MSR300 Safety System Manual Instruction Manual MSR300 Modular Safety Control System Summarized Table of Contents Topic Page - Detailed Table of Contents 2 1 Important User Information 4 2 About This Manual 6 3 MSR300 System: Product and Applications Overview 8 4 MSR300 Modules: Details 20 5 Special Functions: Robot Safety and Combination Logic 41 6 Faults / Errors: Detection and Response 49 7 Installation, Start-Up, Operation, Maintenance 52 8 Application Examples 59 9 Seria
MSR300 Safety System Manual Detailed Table of Contents 1 Important User Information 1.1 Intended Product Applications 1.2 Authorized Personnel 1.3 General Safety Precautions 1.4 Product Warranty and Disclaimer 1.5 Technical Support 2 About This Manual 2.1 Content Guidance 2.2 Annotation Symbols 2.3 Document Disclaimer 3 MSR300 System: Product and Applications Overview 3.1 Safety Standards and Safety Relay Functions 3.1.1 Safety Standards 3.1.1.1 EN 954 - 1 3.1.1.2 EN 61508 3.1.
MSR300 Safety System Manual 4.2 MSR320 Input Module 4.2.1 Terminals 4.2.2 LED Indicators 4.2.3 Settings and Wiring 4.2.3.1 1-Channel Emergency Stop 4.2.3.2 2-Channel Emergency Stop 4.2.3.3 3-Channel Emergency Stop 4.2.3.4 Safety Mats 4.2.3.5 Safety Gate 4.2.3.6 Light Curtain 4.2.3.7 Two-hand Control 4.2.3.8 2-Channel Emergency Stop and Light Curtain 4.2.3.9 Safety Gate and Light Curtain 4.3 MSR330 Output Module 4.3.1 Terminals 4.3.2 LED Indicators 4.4 MSR329 Muting Lamp Module 4.4.1 Terminals 4.4.
MSR300 Safety System Manual 1 Annexure: Product Warranty and Disclaimer User Information The meanings of the following words used in this document should be understood: "Standard" can mean a named / numbered industry standard, EU / IEC directive, technical statute or regulation. "Product" can refer to an MSR300 System consisting of a combination of MSR300 Series Modules or any one of these modules. 1.
MSR300 Safety System Manual Rockwell Automation MSR300 Manual.
MSR300 Safety System Manual 1.3 General Safety Precautions This product, the equipment on which it installed, persons handling the product and equipment, and/or the immediate environment can be harmed if this equipment is operated outside the specified limits of any of its technical parameters. Observe all electrical safety regulations stipulated by the appropriate technical authorities.
MSR300 Safety System Manual 2 About This Manual This manual contains detailed information about the product, and instructions for its installation, operation and maintenance. Operators and other technical personnel responsible for the equipment must read this manual thoroughly before attempting to install or operate this equipment. The latest version of this manual must be readily available with personnel involved installation, operation or replacement of this product.
MSR300 Safety System Manual Chapter 9 has detailed information about the serial data communication protocols. 2.
MSR300 Safety System Manual 3 MSR300 System: Product and Applications Overview 3.1 Safety Standards and Safety Relay Functions Note: In this document, the word "standard" can mean a defined industry standard, EU directive, technical statute or regulation. The safety standards relevant to this product and its application are outlined in brief in Section 3.1.2 below.
MSR300 Safety System Manual 3.1.1 Safety Standards MSR300 Series Modules conform to the Essential Health & Safety Requirements (EHSR's) of the European Machinery Directive (98/37/EC), the relevant requirements of the Low Voltage Directive (73/23/EEC as amended by 93/68 EEC) and the essential protection requirements of the EMC Directive (89/336/EEC as amended by 92/31 EEC). The MSR310P also conforms to EN 292, EN 60204-1, EN61508, EN 954-1, and UL 508. 3.1.1.
MSR300 Safety System Manual the system is. SILs are correlated to the probability of failure of demand (PFD), which is equivalent to the unavailability of a system at the time of a process demand. IEC/EN 61508 is approximately equivalent to ANSI/ISA-S84.0: Application of Safety Instrumented Systems for the Process Industries," Instrument Society of America Standards and Practices, 1996.
MSR300 Safety System Manual 3.1.2 MSR300 Safety Relay Functions MSR300 Systems can be used for various safety relay functions outlined below, when appropriately configured for the respective function. Simultaneity monitoring (sometimes referred to as synchronization monitoring or coincidence gating) is often necessary for many of these safety applications.
