interruption of the mute signals and or the light curtain ESPE signal and S 2 Or S 4 and S4 Sensors without having an effect on the muting sequence simultaneously The Muting Help dialog box also provides definitions for the t sens t espe tunute t mdo and t msdel times which you can configure on the 4 sensor T type dialog box A load that exceeds any of these configured times as it moves across the conveyor causes a muting error which results in the light curtain not being muted A load entering the light curtain sensing field during a muting error triggers a safe stop 11 Click Close to return to the Muting dialog box 12 Type the timing values or use the slider to edit the default values DEK 2 sensor T type 4 sensor T type 2 sensor L type 2 sensor T type with enable Bidirectional muting application Connecting diagram Muting lamp Muting Settings Time Settings Additional Settings t sens s w Muting Lamp monitored t espe s t MV Mute dependant override active A t mute min t mdo s Muted light curtain G 1 C
9. 2 16 09 25 09 PM 03 48 01 15 Chapter1 Product Integration 8 Click OK on the safety notice dialog box 7 From the Inputs GPIO pull down menu choose Muting Micro 400 Important safety notice To use the muting Function an analysis of the system is Necessary The muting Function by passes the safety light curtain Please check the conditions For a correct application of the muting Function according IEC 62046 9 On the Muting dialog box click 4 sensor T type 2 sensor T type 4 sensor T type 2 sensor L type 2 sensor T type with enable Bidirectional muting application Connecting diagram 2 UOI BH 1 M Muting lamp Muting Settings Time Settings Additional Settings t sens s J Muting Lamp monitored t espe s Mute dependant override active A t mute min 5 000 t mdo s 5 000 es light curtain 0 050 EM eneren ped Light curtain interruption monitored cs Check whether the muting times are permitted for the application A Conc Help This dialog box helps you configure your muting system properly The Muting dialog box shows that a load on the conveyor travels left to right passing in sequence through the first two muting sensors and the LC light curtain After passing the light curtain the load passes in sequence the last two sensors An object passing the sensors in the proper sequence and within the configured time constraints
10. Bidirectional 4 sensor T type Muting With MSR42 Relay Connected Components Building Block Allen Bradley Catalog Numbers MSR42 MicroLogix 1100 GuardShield Micro 400 Light Curtains Quick Start 11414132331 a dl e PX INS ma MT Eras JL Lane gg qr et A XUI uu Nm E E 1 UM rz uU V pe T V Rockwell Allen Bradley Rockwell Software Automation Important User Information solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at 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 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 Autom
11. Bradley vadimata None v Lamo None v Outputs Info safety Outputs M Lockout Y Info2 Safety Outputs OSSD Edit System information Safety Design error messages One or more component has manual start but no start is connected Configuration Control apo MSR42 I v1 00 19 12 2008 09 28 09 PM 04 41 58 t MSR42 Configuration And Diagnostic Software Configuration File Design Diagnosis Application info Options Help Configuration Basic configuration Inputs Design Output Micro 400 Micro 400 Light Curtain v Edit GPIO None v M None v Outputs Info Safety Outputs Y Lockout Y Info2 Safety Outputs OSSD Edit System information Safety Design error messages Design OK Configuration Control bo MSR42 v1 00 19 12 2008 09 25 09 PM 03 43 02 Publication CC OS015A EN P November 2009 Product Integration Chapter 1 5 From the IN2 pull down menu choose Start Release Notice that Start Release is shown connected to IN2 Start Release is a feedback circuit that confirms at Start Reset that neither of the two final switching devices FSD normally open NO outputs are shorted that is closed In this application the Start Release circuit goes from 24V through one auxiliary normally closed NC contact of each 100S contactor to the MSR42 relay Similar to EDM if eithe
12. S A
