Laser Scanner Protection for Automated Conveyor Car
Contents
1. October 2007 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 Al 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 Both scanners are active all the time To prevent nuisance stops the field of the scanner not in use should be set to the slow field An object in the warning field of either scanner will energize a signal This allows personnel to back away from the car before a safety stop is initiated The MSR211 relay continuously monitors both scanners and the E Stop push button The safety zone of each scanner must be clear and the E Stop must be reset for the MSR211 relay to be ready for reset Pressing the reset activates closes the safety outputs of the MSR211 and MSR238 relays Obstructing either scanner s safety zone or pressing the E Stop will initiate a stop The safety outputs of the MSR211 relay will open to remove power to the motor drivers The safety outputs of the MSR238 relay will open after the configured time delay expires The time delay is set by jumpers Refer to the Rockwell Automation Safety Products Catalog or MSR211 instruction sheet listed in the Additional Resources section on page 12 for other timing options 0 5 300 s The software dialogs on the following pages illustrate the s2. set 2 Fast Speed Safety field Field set 1 Slow Speed Warning field c Field set 2 Fast Speed Warning field Publication SAFETY AT003A EN P October 2007 Additional Resources For more information about the products used in this example refer to these resources Resource Description safeZone Multizone Safety Laser Scanner Provides information on installing wiring User Manual publication 75046 171 01 A configuration commissioning and troubleshooting a SafeZone scanner Safety Relay Minotaur MSR211P Provides information on operation Installation Instructions publication installation wiring and technical 5 918 1 specifications for the MSR211P safety relay Rockwell Automation Safety Products Provides information on Rockwell Catalog publication S115 Automations safety product offerings Industrial Automation Wiring and Grounding Provides general guidelines for installing a Guidelines publication 1770 4 1 Rockwell Automation industrial system Product Certifications website Provides declarations of conformity http ab com certificates and other certification details You can
3. Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http literature rockwellautomation 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 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 Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Identifies information about practices or circumstances that
4. Introduction Safety Application Example Laser Scanner Protection for Automated Conveyor Car Using MSR200 Series Modular Safety Relay Non networked Hard wired Example Safety on en 3 according to oe 1 J Topic Page Introduction Important User Information General Safety Information Description Setup and Wiring Configure the Laser Scanner OG OT j N 1 Additional Resources 12 Performance Data 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 issues a stop command to the drive motors if an object is detected The scanners are connected to an MSR200 safety relay which monitors both scanners and the E Stop push button Features and Benefits e A single MSR200 relay controls both the E Stop and two laser scanners e No safety control programming is required e This type of solution is applicable to many industries for example material handling packaging and automotive Rockwell ALLEN BRADLEY e ROCKWELL SOFTWARE Automation 2 Laser Scanner Protection for Automated Conveyor Car Using MSR200 Series Modular Safety Relay Important User Information Publication SAFETY ATO03A EN P October 2007 Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the
5. Stationary if the SafeZone MultiZone is operated stationary on a machine or equipment Choose Mobile if the SafeZone MultiZone is operated mobile on a vehicle for example on a AGY The configuration features subsequently available in the SCD depend on the selection made Back Abort Help 4 Configure the scanner Configuration assistant SafeZone MultiZone 1 Step 3 Scanner 1 Front 170 module Sensor head Medium range 5 m Application Mobile Resolution Maximum protective field range 30 mm hand detection 3 30 m 60 ms 40mm hand detection C 4 80 m 120 ms 50 mm leg detection C 70mm leg detection c Basic response time Choose the resolution in millimeters and then the maximum protective field range in meters NOTE If you have already drawn protective fields that are larger than the selected maximum protective field range then you must adjust these prior to transferring the configuration draft CAUTION Mount the scan planes for horizontal stationary applications with 70 mm resolution at a height of at least 300 mm For scan planes higher than 300 mm prevent crawling underneath Mount the scan planes for horizontal mobile applications at a maximum height of 200 mm Publication SAFETY ATOQ3A EN P October 2007 8 Laser Scanner Protection for Automated Conveyor Car Using MSR200 Series Modular Safety Relay 5 Choose the OSSD configuration for the scanner Configuration assistant S
