Home

User manual MSI 100

Contents

1. cceeccceeeseeeeeeeeeeeeeeeeeeeeees 3 7 MSI 100 status indicators ccceecceceeeeeeeeeeeeeaeeees 3 4 MSISAQlCSOMN sicezton fase eeie setae asco ela 2 2 PASSIGNINGNLINST ccccnccte oie ot atone eacehd ined 4 19 Checking and downloading the project 4 18 5 5 Configuring cross circuit detection for inputs 4 16 Configuring the use of a ground switching output 4 17 Connection Editor sosedni 4 3 4 11 Creating a Projeti es tinsione 4 10 Device parameterization editor 2 8 4 15 Documenting the signal assignment of the project 4 19 Functions and features ccccceceeceeeeeeeeseeeeeees 4 1 Hardware editor see Hardware editor Installing the software saennnnenenneenenreesnerernennni 4 1 Modifying device parameters ccccccceeeeeees 4 16 Online tool tiPS oannanannnnnnnnennnnnnnnnnnnsnnnenennnnnnnne 2 12 Operalla snaa E eet oe 4 10 Printing PArAMETESS cccecceeseeeeeeeeeeeeeeeeeaeeees 4 17 POJE CU WIZA Gist ano 4 10 Simulation ModE sesia a a 4 21 Starting up the project cceesseeeeeeeeeees 4 18 5 6 Status bar see MSlsafesoft status bar System requirements ccccecceeessseeeeeeseeeeeeeees 2 18 SOM INET ACC nnana A N 4 3 MSlsafesoft documentation cccccecceeeeeeeseeeeeees 4 2 MSlsafesoft online mode 4 2 5 2 5 9 5 10 MSlsafesoft status bar 3 11 4 4 5 2 5 5 5 9 5 10 5 12 MSlsaf
2. cccceeeeeeeeeeeeeeeees 4 5 Project Wizard for creating a new configuration project using a project template sas seisa tee daisecvewaeged ocean tana dtsadenad iecadnuaatedaieeseuwe 4 10 Inserting safe functional blocks and functions from the toolbox In THE CONNECHION CCILOM serisine 4 11 Opening the hardware editor with the auto hide function enabled 4 12 Inserting a signal in the Connection editor cccceccceeeeeeeeeeeee ees 4 12 Connecting objects USING a line 2 0 ceeecccceeeeeeeeeeeeeeeseaeeeeeesaeeeees 4 14 Connecting unconnected signals to functional blocks or functions USING Crag lt e GOD seken a 4 14 Opening the device parameterization editor for all I Os 4 15 Opening the device parameterization editor for one specific I O 4 15 Opening the device parameterization editor via the context menu 4 16 Modifying device parameters in the device parameterization editor 4 16 Setting the device parameter for the use of ground switching OULOUE OOF a5 accesses Gacsanates E E E 4 17 Jumping to an error location in the safety logic from the message window when checking the configuration project ccccceeceeeeeeees 4 18 Documenting signal assignment in the Assignment Map dialog DOK Cedae siehe a skeacdbvactobe scans tamnirenGhees 4 19 Simulation of the safety controller in MSlsafesoft c 4 21 Icon for simulation mode not activated and activated
3. 119 test pulse T1 must be used for cross circuit detection Please also refer to Signal inputs on page 3 7 and Error detection in I O devices on page 2 8 3 4 5 24 VIO V supply connection The 24 V 0 V supply connection is used to supply the outputs of the safety controller and the clock and ground switching outputs with power 3 4 6 Supply connections A1 and A2 The supply connection A1 A2 is used to supply the logic of the safety controller and the alarm outputs with power At the double terminal block contacts 2 and 3 wire sensors and control devices can be supplied directly by the safety controller Unom 24 V DC CAUTION For 3 wire sensors ensure that the GND potential of the sensor control de vice matches the GND potential of the safety controller The maximum continuous current for devices connected to terminal blocks A1 and A2 is 6 A limiting continuous current for looped through current paths A1 A1 and A2 A2 MSI 100 3 9 Hardware MSI 100 safety controller amp Leuze electronic 3 4 7 Ground switching outputs O0 and 01 The ground switching outputs O0 and O1 increase the shutdown protection and cross circuit protection of the safety system These outputs can be used for example to switch off a contactor connected to the MSI 100 safety controller either via the output or via ground Ground switching output O0 can only be used in connection with output OO ground switching output O1 can only be u
4. Type Master Device Descrphor M51100 10 li 19 aia id AiE i eit l j fa Location ID 0 l t file oo Safe parameter aa p Separate sianal Figure 4 11 Opening the device parameterization editor via the context menu The adjustable parameters are provided in table format At the top left of the table is the device type or the device ID and the location ID which is the unique security ID for the safe device Every safe device can be clearly identified using just this ID Underneath is the name of the import file provided that you have imported pa rameters see the Importing exporting section The available parameters are then listed row by row see description of input parameters and output parameters Every parameter i e every table row consists of a value which can be modified and the parameter name which cannot be modified Please read the next section for more information In the interests of security only predefined parameter values can be selected Proceed as follows 1 Click in the white field of the parameter you wish to change The field now displays an arrow for opening a selection list 2 Click on the arrow to open up the list 3 Click on the required value This list is closed and the selected value is visible in the parameter field Figure 4 12 Modifying device parameters in the device parameterization editor Unless the device parameterization editor is closed or anoth
5. 4 22 MSISIMsoft icon in the Windows taskbar cccccseceeeeeseeeeeeeeaeees 4 22 Flowchart Configuration from A to Z 1 Of 3 eeeecesseeeeeeeeeeeeeees 5 1 Flowchart Configuration from A to Z 2 Of 3 cceeeeceesseseeeeeeaeeeeees 5 2 Flowchart Configuration from A to Z 3 Of 3 ceeeceessseeeeeeeeeeeeees 5 3 USB connection between PC and safety controller c cceecee 5 5 Message dialog box following successful data transmission 5 6 Confirming the configuration with the Confirm button 0 5 6 Pressing the Confirm button while inserting the AC MSI CFG1 5 8 Example of a function test for the safety system using MSlsafesoft online mode srasni ceed AERE 5 11 MSI 100 Leuze electronic 8 2 Index Numerics oO MINDY LOIN Val cesecds hs fhe a las cde Aide 3 14 A AC MSI CFG1 naasis 2 2 3 6 3 12 5 4 5 7 Downloading the configuration to the MSI 100 using AC MSEOF GT oeoa 5 7 Alarm outputs MO M3 aanaaannannnenneennnenna 3 1 3 9 4 13 Antivalent safe functional block ccceeeeeeeeeees 4 6 Application example Application examples for the individual functional DIOCKS aaoi anSetaite tends e 6 1 Cross circuit GEteCtiON cccceecceceeeeeeeeeeeeeeeees 2 8 Ground switching outputs O0 O1 08 3 10 R startiNMDI asenin cree nec ae eee ae ead lee 2 6 Startup inhibit Sates tcc esac ntesccagi Sadnen dence sergundevelts 2 6 Stop
6. Figure 3 11 List of figures Calling the online help in the MSlsafesoft configuration software 1 8 Typical structure of a safety system with MSI 100 ee 2 1 TBUS DIN rail connector from Leuze electronic cccccceeeeeeee anes 2 3 Implementing a startup inhibit restart inhibit and stop category 0 TONS eae OULU OO es sc eh os eel lt kl ne ie 2 7 Implementing cross circuit detection for an emergency stop control device at inputs 10 and 11 of the safety controller 2 8 Parameterizing cross circuit detection for a module input 2 9 Simplified schematic view Hardware diagnostics in the event of an error at a safe functional DIOCK cccccccceecceeeeeeeeeeeeeeeeeeeees 2 10 Simplified schematic view Wiring CHECK ccccseeeeeeseeeeeeeseeeeeens 2 11 Example of an online tool tip in the event of an error 06 2 12 Examples of tool tips in the connection editor in offline mode while editing the Safety logic cccccccceeeeeeeceeeeeeeaeeeeeeeeeeeeeeeaees 2 12 Password protection for the MSI 100 and MSlsafesoft 2 13 MSI 100 safety controller with screw connection left or with spring cage terminal blocks right on 35 mm EN DIN rail 3 1 Block diagram for the MSI 100 safety controller ccecceeeeeeeeeees 3 2 Diagram Possible operating modes status for the MSI 100 safety COM ONCM srpen
7. Or In an active input dialog box or window press lt F1 gt for example in the connection editor The context sensitive online help for the active dialog box or window appears Or In the connection editor select an object and press lt F1 gt in order to view informa tion relating to that object For safe functions and functional blocks general informa tion about the objects can be accessed in this way There is also specific functional block information which can be called via the Help context menu item for the relevant functional block or function MSI 100 Leuze electronic amp Leuze electronic Leuze electronic MSlsafesoft configuration software 4 3 Description of the user interface This section provide an overview of the user interface for the MSIsafesoft configuration software For more detailed information please refer to the online help see also Online help on page 4 2 Cleafacnft i File Edit View Project SafePLC 2 1 vii TEn OO OO CC CO CCC CCC COC COC CCC 4 Leuze electronic A conan Erge msi 100 PA ee e e Figure 4 1 MSlsafesoft user interface The windows may be arranged differently to the format shown here either when the soft ware is delivered or once you have adapted the program to your preferences The user interface consists of the following components 1 Menu The menus contain the available commands for controlling the MSIsafesoft configura tion software
8. Toolbar Frequently used functions can be accessed quickly via the icons in the toolbar Connection editor The connection editor is used to develop the safety logic by dragging graphical func tional blocks from the toolbox and signals from the hardware window to the circuit us ing drag amp drop and connecting them to one another Toolbox The toolbox contains the safe functional blocks and safe functions These elements can easily be dragged from the toolbox to the connection editor Hardware editor The hardware editor contains a graphical representation of the MSI 100 safety control ler When configuring the safety logic input and output signals can be moved from here to the connection editor using drag amp drop Double clicking on the hardware edi tor starts the safe device parameterization editor not shown in the figure N pa m MSI 100 4 3 MSlsafesoft configuration software 4 amp 4 Leuze electronic Status bar When working with the configuration software the status bar displays messages and information as well as the current logon status the status of the safety controller and transmission progress when downloading or uploading the configuration to or from the safety controller The following windows and dialog boxes are not visible in the figure Message window The message window can be used to track the progress of the project checking func tion When the check is started the message window op
9. the MSI 100 safety controller can detect various errors within the safety equipment e g cross circuits Observe startup behavior Some of the safe functional blocks in the MSIsafesoft configuration software have param eters for specifying a startup inhibit and or a restart inhibit An active startup inhibit restart inhibit can be removed by pressing a reset button that is connected and appropriately wired to the safety controller Use these parameters in the MSlsafesoft configuration software to monitor the startup re start of the MSI 100 safety controller Do not carry out any re pairs do not open the housing In the event that an error caused by reconfiguring or modifying the wiring etc cannot be removed please contact Leuze electronic immediately 1 2 MSI 100 Leuze electronic 4 amp 4 Leuze electronic For your safety 1 3 Electrical safety DANGER Hazardous body currents or the loss of functional safety In order to ensure electrical safety please observe the following points and the informa tion in the user manuals for the devices used e g sensors actuators or extension units Direct indirect contact Protection against direct and indirect contact according to DIN VDE 0100 410 must be en sured for all components connected to the MSI 100 safety controller In the event of an er ror parasitic voltages must not occur single fault tolerance Safe isolation Only use devices with safe isolation if hazardo
10. 2 SCONCE DURON geraai eei ea e e a ELS 3 6 3 4 Sidhal COMNCCIONS esre n E eect ce atte eae 3 7 3 4 1 IG MAW TIA UNS expe tusaes eed aceettnt a bdeniel ie ehdeesee aes 3 7 3 4 2 Sale OU US eae th ee a ht oe bee hated 3 8 3 4 3 Alarm outputs MO to M3 soisiu a 3 9 3 4 4 Test pulse outputs TO and 11 uu eeccecccceeeeseeeeeeeeeaeeeeeeeeeaeeesaeess 3 9 3 4 5 24 VIO V supply connection acpi deencceielcesoaashodes cussanaddascastolenausayede 3 9 3 4 6 Supply connections A1 and A2 0 ccc ccccccesececeeceeceeeeeceeeeseeeeeeseeeeees 3 9 3 4 7 Ground switching outputs O0 and O1 e ssssssssssnrseesnrnensnrrresrrrren 3 10 3 5 USB MC ACS ran a a E 3 11 3 6 Data memory module AC MSI CFG1 n nnnnnennnnesennenssnnnnnsnnrrsnnrresrrrrnssrreenn 3 12 3 7 Installing the safety Controller ccccccccccssesececeeeseecceneecessceeeeeeseasesesseaeeeeenes 3 13 3 7 1 Mounting the safety controller ccceccceeseseeeeeeseeeeeseeeeeesaseeeeeeeas 3 13 3 7 2 Connecting the supply voltage eee ccc ceeeecceseeeeeeeesaeeeeeeeseeeeeeaaeees 3 16 3 7 3 Connecting the signal lines cc ceeecccecseeeeeeceeeeeeeeseeeeeeeeseeseeeesaeees 3 17 Leuze electronic MSI 100 i 4 5 6 7 8 4 Leuze electronic MSlIsafesoft configuration software 00 eccceeccceecceececeeeececeeseeeceeeeseeeeseeeseeeesueeseucesseeesueesseeesaess 4 1 4 1 Installing MSIsafesoft ccccceececeeeeeeeeeseeeeeeeseeseeeseaeeeeeseaeeeeesseeee
11. all diagnostic tests are performed during operation the service life is applied for the proof test interval MSI 100 2 17 System description 2 18 4 amp 4 Leuze electronic 2 9 System requirements for the MSlsafesoft configu ration software Under Windows Vista 7 CPU Main memory Under Windows XP 2000 SP4 SP2 CPU Main memory All operating systems Hard disk Monitor resolution Mouse CD ROM drive USB interface Internet Explorer 5 5 or later MSI 100 Minimum 1 GHz x86 architecture 1 GB Minimum 1 GHz x86 architecture 512 MB Minimum 1 GB free memory space SVGA 800 x 600 Required Required Required Required Recommended 2 GHz x86 architecture 2GB Recommended 1 GHz x86 architecture 1 GB Recommended 1 GB free memory space SVGA 800 x 600 Required Required Required Required Leuze electronic 4 amp 4 Leuze electronic Hardware MSI 100 safety controller 3 Hardware MSI 100 safety controller Leuze electronic 3 1 Device description The MSI 100 safety controller is a programmable safety controller with 20 digital safe in puts which enable the connection of a maximum of 20 single channel or 10 two channel safe sensors or control devices The four digital safe outputs OO to O3 are controlled after evaluating the incoming signals according to the configuration which was created with the MSlsafesoft configuration soft ware and downloaded to the MSI 100 safety contro
12. amp Leuze electronic the sensor people MSI 100 Programmable Safety Controllers N O O O N I N O hh b O N Tid We reserve the right to make technical changes USER MANUAL 2011 Leuze electronic GmbH Co KG In der Braike 1 D 73277 Owen Teck Germany Phone 49 7021 573 0 Fax 49 7021 573 199 http www leuze com info leuze de Leuze electronic User Manual Device description configuration and startup of the MSI 100 safety controller 2011 02 18 Designation User manual MSI 100 Revision 01 Order Nr 700921 This user manual is valid for Designation Order No MSI 100 MSI 101 547802 MSI 102 547812 Leuze electronic MSI 100 1 II o BBB 4 amp 4 Leuze electronic Please observe the following notes In order to ensure the safe use of the product described you have to read and understand this manual The following notes provide information on how to use this manual User group of this manual The use of products described in this manual is oriented exclusively to qualified electricians or persons instructed by them who are familiar with applicable standards and other regulations regarding electrical engineering and in particular the relevant safety concepts qualified application programmers and software engineers who are familiar with the safety concepts of automation technology and applicable standards Leuze electronic GmbH
13. archiving or alteration requires the express written con sent of Leuze electronic Violators are liable for damages Leuze electronic reserves all rights in the case of patent award or listing of a registered de sign in as far as this concerns software of Leuze electronic that meets the criteria of tech nicity or has technical relevance Third party products are always named without reference to patent rights The existence of such rights shall not be excluded Windows 3 x Windows 95 Windows 98 Windows NT Windows 2000 Windows XP Win dows Vista and Windows 7 are trademarks of the Microsoft Corporation All other product names used are trademarks of the respective organizations How to contact us Up to date information on Leuze electronic products and our Terms and Conditions can be found on the Internet at www leuze com If there are any problems that cannot be solved using the documentation please contact your Leuze electronic subsidiary Subsidiary contact information is available at www leuze com Leuze electronic GmbH amp Co KG In der Braike 1 73277 Owen Germany Phone 49 0 7021 573 0 Fax 49 0 7021 573 199 MSI 100 Leuze electronic Table of contents T ROR YOUR SATCU siaren a e E 1 1 1 1 Purpose or this Manal c o35 oie eee eee 1 1 1 2 General Safety notes ccccccccccccsseeececeseeeecceeseeecsaeeeeessesecesseeseeesseseeesseaeeeeeeas 1 1 1 3 Electical safely aiar a E ES E uincesdaeet
14. editing a message window appears where the connection editor reports dam aged data a sporadic error or a systematic error Solutions for problems with the graphical connection editor The project concerned is damaged and can no longer be used Use the latest backup copy of the project as described in the online help under Zip ping and extracting projects If the problem persists please contact our technical support team The project is closed automatically You do not have the opportunity to save the most recently made changes If the problem persists when the project is reopened please contact our technical support team 7 3 Device parameterization editor Table 7 3 Problem You have attempted to open the device pa rameterization editor but the data could not be loaded due to a checksum error A corresponding message window is dis played The device parameterization editor re sponds unexpectedly to an entry in the pa rameter table by displaying something other than what has been entered or se lected for example This may be traced back to a sporadic error or a systematic error During editing a message window appears where the device parameterization editor reports damaged data a sporadic error or a systematic error MSI 100 Solutions for problems with the device parameterization editor The project can no longer be used as the parameterization data cannot be deleted Use the lat
15. eeatenaaee 1 3 1 4 Safety of the machine or SYSLEM c cccccccssesececeeseeecceeueeeeseueeeessseeeessaaeeess 1 4 1 5 Directives and SAN GANGS aie se abese ice iee ate iabastaresavabnceruanconigeraaieabdavieaseania suateadeacienie 1 5 1 6 PUES OSC USE ariana in cdshe tonsa siatatencas E katate 1 7 1 7 Documentations a E ENA T 1 8 2 SVSTENTCSCSCHOUOMNY meserii E ona a A S 2 1 2 1 Method of operation and structure of the MSI 100 safety system 08 2 1 2 2 Jsing the Syste Mara Aea A R Aa eaae 2 4 2 3 System startup and restart behavior cece ccceeseeeeeeceeeeeeeeseeeeeesaaeeeeeeseeeeeeeeas 2 5 2 4 Error detection in Ode ViICSS 5 aries sired chs a Ei 2 8 2 0 Diagnostic 1OOIS aieith ciresacctdia ce tiskans viet a a ea 2 9 2 6 FASS WONG OK OLC CU OM N a ee 2 13 2 1 Ordering data essensa E 2 14 2 8 MSG INT CON AL sy aticate acta e a e tial eaae e a a e aa EER 2 15 2 9 System requirements for the MSIsafesoft configuration software 2 18 3 Hardware MSI 100 safety controller 22 0 ccccccecceeeeceseeeeeeceeeeseeeceueeseesesaeesaueesaeeseueesaeeeeas 3 1 3 1 Devicedescrnp pioase e a a a awe 3 1 3 2 Operating modes status of MSI 100 0 0 eecceceseeeeeeseeeeeeesseeeeeesaeeeeeesaaaeees 3 3 3 3 Operating and indication ClEMeNtS ccccsseeeceeeeeeeeeeeeeeeeeeaeeeeeeesaseeeeesaaeeees 3 4 3 3 1 Diagnostic and status indicators cc cceecceeceeeeceeeeeeeeeeeeseeeeesaeeeesaaes 3 4 3 3