MSR300 Safety System Manual 3.1.2.6 • • Two-Hand Control Two-hand control type IIIC (EN 574) Simultaneity detection: 0.5 seconds limit. The two-hand control function ensures that operators keep their hands clear of a hazardous area of a machine. It is meant for use with machines such as mechanical and hydraulic presses. A machine cycle can only be initiated by pressing two momentary pushbutton switches simultaneously. Switches must fulfill the requirements of EN574 type IIIC.
MSR300 Safety System Manual Muting lamps are deployed to indicate that muting is existent. Special safety controls are necessary to ensure that muting lamps operate correctly and safely. The MSR329 Muting Lamp Controller is expressly designed for this purpose. Details of this module are given later in this document. 3.
MSR300 Safety System Manual Unintended modifications to MSR300 Systems are prevented by design. The system configuration is automatically checked when it is first started up, and this information is stored in non-volatile memory (EEPROM) in the Base Module. Whenever the system is started up (or restarted) thereafter, the current system configuration is checked against the stored configuration.
MSR300 Safety System Manual Rotary switches on the side of the MSR320 Input Module are used to set the assignment of inputs to specific output switching groups: each group has a designated Output Module (Output Groups 1, 2 and 3). MSR330 Output Module: Functions: Safety contact outputs. Outputs: Each module: 3 x N/C outputs plus 1 x N/O safety contact outputs. System maximum: 3 x 6 = 18 N/C plus 1 x 6 = 6 N/O auxiliary contacts.
MSR300 Safety System Manual 3.4 MSR300 Modules: Specifications 3.4.1 MSR310 Specifications Standards IEC/EN60204-1, ISOTR12100, ISO13849-1 Approvals CE marked for all applicable directives Power supply Nominal: 24 VDC. Range: 0.8 to 1.
MSR300 Safety System Manual 3.4.2 MSR320 Specifications Standards IEC/EN60204-1, ISOTR12100, ISO13849-1 Approvals CE marked for all applicable directives Power supply Nominal: 24 VDC. Range: 0.8 to 1.1 x rated voltage Power consumption approx. 3W Safety inputs 1 N/C, 2 N/C, 3 N/C, safety mat, light curtain, N/C-N/O, twohand control Solid-state switch output rating 24 VDC (nominal); 20 mA; short-circuit protected Input simultaneity detection 3 secs.
MSR300 Safety System Manual 3.4.3 MSR330 Specifications Standards IEC/EN60204-1, ISOTR12100, ISO13849-1 Approvals CE marked for all applicable directives Power supply 24 VDC from the MSR310 Base Module Power consumption 1.5 W Output fuses (external) 6 A slow blow, or 10 A quick blow. Safety outputs 3 x N/O plus 1 x N/O (safety contacts) Safety contact rating B300, AC-15, 6A / 250 VAC DC-13, 3A / 24 VDC Thermal Current rating 2x6A or 3x5A Min.
MSR300 Safety System Manual 3.4.4 MSR329 Specifications Standards IEC/EN60204-1, ISOTR12100, ISO13849-1 Approvals CE marked for all applicable directives Power supply Nominal: 24 VDC. Range: 0.8 to 1.
MSR300 Safety System Manual 4 MSR300 Modules: Details 4.1 MSR310 Base Module MSR310 Front View MSR310 Internal Block Schematic Diagram Functions: System control, safety and auxiliary output contacts, supervision of bus-connected input and output modules. Auxiliary outputs: 3 solid-state switch outputs for signaling the states of output groups. Serial data interface: two RS232 ports (bi-directional and uni-directional). Selectable start mode: Monitored (manual) or automatic.
MSR300 Safety System Manual Y40, Y41, Y42 Reset configuration S34 Start button Y31 – Y33 Solid-state auxiliary outputs for groups 1, 2 and 3 Y10 +24V for reset circuit and feedback loops Y11 – Y13 Feedback loop inputs for Groups 1, 2 and 3 4.1.
MSR300 Safety System Manual 4.1.3 Settings, Connections, Start-Up Reset mode selection (reset switch connection and jumper settings): Reset button has to be installed at a place where the dangerous area can be visual monitored.