13. ain sensing field pod Gd SYSTEM RUNNING NOT MUTED As the load enters the light curtain sensing field the LC light curtain SAFETY SYSTEM STATUS button turns red to indicate that the light curtain has been interrupted The Safety Output button remains on SYSTEM RUNNING MUTED 32 Publication CC OS015A EN P November 2009 As the load leaves S2 muting ends 4 Press the E stop The screen updates in response 5 Press MORE INFO 6 Press RETURN 7 Twist and release the E stop 8 Press START RESET for three seconds and release The system starts to run and guarded motion begins Publication CC OS015A EN P November 2009 oystem Validation and Application Tips Chapter 2 SAFETY SYSTEM STATUS SYSTEM RUNNING NOT MUTED SAFETY SYSTEM STATUS SYSTEM RUNNING MUTED The Safety Output is off The E Stop has been pressed Twist and release the E Stop Make sure the system is clear and Safe Press and release the Start Reset Button 33 Chapter2 System Validation and Application Tips 9 While avoiding the sensors interrupt the light curtain and keep it interrupted SAFETY SYSTEM STATUS SAFETY OUTPUT OFF LIGHT CURTAIN INTERRUPTED MORE INFO 10 Press MORE INFO 11 Press RETURN Something has interrupted the Light Curtain The object may or may not be present Check to make certain that no people or objects other than a load are in the guarded area Press and release
14. ation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss IMPORTANT Identifies information that Is critical for successful application and understanding of the product ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures gt gt eiie Allen Bradley Rockwell Automation TechConnect MicroLogix PanelView Rockwell Software and GuardShield are trademarks of Roc
15. change This button Indicates There is no load in front of the sensor A load is in front of the sensor The light curtain sensing field is not interrupted The light curtain sensing field is interrupted The E stop has been pressed The following pages illustrate a typical sequence of PanelView screens Confirm that the system and PanelView screens operate as expected by following this sequence When you apply power to the system the Safety System Status screen appears SAFETY SYSTEM STATUS SAFETY OUTPUT OFF SYSTEM IN LOCKOUT MORE INFO Publication CC QS015A EN P November 2009 31 Chapter2 System Validation and Application Tips 1 Press MORE INFO for two seconds Whenever an action may be appropriate for an operator to perform MORE INFO is displayed on the screen Pressing MORE INFO calls the related The System is ready for Start Reset Make sure the system is clear and safe message screen Press and release the Start Reset Button 2 Press RETURN for about five seconds to return to the previous screen 3 Press START RESET for three seconds and release The system should start running Note that the START RESET button is green only when the system is ready for a Start Reset It is no longer green once the system is running As the load enters the system from the left and moves in front of S4 and S3 SAFETY SYSTEM STATUS muting is initiated The load has not yet interrupted the light curt
16. d motion stops e The red stacklight turns on Publication CC QS015A EN P November 2009 29 Chapter2 System Validation and Application Tips Mute Dependent Override from Left 1 While the load is still disrupting the light curtain beam from the previous mute error test press and release the Start Reset button 2 Check the following e The safety output turns on e The two 100S contactors energize e Guarded motion starts e The muting lamp is on and is not blinking e The green stacklight turns on 3 As soon as the load clears the light curtain break the light curtain beam taking care not to block any sensors 4 Check the following e The safety output turns off e The two 100S contactors de energize e Guarded motion stops e The red stacklight turns on 5 Press and release the Start Stop button to start the system Lockout 1 Carefully disconnect and reconnect one of the light curtain RJ45 connectors at the MSR42 relay 2 Make sure the safety output triggers the instant the light curtain is disconnected This completes the validation of the safety systems 30 Publication CC OS015A EN P November 2009 system Validation and Application Tips Chapter 2 Validate Proper Operation of the PanelView Screens Most of the buttons are real time signals from the MSR42 or MSR127 relays driven via the MicroLogix 1100 controller to the PanelView terminal The buttons change their appearance as the signals driving them
