Connected Components Building BlocksLight Curtain Muting Control Application Profile

Connected Components Building Blocks Connected Components Building Blocks (CCBB) from Rockwell Automation provide you with the information you need to quickly and easily implement common control tasks in your machine design.

Take advantage of best practice based examples with:Lists of compatible materials•Panel and wiring drawings •Status and diagnostic control programs and HMI screens •Quick start guide •All available on DVD, CC-QR001_-MU-C•

Light Curtain Muting ControlMany machines, for example automatic palletizing machines, have the potential to accidentally injure workers. In most instances these danger points can be protected by hard guarding. But points where materials or products move in or out of the machine must be guarded another way. Muted light curtain systems are often the best choice for guarding such points.

A typical system features photoelectric sensors located in a pattern dictated by the specific application. When triggered in the proper sequence/timing and integrated with a muting safety relay, the sensors automatically prevent the light curtain from stopping the process as the target object passes. Different arrangements of sensors in relation to the light curtain allow different modes of muting operation: single directional, bi-directional or bi-directional with an enable signal. In each case muting is automatically ended as soon as the target object clears the light curtain/last sensor. Any object or person passing the light curtain without triggering the sensors and light curtain in this proper sequence will shut the system down.

Combine the Micro400/MSR42 system with a MicroLogix 1400 controller, and PanelView Component operator interface for a simple and effective safety solution. Increase the safety of your workers, while maintaining production and performance.

Solution Specific AdvantagesQuick and easy implementation and operation of an efficient, •application appropriate muting light curtain system GuardShield Micro400’s compact size makes retrofit into most •existing systems simple with minimal reworkEffective protection for personnel without hindrance to production•

Connected Component Building Blocks provide the overhead so you can concentrate on making your machine the best in the market

POWER

SENSING

OPERATOR INTERFACESAFETY

(if required by risk assessment)

Principle of OperationThe MSR42 Multifunction Safety Module monitors the outputs of the muting sensors and the Micro400 light curtain to automatically provide safe temporary suspension of the safety function (muting) as a target object passes the light curtain. It will trip if a person attempts to pass the light curtain. It is integrated with an E-Stop via an MSR127 Safety Relay to provide a complete safety system. Pushing the E-Stop at any time will shut the machine down. The system can not be reset, in either case, until the hazard is cleared.

Should a target object become stopped, for some reason, while still in the light curtain, pressing and releasing the reset button after confirming no hazard exists, will start the machine long enough for the target object to clear the light curtain and return the safety system to normal operation.

Using different application-related sensor patterns allows the MSR42 Multifunction Safety Module to be configured to provide the muting mode (Single Direction, Bi-Directional or Bi-directional with an Enable Signal) best suited to the efficient, effective operation of that particular application.

The MicroLogix controller monitors signals from the MSR42 and MSR127 and presents system status and, when necessary, diagnostic information on the PanelView Component HMI. In some instances the PanelView Component is mounted such that the operator has a clear view of the area guarded by the muting system. The PanelView Component may even be configured to provide a reset button function.

CONNECTIVITY

LOGIC CONTROL

Pushbutton (800F) • Modular design• Unparalleled flexibility• Unmatched low-voltage switching• Easy installation for time and cost savings

GSEN

Photoelectric Sensor (42EF) • LED indicators• Reverse polarity protection• Short-circuit protected outputs• Fast 1ms response time (DC)• False pulse protection• Designed to withstand the rigors of food processing and material handling environments

Limit Switch (802T) • Slow and Snap action contact operating mechanisms are available• Snap action limit switches are designed to provide high snap- through force once the mechanism has traveled the required distance

Power Supply (1606-XL)• 15W-960W output (@24V DC)• 1, 2 or 3 phase voltage input• Quick-connect spring clamp or screw terminals• Built-in reserve power up of 150% of nominal current

Circuit Breakers (140U)• Compact size, 30% reduction in panel• Field installable accessories while maintaining UL 489• Dual ratings – UL 489, IEC 60947-2