16. example Download configuration and control parameters t Upload online values Indicator lamp MSlsafesoft on configuration computer during the function test Safe control devices or MSI 100 sensors Single channel or two channel connection to safety controller Eg S68 sss sees cove Control signals for the contactors at the safety controller outputs te ie Be relay Readback signal from the removing active monitoring contacts of the startup restart inhibits contactor kazan Figure 2 1 Typical structure of a safety system with MSI 100 Reset button for ANONENINANNA aaa MSI 100 2 1 System description Hardware MSI 100 Software MSlsafesoft Secure communication 4 amp 4 Leuze electronic The MSI 100 safety controller offers 20 digital safe inputs for connecting a maximum of 20 single channel or 10 two channel safety related sensors and control devices The MSI 100 has 4 digital safe outputs which are semiconductor outputs 24 V DC 2 A to tal current The outputs are designed to meet up to category 4 according to EN 954 1 Depending on the configuration stop category 0 according to DIN EN 60204 1 can be achieved for each output see Stop category 0 on page 2 4 In addition four signaling current paths two test pulses at two outputs each and two ground switching outputs are available For more detailed information abo
17. in the Safe Controller menu The pink background of the status field in the configuration software status bar indi cates that the safety controller is running in standard mode PLC Commissioning The connection editor still displays online values i e signals and connections which are TRUE if green and FALSE if gray The hardware editor is also visible in online mode Forcing signals 3 To force a signal in the connection editor right click on the corresponding signal and select the Force command from the signal context menu WARNING Eliminate hazards due to forcing Be extremely careful when forcing signals with the safety controller running Forcing means that the safe configuration is executed with the values of the signals you have forced Alternatively double click on the signal with the left mouse button The Force dialog box opens 4 The signal designation can be seen at the top of the dialog box The value to be forced is determined automatically from the current signal value and set in the dialog box 5 12 MSI 100 Leuze electronic amp amp Leuze electronic Configuration and startup 5 Click on Force to force the corresponding signal to the set value WARNING Eliminate hazards due to forcing Before forcing any signals ensure that doing so will not pose a risk for people or mate rials 6 Amessage dialog box appears where you must expressly confirm the forcing proce dure once more Clic
18. linking safe functional blocks certi fied according to the PLCopen specification via connecting lines and safe functions Safe functions range from logic operations such as AND OR etc to timer and trigger functions Leuze electronic MSI 100 4 1 MSlsafesoft configuration software Linking I Os with safety logic Parameterizing I Os Downloading uploading the configuration Online mode for function test Startup mode additional Documentation checklist MSISIMsoft simulation Online help 4 amp 4 Leuze electronic MSI 100 inputs and outputs are easily linked with the safety logic using drag amp drop Parameterization of the inputs and outputs of the MSI 100 safety controller using a safe parameterization editor Communication between the MSlsafesoft configuration software and the MSI 100 safety controller You can download the configuration project including all device parameters to the safety controller in just a few steps It is also possible to upload the project saved on the safety controller to the connected PC in order to display or edit it in the configura tion software Diagnostic and startup tools are included for communication During safe operation you can easily read signal values from the safety controller and display them in a special online mode The connection editor indicates the current live status of each signal and the inputs and outputs of each functional block in the safety logic The
19. outputs will not be written Execute the same steps in the MSlsafesoft configuration software as you would if you were working with the real safety controller but ensure that the Simulate Safety Con troller icon on the toolbar is activated see Figure 4 17 on page 4 22 This means that you can force signals or display online values in the connection editor as usual The simulation continues to run in the background with the icon visible in the taskbar no tification field system tray known as systray for short The simulation can be configured for the current application inputs can be activated in the simulation directly and the effects on outputs can be monitored thus simulating the I Os of the actual hardware The timing of the machine system can be simulated in expert mode Leuze electronic MSI 100 4 21 MSlsafesoft configuration software amp Leuze electronic Starting simulation mode Exiting MSlsafesoft simu lation mode To start the simulation and download a project proceed as follows 1 To start the simulation click on the Simulate Safety Controller icon in the toolbar If the icon is activated the simulation is active and all commands executed such as Download or Online Values will relate to the simulation Icon Not activated Activated MSI 100 Simulation Figure 4 17 Icon for simulation mode not activated and activated 2 Once the icon has been selected a message w
20. until it engages with a click 5 Check that the module is fixed securely on the DIN rail 6 When mounting additional modules on the DIN rail e g gateway extension modules or power supply unit place them on the DIN rail with no spacing i e in direct contact with the sides of the housing All standard extension units must be mounted to the left of the MSI 100 safety controller 7 End clamps should be mounted on both sides of the module or module group to stop the module s from slipping on the DIN rail 3 7 1 2 Removal To remove the MSI 100 safety controller proceed as follows 1 Pull the locking latch on the bottom of the module down using a screwdriver for example to release the module from the DIN rail 2 Lift the bottom of the module away from the DIN rail slightly 3 Pull the module diagonally upwards away from the DIN rail MSI 100 3 15 Hardware MSI 100 safety controller amp amp Leuze electronic 3 16 3 7 2 Connecting the supply voltage The MSI 100 safety controller has no main switch and is switched on simply by applying the supply voltage The safety logic and alarm outputs are supplied with power via connections A1 A2 the safe outputs clock outputs and ground switching outputs are supplied via connections 24V 0V Once the PWR status indicator is permanently on the MSI 100 safety controller is ready to operate Outputs A1 and A2 provide the supply voltage for supplying other modules su
21. uration software by a red padlock at the relevant inputs The two signals are then always used as a pair i e both signals are dragged dropped cut or deleted together in the con nection editor However if required this lock can be removed and the dual signal split into two single sig nals Dual signals are not connected to one another internally they are simply grouped togeth er MSI 100 3 7 Leuze electronic Hardware MSI 100 safety controller amp amp Leuze electronic Two channel sensors Cross circuit detection 3 8 me me As input signals with even and odd IDs are processed in different ways in the safety con troller using dual signals ensures that the safety controller will perform redundant process ing To ensure signal redundancy the prepared dual signal must be used to process two chan nel signals 2 wire sensors and control devices For example in order to monitor or eval uate both signals of an emergency stop control device redundantly and to performance level PL e according to DIN EN ISO 13849 1 or EN 954 1 category 4 these two adjacent signal inputs e g 10 and 11 must be connected A cross circuit is an unintentional incorrect connection between redundant circuits The MSI 100 safety controller provides clock outputs TO and T1 as an aid for detecting such a cross circuit For example if two differently clocked signals are routed back to two inputs of the safety controller along
22. 0 safety controller 066 5 9 D0 FOUN CIOM ce E eeen eendceu doe A A 5 10 5 6 SUD MOE ae E E A aedeeaeee 5 11 PADD INCANION CX AIMS S ae E EEE E EA 6 1 Problems and solutions coecencercescensncdsanesevddentineccnadesiudaetinadetinwddisenepctasdeeaeodwccanacsbnesnesenedianssuedesenbene 1 1 7 1 General eee ene ee ee eee ee ee ne eae ee ae oe 7 1 7 2 Graphical connection editor ec ceccccceecceceeeceeaeeeeeeaeeeeeaeeceeaeeeesseeeeesaeeeeeaneees 1 2 7 3 Device parameterization editor ccc ccccccceececeeeeceeeecaeeeeseeeeaeeeeseeeseaeeeaeeeeaaeeeaes 1 2 7 4 Online communication between MSlsafesoft and the MSI 100 safety OM ONG gacenceent casgteeotinsssteceto E EE E E AEEA 1 3 7 9 Safety Controller MESSAGES ccccccceseeeeeeeeeeeeeceeeeeeeeseeeeeeeaeeeeeeseeeeeesseeeeeeeas 1 5 APPENA ooreen rnae gi E E E ET AEA EE AEEA EEEE E E E E EEEE EA 8 1 8 1 C COON OS e E eae meee eee ee eee 8 1 8 2 INU e E E E ete tone ese ceecsesue scene oen 8 3 MSI 100 Leuze electronic 4 Leuze electronic For your safety 1 For your safety Requirements Qualified personnel Leuze electronic A 1 1 Purpose of this manual This manual should enable the user to set up configure and start up the MSI 100 program mable safety controller according to the relevant safety requirements and the risk analysis performed The user manual is therefore designed as a complete system description which provides an introductory syste
23. 1 Alternative Instead of using the safety controller check the function of the safety logic using the MSISIMsoft simulation To do this switch to f simulation mode in MSlsafesoft using the SIM button The project is checked automatically MSISIMsoft is minimized in the taskbar a Download configuration project to the safety controller and acknowledge with the Confirm F f NESTE SSS button see page 5 4 a aAa E After acknowledgment the MSI 100 starts in safe normal operation Is a startup inhibit active If so remove with the reset button Display in the MSlsafesoft status bar PLC Connected Are you using the MSISIMsoft simulation simulation instead of the safety controller aownioaa tne contiguration in tne same way with simulation active see pre vious step Acknowledgment is not re a A quired Display online values in the connection editor F Perform function test see page 5 10 Trigger safety demand via control devices sensors Analyze system response Check device parameters Are you using the MSISIMsoft simulation Use the I O view and expert mode to set the simulation inputs Optional and only additional to function test In MSIsafesoft switch to A standard startup mode Switch connection editor offline unlock safety net works if required make cor rections to the project Standard startup mode see page 5 11 PLC Commissioning Force signals Analy
24. AN 12813 c i819 1108111 Drag amp Drop vafin mans Inserting a signal in the connection editor MSI 100 Leuze electronic amp Leuze electronic MSlsafesoft configuration software Ensuring signal redundancy by using dual signals When evaluating two channel sensors or control devices dual signals should always be used to connect the two channels Dual signals always consist of one even and one odd input signal e g I0 and 11 As input signals with even and odd IDs are processed in different ways in the safety con troller using dual signals ensures that the safety controller will perform redundant pro cessing If required dual signals can be split into two individual signals Please note Dual signals are not connected to one another internally they are simply grouped together Standard alarm signals MO to M3 As well as 20 safe inputs and four safe outputs the safety controller also provides four non safety related alarm outputs These alarm out puts can be used for example to control a standard PLC or a simple detector unit e g a signal lamp Since the alarm signals are not safe they are shown in gray rather than yellow in the connection editor Alarm outputs are edited in the same way as safe I O signals Clock outputs T0 and T1 of the safety controller cannot be moved to the connection editor using drag amp drop To implement cross circuit detection using these two test pulses the relevan
25. Co KG is not liable for damages that result from improper use Proper use also includes knowledge of the information contained in this user manual Explanation of symbols used and signal words jury hazards Obey all safety messages that follow this symbol to avoid pos This is the safety alert symbol It is used to alert you to potential personal in A sible injury or death DANGER This indicates a hazardous situation which if not avoided will result in death or serious injury WARNING This indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION This indicates a hazardous situation which if not avoided could result in minor or moderate injury The following types of messages provide information about possible property damage and general information concerning proper operation and ease of use NOTE This symbol and the accompanying text alerts the reader to a situation which may cause damage or malfunction to the device either hardware or software or surrounding prop erty This symbol and the accompanying text provides additional information to the reader It is also used as a reference to other sources of information manuals data sheets litera ture on the subject matter product etc MSI 100 Leuze electronic 4 amp 4 Leuze electronic Leuze electronic General terms and conditions of use for technical documentation Leuze electronic reserves the rig
26. DINEN 10 6G is Sees ccteaenmecneboatect 1 6 4 7 DIN EN 5025A oie ct tigi eaten anaa ehai 1 6 DIN EN S74 rainane a aeS 1 6 DIN EN 60204 cccccceeeseeeeeeees 1 5 2 2 2 4 4 6 DIN EN 61151 id test ene 1 6 DINEN 6 1A GG sesir a 1 6 DIN BEING 1506 2c eerste Beare ace 1 4 1 5 1 7 DINEN 6200 Tagme eeann 1 4 1 5 1 7 DINEN GJS auina Nett ieee eae 1 6 DIN EN ISO 13849 1 4 1 5 1 7 3 8 ECHOS TA OG ae oe r A 1 6 EN SOTTO irrien seared eet tan 1 6 END SA r R 1 5 3 8 EN ISO T2100 ai eee 1 5 EN ISO 13690 eiere anaa aiae aa kariaan 1 6 IEG 6200 Tiiainen S 1 5 Starting up the Project cceceseeeeeeeeeeeeeeees 4 18 5 6 Startup inhibit ee 1 2 2 5 2 7 5 2 5 6 5 8 Startup mode 2 11 4 2 5 2 5 9 5 11 5 12 Startup restart behavior ccecceseeeeeeeeeeeeeeees 1 2 2 5 Stop category 0 eisowesi cece a teenies dicate 2 2 2 4 2 7 Supply outputs A1 A2 os ok ee 3 9 T TBU S ieee eee ees 2 3 2 12 3 4 3 13 3 14 TBUS DIN rail connector cceceeeeeeee eee eee ees 3 4 3 14 Module COMMUNICATION ccceeceseeeeeeeeeeeeeeees 2 3 Technical data ccc cccccccccseeeceeeeeeeeeeeeeeeeeeeeeeeeeaees 2 15 Test pulses TO T1 2 8 3 1 3 8 3 9 4 13 4 16 TestableSafetySensor safe functional block 2 6 4 9 Time limit when changing operating mode 5 12 TOODO Ksera a AA 4 3 4 11 TwoHandControlTypell safe functional block 4 9 Two
27. HandControlTypelll safe functional block 4 9 U Uploading the configuration from the MSI 100 5 9 Uploading the project from the MSI 100 5 9 USB interface eeaeee 2 2 3 11 5 4 5 7 WISE intended e T 1 7 3 9 W WINN CNECK werrenn e a 2 11 Wiring documentation cccceeeeeeeeeeeeeeeeeeeaeeeeeaees 4 19 A 5
28. N ISO 13849 2 12 2003 Safety of machinery Safety related parts of control systems Part 2 Validation EN ISO 12100 2 Safety of machinery Basic concepts general princi ples for design Part 2 Technical principles DIN EN 62061 Safety of machinery Functional safety of electrical IEC 62061 electronic and programmable control systems for ma chinery Sector standard for machinery created on the basis of IEC 61508 Safety for complex programmable systems Proof of safety of devices as well as evaluation of risk reduction of the entire safety function through calcula tion DIN EN 60204 1 11 1998 Safety of machinery Electrical equipment of ma chines Part 1 General requirements Leuze electronic MSI 100 1 5 For your safety Standard EN ISO 13850 DIN EN 61131 2 02 04 DIN EN 61131 3 02 04 DIN EN 61496 1 06 98 DIN EN 1088 DIN EN 953 DIN EN 574 DIN EN 50254 07 1999 EN 50178 04 1998 EC ISO 7498 MSI 100 4 amp 4 Leuze electronic Contents Safety of machinery Emergency stop principles for design Programmable controllers Part 2 Equipment requirements and tests Programmable controllers Part 3 Programming languages Safety of machinery Electrosensitive protective equipment Part 1 General requirements and tests Safety of machinery Interlocking devices associated with guards Principles for design and selection Safety of machinery Guards General requirements for the
29. NG Serious personal injury or damage to equipment Disregarding this warning may result in damage to equipment and or serious personal injury Only qualified personnel may connect the power start up and operate this device According to the safety instructions in this documentation qualified personnel are per sons who are authorized to start up to ground and to mark devices systems and equip ment according to the standards of safety technology In addition these persons must be familiar with all warning instructions and maintenance measures in this document 3 7 1 Mounting the safety controller CAUTION Risk of injury and damage to equipment Only mount and remove the MSI 100 safety controller when the power supply is discon nected For standard extension modules the MSI 100 safety controller is equipped with an inter face for the TBUS DIN rail connector on the mounting side see page 2 3 3 7 1 1 Mounting CAUTION Risk of damage to equipment due to incorrect installation During mounting observe the following notes Use only the yellow TBUS DIN rail connector Order No 547821 to connect the MSI 100 safety controller Connection with another DIN rail connector is not permit ted Use only the grey TBUS DIN rail connector Order No 547823 to connect the stan dard extension modules Connection with another DIN rail connector is not permit ted Standard extension units must be mounted to the left o
30. Order No 547823 TBUS connection Figure 2 2 TBUS DIN rail connector from Leuze electronic The maximum continuous current for extension modules supplied via the TBUS is 4 A MSI 100 2 3 System description a Safety circuits Stop category 0 Example Equipment on the machine amp Leuze electronic 2 2 Using the system The MSI 100 safety controller configured with MSlsafesoft is designed for monitoring and evaluating safety control devices and safety sensors in machines Machinery Directives and various standards and safety regulations require machine or sys tem manufacturers to meet a high standard of safety The term machine is used here to represent any technical systems according to Ma chinery Directive 2006 42 EC Safety control devices and safety sensors differ as follows Emergency stop control devices can only be detected in the event of dangerous operation and thus operate in the background Safety door switches or light grids for example are often required for operational reasons and therefore regularly control the connection dis connection of the safety related part of the machine The MSI 100 safety controller can be configured flexibly For the creation of the safety logic it has safe functional blocks which are part of the system The MSI 100 can be used to implement various safety functions in different safety circuits Some of the most impor tant options are Emergency stop mo
31. Project menu If the current project status has not yet been saved this is done automatically prior to checking Check values CRC To ensure that any distortions to the configuration data during transmission to the safety controller can be reliably detected a check value CRC is cal culated in the configuration software when the project is checked The safety controller also determines the check value for the downloaded data If the check values on the safety controller and in the configuration software are identical all data has been saved on the safety controller without distortion If the check values differ a corresponding error message is output The check value CRC will also differ if subsequent modifications have been made to the project in the configuration software but have not yet been downloaded to the safety controller A change to the product documentation can also modify the check value for example Once the configuration project has been developed i e the safety logic and the device pa rameterization have been completed the project must be checked This involves checking the safety logic for errors such as open function inputs To check the project proceed as follows 1 Click on the Check Project icon in the toolbar ax 2 The progress of the checking function can be tracked in the message window which opens automatically If the configuration software detects an error the relevant error locati