MSR300 Safety System Manual 4.1.4 Auxiliary Outputs (Solid-State Switches) The MSR310 Base Module has three LEDs and three auxiliary (solid-state switch) outputs that indicate the states of the three Output Groups, respectively. Condition Group 1 active Group 1 inactive Group 2 active Group 2 inactive Group 3 active Group 3 inactive Y31 24V 0V --------- Y32 ----24V 0V ----- Y33 --------24V 0V Wiring These outputs are short-circuit protected. Current limit: 50 mA. Rockwell Automation MSR300 Manual.
MSR300 Safety System Manual 4.1.5 Output Groups Feedback Every output group has its own feedback loop. This loop has to be closed for each group before the respective group can be activated. Function Wiring External device for Group 1 External device for Group 2 External device for Group 3 No external device connected for Group 1 No external device connected for Group 2 No external device connected for Group 3 Rockwell Automation MSR300 Manual.
MSR300 Safety System Manual 4.1.6 Input Fault Logging If inputs are wired for simultaneity monitoring, the following events are registered as faults and stored in EEPROM: • Simultaneity time limit is exceeded. • Not all channels change state as required if input is cycled • The reset switch is closed while not all channels of at least one input are in the correct state for either “on” or “off”. The faults can be cleared by opening and closing the circuits of all channels of one input simultaneously.
MSR300 Safety System Manual 4.2 MSR320 Input Module MSR320 Front View Functions: MSR320 Rotary Switches & Settings (Located on right side of the module) Processing inputs from various safety sensing devices. Assignment of sensing inputs to output switching groups by means of redundant rotary coded switches: one set selects the input function, the other set selects the output group. 2 inputs for single-, dual- or three-channel activation.
MSR300 Safety System Manual An MSR320 Input Module can be set up for any one of the following safety functions: • • • • • • • • • • Logic function (Group3 = Input1 OR Input2 OR Group1) 1-channel emergency stop 2- channel emergency stop or 4-wire safety mat 3- channel emergency stop Safety gate (N/O, N/C) with start-up test Safety gate (N/O, N/C) without start-up test Light curtains: both inputs Two-hand operation Input 1 = 2-channel emergency stop; Input 2 = Light curtain Input 1 = Safety gate without star
MSR300 Safety System Manual Selecting output groups: Switch Function settings 0 OR logic function (*1) (Group 3 = Input 1 OR Input 2 OR Group 1) 1 Group 1 (*²) 2 Group 2 3 Group 1 + 2 4 Group 3 5 Group 1 + 3 6 Group 2 + 3 7 Group 1 + 2 + 3 8 Robot function (incl.
MSR300 Safety System Manual LED indication of Output Group assignment: The Input Module has three LEDs for indicating its assigned Output Group Module. The Input Module has two additional LEDs that give diagnostic information as follows: States 1 2 3 4 5 6 7 8 Function Input 1 valid Input 1 invalid Input 1 switch faulty Input 2 valid Input 2 invalid Input 2 switch faulty Detected configuration does not match that stored in the EEPROM Redundant rotary switches are not set identically.
MSR300 Safety System Manual For following 2- and 3 channel E-stop examples fault exclusion between wiring both e-stop circuits (Input1 and Input2). 4.2.3.
MSR300 Safety System Manual 4.2.3.3 3-Channel Emergency Stop Switch setting: 3 Without simultaneity monitoring. Input 1 Input 2 S11-S12: N/C S21-S22: N/C S31-S32: N/C S11-S42: N/C S21-S52: N/C S31-S62: N/C Solid-state auxiliary output: Input 1 Not available With simultaneity monitoring (3 second limit). Input 1 Input 2 Solid-state auxiliary output: Input 1 S11-S22: N/C S11-S52: N/C Not available S21-S12: N/C S21-S42: N/C S31-S32: N/C S31-S62: N/C 4.2.3.
MSR300 Safety System Manual 4.2.3.5 Safety Gate Switch setting: 4 or 5 Without simultaneity monitoring. Input 1 Input 2 Solid-state auxiliary output: Input 1 S32 Solid-state auxiliary output: Input 2 S62 With simultaneity monitoring (3 second limit). Input 1 Input 2 Solid-state auxiliary output: Input 1 S21-S12: N/C S21-S42: N/C S32 S21-S22: N/O S21-S52: N/O Solid-state auxiliary output: Input 2 S62 S11-S12: N/C S11-S22: N/O Rockwell Automation S11-S42: N/C S11-S52: N/O MSR300 Manual.