17. dran 25 WIO NECU pepada eb rob oe VIAL aded X gt Follow These Steps qc ban nae os es Ee ee 26 Validate Proper Operation of the Safety Systems 26 Validate Proper Operation of the PanelView Screens 31 Table of Contents 6 Publication CC OS015A EN P November 2009 Preface About This Publication This quick start illustrates one way of combining a set of Micro 400 Light Curtains an MSR42 safety relay an MSR45E expansion module an MSR127 safety relay an E stop and two contactors into an integrated safety system providing both a bidirectional four sensor T type muting function and an E stop function A MicroLogix 1100 controller and a PanelView HMI are included to provide a convenient and graphical way to monitor the operation of the safety systems and provide basic diagnostic information and corrective action suggestions when appropriate The MicroLogix controller and PanelView terminal only monitor the safety systems They are not safety components and they have no safety control or function The safety systems operate independently from the MicroLogix controller and PanelView terminal Use this Simple Machine Safety Connected Components Building Block Quick Start in conjunction with the Connected Components Building Blocks Quick Start publication CC QS001 Refer to Additional Resources on page 8 for a listing of quick starts To assist in the design and installation of your system application files and other
18. e Optical Interface into an available USB port on your personal computer Note the new COM port that appears in the list This is the port assigned to Remote System Restore l Automatic Updates General Computer Name Hardware Advanced Device Manager x The Device Manager lists all the hardware devices installed on your computer Use the Device Manager to change the properties of any device Drivers Driver Signing lets you make sure that installed drivers are compatible with Windows Windows Update lets you set up how Windows connects to Windows Update for drivers Hardware Profiles Hardware profiles provide 4 way for you to set up and store different hardware configurations Hardware Profiles Apply the Optical Interface which you will need to select in the Configuration and Diagnostic software as part of the download procedure Close the Control Panel In the Configuration and Diagnostic software choose Options gt USB Comport settings If USB Comport settings is not available check oupport Mode active and choose Options USB Comport settings t MSR42 Configuration And Diagnos File aa Language Publication CC OS015A EN P November 2009 Product Integration Chapter 1 13 On the OptiLink Communication dialog box select Compatibility mode 14 Choose the Comport assigned by Windows Device Manager 15 Click OK 16 From the File menu choo
19. ed during a Muting Error Check to make sure the system is clear and safe The load is still interrupting the light Press and release the Start Reset button curtain Pressing and releasing START RESET initiated a Mute Dependent Override tando The system switches to muted operation Muting ends as soon as the load clears the light curtain or when the configured t mdo expires TIP When the START RESET button is green it may be used in place of the Start Reset push button If requirements dictate that remote reset must not be used do not use it If the operator stationed at the PanelView terminal s location cannot see the guarded area well enough to be certain that no one is in the guarded area you must not use the START RESET button The START RESET button can be disabled by removing three wires from the MicroLogix controller 0 e Wire 6041 e Wire 10231 e Wire 10071 23 Carefully disconnect then reconnect one of the light curtain cables from the SAFETY SYSTEM STATUS MSR42 relay at its RJ45 socket Ed GE SYSTEM IN LOCKOUT RESET SAFETY OUTPUT OFF START MORE INFO 36 Publication CC OS015A EN P November 2009 system Validation and Application Tips Chapter 2 24 Press MORE INFO 25 Press RETURN The system is in Lockout Check the system components and wiring Press and hold the Start Reset button for 10 seconds then release Press and release the Start Reset button normally If the system fails
20. ell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication CC 05015A EN P November 2009 Copyright 2009 Rockwell Automation Inc All rights reserved Printed in the U
