Rockwell Automation Allen-Bradley MicroLogix 1100, Allen-Bradley GuardShield Micro 400, Allen-Bradley MSR42 Quick Start Manual

Bidirectional (4-sensor, T-type) Muting
With MSR42 Relay
Connected Components Building Block

Catalog Numbers MSR42, MicroLogix 1100, GuardShield Micro 400
Light Curtains

Quick Start

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines
for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
Automation sales office or online at http://www.rockwellautomation.com/literature/
between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the
wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that
each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.

available from your local Rockwell

) describes some important differences

IMPORTANT

ATTENTION

SHOCK HAZARD

BURN HAZARD

Allen-Bradley, Rockwell Automation, TechConnect, MicroLogix, PanelView, Rockwell Software, and GuardShield are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Identifies information that is critical for successful application and understanding of the product.

Identifies information about practices or circumstances that can lead to personal injury or death, property damage,
or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may
be present.

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach
dangerous temperatures.

Connected Components Building Block Outline

Follow the path below to complete your connected components building block.

Connected Components

Building Blocks, publication

CC-QS001

Where to Start

Chapter 1 Product

Integration

Chapter 2 System

Validation and Application

Tips

ESC OK

3Publication CC-QS015A-EN-P - November 2009 3

Where to Start

4 Publication CC-QS015A-EN-P - November 2009

Product Integration

System Validation and Application
Tips

Table of Contents

Preface

About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Understand the Safety Function . . . . . . . . . . . . . . . . . . . . . . 10

Set Up the Configuration and Diagnostic Software . . . . . . . . 12

Configure the MSR42 Safety Relay . . . . . . . . . . . . . . . . . . . . 13

Download the Configuration . . . . . . . . . . . . . . . . . . . . . . . . 19

Confirm the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chapter 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Validate Proper Operation of the Safety Systems. . . . . . . . . . 26

Validate Proper Operation of the PanelView Screens . . . . . . 31

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Table of Contents

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Preface

About This Publication

This quick start illustrates one way of combining a set of Micro 400 Light Curtains, an MSR42
safety relay, an MSR45E expansion module, an MSR127 safety relay, an E-stop, and two
contactors into an integrated safety system providing both a bidirectional, four-sensor, T-type
muting function and an E-stop function.

A MicroLogix 1100 controller and a PanelView HMI are included to provide a convenient and
graphical way to monitor the operation of the safety systems and provide basic diagnostic
information and corrective action suggestions when appropriate. The MicroLogix controller and
PanelView terminal only monitor the safety systems. They are not safety components and they
have no safety control or function. The safety systems operate independently from the
MicroLogix controller and PanelView terminal.

IMPORTANT

To assist in the design and installation of your system, application files and other information are
provided on the Connected Components Building Blocks Overview CD, publication CC-QR001.
The CD provides bills of materials (BOM), CAD drawings for panel layout and wiring, control
programs, Human Machine Interface (HMI) screens, and more. With these tools and the built-in
best-practices design, the system designer is free to focus on the design of their machine control
and not on design overhead tasks.

Read these sections carefully before beginning work in each chapter. The beginning of each
chapter contains the following information:

• Before You Begin - This section lists the steps that must be completed and decisions that

must be made before starting that chapter.

• What You Need - This section lists the tools that are required to complete the steps in the

current chapter. This includes, but is not limited to, hardware and software.

• Follow These Steps - This illustrates the steps in the current chapter and identifies which

steps are required to complete the examples.

Use this Simple Machine Safety Connected Components Building Block Quick Start in conjunction
with the Connected Components Building Blocks Quick Start, publication CC-QS001.

Refer to Additional Resources on page 8 for a listing of quick starts.

7Publication CC-QS015A-EN-P - November 2009 7

Preface

Conventions

Convention Meaning Example

Check or uncheck To activate or deactivate a checkbox. Check Disable Keying.

Click

Double-click

Expand Click the + to the left of a given item /folder to show its contents. Expand 1768 Bus under I/O Configuration.