Disconnect (194R)• Panel space savings – smaller footprint• High fault withstanding rating – up to 200kA with UL Class J and CC fuses• Superior short circuit protection – Type 2 coordination

Molded Case Circuit Breakers (140UE)• Field installable accesories while maintaining IEC 60947-2• KEMA-KEUR approval• Multiple levels of interrupting capacity available

Load Switches (194E)• 16...100A• 3 or 6 pole switch conf igurations for OFF-ON or Change-over applications• Front/Door or Base/DIN rail mounting• Wide choice of actuators, all with IP66 protection degree

We o�er products suited for applications around the world. Below are some options:

UL489 Listed Miniature Circuit Breaker (1489)• Rated 0.5 A … 40 A and 480Y/277 VAC, 240 VAC, 48 VDC• 1 pole, 2 pole, 3 pole versions• Bus bars available, 1 phase, 2 phase, 3 phase• Auxiliary contact and shunt trip modules available

IEC Miniature Circuit Breaker (1492-SP)• Rated 0.5 A … 63 A and 240/415 VAC and 48 VDC• 1 pole, 2 pole, 3 pole, 1 pole + N and 3 pole + N versions• Bus bars available, 1 phase, 2 phase, 3 phase, and 4 phase• Auxiliary contact and shunt trip modules available• VDE certification

We o�er products suited for applications around the world. Below are some options:

ptions:

able

Power Distribution Blocks (1492-PDE)• UL recognized, CSA certified, CE compliant• IP20 from the front• Multi-pole assembly possible with easily gangable units• High fault SCCR up to 100 kA

tion Blocks (1492-PDE)

CONNECTIVITY

Limit Switch (802T)• Slow and Snap action contact

operating mechanisms are available• Snap action limit switches are

designed to provide high snap-through force once the mechanismhas traveled the required distance

e

Power Supply (1606-XL• 15W-960W

( V DC)

We o�er products suited for applications around the world. Below are some options:

NECTIVITY

� d i d f li i

Terminal Block (1492-J)• Self-locking screw clamp allows tight connection• Superior jumpering capability• Four-sided funnel wire guides for easy wire installation• Designed for DIN rail mounting with a full range of accessories and specialty blocks

Emergency Stop (800FP-MT)• Trigger action with key release• Push-pull or twist-to-release styles• Illuminated or non-illuminated• Plastic or metal operators available • NC self monitoring contact block

MSR42 Multi-function Safety Relay (440R)• Control module for the GuardShield Micro 400 safety light curtain• Category 4 per EN 954-1• Pair of PNP solid state, 400 mA OSSDs for direct connection to the final switching device• SIL CL3 IEC 61508, IEC 62061- 22.5 mm housing

GuardShield™ Micro 400 Safety Light Curtains (445L)• Pigtail cable with M12 connector • 3 box system with dedicated safety controller • Offered in 14 mm and 30 mm resolutions • Slim profile housing (15 mm x 20 mm)

MSR127 Safety Relay (440R-N23)• Category 4 per EN 954-1• Stop category 0• 3 safety contacts 1 auxiliary contact• Cross fault monitoring• Monitored or automatic reset• Removable terminals• Light curtain, E-stop or safety gate applications

Bulletin 100S-C/104S-C safety contactorsprovide mechanically linked positively guided contacts, required in feedbackcircuits of modern safety applications

Safety Contactor (100S-C/104S-C)

PanelView Component (2711C)• Monitor and setup equipment parameters• Alarm, recipe and security improve diagnostics, reduce errors and protect against unauthorized changes• Web-browser editor reduces number of software tools• Displays ranging from 2” monochrome to 10” color• Serial communication included, Ethernet 10/100 Mbps on 6” and 10”

L)

Bulletin provide guided ccircuits o

M• • • • • • •

equired by risk assessment)

OL

GuardShield™ Micro 400Curtains (445L)• Pigtail cable with M12 c• 3 box system with dedic• Offered in 14 mm and 3• Slim profile housing (15