MSR300 Safety System Manual 4.2.3.6 Light Curtain Switch setting: 6 Without simultaneity monitoring. Input 1 Input 2 Solid-state auxiliary output: Input 1 S32 Solid-state auxiliary output: Input 2 S62 With simultaneity monitoring (0.5 second limit). Input 1 Input 2 Solid-state auxiliary output: Input 1 S11-S12: N/C S21-S42: N/C S32 S11-S22: N/O S21-S52: N/O Solid-state auxiliary output: Input 2 S62 OSSD1-S12 OSSD2-S22 4.2.3.
MSR300 Safety System Manual 4.2.3.8 2-Channel Emergency Stop and Light Curtain Switch setting: 8 Without simultaneity monitoring of Input 1 and Input 2.
MSR300 Safety System Manual 4.2.3.9 Safety Gate and Light Curtain Switch setting: 9 Without simultaneity monitoring of Input 1 and Input 2. Input 1 Input 2 Solid-state auxiliary output: Input 1 S11-S12: N/C OSSD1-S42 S32 S11-S22: N/O OSSD2-S52 Solid-state auxiliary output: Input 2 S62 With simultaneity monitoring (3 second limit) of Input 1 and without simultaneity monitoring of Input 2.
MSR300 Safety System Manual 4.3 MSR330 Output Module 13 23 33 41 13 23 33 41 13 23 33 41 Group 1 Group 2 Group 3 14 24 34 42 14 24 34 42 14 24 34 42 MSR330 Modules: Group 1, Group 2, Group 3 Functions: Outputs: Safety contact outputs. Each module: 3 x N/C outputs plus 1 x N/O safety contact outputs. System maximum: 3 x 6 = 18 N/C plus 1 x 6 = 6 N/O auxiliary contacts. A minimum of one up to a maximum of six Output Modules can be included in a single MSR300 System.
MSR300 Safety System Manual 4.3.2 LED Indicators Function / Diagnostics Relay 1 on Relay 1 off Relay 2 on Relay 2 off 4.4 Ch 1 Green Off - Ch 2 Green Off MSR329 Muting Lamp Module MSR329 Front View Functions: Capacity: MSR329 Connections Connection and control of muting lamps. Two main muting lamps plus two reserve muting lamps Muting is the safe, automatic and temporary suspension of an electrosensitive protective device, in accordance with EN 61496-1 A.7.
MSR300 Safety System Manual ignored, -A kind of muting control is implemented in an MSR300 System as part of the robot safety control function. In this special application safety cam-switches or sensors at the robot shaft initiate the muting process. These provide area position feedback to the MSR300 system in order to ignore e.g. safety light curtains as long as the robot arm is not working in the near of the light curtain protected area. Muting lamps are deployed to indicate the occurrence of muting.
MSR300 Safety System Manual 4.4.2 LED Indicators Function / Diagnostics Muting lamp 1 off Muting lamp 1 on Muting lamp 1 faulty, but reserve lamp 1 OK Muting lamp 1 and reserve lamp 1 faulty Muting lamp 2 off Muting lamp Muting lamp 2 faulty, but reserve lamp 2 OK Muting lamp 2 and reserve lamp 2 faulty Rockwell Automation H1 Off Green Red Flashes red --------- MSR300 Manual.
MSR300 Safety System Manual 5 Special Functions: Robot Safety and Combination Logic 5.1 Robot Safety Control 5.1.1 General Robot safety control is a special function for which an MSR300 System can be set up. This function makes it possible to continuously verify that a robot arm is always within its specified safe operating zone, typically demarcated by light curtain type safety sensors in combination with special cam-switches fitted on robot rotating turrets or arms.
MSR300 Safety System Manual Definitions: Input danger zone: 0: robot is in danger zone 1: robot is not in danger zone Input status of groups: 0: output inactive 1: output active Muting lamp: 0: lamp off 1: lamp on Implementation of an MSR300 System for robot safety control is subject to the following system configuration rules: • One MSR300 System cannot have more than one Robot Module (Input Module set up for robot function).
MSR300 Safety System Manual • • One MSR300 System cannot have more than one Additional Safe Area Module (Input Module set up for additional safe area function). An MSR300 System cannot have an Additional Safe Area Module (Input Module set up for additional safe are function) and a Logic Module (Input Module set up for logic function): i.e., the system can have either one or the other type of module, not both.