21. fi gu re d An d rea dy f Of piden have changed the configuration adhere the enclosed label see below to the side of the operation Configuration changed see Configuration Control Document Date Name Configuration Designation Write the current date your name and the configuration designation on this label You have to check the safety functions on the MSR42 5 Click the Diagnosis tab CJ MSR42 Configuration And Diagnostic Software Configuration File udi dais Diagnosis Procedure 1 Connect Optical Interface Reset 2 OptionslPC settings SW Version Power on hours No relay switches Reaction time t C t LC Output state 202 1138 2224 9 20 ms 4 08 ms 13 28 ms ChA Off ChB OFF Protective field viewer Service information Muting Time Recorder Error History Transmitter off GuartShietd Micro 400 Operation Receiver 22 Publication CC OS015A EN P November 2009 Product Integration Chapter 1 This screen lets you monitor the status of the light curtain when a computer is attached to the MSR42 relay via the Optical Interface It has other helpful diagnostic features that are described in the MSR42 Safety Base Module Operation Manual publication 440R INO17 and the Configuration Tool for MSR42 GS Micro 400 and Safe 2 4 Light Curtains Software Description document available on the CD that ships with the Optical Interface tool Otherwise a personal computer is neit
22. for the muting lamp to start blinking 4 Move the load forward to break the light curtain beam 5 Check the following e The safety output turns off e The two 1008 contactors de energize e Guarded motion stops e The red stacklight turns on 28 Publication CC OS015A EN P November 2009 system Validation and Application Tips Chapter 2 Mute Dependent Override from Right 1 While the load is still disrupting the light curtain beam from the previous mute error test press and release the Start Reset button 2 Check the following e The safety output turns on e The two 100S contactors energize e Guarded motion starts e The muting lamp is on and is not blinking e The green stacklight turns on 3 As soon as the load clears the light curtain break the light curtain beam taking care not to block any sensors 4 Check the following e The safety output turns off e The two 1008 contactors de energize e Guarded motion stops e The red stacklight turns on 5 Press and release the Start Stop button to start the system Muting Error from Left 1 From the left let a load pass 4 and S3 but stop it short of the light curtain sensing field 2 Confirm that the muting lamp turns on 3 Wait the configured t espe delay for the muting lamp to start blinking 4 Move the load forward to break the light curtain beam 5 Check the following e The safety output turns off e The two 100S contactors de energize e Guarde
23. her required nor recommended for normal system Operation 6 Disconnect the Optical Interface tool Publication CC QS015A EN P November 2009 23 Chapter 1 Notes 24 Product Integration Publication CC OS015A EN P November 2009 Chapter 2 System Validation and Application Tips Introduction In this chapter you validate the operation of the two safety functions as well as the operation of the MicroLogix 1100 controller and PanelView Component 600 terminal Before You Begin e Review the Connected Components Building Blocks Quick Start publication CC QS001 verifying that you have completed all of the steps in Chapter 3 of that publication e Verify that you have completed all of the steps in Chapter 1 of this document e Verify that all components of the system are assembled and wired per the Bill of Materials Assembly Diagrams and Wiring Diagrams provided for this Connected Components Building Block and as required for your application e Verify that the MicroLogix controller and the PanelView Component terminal have power applied to them What You Need e Personal computer e Connected Components Building Blocks Overview CD publication CC QROO1 e MicroLogix 1100 controller catalog number 1763 L16BBB e PanelView Component C600 terminal catalog number 2711C T6C e Stratix 2000 Ethernet switch catalog number 1783 USO5T or equivalent to connect the MicroLogix controller to the PanelView terminal e Etherne
24. kwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Where to Start Connected Components Building Block Outline Follow the path below to complete your connected components building block Connected Components Building Blocks publication CC OS001 Chapter 1 Product Integration FanalViaw CGA Chapter 2 System Validation and Application Tips Publication CC OS015A EN P November 2009 3 Where to Start 4 Publication CC OS015A EN P November 2009 Product Integration System Validation and Application Tips Publication CC OS015A EN P November 2009 Table of Contents Preface About This Publication 2 5 i464944484 ex Oe ERU eec do 7 CONVENU ONS aaa a mb ree ae one Roten teilt 8 Additional Resources ecommerce a tue des 8 Chapter 1 AOJO TE uu d ec eee datus Bt db qe UP AC ES wok eS ee RS ee Ge 9 Bel te X OU Be STIS xu dE S vtae hie eo ER est cos UH 9 WE MOU INGE PT 9 Follow These SIGHS s 3 289 4 59 3 G0 Rd ehh dede dei 10 Understand the Safety Function n nero ome 10 Set Up the Configuration and Diagnostic Software 12 Configure the MSR42 Safety Relay nananana aaa aaa 13 Download the Configuration naa aaa aaa a 19 Confirm the Configuration euo e REESE REY eRDY TEE 22 Chapter 2 EIE OCI CHOU eue de tere ho wot seg a a aad oed 3 9 v EU A oe 25 Betore YOU Be Olt ur cun 6 ea aes de dup todos de dos ao de n fe