Right-click

Select Using the mouse to highlight a specific option. Select the New Module folder.
Press Pressing a specific key on the keyboard or button on a touchscreen. Press Enter.
> Use this symbol to indicate the sub-menu name. Choose File
‘Project’ Refers to the application on both the controller side and the PanelView component side.

Click the left mouse button once while the cursor is positioned on
object or selection to initiate an action.

Click the left mouse button twice in quick succession while the cursor
is positioned on object or selection to initiate an action.

Click the right mouse button once while the cursor is positioned on
object or selection.

Click Browse.

Double-click the application icon.

Right-click the 1768 Bus icon.

>Menu>Options.

Additional Resources

Resource Description

Connected Components Building Blocks Quick Start,
publication CC-QS001

Connected Components Building Blocks Overview CD,
publication CC-QR001

Position Control Connected Components Building
Block Quick Start, publication CC-QS003

MicroLogix 1100 Controller User Manual, publication

176

3-UM001

MSR42 Safety Base Module Operating Manual,
publication 440R-IN017

MSR45E Safety Expander Module, Operation Manual,
publication 440R-IN018

GuardShield Micro 400 Safety Light Curtain Operation
Manual, publication 445L-IN001

Configuration Tool for MSR42, GuardShield Micro 400
and Safe 2/4 Light Curtains Software Description

http://www.ab.com
http://www.rockwellautomation.com/knowledgebase
http://www.rockwellautomation.com/components/

connected/blocks.html

Provides information on how to select products and gain access to panel and
wiring information

Provides files for the Connected Components Building Blocks

Provides information installing and setting up the PowerFlex 40P drive
parameters with the pre-configured RSLogix 500 program that controls you base
system including application tips, as well as implementing the drive parameter
backup and restore functionality

Provides information on using the MicroLogix 1100 Programmable Controller

Provides information wiring and operating the MSR42 safety controller

Provides information on using the MSR45E expander module

Provides information on mounting, wiring, and using safety light curtains

Provides information on configuring and programming an MSR42 safety controller
with Configuration Tool software

Provides access to the Allen-Bradley website
Provides access to self-service support
Provides access to the Connected Components website

8 Publication CC-QS015A-EN-P - November 2009

Chapter

1

Product Integration

Introduction

A bidirectional, four-sensor, T-type muting system lets valid loads or objects pass through its light
curtains in either direction without shutting down the machine or process, but will stop the
machine or process if anything or anyone attempts to move past the light curtain in any other
manner. This type of system is often used to guard the access point at a hazardous portion of a
machine or process where material must pass either into or out of the guarded area, such as an
automatic palletizing system or automatic assembly machine. This Connected Components
Building Block is intended to ease the installation, configuration, and implementation of such a
system.

Before You Begin

Review the Connected Components Building Blocks Quick Start, publication CC-QS001, verifying
that you have completed the hardware design and installation as well as software installation.

IMPORTANT

A safety risk assessment must be completed to make sure that all tasks and hazards are
considered and to confirm that the example circuit provides adequate risk reduction for your
specific application.

What You Need

• Personal computer

• Connected Components Building Blocks Overview CD, publication CC-QR001

• MicroLogix 1100 controller, catalog number 1763-L16BBB

• PanelView Component C600 terminal, catalog number 2711C-T6C

• Stratix 2000 Ethernet switch, catalog number 1783-US05T (or equivalent) to connect the

MicroLogix controller to the PanelView terminal

• Ethernet cables, catalog number 1585J-M8TBJM-2 or equivalent

• MSR127 safety relay, catalog number 440R-N231132

• MSR42 safety relay, catalog number 440R-P226AGS-NNR

• MSR45E expander module, catalog number 440R-P4NANS

• Optical Interface Tool, catalog number 445L-AF6150, which includes the Optical Interface

Tool-MSR42 Configuration and Diagnostic Software

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Chapter 1 Product Integration

• Optical Interface Tool Fastener, to attach the Optical Interface securely to the MSR42 relay

• 24V DC power supply, catalog number 1606-XL120D

• Safety components such as E-stops, GuardShield Micro 400 light curtains, as listed in the bill

of material on the Connected Components Building Blocks Overview CD, publication
CC-QR001

Follow These Steps

Start

Understand the Safety Function

on page 10

Set Up the Configuration and

Diagnostic Software on page 12

Configure the MSR42 Safety

Relay on page 13

Download the Configuration on

page 19

Confirm the Configuration on

page 22

Understand the Safety Function

Two separate safety functions are provided.