MSR300 Safety System Manual 5.2 Special Logic Functions An MSR300 System can be configured for applying OR logic to a combination of inputs of one or more Input Modules. This allows e.g. limited access to dangerous areas by use of 3-position enabling switches or enabling pendants (see application examples below).
MSR300 Safety System Manual Example 1 Door closed > = & Pendant enable Hydraulic power Hydraulic power Group 3 2-channel Logic function: Group 1: Group 3: Rockwell Automation Door closed Group 1 Safety gate Output Group 3 Pendant enable Logic function 2-channel Switch setting: 0 Switch setting: 3 Switch setting: 4 MSR300 Manual.
MSR300 Safety System Manual Example 2 Door closed & Light curtain clear Group1 > = Pendant enable CNC E-stop & & CNC E-stop Group2 + 3 2-channel Rockwell Automation Door closed Group 1 + 2 Safety gate Output Group3 Output Group2 Pendant enable Logic function 2-channel Light curtain Group 1 2-channel MSR300 Manual.
MSR300 Safety System Manual Example 3 Pendant enable 1 Door closed & Light curtain clear > = & Pendant enable 2 CNC E-stop Output Group 3 & CNC E-stop Group2 + 3 2-channel Rockwell Automation Door closed Group 1 + 2 Safety gate Output Group 2 Pendant enable Logic function 2-channel Light curtain Group 1 2-channel MSR300 Manual.
MSR300 Safety System Manual Example 4 (Zoning application without OR-logic function) Front gate & CNC E-stop Door closed Light curtain clear Output Group 1 & Output Group 2 CNC E-stop Group 1 + 2 2-channel Rockwell Automation Door closed Group 1 + 2 Safety gate Front gate Group 1 Safety gate Light curtain Group 1 2-channel MSR300 Manual.
MSR300 Safety System Manual 6 Faults Detection and Response [Note: In the following part of this document, "fault" can mean the occurrence of an internal failure or defect, an external wiring or signal error, or a system configuration error]. The MSR300 System has extensive error detection capabilities. Faults, symptoms and corrective action are categorized and described below. 6.1 Major Faults Major faults are indicated by the "Status" LED lighting up red continuously.
MSR300 Safety System Manual 6.2 Recoverable Faults During Start-Up or Operation Recoverable faults are also indicated by the "Status" LED, but by different flashing patterns. The various recoverable faults and their corresponding LED flashing patterns are described below. Note: Shut down power before corrective action (except Input switch fault). After modification of configuration the set-up procedure as described in the next chapter is required.
MSR300 Safety System Manual 6.3 Recoverable Configuration Faults During Start-Up or Operation Recoverable configuration faults are also indicated by the "Status" LED, but by different flashing patterns. The various configuration faults and their corresponding LED flashing patterns are described below. Note: Shut down power before corrective action. After modification of configuration the set-up procedure as described in the next chapter is required.
MSR300 Safety System Manual 7 Installation, Start-Up, Operation, Maintenance 7.1 Safety Precautions and Practices Use this product only for intended applications: The MSR300 Safety System is intended for applications requiring safety monitoring of machinery in accordance with the following directives / standards: • EN954-1: Safety-Related Parts Of Control Systems. • IEC 61508: Functional Safety of Electrical / Electronic / Programmable Electronic Safety-Related Systems, Parts 1-7, 1998.
MSR300 Safety System Manual Observe electrical safety regulations and good practices: Electrical safety regulations stipulated by the appropriate technical authorities must be observed. Do not use if the product is damaged or diminished in any way: Carefully inspect each module before it is installed (or re-installed).
MSR300 Safety System Manual 7.2 Installation 7.2.1 Environmental Considerations MSR300 Series Modules must be installed inside protected control panels / cabinets appropriate for the environmental conditions of the industrial location. The protection class of the panel / cabinet should preferably be IP 54 or higher.
MSR300 Safety System Manual 7.2.2 Mechanical Dimensions: Side view and dimensions: all MSR300 Modules Modules widths: MSR310 = 35 mm / 1.78 in. MSR320 = 17.5 mm / 0.69 in. MSR329 = 17.5 mm / 0.69 in. MSR330 = 22.5 mm / 0.89 in. Spacing: Adequate air space must be provided around the system (modules cluster).