32. The configuration data and device parameters are download ed from the configuration PC to the safety controller Configuration data refers to the application logic which was created using MSlsafesoft The configuration can also be downloaded using the plug in data memory module Please refer to Downloading the configuration from MSlsafesoft on page 5 4 and Downloading the configuration using the data memory module AC MSI CFG1 on page 5 7 Safety controller PC For diagnostic purposes online values can be read from the MSI 100 safety controller via the USB interface and displayed live in the software For more detailed information please refer to Function test on page 5 10 MSI 100 Leuze electronic amp Leuze electronic System description Communication via the TBUS DIN rail connector Leuze electronic l The MSI 100 safety controller is equipped with an interface for the TBUS DIN rail connec tor The TBUS DIN rail connector from Leuze electronic can be used to connect slave ex tension modules Communication with these modules is then established automatically via the connector on the TBUS DIN rail connector Safety related cross wiring is not required see also Mounting the safety controller on page 3 13 DIN rail connector Standard MSI 100 on yellow DIN rail con extension module on grey nector AC MSI TCS Order No DIN rail connector AC MSI TC 547821
33. Z The diagram below describes the simplified sequence i e the general procedure for de veloping a configuration project and for starting up the MSI 100 safety controller For de tailed information please refer to the specified sections and the MSlsafesoft online help MSlsafesoft Create project using the Project Wizard or a project template In MSlsafesoft Parameterize MSI 100 I Os e g cross circuit detection or ground switching output Double clicking on the representation of the safety controller in the hardware editor opens the safe parameter editor see page 4 15 Develop the safety logic in the connection editor Insert I O signals from the hardware editor Enter signal information Project menu Assignment Map Insert functions and functional blocks from the toolbox Connect objects Safety networks MSlsafesoft Check project Errors in the project gt gt Message window in MSlsafesoft Optional Lock safety networks to prevent editing in the connection editor A gt Continued from B Continued A Figure 5 1 Flowchart Configuration from A to Z 1 of 3 MSI 100 5 1 Leuze electronic Configuration and startup amp Leuze electronic Continued B Continued from A Switch on the MSI 100 apply supply voltage see page 3 16 and connect to the USB interface of the PC see page 3 1
34. a safety function MSI 100 Leuze electronic amp Leuze electronic System description Startup Restart il Reset button Implementation using safe functional blocks Leuze electronic Example You are responsible for planning and implementing the startup behavior and the restart behavior according to your risk analysis To prevent an unexpected startup a reset button may be required to generate a manual reset signal at the machine This will depend on both the results of the risk analysis and the signal path Additional safe control devices such as three position enable switches etc may be re quired 2 3 System startup and restart behavior Startup refers to the behavior of the MSI 100 safety controller after switching on or ap plying the supply voltage and following configuration via USB interface or data memory module Unless a startup inhibit is configured the safety controller starts up immediately following successful configuration i e after pressing the Confirm button The signal inputs are then evaluated and the outputs controlled accordingly Restart refers to the behavior of the safety controller after the safety function is triggered and following a return to normal operation for example after unlocking the emergency stop control device which means safe operation is possible again With an active startup restart inhibit the corresponding inhibited safe module output re mains in the safe st
35. ants are always inserted into the connection ed functions in the toolbox itor from the toolbox using drag amp drop To do this proceed as follows 1 Display the toolbox Toolbox in the View menu If the auto hide function is en abled position the cursor over the minimized window as shown in Figure 4 5 for the hardware editor 2 Inthe toolbox open the required section by clicking on the corresponding navigation bar Safe Functions Safe Functional Blocks or Favorites 3 Drag the required object into the connection editor from the toolbox section Left click on the required object and hold the mouse button down Hold the left mouse button down and drag the object from the toolbox to a free po sition in the safety logic and then release the mouse button Signal constants can be dragged directly to functional block connections thus es tablishing the connection immediately on insertion The object is stored at the selected position oriented on the grid of the connection editor Enable Switch Figure 4 4 Inserting safe functional blocks and functions from the toolbox in the con nection editor Signal inputs and signal Input and output signals of the safety controller are always inserted into the connection ed outputs in the hardware itor from the hardware editor using drag amp drop To do this proceed as follows editor Leuze electronic MSI 100 4 11 MSlsafesoft configuration software 4 Leuze e
36. ate This prevents an undesired startup restart of a machine controlled by the relevant output terminal block The safe state of an output terminal block is power off mode signal value FALSE To enable the function of the machine which is controlled by the MSI 100 output affected by the active startup inhibit restart inhibit the inhibit must be removed by a reset signal As in the case of the stop category see page 2 4 the startup and restart behavior of the safety controller depends on a specific output and how this output is connected in the con figured safety logic The reset signal is used at the same time to exit the error state once the error cause has been removed To implement a startup inhibit restart inhibit safe functional blocks must be used in the MSlsafesoft configuration software which have the relevant parameters for activating the startup inhibit and or restart inhibit MSI 100 2 5 System description Example 4 amp 4 Leuze electronic The table below lists the functional blocks that offer these parameters Table 2 1 Functional blocks that support a startup inhibit restart inhibit Functional block Available inhibit name EmergencyStop Emergency stop monitoring Startup inhibit Restart inhibit EDM External device monitoring Startup inhibit EnableSwitch Evaluation of a three position enable Restart inhibit switch ESPE Monitoring of electrosensitive protec Startup inhibit tive equipment e g l
37. c functions used in standard digital technology Safe functions The following safe functions are available in the MSlsafesoft toolbox and can be easily added to the safety logic using drag amp drop in alphabetical order AND Boolean ANDing EQ Boolean comparison F_TRIG detection of a falling edge NOT complement or negator NOT_EQ comparison for Boolean inequality OR Boolean ORing PULSE_GEN safe pulse generator R_TRIG detection of a rising edge RS bistable function priority for resetting SR bistable function priority for setting TOF timer for off delay TON timer for switch on delay TP impulse encoder XOR Boolean EXORing Safe functional blocks The safe functional blocks provide basic safety related functions for implementing the re quired safety circuits Table 4 1 lists the available functional blocks in alphabetical order Leuze electronic MSI 100 4 5 MSlsafesoft configuration software amp Leuze electronic Table 4 1 Safe functional blocks Name Short description Icon in editor Antivalent The Antivalent safe functional block monitors the signals of two safe input terminal blocks for different signal states Typically these signals come from two channel sensors or switches such as an emergency stop control device The EDM external device monitoring safe functional block monitors the defined initial state and the switching beha
38. catego Ova eee 2 6 Assignment S ircen a naive 4 2 Assignment list MSlsafesoft ccccsecceeeeeseeeees 4 19 C Cable lengths to sensors control devices 3 17 Category 4 according to DIN EN ISO 13849 1 4 Check values CRC ccccceeeeeeeeeeees 4 18 4 20 5 7 Checking and downloading the project 4 18 5 1 5 2 5 5 Communication between the MSI 100 and MSlsafesoft 2 2 3 11 Configuration project see Project Connecting objects in the connection editor 4 14 Connection editor 2 2 2 11 3 7 4 3 4 11 5 1 5 10 7 2 Connections on the MSI 100 ce eeeeeeeeeee seers 3 7 Controller password see Password protection Creating a Proje Cl iscaticdiiske wants 4 10 5 1 Cross circuit detection 1 2 2 8 3 8 3 9 4 13 4 16 CroSs CirCuit protection iissa iins 3 10 D Device parameterization editor 2 8 4 15 7 2 Diagnostics Hardware GiaQnostiCs cccscceccsseeeeeeeeeeeeeeeeeaes 2 9 Online TOO TIPS ersre denei ea 2 12 Stat s INGICALONS penoa a N 2 12 Wing CNECK a iaa N 2 11 DIN rail connector see TBUS DIN rail connector Leuze electronic MSI 100 DIN rail see 35 mm DIN rail DIECIIVES aur sania caaeniedta Gas casteanteaaeeieis caress 1 5 DOCUMENTATION cccceecceeeceeeeceeeteeeceseteeetaeeeeneeeees 1 8 Documenting the signal assignment of the project 4 19 Downloading the configuration using the AC MSIHCRG links cx
39. ch as sensors see Supply connections A1 and A2 on page 3 9 3 7 2 1 Direct connection of the supply voltage on the MSI 100 Connect the supply voltage as follows 1 Supply voltage for the safe module outputs the clock and ground switching outputs at terminal block contacts OV and 24V as shown in the diagram below 2 Supply voltage for the logic of the safety controller and the alarm outputs at terminal block contacts A1 24 V and A2 0 V Once the supply voltage has been applied the MSI 100 safety controller executes an ini tialization routine all LEDs on A1 A2 2 terminal blocks each Connections Figure 3 11 Connecting the supply voltage at A1 A2 and 24V 0V a MSI 100 Leuze electronic 4 amp 4 Leuze electronic Hardware MSI 100 safety controller 3 7 3 Connecting the signal lines CAUTION Ensure signal redundancy Ensure signal redundancy when connecting the signal lines of two channel control de vices and sensors to the inputs of the safety controller Please refer to Signal inputs on page 3 7 CAUTION Avoid cross circuits and short circuits Prevent cross circuits and short circuits by using a suitable cable installation Implement cross circuit detection see Cross circuit detection on page 3 8 Cable lengths Many applications use large numbers of sensors or control devices Depending on the size of the machine or system a considerable amount of cabling may be r
40. connected The following example shows a simplified schematic view An emergency stop control device with two N C contacts is connected to inputs 10 and 11 of the safety controller The status of the N C contacts is monitored by the Equivalent safe functional block at the start of the safety logic In our example the functional block reports an error ERR output TRUE the symbol for the functional block is surrounded by a red border with the configuration software in online mode Therefore the LEDs for inputs I0 and 11 which are both directly connected to this functional block flash on the safety controller Safety logic in MSlsafesoft in online mode error EIEE sa FALSE FALSE To TO Ti Ti Mo M1 M2 M3 CFG STICK l CONFIRM LEDs of inputs I0 and 11 on the safety controller ig 19 110 111 16 117 118 119 4 15 16 17 112 113 114 145 Safe control device at inputs I0 and 11 of the MSI 100 safety controller Emergency stop Reset Figure 2 6 Simplified schematic view Hardware diagnostics in the event of an error at a safe functional block MSI 100 Leuze electronic 4 amp 4 Leuze electronic Wiring check Leuze electronic System description If the connection editor is in startup mode the wiring check can be used to easily check the terminal block position of the input used in the logic A graphical link directs the user to the right position and pro
41. control devices and actuators should be wired within the overall safety function How safe functional blocks should be used in the safety logic The safety logic is cre ated using the MSlsafesoft configuration software Within the safe control system used the safe functional blocks support the following safety integrity requirements Upto SIL 3 according to standard DIN EN 61508 Upto SILCL 3 according to standard DIN EN 62061 Up to category 4 according to standard DIN EN ISO 13849 1 Please note that you are responsible for implementing all additional requirements result ing from applicable directives and legislation in order to meet the above safety integrity requirements see also Directives and standards on page 1 5 Please note that you must carry out a validation every time you make a safety related mod ification to your overall system Use the relevant checklists when carrying out the validation and also enter the details requested in the Project Information dialog box in the MSlsafesoft safe configuration software Use your test report to ensure that The safe sensors and actuators are connected correctly in the MSI 100 safety appli cation To do this use the Wiring check function in MSlIsafesoft see page 2 11 The parameterization of the inputs and outputs of the MSI 100 safety controller is cor rect The signals have been connected to the safe sensors and actuators correctly si
42. cs eke eee eens 5 7 Downloading the project using the AC MSI CFG1 5 7 Dualsignals se he tg 3 7 4 11 4 13 E EDM safe functional DIOCk cccceeeeeeees 2 6 4 6 Electrical Safety siea aaar riia 1 3 EMC Directive 2004 108 EC ccccccceseeeceeeeeeeeees 1 5 EmergencyStop safe functional block 2 6 4 6 EnableSwitch safe functional block 2 6 4 6 Equivalent safe functional bDIOCk cccceeseeeeees 4 6 ElrOrdeGleCllon sical tail ecco hates aotaaae 1 2 ESPE safe functional block ccccceeeseeeeeeeeeeeees 2 6 Expert mode MSISIMsoft simulation 06 5 2 F POLCING arero aa 3 11 4 2 4 21 4 22 5 2 5 12 Forcing signals see Forcing FUNCION TOS rinanon a en 5 2 5 7 5 10 Functional blocks with startup or restart inhibit 2 6 Functional blocks functions safe 1 7 4 5 6 1 Functions functional blocks safe 1 7 4 5 6 1 G Ground switching outputs OO0 O1 3 1 3 10 4 17 GuardLocking safe functional block 2 6 4 7 GuardMonitoring safe functional block 2 6 4 7 Guideline for test and certification GS ET 26 1 5 H Hardware diagnostics ccccceccsseecceeeesseeeeeeeeaeeeeaes 2 9 Hardware editor 2 8 3 7 4 2 4 3 4 11 4 15 5 1 5 10 Inserting functional blocks in the connection editor 4 11 Inserting functions in the connection edi
43. ct in the configuration system are identical If you have made a change to a project after startup even something as small as moving an object is classed as a change you must check the project and send it to the safety controller again before you can display online values 5 10 Signal lines and functional block connections are now displayed in the connection editor in different colors according to their state TRUE FALSE and together with the current values The hardware editor also supports the function test through lit LEDs MSI 100 Leuze electronic amp Leuze electronic Configuration and startup 3 Now trigger a safety demand via the safe control devices Monitor the response of the machine and the configuration in the connection editor which has been switched to online mode Example Emergency stop not pressed no safety de mand me TEM ae ae EHEHEHE 02 O 013 Safety demand FALSE l Figure 5 8 Example of a function test for the safety system using MSlsafesoft online mode 5 6 Startup mode In addition to the mandatory function test using online mode see Function test on page 5 10 startup mode can also be used For example instead of pressing the emergency stop control device or opening the safety door in startup mode you can force the signal corresponding to the safe control device in the connection editor WARNING The test in startup mode does not replace the proper f
44. currently in use Is a module status displayed in the status bar Use this safety controller instead of the one used first N o Try to establish the connection using another USB cable oe ste Use the functioning in the status bar cable N o Please contact our technical support team Possible module status on existing connection Controller Timeout Temporary during initialization Controller No project Download project Controller Connected Start function test Leuze electronic MSI 100 7 3 Problems and solutions 4 amp 4 Leuze electronic Table 7 4 Solutions for communication problems Problem Transmission has been inter Start transmission again rupted during the download pro 2 If the download procedure fails once more re cedure move the USB connecting cable from the interface on the configuration computer and reinsert it Once the safety controller has been detected cor rectly see display in the status bar restart the download procedure Following successful project Proceed as follows download the MSIsafesoft safe Download the project to the safety controller again configuration software identifies and acknowledge by pressing the Confirm button that the checksum of the project on the safety controller does not match that of the project on the PC A corresponding message Chiedea No further action still indicated required You can start window is disp
45. data Please refer to Downloading the configuration us ing the data memory module AC MSI CFG1 on page 5 7 1 Ensure that The MSI 100 safety controller is switched on The MSlsafesoft configuration software is installed on the configuration computer this installation also includes the required drivers The MSlsafesoft configuration software is started An data memory module is inserted in the safety controller Otherwise the config uration cannot be downloaded 2 Connect the USB cable to the MSI 100 safety controller mini USB connector 5 pos maximum cable length 3 m and to a USB port on the PC NOTE Electrostatic discharge The MSI 100 safety controller contains components that can be damaged or destroyed by electrostatic discharge When handling the USB interface observe the necessary safety precautions against electrostatic discharge ESD according to EN 61340 5 1 and EN 61340 5 2 MSI 100 Leuze electronic 4 amp 4 Leuze electronic l Leuze electronic Configuration and startup Once the connecting cable has been connected the correspondingly configured PC detects the safety controller automatically and indicates the safety controller status at the bottom right in the status bar see Figure 4 1 on page 4 3 m wk gin yi aas aL Status indicator for CFG LED flashes during MSI 100 data transmission Figure 5 4 USB connection between PC and safety controller The
46. design and construction of fixed and movable guards Safety of machinery Two hand control devices Functional aspects Principles for design High efficiency communication subsystem for small data packages Electronic equipment for use in power installations Information Technology Open Systems Interconnection Leuze electronic 4 amp 4 Leuze electronic For your safety 1 6 Intended use MSI 100 The MSI 100 safety controller should only be used in industrial applications according to standards DIN EN 61508 DIN EN ISO 13849 and DIN EN 62061 The MSI 100 safety controller is designed for evaluating safety related sensors on a ma chine or system which are connected to the inputs of the safety controller and for control ling its outputs according to the configured safety logic The safety controller can only perform its safety related tasks if it has been integrated into the execution process correctly and in such a way as to avoid errors You must observe all information in this manual as well as in the user manuals and online help listed in Documentation on page 1 8 In particular only use the MSI 100 safety con troller according to the technical data specified in Technical data on page 2 15 MSlsafesoft The MSlsafesoft safe configuration software is designed for the configuration of the MSI 100 safety controller Safe functional blocks and The safe functional blocks and functions available in the MSlsafesoft configu
47. e 2 5 If the safety controller is not initialized correctly proceed as described in Problems and solutions on page 7 1 5 6 MSI 100 Leuze electronic amp amp Leuze electronic Configuration and startup Next steps Next continue with the function test see Function test on page 5 10 A Check values CRC To ensure that any distortions to the configuration data during transmission to the safety controller can be reliably detected a check value CRC is cal culated in the configuration software when the project is checked The safety controller also determines the check value for the downloaded data If the check values on the safety controller and in the configuration software are identical all data has been saved on the safety controller without distortion If the check values differ a corresponding error message is output The check value CRC will also differ if subsequent modifications have been made to the project in the configuration software but have not yet been downloaded to the safety controller A change to the product documentation can also modify the check value for example 5 3 Downloading the configuration using the data memory module AC MSI CFG1 WARNING Risk of damage due to unintentional incorrect operations Prior to startup ensure that if the safety controller functions in an unintended or incorrect way this will not cause damage Configurations can not only be downloaded via the USB