25. material must pass either into or out of the guarded area such as an automatic palletizing system or automatic assembly machine This Connected Components Building Block is intended to ease the installation configuration and implementation of such a system Before You Begin Review the Connected Components Building Blocks Quick Start publication CC QS001 verifying that you have completed the hardware design and installation as well as software installation AT safety risk assessment must be completed to make sure that all tasks and hazards are considered and to confirm that the example circuit provides adequate risk reduction for your specific application What You Need e Personal computer e Connected Components Building Blocks Overview CD publication CC QRO001 e MicroLogix 1100 controller catalog number 1763 L16BBB e PanelView Component C600 terminal catalog number 2711C T6C e Stratix 2000 Ethernet switch catalog number 1783 USO5T or equivalent to connect the MicroLogix controller to the PanelView terminal e Ethernet cables catalog number 1585J M8TBJM 2 or equivalent e MSR127 safety relay catalog number 440R N231132 e MSR42 safety relay catalog number 440R P226AGS NNR e MSR45E expander module catalog number 440R P4NANS e Optical Interface Tool catalog number 445L AF6150 which includes the Optical Interface Tool MSR42 Configuration and Diagnostic Software Publication CC OS015A EN P November 2009 9 Chapter1 Pr
26. n taking care not to block any sensors 2 Check the following e The two 1008 contactors de energize e Guarded motion stops e The red stacklight is on 3 While the light curtain beam remains broken press the Start Reset button 4 Confirm that the two 100S contactors do not energize and guarded motion does not start 5 Restore the light curtain beam 6 Press and release the Start Reset button 7 Check the following e The 100S contactors energize e Guarded motion starts e The green stacklight is on Publication CC OS015A EN P November 2009 27 Chapter2 System Validation and Application Tips Muting Function 1 Send a load from the right through the muting system 2 Check the following e S1 switches as the load passes e S2 switches as the load passes e The muting lamp turns on e The load passes through the light curtain without the system shutting off e The muting lamp turns off as the load passes S3 3 Send a load from the left through the muting system 4 Check the following e S4 switches as the load passes e S3 switches as the load passes e The muting lamp turns on e The load passes through the light curtain without the system shutting off e The muting lamp turns off as the load passes 82 Muting Error from Right 1 From the right let a load pass S1 and S2 but stop it short of the light curtain sensing field 2 Confirm that the muting lamp turns on 3 Wait the configured t espe delay
27. oduct Integration e Optical Interface Tool Fastener to attach the Optical Interface securely to the MSR42 relay e 24V DC power supply catalog number 1606 XL120D e Safety components such as E stops GuardShield Micro 400 light curtains as listed in the bill of material on the Connected Components Building Blocks Overview CD publication CC QRO001 Follow These Steps Stat Understand the Safety Function on page 10 Set Up the Configuration and Diagnostic Software on page 12 Configure the MSR42 Safety Relay on page 13 Download the Configuration on page 19 Confirm the Configuration on page 22 Understand the Safety Function Two separate safety functions are provided 1 The GuardShield Micro 400 light curtains and MSR42 safety relay provide a bidirectional four sensor T type muting function 2 The E stop and MSR127 safety relay provide an E stop function These two safety functions are independent of one another When set up properly either safety system is capable of stopping dangerous motion 10 Publication CC QS015A EN P November 2009 Product Integration Chapter 1 The MicroLogix 1100 controller monitors the safety systems and via the PanelView terminal provides a simple graphical representation of the operation and status of the safety systems and recommends corrective actions in response to system faults The controller and the terminal perform no