MSR300 Safety System Manual Vibration and mechanical shock: The MSR300 modules must not be subjected to vibration or mechanical in excess of the specified limits (in accordance with IEC 68 part: 2-6/7): Vibration: 10 – 55 Hz, 0.35 mm Mechanical shock: 10g, 16 msec, 100 shocks 7.2.
MSR300 Safety System Manual 7.3 Set-Up After the MSR300 System has been assembled, it must be programmed with information about the system modules configuration. This data is stored in non-volatile memory and compared with the configuration detected each time the system is switched on. Any difference between the freshly detected configuration and the programmed configuration is interpreted as an error condition. This prevents unintentional modifications in the system configuration.
MSR300 Safety System Manual 7.4 Operation Once an MSR300 System is correctly set up, it starts and operates automatically in accordance with the settings done: it needs no operator attention or action during its normal operation 7.5 Maintenance An MSR300 System that is correctly configured, set up and installed is inherently maintenance-free.
MSR300 Safety System Manual 8 Application Examples Some application examples are presented in this chapter to assist the understanding and usage of this product. The over-all safety system, external devices, and external electrical circuits will have to designed / selected / configured depending on the unique requirements of each application. Application Example 1 MSR 300 system with various Inputs, two output groups with common monitored reset, Group 1 with monitored contactors.
MSR300 Safety System Manual Robot Cell, 2 areas (Input 1 OR Group 1) AND (Input 2 OR Group 2) = Group 3 (muting with cross control) Muting lamp 1 Muting lamp 2 0° On Off Restricted space 270° Station 90° Station Danger zone 2 90° area Danger zone 1 270° area Gat e interlock Input 1 ”1” Input 2 ”0” 90O Input 1 Danger zone 1 270° area Input Status Group 1 270° station Input 2 Danger zone 2 90° area Input Status Group 2 90° station Output Group 3 >Robot Muting Lamp 1 270° station Muting Lam
MSR300 Safety System Manual Robot Cell, 2 areas (Input 1 OR Group 1) AND (Input 2 OR Group 2) = Group 3 (muting with cross control) Muting lamp 1 Off Muting lamp 2 0° On Restricted space 270° Station Muting 90° Station Danger zone 2 90° area Danger zone 1 270° area Gate interlock Input 1 ”0” Input 2 ”1” 270O Input 1 Danger zone 1 270° area Input Status Group 1 270° station Input 2 Danger zone 2 90° area Input Status Group 2 90° station Output Group 3 >Robot Muting Lamp 1 270° station Muti
MSR300 Safety System Manual Robot Cell, 2 areas (Input 1 OR Group 1) AND (Input 2 OR Group 2) = Group 3 (muting with cross control) Muting lamp 1 Muting lamp 2 0° Off On Restricted space Muting 270° Station 90° Station Danger zone 2 90° area Danger zone 1 270° area Input 1 ”1” Input 2 ”0” 90 O Input 1 Danger zone 1 270° area Input Status Group 1 270° station Input 2 Danger zone 2 90° area Input Status Group 2 90° station Output Group 3 >Robot Muting Lamp 1 270° station Muting Lamp 2 90°
MSR300 Safety System Manual Robot Cell, 2 areas (Input 1 OR Group 1) AND (Input 2 OR Group 2) = Group 3 (muting with cross control) Muting lamp 1 Off Muting lamp 2 0° On Restricted space No muting 270° Station 90° Station Danger zone 2 90° area Danger zone 1 270° area Input 1 ”0” Input 2 ”1” 270O Input 1 Danger zone 1 270° area Input Status Group 1 270° station Input 2 Danger zone 2 90° area Input Status Group 2 90° station Output Group 3 >Robot Muting Lamp 1 270° station Muting Lamp 2 90°
MSR300 Safety System Manual Robot Cell, 2 areas (Input 1 OR Group 1) AND (Input 2 OR Group 2) = Group 3 (muting with cross control) Muting lamp 1 Muting lamp 2 0° Off On Restricted space 270° Station 90° Station No muting Danger zone 2 90° area Danger zone 1 270° area Input 1 ”1” Input 2 ”0” 90 O Input 1 Danger zone 1 270° area Input Status Group 1 270° station Input 2 Danger zone 2 90° area Input Status Group 2 90° station Output Group 3 >Robot Muting Lamp 1 270° station Muting Lamp 2
MSR300 Safety System Manual Robot cell, 2 areas Modules and I/O configuration MSR300 System configuration: MSR310 Base Module – 1 MSR320 Input Modules – 3 MSR330 Output Module – 1 MSR329 Muting Lamp Module – 1 I/O: Input 2 ”0” Input 1 ”1” 90 O Input 2 ”1” Input 1 ”0” A, I = Light curtain inputs C, H = Safety mat inputs D, F = Robot cam switch inputs B, G = Muting lamp control E = Robot run/stop output 270O Input 2 ”1” Input 1 ”1” O 0 Base Cam Switches in various Robot Arm Positions Rockwell A
MSR300 Safety System Manual Robot Cell 3 Areas Muting lamp On Pos 2 Restricted space Pos 1 Danger zone 2 90° area Danger zone 1 270° area Light curtain muted Input 1 270°area Status Group 1 Inpur 2 90° area Status Group 2 Add.