48. e to online mode so that online values can be read cyclically from the safety controller and displayed in the connection editor and the hardware editor Once a safety demand has been triggered by activating the safe control devices e g by pressing the emergency stop control device or opening the safety door the behavior of the safety logic can be analyzed precisely in the configuration software as in online mode the connection editor displays the value of every signal live WARNING Risk of injury or damage to equipment due to unintentional system states or incorrect responses Make sure that the act of triggering the safety demand will not pose a risk for people or materials The safety controller is in the startup phase i e unintentional system states or incorrect responses cannot be ruled out Do not enter any hazardous areas and ensure that no other persons can access the dan ger zone either To execute a function test proceed as follows 1 Connect the MSI 100 safety controller which is switched on to the configuration com puter via the USB interface start the MSIsafesoft configuration software and log on for the safety controller The status bar in MSlsafesoft displays the following entry on the right hand side 2 Switch MSlsafesoft to online mode by clicking on the Online Values icon in the tool bar i The system can only display online values if the project in the safety controller and the proje
49. ection left or with spring cage terminal blocks right on 35 mm EN DIN rail MSI 100 3 1 Hardware MSI 100 safety controller amp Leuze electronic A1 A2 TO TO T1 T1 10 H 119 MO M1 M2 M3 TEST PULSE MONITORING OUTPUT SAFE INPUT OUTPUT TBUS NON SAFE lt gt CFG USB STICK 24V OV OO O1 O2 O3 O0 01 Figure 3 2 Block diagram for the MSI 100 safety controller MSI 100 Leuze electronic 4 amp 4 Leuze electronic Hardware MSI 100 safety controller Leuze electronic 3 2 Operating modes status of MSI 100 The diagram below illustrates the possible operating modes status of the MSI 100 safety controller and the possible status transitions When there is a USB connection to the PC the module status is indicated on the far left in the status bar of the MSIsafesoft configura tion software The Safety controller and PC are connected via USB the safety controller is switched on a Temporary condition during Communication PLC Timeout L Initialization Self test No Initial setup y Download project Al Execution will start after confirmation Confirm button on controller Temporary condition during Saving during download PLC Titneout Initialization Self test of the controller Connection editor F Online or offline Change from safe online mode I es all e _ PLC Error commissioning mode PLC Commissioning USB connection PC controller may not be inte
50. eeeseeeseeeeseeeeeees 3 1 I O device error detection cccccsssseesssseeeeeees 2 8 Instalatori ear ea 3 13 LEDs for inputs and Outputs cccceeeeeeeee eee 3 6 MOUNN Geesseen e 3 13 Operating and indication elements 008 3 4 Password protection ccccccccssecceeeeseeesseeenees 2 13 Possible operating Status ccccecseeeecseeeeeeees 3 3 REMOVA asnan oh ese Sa aT 3 15 Safe outputs OO O3 2 0 ceeccccseeeseeeeeeeeeeees 3 8 Safety functions possible ccceccceeeeeeeeeeees 2 4 Signal MOUS otic ene ceiteeec a derit tate i niecadeueaseces 3 7 Slatus INGICAlONS ess ieee Ae 2 12 Supply outputs A1 A2 cc cccececceceeeeeeeeeeeaeeees 3 9 SUD IY VONAGE 2h thee co eer 3 16 System OVELVICW cccccccccesseeeceseeececeeeeeesseaeeess 2 1 TechniGal dalawii 203 ai el 2 15 Uploading the project ccccccsssscessesseseeseeesees 5 9 USB intern t saii ihi 3 11 Using the system noneneeennneennseennrsrensnreserrene 2 4 A 4 MSI 100 MSI 100 confirm button neaannnannnnannnnnnneennneennnennnne 3 6 MSI 100 connection terminal blOcKS 000008 3 1 MSI 100 diagnostic and status indicators 3 4 MS FITOOINPUS aanta n ae tears aes ees acetal eessentseces 3 7 MSI 100 installation ccc ceeccceeeeceeeeeeeeeeeesaneees 3 13 MSI 100 operating Status eeeceeesseeeeeeseeeeeees 3 3 MSI 100 Signal inputs
51. een identified by the muting sensors as permissible for the muting operation to pass through on an assembly conveyor By contrast if the light grid is interrupted by a worker s hand for example the OUT output switches to FALSE to disable the hazard as the safety equipment had not been previously muted The maximum allowable time for the muting operation is monitored using the four muting sensors 4 8 MSI 100 Leuze electronic 4 amp 4 Leuze electronic MSlsafesoft configuration software Table 4 1 Safe functional blocks Fortsetzung Name Short description Icon in editor TestableSafetySensor The TestableSafetySensor functional block evaluates the status of a connected optoelectronic protective device e g light curtain The functional block also has a test function for checking the connected protective equipment 0 01 FALSE _ FALSE TwoHandControlTypell The TwoHandControlTypell safe functional block evaluates the switching behavior of a Type II two hand control device connected to the safety controller TwoHandControlTypelll The TwoHandControlTypelll safe functional block evaluates the switching behavior of a Type III two hand control device ay connected to the safety controller A detailed description of each functional block and function is available in the online help To open the help for a particular safe functional block or safe function right click on the corresponding block in the MSlsafesoft con
52. eeseeeeeesaaees 4 1 4 2 Overview of functions and features cece eeeccc ee eeceeeeeeeeaeeceesueeessaeeeeseeeeeeaeeees 4 1 4 3 Description of the user interface cece cc eeeccceeeeeceeeeeeseeeeeeaeeeeeaneeeseeeeeesneeeees 4 3 4 4 Safe functional blocks ANd FUNCTIONS cece cecccceeeececeeceeceeeeeseeeeeceeeeeseeeeesaaes 4 5 4 5 Operating the MSlsafesoft configuration software ccccseeeeeeeeeeeeeeeeeaaeees 4 10 4 5 1 Creating the Configuration project ccccceeccceeeeeeeeeeeeeeeesaeeeeeeseaees 4 10 4 5 2 Adding and connecting functions functional blocks and signals I the safety OGIO ae cccee sina eee stecnuch aikaa Enni Ea aa 4 11 4 5 3 Device parameterization in the safe parameter editor 4 15 4 5 4 Checking downloading and starting up the project 4 18 4 5 5 Documenting the signal assignment and the project 008 4 19 4 6 Simulation Mode in MSISafesSoft cecccccsseccecseeeseeeceseeeeeseeeeeseeeeesseeeeesees 4 21 Configuration and StarnUD erreira ce sevantsagetonsbaumescassseie 5 1 5 1 Configuration overview from A tO Z ccccecccecseeceeeeeeeeeeeesaeeeeeeeaaeeeeesaaaeseessaaeeees 5 1 5 2 Downloading the configuration from MSISafesoft ccccseccceesssseeeeeeeeeeeeneees 5 4 5 3 Downloading the configuration using the data memory module ACMS ECF 4 peur tee een sra E E SE 5 7 5 4 Uploading the configuration from the MSI 10
53. eneral Table 7 1 Solutions for general problems Problem Uninstall the safe configuration software then reinstall it by running the setup pro gram from the installation CD When the MSlsafesoft safe configuration software was launched the installation check identified a faulty system file A corresponding message window is dis played The operating system test routine has iden tified that you are trying to launch the MSlsafesoft configuration software on an operating system that is not supported An error has occurred accompanied by a corresponding message which cannot be removed using any of the measures de scribed here The MSlsafesoft safe configuration soft ware or one of its functions is not behaving as described in the user documentation or the online help MSI 100 Install an operating system supported by MSlsafesoft see System requirements for the MSlsafesoft configuration software on page 2 18 or consult the technical support team to find out whether a newer version of MSlsafesoft is available which supports your current operating system Please contact our technical support team Please contact our technical support team 7 1 Problems and solutions 4 amp 4 Leuze electronic 7 2 Graphical connection editor Table 7 2 You have attempted to open a project but the safety logic could not be loaded due to a checksum error A corresponding message window is dis played During
54. ens automatically If the sys tem detects an error when checking the project the relevant error location can be accessed directly by double clicking with the left mouse button on the message in the message window Assignment list for signals The assignment list contains the signal assignments for the individual inputs and out puts of the MSI 100 safety controller It provides wiring documentation which makes the project easier to understand and helps to prevent incorrect connections being es tablished in the connection editor Project information dialog box This dialog box can be used to enter and display the most important information for the current configuration project e g project related data manufacturer data operator installation location data relating to safety inspections revision history for the project MSI 100 Leuze electronic amp Leuze electronic MSlsafesoft configuration software 4 4 Safe functional blocks and functions The MSI 100 safety controller is configured in the MSlsafesoft configuration software by graphically connecting prepared safe functions and safe functional blocks Safe function blocks Figure 4 2 Safe functional blocks in the toolbox excerpt The connections are made intuitively using the mouse and the editor prevents impermis sible connections e g between certain outputs The safe functions include simple Boolean operations and basi
55. equired safety integrity as defined by DIN EN 61508 DIN EN ISO 13849 or DIN EN 62061 you must take into consideration the entire path of the safety func tion safety controller device parameterization wiring sensors actuators single channel or two channel operation etc starting from the functional block I O in terface Validate the entire path on completion Leuze electronic MSI 100 1 7 For your safety Latest documentation Calling online help 1 4 amp 4 Leuze electronic f Documentation Make sure you always use the latest documentation Find out from the manufacturer or their homepage on the Internet whether any changes or additions have been made to the documentation used When working on and with the MSI 100 safety controller you must always keep this doc umentation and other items of product documentation to hand and observe the information therein You must observe all information In the technical description of the MSI 100 safety controller In the user documentation for I O devices e g sensors actuators etc connected to the MSI 100 safety controller and connected to safe functional blocks in the safety log ic MSlsafesoft configuration software In the online help for the MSlsafesoft configuration software see also Figure 1 1 and for each of the safe functional blocks In the documentation for the supplementary standard technology if applicable The diagram below illustrates the various
56. equired to wire the sensors Make sure that the specified cable lengths are not exceeded so as to ensure error free operation of the safety circuits and therefore a reliable safety demand For reliable and touch proof contacts strip the cable ends as follows 8 mm A B Screw ter Spring cage minal terminal blocks blocks Figure 3 12 Connection to screw terminal blocks left and spring cage terminal blocks right Leuze electronic MSI 100 3 17 Hardware MSI 100 safety controller 3 18 MSI 100 4 amp 4 Leuze electronic Leuze electronic 4 amp 4 Leuze electronic MSlsafesoft configuration software 4 MsSlsafesoft configuration software 4 1 Installing MSlsafesoft The installation routine for the configuration software also includes the installation of the required driver for the USB interface This driver is required to enable communication be tween the PC on which MSlsafesoft is installed and the MSI 100 safety controller To ensure that the configuration software detects the safety controller automatically and correctly the software must be fully installed on the computer before the device is con nected for the first time Proceed as follows 1 Ifyou have downloaded the configuration software extract the downloaded file and start the installation program setup file If you have purchased the commissioning set MSI SWC7 insert the supplied CD in the drive A graphical menu open
57. er device is selected several editing steps can be undone lt Ctrl gt lt Z gt and redone lt Ctrl gt lt Y gt If you have modified parameters and then close the editor with OK you are prompted to save the changes that have been made A cross circuit is an unintentional incorrect connection between redundant circuits The safety controller provides clocked outputs TO and T1 as an aid for detecting such a cross circuit MSI 100 Leuze electronic amp Leuze electronic MSlsafesoft configuration software To activate cross circuit detection for an output set the corresponding cross circuit detec tion parameter no yes with test pulse T to yes with test pulse T See Figure 4 12 above The MSlsafesoft configuration software specifies the clock signals to be used Cross cir cuit detection is implemented with test pulse TO for even inputs 10 12 14 118 For odd inputs 11 13 15 119 test pulse T1 must be used for cross circuit detection For additional information about cross circuit detection please refer to Signal inputs on page 3 7 and Error detection in I O devices on page 2 8 An application example is also provided there Output parameters for the The additionally ground switching contact parameter no yes with O is only avail safety controller able for outputs OO and O1 Output OO is connected to ground switching output O0 output Ground switching output O1 to ground
58. esoftchecklist ccccecccesceeseeeeeeeeceeeeeeeeeens 4 2 MSlsafesoftTOOlDOX ccccccceceeceeeeeeeeeeeeceeeeeeeeenens 4 3 MutingPar safe functional block ccceeeeeeeeees 4 8 MutingPar_2Sensor safe functional block 2 6 4 8 MutingSeq safe functional DIOCk ccccceeeeeeeees 4 8 O COMMON Oi iira eh eeaates ers cies E Bee 6 1 SAW casiateiieescrtte dats tease latest sna cbihaneiee sean 1 8 4 2 4 9 Online tool tips in the connection editor 2 12 OUTPUTS O0 OZ rreren een 3 1 3 7 3 8 Leuze electronic P Parameterization CCItOr cccccecceeeeeeeeeeeeeeeeeeeees 4 15 Parameterizing inputs and outputs 4 15 5 1 Password protection cccccceseccseeecseeeeeeteees 2 13 5 9 Performance level PLe according to DIN EN ISO 13849 3 8 Personnel requireMents ccceccesecceeeeeeeeeeeeeeeees 1 1 Power supply for sensors and control devices 3 9 Printing parameters ccccceececeeseeseeseesseeeesseaeees 4 17 Problems and solutions cccceeeeeeeeeeeeeeeeeeeeeaaees 7 1 Project configuration and startup overview 5 1 Project documentation ccccceececeeeeeeeeeeaees 4 19 5 3 Project password see Password protection Project Wizard cciedsiiedi states suainbinecadesurcindesedeasansatevules 4 10 Purpose of this manual cccececeeeeeeeeeeeeeeeeeeeaes 1 1 Q Quali
59. est backup copy of the project as described in the online help under Zip ping and extracting projects Undo the last entry by pressing lt Ctrl gt lt Z gt then repeat the entry If the result is still incorrect please contact our technical support team The project is closed automatically You do not have the opportunity to save the most recently made changes If the problem persists when the project is reopened please contact our technical support team Leuze electronic amp Leuze electronic Problems and solutions 7 4 Online communication between MSlsafesoft and the MSI 100 safety controller Table 7 4 Solutions for communication problems Problem A connection cannot be estab Proceed as follows lished to the safety controller i Remove the USB connecting cable from the PC and safety The status bar does not display controller then reinsert it a status for the safety controller Timeout No project or Connected see information i l Communication with under the diagram below aa S MSI 100 is in the status bar possible No further The status bar looks like this lai a for example Project Read Write No Insert the USB cable in a different USB connection on your PC The first USB connection TS a used on the PC may be in the status bar faulty Use this port instead of the one used first No Try to establish a USB connection to another safety controller that is not
60. evel Pollution degree Surge voltage category Mounting position Dimensions W H D MSI SCP MSI SPP Conductor cross section Screw connection Spring cage connection Housing material Cable length for USB configuration cable MSI 100 4 amp 4 Leuze electronic 2 24 V DC A1 A2 100 mA 1 ms approx Yes 4 24 V DC A1 A2 100 mA Yes 20 C 55 C 20 C 70 C 100 operating factor IP20 IP20 IP54 minimum Yes between power supply for logic A1 A2 and power supply for safe outputs 24 V O V Suppressor diode According to DIN EN 50178 1998 04 1 Basic insulation 50 V 0 8 kV 2 III Horizontal 67 5 114 5 99 mm 67 5 114 5 112 mm 0 2 2 5 mm 24 12 AWG 0 2 1 5 mm 24 16 AWG Polyamide PA non reinforced 3 m maximum Leuze electronic 4 amp 4 Leuze electronic Leuze electronic System description Safety characteristic data Category according to EN 954 1 4 Performance level according to ISO 13849 1 e SILCL according to IEC 62061 3 Safety integrity level SIL according to IEC 61508 3 Characteristic data according to ISO 13849 MTTFp 8324 years high DC 99 high 1 Data only applies if the safety function is demanded at least once a year Characteristic data according to IEC 61508 EN 62061 1 PFH 1 4 x 108 1 h Proof test interval T4 240 month 1 Data only applies if the safety function is demanded at least once a year 2 Since
61. f the basic device Leuze electronic MSI 100 3 13 Hardware MSI 100 safety controller amp amp Leuze electronic To mount the MSI 100 safety controller proceed as follows Mounting a 35 mm DIN rail 1 The safety controller should only be mounted on 35 mm DIN rails according to DIN EN 60715 To avoid contact resistance only use clean and corrosion free DIN rails Mounting TBUS DIN rail 2 To use TBUS DIN rail connectors to create a connection station with a system power connectors optional supply unit or with extension units proceed as follows Connect together the required number of MSI DIN rail connectors for the connec tion station see Figure 3 9 A Snap this group of MSI DIN rail connectors onto the DIN rail see B and C Figure 3 9 Mounting TBUS DIN rail connectors Mounting the MSI 100 3 Place the module onto the DIN rail from above as shown in Figure 3 10 so that the up safety controller per holding keyway of the module is hooked onto the top edge of the DIN rail When using MSI DIN rail connectors ensure that the contact opening in the base of the module is aligned correctly over the contact block of the MSI DIN rail connector Figure 3 10 Attaching the MSI 100 safety controller to the DIN rail 3 14 MSI 100 Leuze electronic 4 amp 4 Leuze electronic Leuze electronic Hardware MSI 100 safety controller 4 Push the lower part of the module that is furthest from the DIN rail towards the DIN rail
62. f the relevant signals and connection areas are displayed within a green border see Figure 4 8 1 release the mouse button If the connection between the two objects is not permitted these items are not dis played within a green border In this case no connection can be established The dragged object is positioned automatically and the connecting line is also created au tomatically automatic routing If required the objects can then be moved whereby the connection editor manages the connecting lines automatically 2 Figure 4 8 Connecting unconnected signals to functional blocks or functions using drag amp drop MSI 100 Leuze electronic amp Leuze electronic Opening the device parameterization editor Leuze electronic MSlsafesoft configuration software 4 5 3 Device parameterization in the safe parameter editor The inputs and outputs of the safety controller can be parameterized Specific properties can be defined for each input and output in a special safe parameter editor When checking a project in the MSIsafesoft configuration software this data is used to cre ate a parameterization file which is subsequently transmitted to the safety controller auto matically as part of the configuration project The parameters can only be edited if you have logged on with the correct project pass word Log On in the Project menu The device parameterization editor is a component of the hardware edi