1. The GuardShield Micro 400 light curtains and MSR42 safety relay provide a bidirectional,

four-sensor, T-type muting function.

2. The E-stop and MSR127 safety relay provide an E-stop function.

These two safety functions are independent of one another. When set up properly, either safety
system is capable of stopping dangerous motion.

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Product Integration Chapter 1

The MicroLogix 1100 controller monitors the safety systems and, via the PanelView terminal,
provides a simple, graphical representation of the operation and status of the safety systems and
recommends corrective actions in response to system faults. The controller and the terminal
perform no safety or control functions.

If the PanelView terminal is mounted so that it provides the operator a clear and complete view
of the hazard area, and local safety regulations permit, the PanelView START RESET button may
be used to start or reset the safety systems, just like the Start – Reset push button.

IMPORTANT

If the operator stationed at the PanelView terminal’s location cannot see the guarded area well
enough to be certain that no one is in the guarded area, you must not use the START RESET
button.

The START RESET button can be disabled by removing three wires from the MicroLogix controller
I/O.

• Wire 6041

• Wire 10231

• Wire 10071

Safety Systems Diagram

800F

Start

Reset

MicroLogix 1100

Stratix

2000

PanelView

Component

Term in al

Personal

Computer

MSR45E

Expansion

Controller

MSR127

Safety

Relay

100S-C

100S-C

M

RightSight

Sensors

RightSight

Sensors

GuardShield Micro 400

Light Curtains

MSR42

Multi-

function

Safety

Relay

800FP

STOP

Publication CC-QS015A-EN-P - November 2009 11

Chapter 1 Product Integration

Set Up the Configuration and Diagnostic Software

Follow these steps to install and set up the Configuration and Diagnostic software.

1. If you do not have the Configuration and Diagnostic software, go to

http://www.ab.com/safety/logic/relays/msr4x/ to download the Configuration Tool for

MSR42 relay, GuardShield Micro 400 and Safe2/4 Light Curtains.

a. Go to Related Links on the right side of the page and choose ‘Safety Software [ZIP]’.
b. Save the zip file to your personal computer.
c. Unzip the file.
d. Run the SetupDiagnosticAndConfiguration_Vxxx.exe file to install the software.

2. Start the Configuration and Diagnostic software.

3. Click MSR42 and then OK.

4. If this is the first time you have used

the Configuration and Diagnostic
software, register the software.

a. From the Options menu, choose

User Registration.

b. Type in your information and

click OK.

TIP

It is not necessary to change the password for this building block. The default password is
ABGM.

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Configure the MSR42 Safety Relay

1. On the Configuration

dialog box, select ‘Micro
400 Light Curtain’ from the
Micro 400 Inputs
pull-down menu.

Product Integration Chapter 1

2. Edit the settings as shown.

a. Choose Manual.
b. Leave Stop Delay set to No.
c. Choose Resolution 30 mm.
d. From the Protective height

pull-down menu, choose 1200
mm.

The software automatically
displays 48 as the ‘Total beam
number of system (n):’.

e. Leave Double Scan set to Yes.

3. Click OK.

Publication CC-QS015A-EN-P - November 2009 13

Chapter 1 Product Integration

Notice that Micro 400 Light
Curtains have been added
to the Design Output
diagram.

4. On the Configuration

dialog box, select Start
from the IN1 Inputs
pull-down menu.