MSR300 Safety System Manual Robot cell 3 areas Modules and I/O configuration Muting lamp On Muting lamp 0 degrees Additional safe area Operator Load Station 1 Light curtain muted Operator Load Station 2 Light curtain active Restricted space Restricted space F G 270° A 90° B C E D H I J 13 Input MSR320P MSR320P 1 2 1 2 1 Input 1 2 3 H11 H21 H12 H22 Gr Input 2 S42 S52 S62 Input 1 2 3 Gr Input 2 S42 S52 S62 1 2 Input 3 Gr Input 2 S42 S52 S62 2 Input 1 2 3 2 MSR320P 1
MSR300 Safety System Manual Robot cell, 3 areas Modules and I/O configuration: external device linkages Module Configuration Muting Lamp Control = 2 Lamps + 2 Reserve Lamps Input Module 1 = Group selection 1, Function 8 Input Module 2 = Group selection 2, Function 8 Input Module 3 = Group selection 8, Function 5 Input Module 4 = Group selection 9, Function 5 Base Module = Y40-S34 linked: Auto reset Output Module = Group 3 Type MSR 300 three-zone Robot Cell application allowing safe m
MSR300 Safety System Manual 9 Serial Data Communication: Details The MSR310 is equipped with two RS232 serial data interfaces: one can be used in bidirectional, the other in uni-directional mode. 9.1 Serial Data Interface Connections The serial interface connections are illustrated below. TxD1 RxD1 GND TxD2 GND RS-232 Bidirectional 9.
MSR300 Safety System Manual Read Multiple Registers (0x03) Query: Fieldname Slave Address Function Code Start Address (High byte) Start Address (Low byte) Number of registers (High byte) Number of registers (Low byte) CRC (High byte) CRC (Low byte) Example 0x01 0x03 0x00 0x02 0x00 0x02 0x65 0xCB Response: Fieldname Slave Address Function Code Byte Count Data (High byte) Data (Low byte) Data (High Byte) Data (Low Byte) CRC (High byte) CRC (Low byte) Example 0x01 0x03 0x04 0x1F 0x70 0xC0 0x04 0xAD 0xFF Er
MSR300 Safety System Manual Write Single Registers (0x06) Query: Fieldname Slave Address Function Code Start Address (High byte) Start Address (Low byte) Data (High byte) Data (Low byte) CRC (High byte) CRC (Low byte) Example 0x01 0x06 0x00 0x03 0x00 0x02 0xF8 0x0B Response: Fieldname Slave Address Function Code Start Address (High byte) Start Address (Low byte) Data (High Byte) Data (Low Byte) CRC (High byte) CRC (Low byte) Example 0x01 0x03 0x00 0x03 0x00 0x02 0x34 0x0B Error Response: Fieldname Slave
MSR300 Safety System Manual 9.2.
MSR300 Safety System Manual Low Byte: Bit Function 7 Fault 6 Cross loop 5 Group 3 interrupted 4 Group 2 interrupted 3 Group 1 interrupted 2 Group 3 EDM Loop closed 1 Group 2 EDM Loop closed 0 Group 1 EDM Loop closed Input status 1 (Parameter 2: states of safety inputs) High Byte: Bit Function 7 Extension module 8 Input 2 interrupted 6 Extension module 8 Input 1 interrupted 5 Extension module 7 Input 2 interrupted 4 Extension module 7 Input 1 interrupted 3 Extension module 6 Input 2 interrupted 2 Extension m
MSR300 Safety System Manual Low Byte: Bit Function 7 Reserved 6 Fault: Different switch settings of input modules between the two channels 5 Fault: Invalid configuration of extension modules 4 Fault: Reserve Muting lamp 2 3 Fault: Muting lamp 2 2 Fault: Reserve Muting lamp 1 1 Fault: Muting lamp 1 0 Fault: at least one Input (lock-out-release, no synchrony activity) Configuration status (Parameters 4 ... 13: current configuration of Extension modules 1...