63. fications for personnel cccecceeseeeeeeeeeeaeees 1 1 R REPAIS anaa a aces taeda ease aas ews 1 2 Requirements for personnel c scccceeeeeeeseeeeeees 1 1 Restart MAMI incase teocstiodancieniiedak heaved oedennic 1 2 2 5 2 7 Risk analysis sacs Gaemieinandeaseaners 1 4 S Safe functional blocks and functions 0006 4 5 Safe outputs see Outputs O0 O3 Safety CONCEP cccccccccsssececceeseeecsceseeeeceseeesesaaees 1 4 Safety Nte sents Nee oes 1 4 1 7 Safety notes OCI Gall nateilesatcth Sith ease aes etl eke ho is oe OS to 1 3 Gee lal etnies a A 1 1 Safety of the machine SysteM ccceceeeeeees 1 4 Safety of personnel and equipment c eee 1 2 Safety of the machine SySteM cccceeeseeeeeeeeeees 1 4 Safety requireMent ccccccssseeececesseeeceseeeeseaeees 1 4 Screw CONNECTIONS ccecceceeceeceeeececeeeeeeeeees 3 1 3 17 Signal ASSIGNMEM cc eH ec ee es AR 4 2 Signal sequence diagrams for functional blocks 6 1 SIL 3 according to DIN EN 61508 cess 1 4 SILCL 3 according to DIN EN 62061 1 4 SIMULATION eer e es Say Sat has eee 4 21 5 2 Software system requirement ccccccceeeeeee eens 2 18 Solutions for ProbleMsS cccccccccseeeecseeeeseeeeesaeeees 7 1 Spring cage CONNECTIONS cccceeeeeeeeeeeeees 3 1 3 17 Leuze electronic MSI 100 Index Standards
64. ft status bar If a project with the same name as the project which has just been uploaded already exists on the PC a prompt will appear where you must decide whether you want to overwrite the project which is already loaded or not In this prompt dialog box click Yes to overwrite the data of the existing project with that of the project which has just been uploaded Overwriting means that the current data will be lost and it will not be possible to recover it No to save the uploaded project under a different name or in a different directory The Save Project As dialog box appears Here select a directory enter a file name and click on Save You are now asked to enter the project password Once you have entered the password you can edit and check the project load it to the safety controller and start it up there as usual MSI 100 5 9 Configuration and startup Configuration and startup CCC Leuzeelectronic Validation Online mode in MSlsafesoft Safety demand monitoring signals A Connected logged on 5 5 Function test Once the project has been loaded onto the MSI 100 safety controller and executed from this point following manual confirmation you must perform a function test to ensure that the safety controller is working correctly and therefore that the safety logic and all the ca bling are working correctly as well To support you in this you can switch the MSlsafesoft configuration softwar
65. hardware editor in online mode maps the LEDs on the safety control ler In addition to the mandatory function test activating safe control devices e g emergency stop safety door etc standard startup mode can be used to exe cute a function test while the system is operating For example instead of pressing the actual switch you can force the corresponding signal in the connection editor and test the safety logic in this way The configuration software provides a detailed project information dialog box where all information relating to the project can be stored and a safety related checklist can be completed This information dialog box is supplemented by an assignment list where comments can be added to the signals of the safe devices used in order to doc ument the wiring All documentation including the graphical safety logic the assignment list and the de vice parameters can be printed out in a clear format Simulation of the safety controller for example for preliminary testing of the developed safety logic even if no safety controller is available A description of the wide range of functions offered by MSlsafesoft exceeds the scope of this user manual However the online help for the software contains detailed descriptions of each function To call the online help In the menu select the Help Topics menu item The table of contents for the online help appears Search for a help topic as described below
66. he configuration PC the MSlsafesoft configuration software must be installed with the appropriate USB drivers for the module y NOTE Electrostatic discharge Ate The MSI 100 safety controller contains components that can be damaged or destroyed by electrostatic discharge When handling the USB interface observe the necessary safety precautions against electrostatic discharge ESD according to EN 61340 5 1 and EN 61340 5 2 Once the USB connecting cable mini USB connector 5 pos maximum cable length 3 m has been connected the appropriately configured PC detects the safety controller automatically If the MSlsafesoft configuration software is already running the software detects the status of the safety controller and indicates it at the bottom right in the status bar Figure 3 7 Status bar in the MSlsafesoft configuration software safety controller al ready contains a configuration project Leuze electronic MSI 100 3 11 Hardware MSI 100 safety controller amp Leuze electronic Data memory module as a hardkey 3 6 Data memory module AC MSI CFG1 The MSI 100 safety controller is equipped with a plug in memory module the AC MSI CFG1 Figure 3 8 Data memory module AC MSI CFG1 on the MSI 100 The data memory module must be inserted in the MSI 100 safety controller both during normal operation and for downloading configuration data from MSlsafesoft via the USB in terface If no data memory module i
67. ht to alter correct and or improve the technical documen tation and the products described in the technical documentation at its own discretion and without giving prior notice insofar as this is reasonable for the user The same applies to any technical changes that serve the purpose of technical progress The receipt of technical documentation in particular data sheets installation instructions manuals etc does not constitute any further duty on the part of Leuze electronic to furnish information on alterations to products and or technical documentation Any other agree ment shall only apply if expressly confirmed in writing by Leuze electronic Please note that the supplied documentation is product specific documentation only and that you are re sponsible for checking the suitability and intended use of the products in your specific ap plication in particular with regard to observing the applicable standards and regulations Although Leuze electronic makes every effort to ensure that the information content is ac curate up to date and state of the art technical inaccuracies and or printing errors in the information cannot be ruled out Leuze electronic does not offer any guarantees as to the reliability accuracy or completeness of the information All information made available in the technical data is supplied without any accompanying guarantee whether expressly mentioned implied or tacitly assumed This information does not include a
68. ight grid Restart inhibit GuardLocking Monitoring of safety door with four Startup inhibit state interlocking Restart inhibit GuardMonitoring Monitoring of safety door with two state Startup inhibit interlocking Restart inhibit MutingPar_2Sensor Monitoring of two muting sensors and Startup inhibit light grid TestableSafetySensor Monitoring of a connected optoelec Startup inhibit tronic protective device e g light cur Restart inhibit tain with test function To configure a startup inhibit for a specific safe output for example this output must be directly connected in the safety logic to the output of a safe functional block for which the startup inhibit is set via the parameters In the example below EmergencyStop as well as a startup inhibit S_RES parameter FALSE and a restart inhibit A_ RES FALSE are specified for the safe functional block The OUT enable output for the functional block is connected directly to safe output OO where OO offers a restart inhibit and a startup inhibit EmergencyStop executes stop cat egory 0 at the output which is also transmitted to OO by the direct connection MSI 100 Leuze electronic amp Leuze electronic System description EmergencyStop Wiring the safety controller with safe con p trol devices sensors and actuators 13 123 S1 12 Reset 413 q4 7 K1 Not Halt 1 E Stop 14 24 24V Figure 2 3 Implementing a startup inhibit
69. indow appears stating Simulation be ing activated The project is then saved and checked automatically Any errors detected are output in the message window 3 Once a check has been completed without errors the project can be downloaded as usual by clicking on the icon of the same name in the toolbar Unlike with the actual safety controller you do not have to log on with a controller pass word when using the simulation 4 Once the simulation has been started the following entry is indicated on the far right in the status bar The MSISIMsoft application is now minimized in the Windows taskbar MSTSIMsoFt Figure 4 18 MSISIMsoft icon in the Windows taskbar To switch from the MSISIMsoft simulation to the real safety controller in the MSlsafesoft configuration software click on the simulation icon in the toolbar which already appears activated al The simulation is now deactivated see information in the message window and the proj ect is saved automatically again and checked for use with the real safety controller WARNING Risk of unintentional operations As soon as simulation mode is exited all online operations such as downloading or 4 22 forcing signals affect the real safety controller again MSI 100 Leuze electronic amp Leuze electronic MSlsafesoft configuration software a Exiting simulation mode is not the same as exiting the MSISIMsoft simulation Once the Simulate Safety Con
70. interface but can also be down loaded using the data memory module This means that the configuration from one device can be cloned for other safety controllers This is useful if no configuration computer is available at an installation location or for transferring the configuration to a new device on device replacement To replace the data memory module proceed as follows This sequence ensures that the active configuration is not overwritten by accidental insertion of an data memory module Removing the data memo 1 The data memory module should not be replaced during operation If the safety con ry module troller is already running proceed as follows a First shut down the machine b Switch off the safety controller c Remove the current data memory module Inserting the new data 2 Insert the new data memory module in the safety controller which is switched off The memory module data memory module is mechanically keyed and cannot be inserted in the device in correctly 3 Switch the safety controller on and wait until it has initialized all four status LEDs light up once during initialization The safety controller now detects the previously unknown data memory module and indicates this by making the CFG status LED flash 4 Remove the data memory module again 5 Press the Confirm button on the device and hold it down Leuze electronic MSI 100 5 7 Configuration and startup CSS Leuze electronic 6 Reinsert
71. itor To create a new project select New Project in the File menu use the keyboard short cut lt Ctrl gt lt N gt or click on the following icon Ld In the New Project dialog box that appears select either the Project Wizard or a specific project template SS Project Wizard Cancel 1kan_man_start 2kan_auto_start se 2kan_man_start 2kan_man_start_con Figure 4 3 Project Wizard for creating a new configuration project using a project template MSI 100 Leuze electronic amp Leuze electronic MSlsafesoft configuration software 4 5 2 Adding and connecting functions functional blocks and signals in the safety logic The safety logic is created in the connection editor as a network of safe functions and func tional blocks They are available in the various sections of the toolbox and must be inserted in the connection editor from there In order to process the various signals inputs outputs and alarm outputs of the MSI 100 safety controller in the connection editor the signals must be inserted in the connection editor from the hardware editor and connected to other objects Input and output signals can only be inserted into the connection editor from the hard ware editor and linked to functional blocks in the connection editor if you have logged on with the correct project password Log On in the Project menu Functional blocks and Safe functional blocks functions and const
72. k Yes to continue The signal remains at the forced value until the forcing function is reset Resetting forcing Right click on the signal you want to reset and select the Force command from the con text menu The Force dialog box opens In this dialog box you can either reset just the forced signal that is currently selected or all forced signals a If startup mode is exited while signals are forced they will be reset Exiting startup mode To exit startup mode switch back to normal online mode which will cause the safety con troller to run in a safe operating mode again 1 Inthe Safe Controller menu select the highlighted Startup Mode menu item when startup mode is active the icon next to the menu item appears activated 2 Aconfirmation dialog box appears where Yes should be clicked to exit startup mode The yellow background of the status field on the right hand side of the status bar indi cates that the safety controller is running in safe normal operation again Leuze electronic MSI 100 5 13 Configuration and startup amp Leuze electronic 5 14 MSI 100 Leuze electronic amp Leuze electronic lication examples Application examples 6 Application examples Functional block help Application examples are available in the online help for the safe functional blocks Application for each func tional block The online help describes at least one typical application for each functional block and show
73. l SIL 3 self defined meaningful description e g Machine 1 Safety Door Front Figure 2 9 Examples of tool tips in the connection editor in offline mode while editing the safety logic MSI 100 Leuze electronic amp Leuze electronic System description Controller password il Project password l Automatic logoff due to a long period of inactivity in MSlsafesoft Leuze electronic 2 6 Password protection The MSI 100 and MSlsafesoft use two passwords to offer dual protection against unau thorized modifications to the configuration and the project in the configuration software Figure 2 10 Password protection for the MSI 100 and MSlsafesoft The controller password protects the configuration on the MSI 100 safety controller against unauthorized access and the safety controller itself against unauthorized modification of the operating mode However online values can be read from the safety controller and dis played in MSlsafesoft without entering the controller password However a new configu ration or new device parameters can only be downloaded to the safety controller and the safety controller can only be launched accordingly once the controller password has been entered When an unconfigured MSI 100 safety controller is connected to the configuration com puter for the first time MSlsafesoft automatically prompts the user to specify a controller password This password can be modified later if
74. l blocks A1 and A2 looped through current paths A1 A1 and A2 A2 Limiting continuous current via TBUS on supply of external modules via TBUS 1 components e g contactors System description MSI 101 547802 MSI 102 547812 24 V DC A1 A2 0 85 1 1 x Un 200 mA lt 30 ms 20 ms lt 5s 4 LEDs green red 20 up to SIL 3 IEC 62061 24 V DC to ground A2 4mA lt 5V gt 11V lt 35 ms 20 LEDs green 4 Cat 4 EN 13849 1 EN 954 2 24 V DC 24 V 0 V 0 85 1 1 x Un 2 A see derating 1 UF max 1 uF electronic components 0 1 Hz lt ims Yes to ground lt 1 2V 4 LEDs green 6A 4A No capacitive load must be taken into account when using electromechanical A suitable and effective protective circuit is to be provided for inductive loads One recommended measure is the use of free wheeling diodes MSI 100 2 15 System description 2 16 Clock outputs Number Nominal voltage Limiting continuous current Test pulses Short circuit protection Alarm outputs Number Nominal voltage Limiting continuous current Short circuit protection General data Permissible ambient temperature Operation Storage Nominal operating mode Degree of protection according to VDE 0470 1 Housing Connection terminal blocks Installation location Electrical isolation Surge protection Air and creepage distances between the circuits Rated voltage Impulse voltage withstand l
75. layed the function test Yes Download the project to another safety module that is not currently in use Checksum error Use this safety controller still indicated instead of the one used first Please contact our technical support team 7 4 MSI 100 Leuze electronic 4 amp 4 Leuze electronic Problems and solutions 7 5 Safety controller messages Table 7 5 Solutions for MSI 100 safety controller messages Following acknowledgment of the newly Switch the safety controller off and on loaded configuration the safety controller again is not initialized correctly Controller Er Download the project to the safety con ror in the status bar and flashing ERR troller again and acknowledge the new status indicator on the safety controller configuration by pressing the Con firm button on the device If the problem persists please contact our technical support team The safety controller reports an internal er Please contact our technical support team ror Leuze electronic MSI 100 7 5 Problems and solutions MSI 100 4 amp 4 Leuze electronic Leuze electronic 8 Appendix Section 1 Section 2 Section 3 8 1 Figure 1 1 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10
76. lectronic 1 Display the hardware editor Hardware Editor in the View menu If the auto hide function is enabled position the cursor over the minimized window as shown in the fig ure below i i Hardware o T A Fi Figure 4 5 Opening the hardware editor with the auto hide function enabled 2 Drag the required dual input signal or output signal from the hardware editor into the connection editor as follows see Figure 4 6 on page 4 12 Left click on the required dual signal and hold the mouse button down Please refer to the information below on using dual signals Hold the left mouse button down and drag the dual signal from the hardware ed itor directly to a free connection or two free connections in the case of a dual sig nal in the safety logic then release the mouse button Alternatively you can store signals at any free position in the connection editor The free signals must then be linked to free functional block connections manually see Connecting objects on page 4 14 The dual signal is stored at the selected position aligned with the grid and if appli cable directly connected to the corresponding connection Figure 4 6 4 12 Al Al A2 AZT TO TO Ti T1 Hv OV OO OT MO M1 M2 M3 CFG STICK l l CORMAN a l Il l ll l Leuze electronic Facom eeee sk ee J uo Wo O k i SEAE g aeo i l l e l D
77. ller via USB interface The MSI 100 safety controller also has two ground switching outputs O0 and O1 which can be used for example to switch off a contactor connected to the safety controller either via the output or via ground Use of the ground switching outputs increases the shutdown protection and cross circuit protection of the safety circuit In addition the safety controller has four non safety related digital alarm outputs MO to M3 which can be used for example to control a standard PLC or signaling units The two asynchronous test pulses at TO and T1 provide safe cross circuit detection at the inputs of the safety controller as described in Error detection in I O devices on page 2 8 All connection terminal blocks are plug in The individual terminal block bases are mechanically keyed to prevent incorrect connection The MSI 100 safety controller is avail able either with screw connections on the left in Figure 3 1 or with spring cage connec tions on the right in Figure 3 1 0 IN On Vey NS 0 VA MA D 7 0 V y QA 9 WS ee AM N MO HH QE AZ N F I2 ve o O A AK yi MD AA MN r AD LAD 0 x K AWD LA f 2 fa CO SS S LA y i My lf Uh L 1 1 7 WS A D lt Q Dy SW QS SS SDO Figure 3 1 MSI 100 safety controller with screw conn
78. m overview then describes the MSI 100 programmable safety con troller and the associated MSlsafesoft configuration software in detail and finally explains the necessary steps for configuration and startup For additional information and detailed step by step instructions for MSlsafesoft please refer to the online help for the configuration software This user manual is oriented exclusively to qualified electrical engineers and safety spe cialists application programmers and software engineers who are familiar with the rele vant safety concepts of automation technology as well as applicable standards and other regulations Please also read the Qualified personnel section in General safety notes on page 1 1 The MSI 100 programmable safety controller is referred to in this documentation as safety controller for short 1 2 General safety notes WARNING Personal injury and damage to equipment if these safety notes are not followed When working with the MSI 100 safety controller please observe all the safety notes included in this section Knowledge of the following is required The MSI 100 safety controller used and the I O devices extension units sensors ac tuators The MSlsafesoft configuration software The safety directives for the field of application WARNING In the context of the use of the MSI 100 safety controller with MSlsafesoft configuration software and safe functional blocks the following