In addition to the
Micro 400 Light Curtains, a
NO momentary push
button, connected to IN1,
appears on the Design
Output diagram. The red
error message disappears,
replaced by ‘Design OK’.

14 Publication CC-QS015A-EN-P - November 2009

5. From the IN2 pull-down

menu, choose Start
Release.

Notice that Start Release is
shown connected to IN2.

Start Release is a feedback
circuit that confirms, at
Start – Reset, that neither of
the two final switching
devices (FSD)
normally-open (NO)
outputs are shorted, that is,
closed.

In this application, the Start
Release circuit goes from
+24V through one auxiliary
normally-closed (NC)
contact of each 100S
contactor to the MSR42
relay. Similar to EDM, if
either or both of these NC
contacts are open, the
MSR42 relay cannot be
started or reset.

Product Integration Chapter 1

6. From the Outputs Info1

pull-down menu, choose
Micro 400 Light Curtain.

Status Micro 400 Light
Curtain is shown
connected to Info1. This
output switches High or
Low, depending on
whether the light curtain
beam is broken or
complete. This is
independent of the safety
output and can be
considered an auxiliary
output.

Publication CC-QS015A-EN-P - November 2009 15

Chapter 1 Product Integration

7. From the Inputs GPIO pull-down menu, choose Muting Micro 400.

8. Click OK on the safety notice dialog box.

9. On the Muting dialog box, click 4 sensor T-type.

This dialog box helps you configure your muting system properly.

The Muting dialog box shows that a load on the conveyor travels left-to-right, passing in
sequence through the first two muting sensors and the LC (light curtain). After passing the
light curtain, the load passes, in sequence, the last two sensors. An object passing the
sensors in the proper sequence and within the configured time constraints is permitted to
pass though the light curtains without triggering a safe stop. The light curtains are ignored
by the safety system until the object passes completely through, clearing the light curtain
sensing field and passing the third sensor, ending the muting period.

As soon as the third sensor is cleared, the safety system will again trigger a safe stop if
anything breaks the sensing field without first passing S1 and S2 in the proper order and
within the configured time constraints.

10. Click Help in the lower right corner of the Muting dialog box.

16 Publication CC-QS015A-EN-P - November 2009

The Muting Help dialog box shows
the proper timing sequence for 4
sensor, T-type muting. An object
must not only pass the sensors and
the light curtain in the proper
sequence. To initiate muting, an
object moving right to left in the
diagram must be in front of both
S1 and S2 for an instant. When
moving left to right, an object must
be in front of both S3 and S4, for
an instant. Take this timing and the
size of the load into consideration
when mounting the sensors. The
minimum load must be long
enough to be in front of both S1
and S2 or S3 and S4 sensors
simultaneously.

Product Integration Chapter 1

The Muting Help dialog box also provides definitions for the t(sens), t(espe), t(mute),
t(mdo), and t(msdel) times, which you can configure on the 4 sensor T-type dialog box. A
load that exceeds any of these configured times as it moves across the conveyor causes a
muting error, which results in the light curtain not being muted. A load entering the light
curtain sensing field during a muting error triggers a safe stop.

11. Click Close to return to the Muting dialog box.

12. Type the timing values or use the slider to edit the default values.

Publication CC-QS015A-EN-P - November 2009 17

Chapter 1 Product Integration

Time settings are intended to help make sure that only valid objects of the right size, moving
at the right speed, can initiate and maintain a muting sequence.

You may want to add a few seconds to some of your calculations to allow for variations.