MSR300 Safety System Manual Low Byte: Bit Function 7 Input error monitoring, extension module 4, input 2 6 Input error monitoring, extension module 4, input 1 5 Input error monitoring, extension module 3, input 2 4 Input error monitoring, extension module 3, input 1 3 Input error monitoring, extension module 2, input 2 2 Input error monitoring, extension module 2, input 1 1 Input error monitoring, extension module 1, input 2 0 Input error monitoring, extension module 1, input 1 Configuration status (Paramet
MSR300 Safety System Manual Low Byte Bit Function 7 Faulty input switch, extension module 4, input 2 6 Faulty input switch, extension module 4, input 1 5 Faulty input switch, extension module 3, input 2 4 Faulty input switch, extension module 3, input 1 3 Faulty input switch, extension module 2, input 2 2 Faulty input switch, extension module 2, input 1 1 Faulty input switch, extension module 1, input 2 0 Faulty input switch, extension module 1, input 1 Error status 2 (Parameter 17: input switch faults, ot
MSR300 Safety System Manual 9.2 RS232 Unidirectional Baud rate: 4800 Circle time: 1s Data transmission without query Byte No.
MSR300 Safety System Manual 6 Input status 3 7 Muting lamp status 8 Number of split bytes Split byte CRC (high bytes) CRC (low bytes) Stop byte 9 10 11 12 Rockwell Automation Bit 7: reserved Bit 6: reserved Bit 5: reserved Bit 4: reserved Bit 3: Extension module 10 Input 2 interrupted Bit 2: Extension module 10 Input 1 interrupted Bit 1: Extension module 9 Input 2 interrupted Bit 0: Extension module 9 Input 1 interrupted Bit 7: reserved Bit 6: reserved Bit 5: reserved Bit 4: Fault: Reserve Muting l
MSR300 Safety System Manual Split bytes: Byte Name No.
MSR300 Safety System Manual 9.3 CRC Generation (Code Examples) CRC Calculation Basics The CRC calculation is started by first preloading a 16-bit register to all 1’s. Then a process begins of applying successive eight-bit bytes of the message to the current contents of the register. During generation of the CRC, each eight-bit character is XORed with the current register contents.
MSR300 Safety System Manual Example 1: The following example calculates the CRC using the method described earlier. Note: This function performs the swapping of the high/low CRC bytes internally. Therefore the CRC value returned from the function can be directly placed into the message for transmission. The function returns the CRC as a type UINT16, and takes two arguments: • UINT8 *pabMessage; A pointer to the message buffer containing binary data to be used for generating the CRC.
MSR300 Safety System Manual Example 2 This example uses another approach to calculate the CRC; All of the possible CRC values are pre-loaded into two arrays, which are simply indexed as the function increments through the message buffer. One array contains all of the 256 possible CRC values for the high byte of the 16-bit CRC field, and the other array contains all of the values for the low byte.
MSR300 Safety System Manual 0x00, 0xC1, 0x81, 0x40, 0x01, 0x00, 0xC1, 0x81, 0x40, 0x01, 0x00, 0xC1, 0x81, 0x40, 0x00, 0x00, 0xC1, 0x81, 0x40, 0x01, 0x00, 0xC1, 0x81, 0x40 }; static UINT8 abCrcLo[] = 0xC0, 0xC0, 0xC1, 0xC0, 0x80, 0x80, 0x81, 0x80, 0x41, 0x41, 0x40, 0x41, 0x00, 0x01, 0x01, 0x01, 0xC1, 0xC0, 0xC0, 0xC0, 0x81, 0x80, 0x80, 0x80, 0x40, 0x41, 0x41, 0x41, 0x00, 0xC0, 0xC1, 0x01, 0xC3, 0x03, 0x05, 0xC5, 0xC4, 0x04, 0xCC, 0x0C, 0x0A, 0xCA, 0xCB, 0x0B, 0xC9, 0x09, 0x1B, 0xDB, 0xDA, 0x1A, 0x1E,
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