79. ndicator combinations and their meanings please refer to Diagnostic and status indicators on page 3 4 In online mode when the MSlsafesoft configuration software reads signal values from the MSI 100 safety controller and displays them live in the connection editor the safe func tional blocks indicate their status and in the event of an error a description of the error as a tool tip as soon as you position the cursor over the symbol for a functional block In the event of an error the tool tip contains not only a description of the error but also information on how to remove it In the event of an error the functional block symbol is also outlined in red This ensures that in online mode errors can be identified at a glance Equivalent Signal Evaluation Description When the discrepance time elapsed was CH_4 FALSE and CH_B TRUE Possible Remedies Set CH_4 FALSE and CH_B FALSE Check the time value specified at the parameter DT and the connected hardware Service code CODZ Figure 2 8 Example of an online tool tip in the event of an error Tool tips are also available while editing the safety logic in the connection editor For all functional blocks functions and their I Os as well as for the buttons in the toolbar descrip tions are displayed as soon as the cursor is positioned over the item 2 input 1 Status of button 1 of the two hand control device O10 Safe input signa
80. nection editor and select Help from the con text menu Leuze electronic MSI 100 4 9 MSlsafesoft configuration software amp Leuze electronic Intuitive operation Details in the online help 4 10 4 5 Operating the MSlsafesoft configuration software The MSlsafesoft configuration software follows the Windows standard for all user activities However MSlsafesoft offers a wide range of functions which far exceeds the standard level of performance in this sector Examples include online diagnostic tools and simulation of the safety controller A description of the wide range of functions exceeds the scope of this user manual there fore please refer to the online help which contains a detailed description of each software function For an overview of the steps required when configuring a project please refer to Config uration overview from A to Z on page 5 1 The following sections provide a brief introduction to the most important software functions 4 5 1 Creating the configuration project When creating a new project either use a project template or create an empty project using the Project Wizard Empty means that although the safety controller is already available in the hardware ed itor for wiring the signals the connection editor does not yet contain any safety logic If a project template is used a predefined circuit which can be modified or extended as required will be inserted into the connection ed
81. ng The GuardLocking safe functional block supports the monitoring of a guard with guard locking safety door moni toring with four state interlocking according to DIN EN 1088 FALSE FALSE GuardMonitoring The GuardMonitoring safe functional block monitors a guard e g safety door with two state interlocking according to DIN EN 1088 FALSE FALSE ModeSelector The ModeSelector functional block evaluates the states of a mode selector switch with up to five positions A mechanical mode selector switch can be used for example to set a specific safety level e g service mode setup mode cleaning mode etc for operation of the safe application Leuze electronic MSI 100 4 7 MSlsafesoft configuration software amp Leuze electronic Table 4 1 Safe functional blocks Fortsetzung Name Short description Icon in editor MutingPar_2Sensor The MutingPar_2Sensor safe functional block evaluates the signals of two muting sensors and one optoelectronic protec tive device e g light grid in an application for parallel mut ing using two sensors and sets the enable signal at output OUT This function can be used to temporarily deactivate or mute protective equipment in the form of a light grid for example in order to allow an object which has been iden tified by the muting sensors as permissible for the muting op eration to pass through on an assembly conveyor 1 0 However if the light grid is in
82. ngle channel or two channel Cross circuit detection is implemented in your application if required see page 2 8 All safe functional blocks and functions in the MSlsafesoft configuration software are connected correctly MSI 100 Leuze electronic amp Leuze electronic For your safety 1 5 Directives and standards The manufacturers and operators of machines and systems in which the MSI 100 safety controller is used are responsible for adhering to all applicable directives and legislation Directives and standards considered in the development and implementation of the MSI 100 safety controller Directives Machinery Directive 2006 42 EC Machinery Directive 98 38 EC EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC Guideline for test and certification GS ET 26 Bus systems for the transmission of safety related messages Standards Standard Contents DIN EN 61508 1 11 2002 Functional safety of electrical electronic programma DIN EN 61508 2 12 2002 ble electronic safety related systems DIN EN 61508 3 12 2002 DIN EN 61508 4 1 1 2002 DIN EN 61508 5 1 1 2002 DIN EN 61508 6 06 2003 DIN EN 61508 7 06 2003 DIN EN ISO 13849 1 Safety of machinery Safety related parts of control systems best suited for less complex systems Part 1 General principles for design This standard was created on the basis of EN 954 1 1996 quality management and reliability as pects have been added DIN E
83. nitoring Safety door monitoring with and without guard locking Two hand control devices Types II and III External device monitoring feedback monitoring Monitoring and checking electrosensitive protective equipment Mode selector switch evaluation of a mode selector switch and an enable switch Muting applications light grid monitoring with parallel muting Depending on the safety logic configured for the actual application MSI 100 safety control ler outputs can be used to stop machines drives with stop category 0 according to DIN EN 60204 1 DIN EN 60204 1 defines stop category 0 as uncontrolled stopping by immediate removal of power to a machine Whether a safe output meets stop category 0 depends on the safe functional blocks con nected in the safety logic only if the module output is connected directly to the enable out put of a safe functional block which executes stop category 0 at its output can the module output also meet this category The EmergencyStop functional block executes stop category 0 at its enable output If this block output is connected directly to a module output the safety controller also executes stop category 0 at this output Figure 2 3 on page 2 7 shows an example of this type of connection The configuration and startup of the relevant safety circuit must be planned and verified precisely Different machines are subject to different requirements for the implementation of
84. ny guarantees regarding quality does not describe any fair marketable quality and does not make any claims as to quality guarantees or guarantees regarding the suitability for a special pur pose Leuze electronic accepts no liability or responsibility for errors or omissions in the content of the technical documentation in particular data sheets installation instructions manuals etc The aforementioned limitations of liability and exemptions from liability do not apply in so far as liability must be assumed e g according to product liability law in cases of premed itation gross negligence on account of loss of life physical injury or damage to health or on account of the violation of important contractual obligations Claims for damages for the violation of important contractual obligations are however limited to contract typical pre dictable damages provided there is no premeditation or gross negligence or that liability is assumed on account of loss of life physical injury or damage to health This ruling does not imply a change in the burden of proof to the detriment of the user MSI 100 1 Ill Internet Subsidiaries Published by 1 IV 4 amp 4 Leuze electronic Statement of legal authority This manual including all illustrations contained herein is copyright protected Use of this manual by any third party is forbidden Reproduction translation and public disclosure as well as electronic and photographic
85. of the device Table 3 2 Operating LEDs for the safe inputs and outputs No switching signal at the relevant input Switching signal active at the input For each input 10 to 119 For each output O0 to O3 Output inactive xt Output active The diagnostics routine of the device has discovered an error on the corresponding output Possible causes are feedback of 24 V DC a cross circuit or overload 3 3 2 Confirm button The diagnostics routine of the device has discovered an error on the corresponding in put Possible causes are incorrect wiring of the input or from the perspective of the secure functional block connected to this input in correct switching signals Note the diagnos tic tools described in section 2 5 starting on page 2 9 xt 74 0 74 0 The Confirm button is on the right hand side on the front of the MSI 100 safety controller above the USB interface Press this button using a pen to confirm a new configuration downloaded via the USB interface before it is accepted by the safety controller See also Downloading the configuration from MSlsafesoft on page 5 4 The Confirm button also plays an important role when replacing the data memory mo dule To download a new configuration by replacing the data memory module rather than via the USB interface press and hold down the Confirm button while removing and in serting the data memory module using the specified procedure For the p
86. on can be ac cessed directly by double clicking with the left mouse button on the message in the message window In the example below an input is not connected Double clicking on the error message highlights the affected object in a green border in the connection editor Message Window Verifying Step 1 36 Verifying Step 2 36 Verifying Step 3 36 Verifying Step 4 36 Verifying Step 5 36 Verifying Step 6 36 Figure 4 14 Jumping to an error location in the safety logic from the message window when checking the configuration project 3 Correct the error and check the project again MSI 100 Leuze electronic 4 amp 4 Leuze electronic MSlsafesoft configuration software Documenting signal as signment Entering project documen tation Leuze electronic a a a 4 Once a check has been completed without errors the project can be transmitted to the safety controller For information about downloading a configuration project and the associated startup of the safety controller please refer to Downloading the configu ration from MSlsafesoft on page 5 4 4 5 5 Documenting the signal assignment and the project The system offers the option of maintaining a signal list or more accurately a signal as signment list We strongly recommend that this wiring documentation is maintained on an ongoing basis as it makes both the safety logic that has been created and the project as a whole easier to understand and hel
87. onding message dialog box ap pears in the configuration software MSI 100 5 5 Configuration and startup CS Leuze electronic Do not confirm this message yet first complete the following step Please note First acknowledge the configuration on the safety controller see step 6 before clicking OK Figure 5 5 Message dialog box following successful data transmission 6 Confirm the new configuration by pressing the Confirm button using a pen see Figure 5 6 AN WARNING Risk due to activated outputs Following the confirmation described in this step the safety controller starts running im mediately Provided that no startup inhibit which must be cancelled manually is active outputs may be activated immediately after startup Make sure that the safety controller startup will not lead to any hazardous situations Figure 5 6 Confirming the configuration with the Confirm button The safety controller is then reinitialized all status indicators are on briefly and then switches to safe normal operation only PWR LED on i Startup inhibit active If a startup inhibit has been predefined in the configuration it will now be active following startup An active startup inhibit must be cancelled by pressing a reset button which is connected to the safety controller according to the configuration For additional information please refer to System startup and restart behavior on pag
88. ools that can be used to diagnose the active configuration on the safety controller Hardware diagnostics in the event of a safe functional block error Wiring check Status indicators on the safety controller Online tool tips in the connection editor If a safe functional block detects an error it sets its ERR error output to TRUE and the OUT enable output to the safe status FALSE For additional information refer to the descriptions of the safe functional blocks in the MSlsafesoft online help particularly in the corresponding ERR output help topic If the ERR output of a safe functional block is TRUE all the inputs that are connected di rectly to the inputs of this functional block flash on the safety controller MSI 100 2 9 System description 2 10 a 4 amp 4 Leuze electronic This makes it easy to see which input of the safety controller has been affected by the prob lem and further measures can be taken to remove the fault check the connecting cables to the sensors or the connected sensors themselves etc This function enables hardware errors to be located even without a PC configuration software as the error is also visualized on the hardware thanks to the flashing LED s at the safety controller inputs The project documentation also enables conclusions to be drawn regarding the relevant safe functional block i e the one reporting the error using the flashing module input without a PC being
89. oper ations may only be carried out by qualified personnel Planning parameterization configuration development of safety logic Installation startup servicing Maintenance decommissioning This user manual is therefore aimed at Qualified personnel who plan and design safety equipment for machines and systems and are familiar with regulations governing safety in the workplace and accident pre vention MSI 100 1 1 For your safety 0 CS Luz electronic Qualified personnel who install and operate safety equipment in machines and sys tems Within the context of the safety notes in this documentation qualified personnel are per sons who because of their education experience and instruction and their knowledge of relevant standards regulations accident prevention regulations and service conditions have been authorized to carry out any required operations and who are able to recognize and avoid any possible dangers Documentation a You must observe all information in this documentation as well as in the documentation listed in Documentation on page 1 8 Safety of personnel and The safety of personnel and equipment can only be assured if the safe functional blocks equipment are used correctly see Intended use on page 1 7 Q NOTE Please note that responsibility for fault avoidance lies with the user Error detection Depending on the wiring and parameterization of the inputs and outputs
90. options for opening the online help and searching for information via context sensitive help or via the contents or index Help page for the dia log box or area Start page for the help system E Hide Locate cre ALT Home FP Contents idle Search Favortes In this way for all object types Figure 1 1 Calling the online help in the MSlsafesoft configuration software MSI 100 Leuze electronic amp Leuze electronic System description 2 System description The overall system Hardware and software Leuze electronic 2 1 Method of operation and structure of the MSI 100 safety system The MSI 100 safety system consists of the following components MSI 100 safety controller MSlsafesoft configuration software Suitable safe control devices sensors and actuators depending on the application The MSI 100 safety controller is designed for monitoring and evaluating safety related con trol devices in machines and systems see Intended use on page 1 7 The safety con troller monitors safe control devices and safety sensors connected at its inputs evaluates the incoming signals according to its configuration and controls the outputs accordingly The MSlsafesoft configuration software is used to configure the MSI 100 safety controller and therefore provides the relevant editors as well as suitable startup and diagnostic tools The diagram below illustrates the overall system in an application
91. pe senavaas aeavecasnl one eiweanae ae eeceaete 3 3 Operating and indication elements of the MSI 100 safety controller 3 4 MSI 100 signal connections ccccceceeccseeeeececeeeeececeeseeeseeseeeessaaees 3 7 Example application for ground switching outputs O0 and O1 3 10 Status bar in the MSlsafesoft configuration software safety controller already contains a configuration project ccceeeeeees 3 11 AC MSI CFG1 on the MSI 100 cccccccccceeeeesseeeeeeeeeeeeeeeeeaaeees 3 12 Mounting TBUS DIN rail connectors 0 0 eee ccc eeeeeeeeeeeeaeeeeeeaeees 3 14 Attaching the MSI 100 safety controller to the DIN rail 3 14 Connecting the supply voltage at A1 A2 and 24V 0V cccceee 3 16 MSI 100 A 1 Leuze electronic MSI 100 Section 4 Section 5 A 2 Figure 3 12 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 Figure 4 10 Figure 4 11 Figure 4 12 Figure 4 13 Figure 4 14 Figure 4 15 Figure 4 16 Figure 4 17 Figure 4 18 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 5 6 Figure 5 7 Figure 5 8 Connection to screw terminal blocks left and spring cage terminal DIOCKS OM ond a oP al Medea el een seiko 3 17 MSlsafesoft user interface cccccccccsssececceeseceeccesseeeeseaeeeessaaeeeess 4 3 Safe functional blocks in the toolbox excerpt
92. project can only be downloaded to the MSI 100 safety controller if you have logged on in MSlsafesoft with the correct controller password In the Safe Control ler menu select Log On enter the controller password in the dialog box and click OK Provided that the current project has been checked and has no errors see page 4 18 or the MSlsafesoft online help the project loaded in MSIsafesoft can be downloaded to the safety controller by clicking on the following icon in the toolbar A Is there already a project on the safety controller If the status bar has a yellow entry on the right Controller No project the project is transmitted to the safety controller without any further prompts If another project or another version of the same project is already available on the safety controller and is being executed a corresponding dialog box appears indicating this fact Click Yes in this message dialog box to overwrite the current controller con figuration on the safety controller During data transmission A progress indicator is displayed in the MSlsafesoft status bar The CFG status indicator flashes quickly on the MSI 100 safety controller ap proximately 6 Hz If the data transmission is interrupted during the download please refer to Problems and solutions on page 7 1 5 Once data transmission has been completed successfully the CFG status indicator flashes slowly approximately 1 5 Hz and a corresp
93. ps to prevent incorrect connections being established in the connection editor In practice it is better to enter signal names before editing the safety logic because any text entered in the connection editor is visible as tool tips 1 Click on the following icon in the toolbar The Assignment Map dialog box opens 2 For each input enter a meaningful short description in the right hand field of the list by double clicking in the field and typing in the text Ed omen 4 Signals aster Device self detined meaningful signal description e g Machine 1 Safety Door Front Machine 1 _oatety Door Rear Machine 1 Emergency Stop 13 i Machine 1 Emergency Stop 2 Figure 4 15 Documenting signal assignment in the Assignment Map dialog box 3 Once all the required texts have been entered confirm the dialog box with OK to save the signal list For additional information about signal information please refer to the online help which is opened by pressing lt F1 gt when the Assignment Map dialog box is active Open the Project Info dialog box by selecting Project Information in the Project menu This dialog box can be used to enter the most important information about the current proj ect from project specific data description of the application designation name of the cre ator editor etc to manufacturer data the operator and installation location through