28. ome Instances loads may have gaps that the first two sensors might sense through as the load passes This could lead to a muting error One method to avoid such errors is to delay the sensors response to allow for seeing through gaps The t msdel configures that delay time Unless the gap is very long or the load is moving very slowly the gap is present for only a short time In most instances the default 0 050 is suitable Leave this value set at 0 050 Notice that the Connecting diagram shows a lamp as well as muting sensors connected to GPIO1 and GPIO2 and that IN1 is labeled Start Mute override In this application a Muting Lamp is required for safety purposes to warn personnel in the area when the light curtain is muted Review the Additional Settings a Make sure that the Muting Lamp monitored box is checked Muting lamp monitoring means that should the muting lamp fail short or open the MSR42 controller will sense it and not initiate or maintain muting In applications where a muting lamp is required generally the muting lamp is required to be monitored b Because you entered a t mdo time earlier leave the Mute dependent override box checked c In the Muted light curtain section note that GuardShield Micro 400 is selected and disabled and make sure that the Light curtain interruption monitored box is checked Publication CC OS015A EN P November 2009 Product Integration Chapter 1 14 Click OK to complete
29. on Control v1 00 19 12 2008 po 09 25 09 PM 03 32 06 GuardShield Micro 400 Choose Manual Start Stop Settings Connecting diagram Start Mode R i Leave Stop Delay set to No EI eceiver Choose Resolution 30 mm Stop Delay C Yes From the Protective height pull down menu choose 1200 Transmitter mum Light curtain parameters optional Double scan Physical resolution of light curtain Additional Filter EMC and optical Disturbences The software automatically PUMA om A E displays 48 as the Total beam Resolution 30mm number of system n Total beam number of system n 48 M Protective height UNE mn tea Leave Double Scan set to Yes 3 Click OK Publication CC QS015A EN P November 2009 13 Chapter 1 Product Integration 14 Notice that Micro 400 Light Curtains have been added to the Design Output diagram 4 On the Configuration dialog box select Start from the IN1 Inputs pull down menu In addition to the Micro 400 Light Curtains a NO momentary push button connected to INI appears on the Design Output diagram The red error message disappears replaced by Design OK t MSR42 Configuration And Diagnostic Software Configuration1 File Design Diagnosis Application info Options Help Configuration Basic configuration Inputs Design Output Micro 400 Micro 400 Light Curtain Y i Edit GPIO None n O Aften
30. r or both of these NC contacts are open the MSR42 relay cannot be started or reset 6 From the Outputs Infol pull down menu choose Micro 400 Light Curtain Status Micro 400 Light Curtain is shown connected to Infol This output switches High or Low depending on whether the light curtain beam is broken or complete This is independent of the safety output and can be considered an auxiliary output Publication CC OS015A EN P November 2009 t MSR42 Configuration And Diagnostic Software Configuration1 File Options Help Design Diagnosis Application info Configuration Basic configuration Inputs Design Output Micro 400 Micro 400 Light Curtain v Edit GPIO Mone T Start m Start Release v Outputs Info1 Safety Outputs m Info2 Lockout m Safety Safety Outputs OSSD Edit System information Design error messages Design OK Configuration Control v1 00 19 12 2008 bo 2 MSR42 Configuration And Diagnostic Software Confisuration1 File Options Help Design Diagnosis Application info Configuration Basic configuration Inputs Design Output Micro 400 Micro 400 Light Curtain hd Edit GPIO None v Start m None m Outputs Info Micro 400 Light Curtain d Info2 Lockout m Safety Safety Outputs OSSD Edit System information Design error messages Design OK Configuration Control v1 00 19 12 2008 po 09 25 09 PM 03 4