Time Setting Description

t(sens) Since both S1 and S2 or both S3 and S4 sensors must be broken simultaneously to initiate a muting sequence,

these sensors should be spaced no further apart than the length of the smallest typical load. Calculate how
long a load takes from the time it first reaches S1 until it reaches S2 (or S3 until it reaches S4), based on the
speed of the conveyor. This is the t(sens) time for your system.

t(espe) The t(espe) field is disabled until you check the Light curtain interruption monitored checkbox under Additional

Settings. The t(espe) of your system is the time from the moment a load reaches the second sensor (S2 from
the right or S3 from the left) until it enters the light curtain sensing field. Once the light curtain is muted, the
load must interrupt the light curtain within 3 seconds. Therefore, the second sensor must be placed within 3
seconds travel time from the light curtain. t(espe) should be no longer than 3 seconds except in extraordinary
circumstances supported by the risk assessment.

t(mute) This setting establishes the maximum length of time the light curtain remains muted. Calculate the length of

time it takes the load to travel from the point where it first reaches the second sensor until the trailing edge of
the load leaves the light curtain based on the speed of the conveyor. This is the minimum t(mute) for your
system, which is entered in minutes.

t(mdo) This setting establishes the maximum length of a Mute Dependent Override. Occasionally, a load may stop

within the light curtain sensing field. It may be difficult to move the load past the light curtain sensing field
with a safe stop in effect. Mute Dependent Override is a function that lets a safety stop be paused and muting
to be re-initiated for the duration of the t(mdo) setting, which lets the load move beyond the light curtain
sensing field. As soon as the load moves past the light curtain sensing field, muting ceases. If the hazardous
area is in clear view of the operator and no personnel or objects are in the hazard area, Mute Dependent
Override can be initiated, in this case, by pressing and releasing the Start/Reset button. Calculate the time it
takes the load to travel from the point where it first reaches the second sensor (S2 from the right, or S3 from
the left) until the trailing edge of the load leaves the light curtain sensing field, based on the speed of the
conveyor.

t(msdel) In some instances, loads may have gaps that the first two sensors might sense through as the load passes.

This could lead to a muting error. One method to avoid such errors is to delay the sensors’ response to allow
for seeing through gaps. The t(msdel) configures that delay time. Unless the gap is very long or the load is
moving very slowly, the gap is present for only a short time. In most instances, the default 0.050 is suitable.
Leave this value set at 0.050.

Notice that the Connecting diagram shows a lamp, as well as muting sensors connected to
GPIO1 and GPIO2, and that IN1 is labeled Start/Mute override. In this application a Muting
Lamp is required for safety purposes to warn personnel in the area when the light curtain is
muted.

13. Review the Additional Settings.

a. Make sure that the Muting Lamp monitored box is checked.

Muting lamp monitoring means that should the muting lamp fail, short, or open, the
MSR42 controller will sense it and not initiate or maintain muting. In applications where a
muting lamp is required, generally the muting lamp is required to be monitored.

b. Because you entered a t(mdo) time earlier, leave the Mute dependent override box

checked.

c. In the Muted light curtain section, note that GuardShield Micro 400 is selected and

disabled and make sure that the Light curtain interruption monitored box is checked.

18 Publication CC-QS015A-EN-P - November 2009

14. Click OK to complete the

configuration.

15. Choose File>Save and

save the configuration as
‘4sensor T-type muting’.

16. Do not exit the MSR42

configuration and
diagnostic software.

Product Integration Chapter 1

Download the Configuration

1. Write down the device number from the label on the side of the MSR42 relay.

2. Apply power to the MSR42 relay.

3. Attach the suction-cup connector to the interface window on the side of the MSR42 relay.

Publication CC-QS015A-EN-P - November 2009 19

Chapter 1 Product Integration

4. In Microsoft Windows,

open the Control Panel.

5. Double-click on System.

6. On the System Properties

dialog box, click
Hardware.

7. Click Device Manager.

8. Expand Ports (COM &

LPT).

9. Plug the USB connector of

the Optical Interface into
an available USB port on
your personal computer.

10. Note the new COM port

that appears in the list.

This is the port assigned to
the Optical Interface, which you will need to select in the Configuration and Diagnostic
software as part of the download procedure.

11. Close the Control Panel.

12. In the Configuration and Diagnostic software, choose

Options>USB/Comport settings.

TIP

If USB/Comport settings is not available, check
Support Mode active and choose
Options>USB/Comport settings.

20 Publication CC-QS015A-EN-P - November 2009

13. On the OptiLink Communication dialog box,

select Compatibility mode.