94. ration soft functions in MSlsafesoft ware for creating the safety logic are designed solely for use within the MSI 100 safety con troller and support specific safety functions The safe functional blocks functions can only perform their safety related tasks within the safe control system if they have been integrated into the execution process correctly and in such a way as to avoid errors examples of the use of the safe functional blocks are described in Application exam ples a You must observe all information in the online help for each functional block Theoretical The area of responsibility of the block manufacturer in terms of the function of a safe func tional block or a safe function ends at the user interface which is generated by the inputs and outputs of the functional blocks functions In order to fully execute a safety function it is your responsibility to connect the inputs and outputs of the safe functional blocks functions in the MSlsafesoft configuration software To your safety network To the single channel or two channel sensors and actuators connected to the inputs and outputs of the safety controller In defining the safety integrity level or category for the overall safety function you must take into consideration all components involved in the execution of this safety function Sensors actuators wiring etc WARNING In order to use a safe functional block or a safe function according to the r
95. recise procedure please refer to Downloading the configuration using the data memory module AC MSI CFG1 on page 5 7 MSI 100 Leuze electronic 4 amp 4 Leuze electronic Hardware MSI 100 safety controller Signal redundancy due to dual signals a 3 4 Signal connections All input and output connections with the exception of the USB interface are made via plug in keyed connection terminal blocks SSeS EN na i E Test pulses for cross circuit detection Supply for logic and alarm outputs Standard alarm outputs Supply for safe outputs Ground switching outputs Safe inputs Safe outputs Figure 3 5 MSI 100 signal connections The various signal connections are described in the following sections 3 4 1 Signal inputs The MSI 100 safety controller has 20 digital signal inputs 24 V HTL 3 mA for the direct connection of safe control devices and or safety sensors for monitoring and evaluating pro cesses The safe inputs are linked to the safety logic in the connection editor of the MSlsafesoft configuration software See also Adding and connecting functions functional blocks and signals in the safety logic on page 4 11 Every two adjacent signal inputs i e I0 and 11 I2 and I3 etc are grouped together and locked by default to form a dual signal in the MSlsafesoft configuration software This is indicated in the representation of the safety controller in the hardware editor of the config
96. required The project password protects the configuration project in MSIsafesoft against unauthor ized modifications to the safety logic and the project information You can still open and display projects without a password but you can only change and save them once you have entered a project password This ensures that only authorized persons in possession of the correct project password can change the safety logic When creating a new project you will be automatically requested to define a password If no user activity is detected in MSlsafesoft for a certain period of time you will be logged off from the project automatically This prevents unauthorized persons from making changes to the project if you have not logged off from the project For the MSI 100 safety controller after a long period of inactivity you must enter the con troller password again in order to communicate with the safety controller in MSlsafesoft MSI 100 2 13 Systemdescription CS Leeurze electronic During automatic logoff for safety reasons the safety controller remains in the mode that was running prior to automatic logoff Example The automatic logoff does not cause startup mode to be exited but you must log on again before you will be able to influence signals once more a For additional information about password protection please refer to the online help for MSlsafesoft 2 7 Ordering data Products Description Type Order No Pcs Pkt P
97. restart inhibit and stop category 0 for safe output OO Leuze electronic MSI 100 2 7 System description Cross circuit detection Clock outputs T0 and T1 4 amp 4 Leuze electronic 2 4 Error detection in I O devices Cross circuits of the connected signal lines can be detected at the safe inputs A cross circuit is an unintentional incorrect connection between redundant circuits The safety controller provides clock outputs TO and T1 as an aid for detecting such a cross circuit The test pulses output here are asynchronous For example if two differently clocked signals are routed back to two inputs of the safety controller along two channels via an emergency stop control device a cross circuit can be reliably detected in this emergency stop circuit In the event of a cross circuit the same clock signal would be present at both inputs instead of two different ones MSlsafesoft configuration software specifies the clock signals to be used for all even inputs 10 12 14 118 cross circuit detection is implemented with test pulse TO For odd inputs 11 13 15 119 test pulse T1 must be used for cross circuit detection Parameter editor in MSlsafesoft S2 lia Reset 13 c 24V C s4 112122 No J E A E Not Halt 11 21 E Stop LL niga Figure 2 4 Implementing cross circuit detection for an emergency stop control device at inputs IO and 11 of the safety controller For this purpose cross circuit de
98. ristor for safe outputs OO to O3 is strongly recommended The safe output signals are clocked with a test pulse of 1 ms MSI 100 Leuze electronic amp Leuze electronic Hardware MSI 100 safety controller Leuze electronic A il 3 4 3 Alarm outputs M0 to M3 The non safety related alarm outputs MO M1 M2 and M3 are designed as digital semi conductor outputs for 24 V DC 100 mA These alarm outputs can be used for example to control a standard PLC or a detector unit e g a signal lamp As is the case for safe inputs and outputs the alarm outputs are linked in the connection editor of MSIsafesoft see Adding and connecting functions functional blocks and signals in the safety logic on page 4 11 NOTE Alarm outputs must not be connected in parallel Feedback to alarm outputs is not permitted 3 4 4 Test pulse outputs T0 and T1 The test pulses output at outputs TO and T1 are used for cross circuit detection at the in puts Each output is available twice The output test pulses TO and T1 are asynchronous i e TO does not equal T1 To implement cross circuit detection the relevant safe inputs must be configured accord ingly using the device parameterization editor part of the hardware editor in MSIsafesoft The MSlsafesoft configuration software specifies the clock signals to be used Cross circuit detection is implemented with test pulse TO for even inputs 10 12 14 118 For odd inputs 11 13 15
99. rogrammable safety controller Module with screw connections MSI 101 547802 1 Module with spring cage connections MSI 102 547812 1 Memory module for the MSI 100 AC MSI CFG1 547820 10 supplied as standard with the safety controller Accessories Description Type Order No Pcs Pkt AC MSI TC MSI TBUS standard connection plug 547823 10 for fieldbus gateways AC MSI TCS MSI TBUS safety connection plug 547821 10 MSI SWC1 MSI commissioning set 547825 1 AC MSI USB MSI USB cable MSI PC 3 m 547822 1 2 14 MSI 100 Leuze electronic 4 amp 4 Leuze electronic Leuze electronic 2 8 Technical data Connection method Plug in screw terminal blocks Order No Plug in spring cage terminal blocks Order No Logic input data Nominal input voltage Uyn Permissible range Typical current consumption at Uyn Maximum response time Buffering of voltage dips Recovery time restart Status indicator Inputs IN Number of safe inputs Nominal voltage Uyn Typical current consumption at Uyn Signal level at 0 Signal level at 1 Input delay Status indicator Output data Safe semiconductor outputs Ground switching outputs Nominal voltage Permissible range Limiting continuous current Maximum capacitive load Load Capacitive load inductive load 2 Maximum switching frequency on inductive load Test pulses Short circuit protection Residual voltage at 0 Status indicator Limiting continuous current for devices at termina
100. ronic Leuze electronic The LED symbols in the table mean LED OFF LED ON xy LED flashing Slowly 1 7 Hz 74 0 Fast 6 3 Hz Table 3 1 Meaning of the status LEDs Hardware MSI 100 safety controller PWR EXT ERR CFG green green red green Device is switched off no power supply at A1 A2 MSI 100 Acknowledgment of new configuration re quired after download Press the Confirm button on the de vice Acknowledgment of a new data memory module program transmission via data memory module Extension unit replaced acknowledgment required Press the Confirm button on the de vice Normal operation without connected ex tension units TBUS communication Normal operation with connected exten sion units TBUS communication Limited operation with error for at least one I O Remove error deactivate I O Press the Confirm button on the device to reset the error message No configuration data on the data memory module Download project with MSlsafesoft No data memory module gt Insert data memory module and apply power supply An error has occurred Read out the error code with MSlsafesoft 3 5 Hardware MSI 100 safety controller amp amp Leuze electronic LEDs for signal I Os Confirming the new configuration Replacing the data memo ry module The state of each of the 20 safe inputs and 4 safe outputs is indicated by an LED on the front
101. rrupted and the project in MSlsafesoft may not be changed If this happens the controller will stop and switch to a safe condition after 10 minutes Figure 3 3 Diagram Possible operating modes status for the MSI 100 safety con troller MSI 100 3 3 Hardware MSI 100 safety controller amp amp Leuze electronic Status indicators 3 3 Operating and indication elements All operating and indication elements for the MSI 100 safety controller are located on the front of the device The elements are described in the following sections Status indicators LEDs Status of the safe I Os Figure 3 4 Operating and indication elements of the MSI 100 safety controller 3 3 1 Diagnostic and status indicators The four status indicators on the front of the device can be used to read the operating sta tus of the safety controller The following LEDs are available from left to right PWR Indicator for the power supply of the safety controller EXT Indicator for communication with extension devices with without TBUS DIN rail connector This LED is only on if a TBUS device is connected ERR Error indicator CFG Indicator for the configuration status and communication via the USB interface The following table lists the possible indicator combinations for the status LEDs and their meanings A distinction is made between slow flashing and fast flashing LEDs MSI 100 Leuze electronic amp Leuze elect
102. s Select Install software to start the installation pro gram If you have deactivated the auto start option on your computer open the MSlsafesoft folder on the CD and execute the setup file 2 Select the desired language for the installation routine This also sets the language for the MSlsafesoft user interface which is set when the software is started for the first time 3 The installation program now guides you through the installation step by step Follow the on screen instructions 4 Once MSlsafesoft is installed you will be prompted to install the drivers for the safety controller Follow the on screen instructions 5 In the Windows dialog box for driver installation select Install the software automati cally recommended Finally a message appears indicating that the configuration software and drivers for the safety controller have been fully installed 4 2 Overview of functions and features The MSlsafesoft safe configuration software is used only for the configuration of the MSI 100 safety controller The software supports the user in all operating phases from planning the application through configuration to starting up the MSI 100 safety controller and compiling system documentation The following MSlIsafesoft functions are available Creating the safety logic Creation of the safety logic using a graphical connection editor The circuit which the safety controller runs on is created by graphically
103. s inserted in the safety controller or if it is removed the safety controller behaves as follows If no data memory module is inserted when downloading configuration data the con figuration cannot be downloaded and MSlsafesoft outputs an error message Ifno data memory module is inserted when the safety controller is started the module sets all outputs to FALSE and indicates an error The safety controller does not exe cute any functions Ifthe data memory module is removed during operation the safety controller sets all outputs to FALSE and indicates an error The safety controller does not execute any more functions Ifthe data memory module is removed from the safety controller and reinserted as de scribed in Downloading the configuration using the data memory module AC MSI CFG1 on page 5 7 the safety controller sets all outputs to FALSE and does not execute any functions until the data memory module is inserted again correctly The safety controller does not indicate an error As an alternative to downloading the configuration via the USB interface it can be down loaded to the MSI 100 safety controller using the data memory module For a description of this procedure please refer to Downloading the configuration using the data memory module AC MSI CFG1 on page 5 7 3 12 MSI 100 Leuze electronic 4 amp 4 Leuze electronic Hardware MSI 100 safety controller 3 7 Installing the safety controller WARNI
104. s the safety logic configured in MSlIsafesoft as well as the wiring of the MSI 100 safety controller in the form of schematic views The online help also includes typical signal sequence diagrams which illustrate the behav ior of each functional block The following application examples are included in the online help for the functional blocks Single channel and two channel emergency stop circuits Single channel and two channel safety door monitoring with and without locking Mode selector switch selection with locking of the set operating mode and manual op erating mode acknowledgment Evaluation of a three position enable switch with confirmation of the selected safe op erating mode Parallel muting with two sensors Evaluation of a light curtain connected via a single channel Type Il and Type III two hand control devices MSI 100 6 1 Leuze electronic Application examples CS Leuze electronic 6 2 MSI 100 Leuze electronic Problems and solutions 4 amp 4 Leuze electronic 7 Problems and solutions This section provides a list of possible problems which may occur when working with the MSlsafesoft configuration software and the MSI 100 safety controller The action to be taken and the way in which the user must respond in order to solve the issue is described for each individual problem The following descriptions are divided into categories that relate to the different sections of the configuration software 7 1 G
105. sed in connection with output O1 The diagram below shows an example application The two contactors K1 and K2 are switched between safe module output OO and ground switching output O 42 13 23 33 K1 eee Se ee 41 12 24 34 i 14 42 Ka 13123133 s1 22 DA ae ee q J a Reset 43 41 o ya E Not Halt 21 E Stop 24V Figure 3 6 Example application for ground switching outputs O0 and O1 In order to use the ground switching outputs the corresponding parameters must be set for outputs OO and O1 in the MSlsafesoft configuration software For more detailed in formation please refer to the online help topic Parameterizing the I Os of the safety con troller 3 10 MSI 100 Leuze electronic 4 amp 4 Leuze electronic Hardware MSI 100 safety controller 3 5 USB interface The USB interface standard USB 2 0 is used for communication between the MSI 100 safety controller and the MSlsafesoft configuration software This includes Downloading configuration data i e the MSlsafesoft project Optional upload of the configuration in order to open it as a project and edit it as re quired in MSlsafesoft Reading values from the safety controller during operation and displaying the read val ues live in the connection editor of MSlsafesoft online mode Forcing signals on the running safety controller for startup purposes standard startup mode Before the MSI 100 safety controller is connected to t
106. switching output O1 This parameter is used to specify whether the specified ground switching output which can assist in shutting down a single channel application safely should be switched in addition to the relevant safe module output a Use of ground switching outputs O0 and O1 increases the cross circuit protection For more detailed information about using ground switching outputs O0 and O1 and a cor responding example application please refer to Ground switching outputs O0 and O1 on page 3 10 Figure 4 13 Setting the device parameter for the use of ground switching output O0 Exporting and importing Once the inputs and outputs of the safety controller have been parameterized the param parameters eter list can be exported to a file so that it can be used again later For information about exporting and importing parameters please refer to the online help see Parameterizing the I Os of the safety controller Printing parameters The print dialog box Print Project in the File menu contains a Safe parameters checkbox If this checkbox is selected before printing a project all the parameters of the safe device are printed too Leuze electronic MSI 100 4 17 MSlsafesoft configuration software amp Leuze electronic 4 18 me me me 4 5 4 Checking downloading and starting up the project The project can only be checked if you have logged on with the correct project password Log On in the
107. t safety controller inputs must instead be parameterized accordingly MSI 100 4 13 Leuze electronic MSlsafesoft configuration software amp Leuze electronic Connecting objects 4 14 As shown in Figure 4 6 on page 4 12 signal inputs and outputs as well as constants can be connected as soon as they are inserted in the connection editor using drag amp drop Free terminal points are connected as described below Connecting objects by drawing a connecting line 1 Position the cursor over the connection area where the connecting line is to start The cursor now appears as a cross see 1 in the figure below 2 Left click hold the mouse button down and drag the mouse directly to the destination connection area If the connection is permitted the line is green If the connection between the two objects is not permitted the line is not displayed in green In this case no connection can be established 3 Now release the mouse button to create the connection The connection editor auto matically determines the path for the connecting line automatic routing 1 2 3 Figure 4 7 Connecting objects using a line Connecting objects using drag amp drop This method is only suitable for connecting inputs outputs and signal constants 1 Click on the dual signal or the constant to be connected and hold the mouse button down see Figure 4 8 2 Drag the object to the desired destination connection point I
108. tection for the safety controller inputs to be monitored must be activated in the MSlsafesoft configuration software in the device parameterization editor of the hardware editor MSI 100 Leuze electronic 4 amp 4 Leuze electronic Hardware diagnostics in the event of a safe func tional block error Leuze electronic System description Activating cross circuit detection for the safety controller inputs 1 Open the parameter editor by double clicking in the MSlsafesoft hardware editor 2 Select the corresponding input 3 Inthe selection box for this input set cross circuit detection as shown in the image below for inputs 0 and 1 MSlsafesoft 2 7 Type Master Device Description MSI100 Location ID 0 Import file Al Al A2 AT TO TO Ti TI CFG HV 0Y OO 01 M0 M1 M2 M3 STICK Input 10 it detec no Leuze electronic inputit 20 e Input g m amp e D 3 e 6 e Ls e put 14 4 e pel Doppeiki Ke e b Input i F Double ciek _ ___ e Input l6 Input I7 cross circuit detectid cross circuit detection no Input 18 Innst in Figure 2 5 Parameterizing cross circuit detection for a module input 2 5 Diagnostic tools For an overview of the diagnostic and status indicators please refer to Table 3 1 on page 3 5 The MSlsafesoft configuration software and the MSI 100 safety controller provide various t