31. s positioned on l or Click Browse object or selection to initiate an action Double click the application icon Click the to the left of a given item folder to show its contents Expand 1768 Bus under I O Configuration Click the right mouse button once while the cursor Is positioned on Right click the 1768 Bus icon object or selection Select the New Module folder Pressing a specific key on the keyboard or button on a touchscreen Press Enter gt Use this symbol to indicate the sub menu name Choose File gt Menu gt Options Project Additional Resources Resource Connected Components Building Blocks Quick Start publication CC OS001 Connected Components Building Blocks Overview CD publication CC ORO01 Position Control Connected Components Building Block Quick Start publication CC OS003 MicroLogix 1100 Controller User Manual publication 1763 UM001 MSR42 Safety Base Module Operating Manual publication 440R INO17 MSR45E Safety Expander Module Operation Manual publication 440R IN018 Guardshield Micro 400 Safety Light Curtain Operation Manual publication 445L INOO01 Configuration Tool for MSR42 GuardShield Micro 400 and Safe 2 4 Light Curtains Software Description http http http www rockwellautomation com components connected blocks html www ab com www rockwellautomation com knowledgebase Refers to the application on both the controller side and the PanelView component side
32. se PC gt MSR42 Download 17 When prompted type the password ABGM 18 On the Controller Description dialog box type the six digit Device number and click OK 19 Cycle power to the MSR42 relay to allow the download to proceed Ti Download PC to MSR42 Download Connect Mea Y Download Messages Start Download Try to connect Please connect Optilink and power up MSR42z Once the download is complete the Configuration control document dialog box appears Publication CC OS015A EN P November 2009 OptiLink Communication If you use Optical Interfaces with software gt 2 00 the Configurator can find the correct communication port For the Optical Interfaces with software smaller than 2 00 please use the compatibility mode and select the Comport manually C Auto mode Compatibility mode Exit Controller Description 4dd controller information Device number Q Alten Bradiey MSRP erint BASE MODULE aud Porter catNo 440 R xexxxex xEx 107 177 IDM 00000 0807281000123 Device number ENN Configuration designation Designation max 35 digits Selected Comport t MSR42 Configuration And Diagnost AEF Options Help MSR42 gt PC Upload PC gt MSR42 Download Ctrl D _ New Ctrl N B Open Ctril o0 bel Save Cis De bel Save as Shift CtrS A Configuration control document amp Print configuration control document Ctrl P
33. t cables catalog number 1585J M8TBJM 2 or equivalent Publication CC QS015A EN P November 2009 25 Chapter2 System Validation and Application Tips Follow These Steps eo Validate Proper Operation of the safety Systems on page 26 Validate Proper Operation of the PanelView Screens on page 31 Validate Proper Operation of the Safety Systems To confirm that the system is operating properly you need to perform a series of tests Start Up 1 Apply power to the system 2 Check the following e The 100S contactors do not energize e Guarded motion does not start e The red stacklight is on 3 Press and release the Start Reset button 4 Check the following e The 100S contactors energize e Guarded motions starts e The green stacklight is on E stop Function 1 Press the E stop 2 Check the following e The two 100S contactors de energize e Guarded motion stops e The red stacklight is on 26 Publication CC OS015A EN P November 2009 system Validation and Application Tips Chapter 2 3 Press and release the Start Reset button 4 Confirm that the two 100S contactors do not energize and guarded motion does not start 5 Twist and release the E stop button 6 Press and release the Start Reset button 7 Check the following e The 100S contactors energize e Guarded motion starts e The green stacklight is on Light Curtain Function 1 Break the light curtain beam and keep it broke
34. the FJ msr42 Configuration And Diagnostic Software Configuration configuration Fie Options He Design Diagnosis Application info Configuration Basic configuration Inputs 15 Choose File gt Save and save the configuration as 4sensor T type muting e x GPIO Muting Micro 400 Y i Outputs Infol Micro 400 Light Curtain Y 16 Do not exit the MSR42 configuration and dia gno stic software Safety safety Outputs OSSD Edt System information Design error messages Design OK Configuration Control v1 20 07 09 2009 ipo GuardShield Micro 400 Transmitter 09 29 09 PM 12 52 39 Download the Configuration 1 Write down the device number from the label on the side of the MSR42 relay 2 Apply power to the MSR42 relay 3 Attach the suction cup connector to the interface window on the side of the MSR42 relay Publication CC QS015A EN P November 2009 19 Chapter 1 4 10 11 12 20 Product Integration In Microsoft Windows Control Panel open the Control Panel le Edit View Favorites Tools Help d P earch li Folders italy Double click on System address gt Control Panel Speech V Control Panel On the System Properties dialog box click Hardware Je Switch to Category View See Also A Windows Update 9 Help and Support Click Device Manager Expand Ports COM amp LPT Plug the USB connector of th