6. afeZone MultiZone 1 Step 4 OSSDs Scanner 1 Front Object in the allocated protective field switches OSSDs ce f Object in the simultaneous protective field switches OSSDs c I External device monitoring active If the internal OSSDs on the SafeZone MultiZone are switched you can also activate the external device monitoring Configuration assistant SafeZone MultiZone 1 Step 5 Control inputs Va Sampling for the static control inputs Switching timing advance Complementary N O N C Allocated field set Simultaneous field set oe Scanner 1 Input delay ms 100 130 X 180 180 ms For monitoring case switching activate the control inputs used and the type of sampling of the inputs Choose the device with the control inputs you want to use For the input delay choose the time in which your control device can reliably switch to a corresponding input condition See under Switching timing advance the time resulting from the transfer time for control input signals and OSSD signals via communication protocol and the input delay On a system with two SafeZone MultiZones the times for scanner 1 and 2 are different You must advance the timing of the monitoring case switching for the related scanner by the corresponding time CAUTION Always switch in real time Note the corresponding section in the operating instructions T a Back abot Helo 7 Configure the scanner s output Configuration assis
7. 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 MEURT ANI understanding of the product 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 ATTENTION STA Wan Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present TDA Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ala tal ha Laser Scanner Protection for Automated Conveyor Car Using MSR200 Series Modular Safety Relay 3 General Safety Information IMPORTANT This application example IS for advanced users and assumes that you are trained and experienced in safety system requirements A risk assessment should be performed to make sure all task and hazard combinations have been identified and addressed The risk assessment may require additional circuitry to reduce the risk to a tolerable level Safety circuits must take into consideration safety distance calculations which are not part of the scope of this document ATTENTION gt i Contact Rockwell Automation to find out mor
8. e about our safety risk assessment services Description Wall Conveyor Car Movement The automated conveyor car moves forward and back within a designated aisle The conveyor transports materials from one fixed conveyor line to another 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 Publication SAFETY AT003A EN P October 2007 4 Laser Scanner Protection for Automated Conveyor Car Using MSR200 Series Modular Safety Relay 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 Stopping Time and Safety Distance Calculate the necessary safety field length using the formula Safety Field Length SA ZG ZR ZF ZB where e SA Stopping distance e ZG General safety supplement 100 mm 3 94 in e ZR Supplement for any measurement error of the SafeZone Multizone safety laser scanner related to reflection e ZF Supplement for any lack of ground clearance of the vehicle e 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 171 01 A for details on the safety dis
9. ep 8 Create the field sets Sensor 1 Front Field set Allocated to the monitoring cases Slow Speed Slow Speed Fast Speed For the SafeZone Multone you can define up to two field sets For these field sets you define a protective field and a warning field later in the field set editor You can add or delete field sets and change the name of a field set ee Back abot He 10 Review and finalize the configuration for each field set you created Configuration assistant SafeZone MultiZone 1 Step 9 x Configuration assistant SafeZone MultiZone 1 Step 9 Single representation Overview Single representation Overview Monitoring cases Parameters for the case selected Monitoring cases Parameters for the case selected 1 Slow Speed Monitoring case Slow Speed 3f f1 Slow Speed Monitoring case Fast Speed 2 Fast Speed Control inputs 0 E Control inputs 4 1 Following case Any Following case Any Field set Slow Speed Field set Fast Speed ossD Front ossD Front Multiple sampling 2 pol Multiple sampling 2 Response time 60 ms Pt Response time 60 ms You can see the monitoring cases already created in the single representation or the overview Implausible monitoring cases are s z zi d You can see the monitoring cases already created in the single representation or the overview Implausible monitoring cases are displayed in yellow Change their input conditions displayed in yellow Change their input conditio