109. terrupted by a worker s hand for example output OUT is set to FALSE to disable the hazard as the protective equipment had not been previously muted FALSE MutingPar The MutingPar safe function block evaluates the signals of four muting sensors and one item of optoelectronic safety equipment a light grid for example in an application for par allel muting with four sensors It also switches the enable sig nal at the OUT output This function can be used to temporarily deactivate or mute safety equipment in the form of a light grid for exam ple in order to allow an object which has been identified by the muting sensors as permissible for the muting operation to pass through on an assembly conveyor By contrast if the light grid is interrupted by a worker s hand for example the OUT output switches to FALSE to disable the hazard as the safety equipment had not been previously muted The maximum allowable time for the muting operation is monitored using the four muting sensors MutingSeq The MutingSeq safe function block evaluates the signals of four muting sensors and one item of optoelectronic safety equipment a light grid for example in an application for se quential muting with four sensors It also switches the enable signal at the OUT output This function can be used to temporarily deactivate or mute safety equipment in the form of a light grid for exam ple in order to allow an object which has b
110. the data memory module while holding down the Confirm button Hold down the Confirm button while inserting the data memory mod ule Figure 5 7 Pressing the Confirm button while inserting the data memory module 7 Release the Confirm button once the data memory module is inserted correctly The safety controller now initializes with the new configuration WARNING Risk due to activated outputs When the data memory module is replaced outputs may be activated Once the config uration has been downloaded in this way the safety controller starts with the program execution Provided that no startup inhibit which must be cancelled manually is active outputs may be activated immediately Make sure that the safety controller startup will not lead to any hazardous situations Startup inhibit active If a startup inhibit has been predefined in the configuration it will now be active following startup An active startup inhibit must be cancelled by pressing a reset button which is connected to the safety controller according to the configuration For additional information please refer to System startup and restart behavior on page 2 5 If the safety controller is not initialized correctly proceed as described in Problems and solutions on page 7 1 When the data memory module has been removed correctly all of the safety controller outputs are FALSE While the data memory module is not inserted the safet
111. to data relating to safety inspections and a revision history for the project To ensure compliance with standards the fields with yellow row headers must be com pleted each time a new project version is developed The fields with a gray background are less important However it is highly recommended that you enter data in all fields MSI 100 4 19 MSlsafesoft configuration software amp Leuze electronic i Check values CRC If the project documentation is modified the check value is recal culated i e the system detects that the project on the safety controller differs from the configuration project If the check values on the safety controller and in the configuration software are not identical a corresponding message is output For additional information about project information and documentation please refer to the online help which is opened by pressing lt F1 gt when the Project Information dialog box is active Printing project documen The entire project can then be printed tation 1 Inthe File menu select Print Project A dialog box of the same name appears 2 Select all checkboxes in the dialog box and click OK i For additional information about printing page layouts and print settings please refer to the online help which is opened by pressing lt F 1 gt when the Print Project dialog box is active 4 20 MSI 100 Leuze electronic amp Leuze electronic MSlsafesoft configuration sof
112. tor 4 11 Inserting signal inputs and outputs in the connection editor aaeoa E ne eae yeeros Stele Geass 4 11 intended USE haai ia 1 7 3 9 A 3 MSI 100 L LEDs for inputs and Outputs ccccceceeeeeseeeeeeee ee 3 6 Low Voltage Directive 2006 95 EC ccceeeee eee 1 5 M Machinery Directive 2006 42 EC ccccee 1 5 2 4 Machinery Directive 98 38 EC cccccceeeeeeeeeeeeees 1 5 Method of operation of the MSI 100 system 2 1 ModeSelector safe functional block 00c08 4 7 WAS OO ia a a 2 5 COn DUMON eei a ees 3 6 AC MSI CFG1 see AC MSI CFG1 Alarm outputs MO M3 cccccecccseeeeeeeeeeeeeeaes 3 9 Behavior with no AC MSI CFG4 3 12 5 8 Clock outputs TO 11 cccccsssessseeeeeeeees 2 8 3 9 Confirm buU sanna 2 5 3 4 5 2 GCONTIPMTMDUTION serere R 5 6 5 7 Connecting the signal lines ccceeeeeeeee ees 3 17 Connecting the supply voltage cceeeeee 3 16 Connection terminal blocks ccccccsseeeeeeeeeees 3 1 Cross circuit CEtECtION ccceceeeeeeeeeeeeeeeeeeaeeees 2 8 Diagnostic and status indicators 0cccee 3 4 Diagnostic tOOIS cccceeeeeceeeeeeeeeeeeeeeeeaeeeeeeees 2 9 Downloading the configuration using the AC MSI SU sie E EE oes EE E A EE eae 5 7 Ground switching outputs OO O1 0 3 10 Hardware description c cceccss
113. tor To open this ed itor for all I Os general view double click on the representation of the safety controller in the hardware editor MSlsafesoft 2 7 Type Master Device Description MS1100 Location ID 0 Import file A1 A1 A2 A2 TO TO T1 T1 24V OV O0 01 MO M1 M2 M3 mon p r n Input 12 j Input 13 Aput 14 Input 16 Input Input 18 tanet in Figure 4 9 Opening the device parameterization editor for all I Os To open the device parameterization editor for only one specific I O double click on the relevant signal in the graphical representation of the device Doppelklick Double click ae Type Master Device Description M51100 Location D 0 Import file Figure 4 10 Opening the device parameterization editor for one specific I O Instead of double clicking you can also open the device parameterization editor via the context menu Right click either directly on a specific I O to open the parameters for this I O or on any empty position in the graphical representation of the device to open the gen eral view MSI 100 4 15 MSlsafesoft configuration software amp Leuze electronic Structure of the device parameterization editor Modifying device parame ters Input parameters for the safety controller Cross circuit detection 4 16 In both cases select Parameters from the context menu
114. troller icon is selected again the destination system is reset in the configuration software from the MSISIMsoft simulation to the real MSI 100 safety controller This means that essentially the connection between the configuration software and the simulation software is only interrupted The MSISIMsoft simulation ap plication is not exited automatically see below Exiting the MSISIMsoft To exit the MSISIMsoft simulation simulation 1 First exit simulation mode in the configuration software deselect the Simulate Safety Controller button 2 Then select Exit in the MSISIMsoft context menu in the Windows taskbar or click on Exit in the MSISIMsoft window i If MSISIMsoft is exited while the Simulate Safety Controller button is activated in MSlsafesoft MSISIMsoft restarts automatically after being exited Additional information For additional information about the MSISIMsoft controller simulation please refer to the about operating MSISIMsoft controller simulation section in the online help for the MSlsafesoft configura MSISIMsoft tion software Operating MSISIMsoft Simulating time sequences in MSISIMsoft expert mode Status of the MSISIMsoft simulation Leuze electronic MSI 100 4 23 MSlsafesoft configuration software amp Leuze electronic 4 24 MSI 100 Leuze electronic Configuration and startup 4 amp 4 Leuze electronic 5 Configuration and startup 5 1 Configuration overview from A to
115. tware 4 6 Simulation mode in MSlsafesoft The MSlsafesoft configuration software includes the MSISIMsoft controller simulation which can be used to simulate the execution of the safety logic Ifno MSI 100 safety controller is available Ifa simulated function test is recommended prior to actual startup of the real MSI 100 safety controller Sax MsSISIMsoft lt lt I Os Exit Preset 2 type Description Terminal BOOL Eingang l0 10 Eingan BOOL Engang n M Eingan BOOL 2 Eingan BOOL Eingang 3 13 Eingan BOOL l4 Eingan BOOL IS Eingan BOOL Eingang I7 ss 8 Ausgang 00 Ausgang 01 O Ausgang 02 02 ae SAFEBOOL T Engan SAFEBOOL BOO AFEBOO gt 5 a 6 a aH 3 Ww rf Set Preset 1 Set Preset 2 Set Preset 3 Figure 4 16 Simulation of the safety controller in MSlsafesoft WARNING A simulation does not replace a function test The simulation of the safety application must not replace the proper function test using the safety controller and safe control devices sensors actuators The test using simula tion may only be performed in addition to the standard function test as a preliminary test for example When working with the MSISIMsoft simulation instead of the safety controller Ifa safety controller is connected it will not be addressed i e its inputs will not be read and its
116. two channels via an emergency stop control device a cross circuit can def initely be detected in this emergency stop circuit In the event of a cross circuit the same clock signal would be present at both inputs instead of two different ones The MSlsafesoft configuration software specifies the clock signals to be used Cross circuit detection is implemented with test pulse TO for even inputs 10 12 14 118 For odd inputs 11 13 15 119 test pulse T1 must be used for cross circuit detection For an example of two channel connection of an emergency stop control device with dual signal and cross circuit detection please refer to Figure 2 4 in Error detection in I O devices on page 2 8 3 4 2 Safe outputs The safety related outputs OO to O3 are designed as digital semiconductor outputs for 24 V DC 2 A total current up to category 4 according to EN 954 1 The outputs are controlled according to the configured safety logic The safe outputs are linked to the safety logic that is used to control the outputs in the connection editor of the MSlsafesoft configuration software See also Adding and connecting functions functional blocks and signals in the safety logic on page 4 11 To increase cross circuit protection outputs O0 and O1 can also be used in connection with ground switching outputs O0 and O1 see Ground switching outputs O0 and 01 on page 3 10 An appropriate protective circuit diode or va
117. unction test The test of the safety application using startup mode must not replace the proper function test using safe control devices The test in startup mode may only be performed in addi tion to the standard function test as a preliminary test for example Leuze electronic MSI 100 5 11 Configuration and startup CS Leuze electronic Forcing signals in the online display of the connection editor directly controls the safety controller WARNING Eliminate hazards Before forcing any signals ensure that doing so will not pose a risk for people or mate rials WARNING Startup mode is a standard operating mode As in online mode the connection editor displays online values which are read from the safety controller However as signals can also be influenced in startup mode which is not possible in online mode startup mode is a standard operating mode Once the supplementary function test has been performed in startup mode exit startup mode again This resets forced signals gt D Starting startup mode 1 In MSlsafesoft select Startup Mode from the Safe Controller menu 2 Amessage appears alerting you to possible hazards Click Yes in this dialog box to exit safe mode and switch to standard startup mode Time limit You have 30 seconds to change the operating mode i e to click Yes Af pe ter this time a corresponding error message is displayed and Startup Mode must be selected again
118. us contact voltages can occur at their con nections Power supply unit Only use power supply units with safe isolation and PELV according to DIN EN 50178 VDE 0160 PELV This prevents short circuits between primary and sec ondary sides ESD sb NOTE Electrostatic discharge Ate The device contains components that can be damaged or destroyed by electrostatic dis charge When handling the device observe the necessary safety precautions against electrostatic discharge ESD according to EN 61340 5 1 and EN 61340 5 2 Leuze electronic MSI 100 1 3 For your safety A Draw up and implement a safety concept l Check hardware and de vice parameterization 4 amp 4 Leuze electronic 1 4 Safety of the machine or system WARNING Ensure the safety of the machine or system The operator bears sole responsibility for the safety of the machine or system The Ma chinery Directive must thus be observed In order to use the system described in this document with the associated safe functional blocks you must have drawn up an appropriate safety concept for your machine or system This includes a hazard and risk analysis as well as a test report for validating the safety functions The target safety integrity level SIL according to DIN EN 61508 and category according to DIN EN ISO 13849 1 is ascertained on the basis of the risk analysis The safety integrity level or category ascertained determines How safe sensors
119. ut the safety controller please refer to the device de scription in Section 3 The MSI 100 safety controller can only be configured and parameterized using the MSlsafesoft safe configuration software which is executed on a separate Windows PC The software offers a graphical connection editor for this purpose The safety logic can be created here by graphically connecting prepared safe functions and functional blocks to the inputs and outputs of the safety controller The connections are made intuitively using the mouse and the editor prevents impermissible connections e g between certain outputs In addition the software provides a safe parameter editor which can be used to configure each input and output of the MSI 100 safety controller A special online mode supports a detailed function test of the safety logic executed in the MSI 100 safety controller Current signal values can be read from the MSI 100 safety con troller transmitted to the configuration software and displayed there live in the connec tion editor For more detailed information about the configuration software please refer to the software description in Section 4 Communication between the MSI 100 safety controller and the configuration software is via a USB interface A special security protocol enables secure data transmission via the USB interface There is communication between the two components in both directions PC gt safety controller
120. vides a better overview of the control cabinet 1 Requirement The MSI 100 safety controller must be running Switch the connection editor to online mode then to startup mode 2 In the connection editor position the cursor over the symbol for the input or output you want to check without clicking The symbol starts to flash after around one second At the same time the LED for the corresponding I O also starts to flash on the MSI 100 safety controller Safe input signal SIL 3 Reset Startup inhibit machine 1 _ At A1 A2 A2 TO To T1 TI GFG HV OV OQ 01 M0 M1 M2 M3 STICK Leuze electronic OE comrinn TE R g LED for the wired input k amp o E UR ot OZ i eer aia cn G e esoe ess _ a AA O mie fa he a k Emergency stop Reset Figure 2 7 Simplified schematic view Wiring check MSI 100 System description Status indicators on the MSI 100 safety controller a Online tool tips in the con nection editor Offline tool tips 2 12 4 amp 4 Leuze electronic There are four LEDs on the MSI 100 safety controller PWR green Indicator for the power supply of the safety controller EXT green Indicator for communication with extension devices with without TBUS ERR red Error display CFG green Indicator for the configuration status and communication via the USB in terface The LEDs indicate the status of the safety controller For a detailed list of possible i
121. vior of contactors connected to the safety controller EmergencyStop The EmergencyStop safe functional block monitors the switching states of an emergency stop control device When the connected emergency stop device is actuated the enable signal at output OUT is set to FALSE FALSE FALSE EnableSwitch The EnableSwitch safe functional block evaluates the signals of a manually actuated three position enable switch accord ing to DIN EN 60204 in order to identify its switch position and switching direction This means that an enable switch can be used to remove safeguarding provided that the appropriate safe operating mode e g limitation of the speed or range of motion is se lected and active Equivalent The Equivalent safe functional block monitors the signals of two safe input terminal blocks for the same signal states Typically these signals come from two channel sensors or switches such as an emergency stop control device 4 6 MSI 100 Leuze electronic amp Leuze electronic MSlsafesoft configuration software Table 4 1 Safe functional blocks Fortsetzung Name Short description Icon in editor The ESPE electrosensitive protective equipment safe func tional block monitors the switching states of electrosensitive protective equipment e g light grids When the protective equipment is triggered i e the light grid beam is interrupted the enable signal at output OUT is set to FALSE GuardLocki
122. y controller has no function e If the data memory module is not removed correctly the safety controller also displays an error message 5 8 MSI 100 Leuze electronic amp Leuze electronic Configuration and startup 5 4 Uploading the configuration from the MSI 100 safety controller A project which is downloaded to the MSI 100 safety controller is saved there and can be uploaded to the PC and the configuration software again if required This may be required for example if a project has to be read from the safety controller for diagnostic purposes It is possible to upload a project from the safety controller to the configuration software without the controller password However to edit the uploaded project you will need the correct project password To upload the project proceed as follows 1 Leuze electronic lf a project is currently open in the configuration software save it before uploading the required project from the safety controller If necessary exit startup mode and the online mode of the configuration software The Online Values icon must not be selected prior to starting the upload and the sta tus bar must show the controller status Controller Connected Click on the Upload icon in the toolbar Click Yes in the prompt dialog box that appears to confirm the upload Transmission from the safety controller to the PC starts and a progress indicator is dis played in the MSlsafeso
123. ze system response Continued from D Continued C Figure 5 2 Flowchart Configuration from A to Z 2 of 3 5 2 MSI 100 Leuze electronic amp amp Leuze electronic Configuration and startup Continued D ee rom Function test completed without errors No Switch connection editor offline Startup completed Optional Certify safety networks in the 3 Fal connection editor E X Documentation in MSlsafesoft Complete the project information Project menu Project Information Archive the project in MSlsafesoft zip and save to backup medium Print the project in MSIsafesoft Figure 5 3 Flowchart Configuration from A to Z 3 of 3 Leuze electronic MSI 100 5 3 Configuration and startup A 4 amp 4 Leuze electronic 5 2 Downloading the configuration from MSlsafesoft WARNING Risk of damage due to unintentional incorrect operations Prior to startup ensure that if the safety controller functions in an unintended or incorrect way this will not cause damage The configuration including the device parameterization is created in the MSIsafesoft con figuration software as a project and must be downloaded to the MSI 100 safety controller once complete This data is usually transmitted via the USB interface of the safety controller Alternatively the configuration can also be downloaded by inserting an data memory mo dule that contains the relevant

Download Pdf Manuals

Related Search

Related Contents

Couverture - Astronomie  Handy Home Products 18811-4 Instructions / Assembly    Folleto - Oxygenar  bacto`san pro  Notice - Castorama    Mode d`emploi  Manuale - Hanna Instruments  WZ810 スリムスティック  

Copyright © All rights reserved. Failed to retrieve file