14. Choose the Comport assigned by Windows

Device Manager.

15. Click OK.

16. From the File menu, choose PC->MSR42 (Download).

Product Integration Chapter 1

17. When prompted, type the password ‘ABGM’.

18. On the Controller Description dialog box, type

the six-digit Device number and click OK.

19. Cycle power to the MSR42 relay to allow the

download to proceed.

Once the download is complete, the Configuration control document dialog box appears.

Publication CC-QS015A-EN-P - November 2009 21

Chapter 1 Product Integration

Confirm the Configuration

1. On the Configuration control document

dialog box, review the configuration
and check the confirmation box.

2. Click Continue.

3. When prompted to print the document,

click No.

The software saves a copy that can be
printed later from the File menu.

4. On the Attach Safety Configurator Label dialog

box, click OK.

The MSR42 is now fully configured and ready for
operation.

5. Click the Diagnosis tab.

22 Publication CC-QS015A-EN-P - November 2009

Product Integration Chapter 1

This screen lets you monitor the status of the light curtain when a computer is attached to
the MSR42 relay via the Optical Interface. It has other helpful diagnostic features that are
described in the MSR42 Safety Base Module Operation Manual, publication 440R-IN017, and
the Configuration Tool for MSR42, GS Micro 400 and Safe 2/4 Light Curtains Software
Description document, available on the CD that ships with the Optical Interface tool.

Otherwise, a personal computer is neither required, nor recommended, for normal system
operation.

6. Disconnect the Optical Interface tool.

Publication CC-QS015A-EN-P - November 2009 23

Chapter 1 Product Integration

Notes:

24 Publication CC-QS015A-EN-P - November 2009

Chapter

2

System Validation and Application Tips

Introduction

In this chapter, you validate the operation of the two safety functions as well as the operation of
the MicroLogix 1100 controller and PanelView Component 600 terminal.

Before You Begin

• Review the Connected Components Building Blocks Quick Start, publication CC-QS001,

verifying that you have completed all of the steps in Chapter 3 of that publication.

• Verify that you have completed all of the steps in Chapter 1 of this document.

• Verify that all components of the system are assembled and wired per the Bill of Materials

Assembly Diagrams and Wiring Diagrams provided for this Connected Components Building
Block, and as required for your application.

• Verify that the MicroLogix controller and the PanelView Component terminal have power

applied to them.

What You Need

• Personal computer

• Connected Components Building Blocks Overview CD, publication CC-QR001

• MicroLogix 1100 controller, catalog number 1763-L16BBB

• PanelView Component C600 terminal, catalog number 2711C-T6C

• Stratix 2000 Ethernet switch, catalog number 1783-US05T (or equivalent) to connect the

MicroLogix controller to the PanelView terminal

• Ethernet cables, catalog number 1585J-M8TBJM-2 or equivalent

25Publication CC-QS015A-EN-P - November 2009 25

Chapter 2 System Validation and Application Tips

Follow These Steps

Start

Validate Proper Operation of the

Safety Systems on page 26

Validate Proper Operation of the

PanelView Screens on page 31

Validate Proper Operation of the Safety Systems

To confirm that the system is operating properly, you need to perform a series of tests.

Start Up

1. Apply power to the system.

2. Check the following:

• The 100S contactors do not energize.

• Guarded motion does not start.

• The red stacklight is on.

3. Press and release the Start-Reset button.

4. Check the following:

• The 100S contactors energize.

• Guarded motions starts.

• The green stacklight is on.

E-stop Function

1. Press the E-stop.

2. Check the following:

• The two 100S contactors de-energize.

• Guarded motion stops.

• The red stacklight is on.

26 Publication CC-QS015A-EN-P - November 2009

System Validation and Application Tips Chapter 2

3. Press and release the Start-Reset button.

4. Confirm that the two 100S contactors do not energize and guarded motion does not start.

5. Twist and release the E-stop button.

6. Press and release the Start-Reset button.

7. Check the following:

• The 100S contactors energize.