35. the Start Reset Button 12 Remove the object interrupting the light curtain Once the light curtain is no longer interrupted the display returns to the SAFETY SYSTEM STATUS Ready for START RESET screen 13 Press START RESET for three seconds MUTE and release SAFETY OUTPUT OFF SYSTEM READY FOR START 14 Move a load in front of S1 and S2 but RESET MORE INFO do not interrupt the light curtain 15 Leave the load where it is 34 Publication CC OS015A EN P November 2009 system Validation and Application Tips Chapter 2 After the configured t espe the time it should take a load to travel between S2 SAFETY SYSTEM STATUS and the light curtain the muting lamp begins to blink The screen reflects the SYSTEM RUNNING MUTING ERROR MORE INFO 16 Press MORE INFO 17 Press RETURN 18 Move the load until it interrupts the The System is running light curtain A There has been a muting sequence error The Safety Output will turn off if anything interrupts The light curtain during muting sequence error 19 Leave the load in the light curtain sensing field SAFETY SYSTEM STATUS SAFETY OUTPUT OFF MUTING ERROR MORE INFO Publication CC OS015A EN P November 2009 35 Chapter2 System Validation and Application Tips 20 Press MORE INFO 21 Press RETURN 22 Press START RESET for three seconds The Safety Output is off and release e Safety Output Is o Light Curtain was interrupt
36. to start there is an internal error Replace the MSR42 26 Press and hold START RESET for 10 seconds SAFETY SYSTEM STATUS SAFETY OUTPUT OFF SYSTEM READY FOR START RESET MORE INFO Publication CC QS015A EN P November 2009 37 Chapter 2 Notes 38 system Validation and Application Tips Publication CC OS015A EN P November 2009 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals a knowledge base of FAQs technical and applicationnotes samplecodeandlinkstosoftwareservice packs andaMySupportfeaturethatyoucancustomizetomakethe best use of these tools Foranadditionallevel oftechnical phone supportfor installation configuration andtroubleshooting we offerTechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience an anomoly within the first 24 hours of installation review the information that s contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 11 440 646 3434 Outside United States or Use the Worldwide Locator at http www rockwellautomation com support americas phone en html Canada or contact your local Rockw
37. uld be no longer than 3 seconds except in extraordinary circumstances supported by the risk assessment This setting establishes the maximum length of time the light curtain remains muted Calculate the length of time it takes the load to travel from the point where it first reaches the second sensor until the trailing edge of the load leaves the light curtain based on the speed of the conveyor This is the minimum t mute for your system which is entered in minutes This setting establishes the maximum length of a Mute Dependent Override Occasionally a load may stop within the light curtain sensing field It may be difficult to move the load past the light curtain sensing field with a safe stop in effect Mute Dependent Override is a function that lets a safety stop be paused and muting to be re initiated for the duration of the t mdo setting which lets the load move beyond the light curtain sensing field As soon as the load moves past the light curtain sensing field muting ceases If the hazardous area Is in clear view of the operator and no personnel or objects are in the hazard area Mute Dependent Override can be initiated in this case by pressing and releasing the Start Reset button Calculate the time it takes the load to travel from the point where it first reaches the second sensor S2 from the right or S3 from the left until the trailing edge of the load leaves the light curtain sensing field based on the speed of the conveyor In s
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