10. ns With the buttons on the left you can create new monitoring cases edit rename or delete monitoring cases and change the switching sequence between monitoring cases With the buttons on the left you can create new monitoring cases edit rename or delete monitoring cases and change the switching sequence between monitoring cases Configuration ae z Configuration A Se _ Beck abot Heb j A Soni AMC Beck mee pes Publication SAFETY ATOQ3A EN P October 2007 10 Laser Scanner Protection for Automated Conveyor Car Using MSR200 Series Modular Safety Relay 11 Enter the user name you want to appear in the configuration protocol and diagnostic reports Configuration assistant SafeZone MultiZone 1 Step 10 Name of the user Dukich The name of the user is listed in the configuration protocol and in the diagnostics reports aoe Back Abot To 12 Repeat these configuration steps for the second scanner TIP Press the PgDn key to let the program download The Acknowledge becomes live Publication SAFETY ATO03A EN P October 2007 Laser Scanner Protection for Automated Conveyor Car Using MSR200 Series Modular Safety Relay 11 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 Field set 1 Slow Speed Safety field Field
11. tance length for mobile applications Example Bill of Materials This safety application example uses these components 800FM P6 Reset required pilot light blue round metal operator 800F MN3B Metal latch LED screw clamp 24V dc blue 1 442L CSFZNMZ 10 is a 10 m 32 8 ft cable aho ep Reset required piot gt He ound meral operor Metal eich LED screw clamo 2V cbe fi Publication SAFETY ATO03A EN P October 2007 Laser Scanner Protection for Automated Conveyor Car Using MSR200 Series Modular Safety Relay 5 Setup and Wiring For detailed information on installing and wiring refer to the product manuals listed in the Additional Resources section on page 12 System Overview SafeZone Multizone laser Scanner SafeZone Multizone Laser Scanner Contact Block E Stop Push Button yy aj lt OOOO OOOO Reset required aa Pilot Light nh Reset Button OO Sees SEEE SERS Contact Block Wiring 24 VDC Field Set Selection SafeZone Multizone Front Delay set by jumpers 4s shown le MSR211P 440R H23177 Master Relay Push to Reset from Object in Stopping arning Field Devices Immediate Stop Signal Signal Publication SAFETY ATOQ3A EN P October 2007 6 Laser Scanner Protection for Automated Conveyor Car Using MSR200 Series Modular Safety Relay Configure the Laser Scanner Publication SAFETY ATO03A EN P
12. tant SafeZone MultiZone 1 Step 6 Application diagnostic output Scanner 1 Front Application diagnostic output SADE a a a OEEETE s a For the application diagnostic output you must decide in which case the output is active T Ne Back abot Hee Publication SAFETY ATO03A EN P October 2007 Laser Scanner Protection for Automated Conveyor Car Using MSR200 Series Modular Safety Relay 9 8 Choose the type of restart for the scanner The Configuration Assistant dialog provides information about each type of restart Configuration assistant SafeZone MultiZone 1 Step 7 Restart Scanner 1 Front Restart of the internal OSSDs Without restart interlock With restart interlock Time delayed by Without restart interlock CAUTION Only if it is not possible to leave the protective field to approach the hazardous point The OSSDs are released immediately if there is no longer an object in the protective field With restart interlock The OSSDs are only released again when the operator operates the control switch for restarting or resetting Time delayed CAUTION Only if it is not possible to leave the protective field to approach the hazardous point The OSSDs are released when there is no longer an object in the protective field for the time given 2 60 s Configuration changed 9 Create two field sets for the scanner Configuration assistant SafeZone MultiZone 1 St
13. teps and configuration settings needed to configure this application example using the Configuration Assistant in the Safety Configuration and Diagnostic SCD software The SafeZone Multizone software cannot run while RSLinx software TIP E is running In your icon tray right click the RSLinx icon and choose Shutdown RSLinx RSLinx software automatically loads again when you run RSNetworx for DeviceNet software The default password for the laser scanner is ABGM For demonstration purposes log in as an Authorized Client Laser Scanner Protection for Automated Conveyor Car Using MSR200 Series Modular Safety Relay 7 1 Enter a name for your application 2 Enter a unique name for the SafeZone MultiZone scanner Configuration assistant SafeZone MultiZone 1 Step 1 Application name Automated Conveyor Car Scanner name 1 Front Enter a name for your application The application name is saved in each device after the configuration has been transferred The name chosen may be the name of the system or the machine Enter a name for each of the SafeZone MultZones Unique device names make the subsequent configuration steps easier for example on allocating the control inputs or the OSSDs 3 Choose the type of application to indicate whether the SafeZone MultiZone scanner is operated on a stationary machine or mobile vehicle Configuration assistant SafeZone MultiZone 1 Step 2 Application C Stationary Choose
14. view or download publications at http literature rockwellautomation com To order paper copies of technical documentation contact your local Rockwell Automation distributor or sales representative Allen Bradley Rockwell Automation SafeZone Minotaur RSNetWorx for DeviceNet RSLinx and QuadCONNECT are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 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 SAFETY ATO03A EN P October 2007 Copyright 2007 Rockwell Automation Inc All rights reserved Printed in the U S A
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