• Guarded motion starts.

• The green stacklight is on.

Light Curtain Function

1. Break the light curtain beam and keep it broken, taking care not to block any sensors.

2. Check the following:

• The two 100S contactors de-energize.

• Guarded motion stops.

• The red stacklight is on.

3. While the light curtain beam remains broken, press the Start-Reset button.

4. Confirm that the two 100S contactors do not energize and guarded motion does not start.

5. Restore the light curtain beam.

6. Press and release the Start-Reset button.

7. Check the following:

• The 100S contactors energize.

• Guarded motion starts.

• The green stacklight is on.

Publication CC-QS015A-EN-P - November 2009 27

Chapter 2 System Validation and Application Tips

Muting Function

1. Send a load from the right through the muting system.

2. Check the following:

• S1 switches as the load passes.

• S2 switches as the load passes.

• The muting lamp turns on.

• The load passes through the light curtain without the system shutting off.

• The muting lamp turns off as the load passes S3.

3. Send a load from the left through the muting system.

4. Check the following:

• S4 switches as the load passes.

• S3 switches as the load passes.

• The muting lamp turns on.

• The load passes through the light curtain without the system shutting off.

• The muting lamp turns off as the load passes S2.

Muting Error (from Right)

1. From the right, let a load pass S1 and S2, but stop it short of the light curtain sensing field.

2. Confirm that the muting lamp turns on.

3. Wait the configured t(espe) delay for the muting lamp to start blinking.

4. Move the load forward to break the light curtain beam.

5. Check the following:

• The safety output turns off.

• The two 100S contactors de-energize.

• Guarded motion stops.

• The red stacklight turns on.

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System Validation and Application Tips Chapter 2

Mute Dependent Override (from Right)

1. While the load is still disrupting the light curtain beam from the previous mute error test,

press and release the Start-Reset button.

2. Check the following:

• The safety output turns on.

• The two 100S contactors energize.

• Guarded motion starts.

• The muting lamp is on and is not blinking.

• The green stacklight turns on.

3. As soon as the load clears the light curtain, break the light curtain beam, taking care not to

block any sensors.

4. Check the following:

• The safety output turns off.

• The two 100S contactors de-energize.

• Guarded motion stops.

• The red stacklight turns on.

5. Press and release the Start-Stop button to start the system.

Muting Error (from Left)

1. From the left, let a load pass S4 and S3, but stop it short of the light curtain sensing field.

2. Confirm that the muting lamp turns on.

3. Wait the configured t(espe) delay for the muting lamp to start blinking.

4. Move the load forward to break the light curtain beam.

5. Check the following:

• The safety output turns off.

• The two 100S contactors de-energize.

• Guarded motion stops.

• The red stacklight turns on.

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Chapter 2 System Validation and Application Tips

Mute Dependent Override (from Left)

1. While the load is still disrupting the light curtain beam from the previous mute error test,

press and release the Start-Reset button.

2. Check the following:

• The safety output turns on.

• The two 100S contactors energize.

• Guarded motion starts.

• The muting lamp is on and is not blinking.

• The green stacklight turns on.

3. As soon as the load clears the light curtain, break the light curtain beam, taking care not to

block any sensors.

4. Check the following:

• The safety output turns off.

• The two 100S contactors de-energize.

• Guarded motion stops.

• The red stacklight turns on.

5. Press and release the Start-Stop button to start the system.

Lockout

1. Carefully disconnect and reconnect one of the light curtain RJ45 connectors at the MSR42

relay.

2. Make sure the safety output triggers the instant the light curtain is disconnected.

This completes the validation of the safety systems.

30 Publication CC-QS015A-EN-P - November 2009

System Validation and Application Tips Chapter 2

Validate Proper Operation of the PanelView Screens

Most of the buttons are real-time signals from the MSR42 or MSR127 relays, driven via the
MicroLogix 1100 controller to the PanelView terminal. The buttons change their appearance as
the signals driving them change.

This button Indicates

SEN

1

SEN

1

LC

LC

E-STOP

There is no load in front of the sensor.

A load is in front of the sensor.

The light curtain sensing field is not interrupted.

The light curtain sensing field is interrupted.

The E-stop has been pressed.

The following pages illustrate a typical sequence of PanelView screens. Confirm that the system
and PanelView screens operate as expected by following this sequence.

When you apply power to the system, the Safety System Status screen appears.

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Chapter 2 System Validation and Application Tips

1. Press MORE INFO for two seconds.

Whenever an action may be
appropriate for an operator to perform,
MORE INFO is displayed on the screen.
Pressing MORE INFO calls the related
message screen.

2. Press RETURN for about five seconds to

return to the previous screen.

3. Press START RESET for three seconds

and release.

The system should start running. Note that the START RESET button is green only when the
system is ready for a Start Reset. It is no longer green once the system is running.

As the load enters the system from the
left and moves in front of S4 and S3,
muting is initiated. The load has not yet
interrupted the light curtain sensing
field.

As the load enters the light curtain
sensing field, the LC (light curtain)
button turns red to indicate that the
light curtain has been interrupted. The
Safety Output button remains on.

32 Publication CC-QS015A-EN-P - November 2009

As the load leaves S2, muting ends.

4. Press the E-stop.

The screen updates in response.

System Validation and Application Tips Chapter 2

5. Press MORE INFO.

6. Press RETURN.

7. Twist and release the E-stop.

8. Press START RESET for three seconds

and release.

The system starts to run and guarded
motion begins.

Publication CC-QS015A-EN-P - November 2009 33

Chapter 2 System Validation and Application Tips

9. While avoiding the sensors, interrupt

the light curtain and keep it interrupted.

10. Press MORE INFO.

11. Press RETURN.

12. Remove the object interrupting the light

curtain.

Once the light curtain is no longer
interrupted, the display returns to the
Ready for START RESET screen.

13. Press START RESET for three seconds

and release.

14. Move a load in front of S1 and S2, but

do not interrupt the light curtain.

15. Leave the load where it is.

34 Publication CC-QS015A-EN-P - November 2009

After the configured t(espe), the time it
should take a load to travel between S2
and the light curtain, the muting lamp
begins to blink. The screen reflects the
muting error.

16. Press MORE INFO.

17. Press RETURN.

18. Move the load until it interrupts the

light curtain.

System Validation and Application Tips Chapter 2

19. Leave the load in the light curtain

sensing field.

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Chapter 2 System Validation and Application Tips

20. Press MORE INFO.

21. Press RETURN.

22. Press START RESET for three seconds

and release.

The load is still interrupting the light
curtain. Pressing and releasing START
RESET initiated a Mute Dependent
Override, t(mdo). The system switches
to muted operation. Muting ends as
soon as the load clears the light curtain
or when the configured t(mdo) expires.

TIP

When the START RESET button is green, it may be used in place of the Start Reset push button. If
requirements dictate that remote reset must not be used, do not use it. If the operator stationed at
the PanelView terminal’s location cannot see the guarded area well enough to be certain that no
one is in the guarded area, you must not use the START RESET button.

The START RESET button can be disabled by removing three wires from the MicroLogix controller
I/O.

• Wire 6041

• Wire 10231

• Wire 10071

23. Carefully disconnect then reconnect

one of the light curtain cables from the
MSR42 relay at its RJ45 socket.

36 Publication CC-QS015A-EN-P - November 2009

24. Press MORE INFO.

25. Press RETURN.

26. Press and hold START RESET for 10

seconds.

System Validation and Application Tips Chapter 2

Publication CC-QS015A-EN-P - November 2009 37

Chapter 2 System Validation and Application Tips

Notes:

38 Publication CC-QS015A-EN-P - November 2009

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If you experience an anomoly within the first 24 hours of installation, review the inform ation that's contained in this manual.
You can contact Customer Support for initial help in getting your product up and running.

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Publication CC-QS015A-EN-P - November 2009 40

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