MicroLogix (1761, 1762, 1763, 1764, 1766)• Five controller versions to choose from• Available communication options include DeviceNet, Ethernet and Serial protocols• High-speed embedded I/O with the flexibility of expansion I/O• Online editing, embedded display and built-in 10/100 Mbps EtherNet/IP on 1100 and 1400

MSR45E Expansion Safety Relays• Category 4 per EN 954-1- SIL CL3 per IEC 61508- Stop category 0 or 1

time and cost savings

SMC-3 Smart Motor Controller (150-C)• 1...480 A range• Delta compatibility• Built-in SCR run/bypass• Built-in electronic motor overload protection

Terminal Block Relay (700-HL)• Designed for a variety of high-density isolation and interposing applications• Slim build of only 14mm wide that meets the demand for panel space-savings• C-UL-US listed relay and socket combinations• 10 Amp Contact Rating

t

g

MSR127 Safety RelayM

LOGIC CONTRO

MSR• Cat 61

Connected Components For Light Curtain Muting Control

Above is a typical representation of the components used in this system solution. Your requirements could vary based on your specific machine needs.

POWER

SENSING

OPERATOR INTERFACESAFETY

(if required by risk assessment)

Principle of OperationThe MSR42 Multifunction Safety Module monitors the outputs of the muting sensors and the Micro400 light curtain to automatically provide safe temporary suspension of the safety function (muting) as a target object passes the light curtain. It will trip if a person attempts to pass the light curtain. It is integrated with an E-Stop via an MSR127 Safety Relay to provide a complete safety system. Pushing the E-Stop at any time will shut the machine down. The system can not be reset, in either case, until the hazard is cleared.

Should a target object become stopped, for some reason, while still in the light curtain, pressing and releasing the reset button after confirming no hazard exists, will start the machine long enough for the target object to clear the light curtain and return the safety system to normal operation.

Using different application-related sensor patterns allows the MSR42 Multifunction Safety Module to be configured to provide the muting mode (Single Direction, Bi-Directional or Bi-directional with an Enable Signal) best suited to the efficient, effective operation of that particular application.

The MicroLogix controller monitors signals from the MSR42 and MSR127 and presents system status and, when necessary, diagnostic information on the PanelView Component HMI. In some instances the PanelView Component is mounted such that the operator has a clear view of the area guarded by the muting system. The PanelView Component may even be configured to provide a reset button function.

CONNECTIVITY

LOGIC CONTROL

Pushbutton (800F) • Modular design• Unparalleled flexibility• Unmatched low-voltage switching• Easy installation for time and cost savings

GSEN

Photoelectric Sensor (42EF) • LED indicators• Reverse polarity protection• Short-circuit protected outputs• Fast 1ms response time (DC)• False pulse protection• Designed to withstand the rigors of food processing and material handling environments

Limit Switch (802T) • Slow and Snap action contact operating mechanisms are available• Snap action limit switches are designed to provide high snap- through force once the mechanism has traveled the required distance

Power Supply (1606-XL)• 15W-960W output (@24V DC)• 1, 2 or 3 phase voltage input• Quick-connect spring clamp or screw terminals• Built-in reserve power up of 150% of nominal current

Circuit Breakers (140U)• Compact size, 30% reduction in panel• Field installable accessories while maintaining UL 489• Dual ratings – UL 489, IEC 60947-2

Disconnect (194R)• Panel space savings – smaller footprint• High fault withstanding rating – up to 200kA with UL Class J and CC fuses• Superior short circuit protection – Type 2 coordination

Molded Case Circuit Breakers (140UE)• Field installable accesories while maintaining IEC 60947-2• KEMA-KEUR approval• Multiple levels of interrupting capacity available

Load Switches (194E)• 16...100A• 3 or 6 pole switch conf igurations for OFF-ON or Change-over applications• Front/Door or Base/DIN rail mounting• Wide choice of actuators, all with IP66 protection degree

We o�er products suited for applications around the world. Below are some options:

UL489 Listed Miniature Circuit Breaker (1489)• Rated 0.5 A … 40 A and 480Y/277 VAC, 240 VAC, 48 VDC• 1 pole, 2 pole, 3 pole versions• Bus bars available, 1 phase, 2 phase, 3 phase• Auxiliary contact and shunt trip modules available

IEC Miniature Circuit Breaker (1492-SP)• Rated 0.5 A … 63 A and 240/415 VAC and 48 VDC• 1 pole, 2 pole, 3 pole, 1 pole + N and 3 pole + N versions• Bus bars available, 1 phase, 2 phase, 3 phase, and 4 phase• Auxiliary contact and shunt trip modules available• VDE certification

We o�er products suited for applications around the world. Below are some options:

ptions:

able

Power Distribution Blocks (1492-PDE)• UL recognized, CSA certified, CE compliant• IP20 from the front• Multi-pole assembly possible with easily gangable units• High fault SCCR up to 100 kA

tion Blocks (1492-PDE)

CONNECTIVITY

Limit Switch (802T)• Slow and Snap action contact

operating mechanisms are available• Snap action limit switches are

designed to provide high snap-through force once the mechanismhas traveled the required distance

e

Power Supply (1606-XL• 15W-960W

( V DC)

We o�er products suited for applications around the world. Below are some options:

NECTIVITY

� d i d f li i

Terminal Block (1492-J)• Self-locking screw clamp allows tight connection• Superior jumpering capability• Four-sided funnel wire guides for easy wire installation• Designed for DIN rail mounting with a full range of accessories and specialty blocks

Emergency Stop (800FP-MT)• Trigger action with key release• Push-pull or twist-to-release styles• Illuminated or non-illuminated• Plastic or metal operators available • NC self monitoring contact block

MSR42 Multi-function Safety Relay (440R)• Control module for the GuardShield Micro 400 safety light curtain• Category 4 per EN 954-1• Pair of PNP solid state, 400 mA OSSDs for direct connection to the final switching device• SIL CL3 IEC 61508, IEC 62061- 22.5 mm housing

GuardShield™ Micro 400 Safety Light Curtains (445L)• Pigtail cable with M12 connector • 3 box system with dedicated safety controller • Offered in 14 mm and 30 mm resolutions • Slim profile housing (15 mm x 20 mm)

MSR127 Safety Relay (440R-N23)• Category 4 per EN 954-1• Stop category 0• 3 safety contacts 1 auxiliary contact• Cross fault monitoring• Monitored or automatic reset• Removable terminals• Light curtain, E-stop or safety gate applications

Bulletin 100S-C/104S-C safety contactorsprovide mechanically linked positively guided contacts, required in feedbackcircuits of modern safety applications

Safety Contactor (100S-C/104S-C)

PanelView Component (2711C)• Monitor and setup equipment parameters• Alarm, recipe and security improve diagnostics, reduce errors and protect against unauthorized changes• Web-browser editor reduces number of software tools• Displays ranging from 2” monochrome to 10” color• Serial communication included, Ethernet 10/100 Mbps on 6” and 10”

L)

Bulletin provide guided ccircuits o

M• • • • • • •

equired by risk assessment)

OL

GuardShield™ Micro 400Curtains (445L)• Pigtail cable with M12 c• 3 box system with dedic• Offered in 14 mm and 3• Slim profile housing (15

MicroLogix (1761, 1762, 1763, 1764, 1766)• Five controller versions to choose from• Available communication options include DeviceNet, Ethernet and Serial protocols• High-speed embedded I/O with the flexibility of expansion I/O• Online editing, embedded display and built-in 10/100 Mbps EtherNet/IP on 1100 and 1400

MSR45E Expansion Safety Relays• Category 4 per EN 954-1- SIL CL3 per IEC 61508- Stop category 0 or 1

time and cost savings

SMC-3 Smart Motor Controller (150-C)• 1...480 A range• Delta compatibility• Built-in SCR run/bypass• Built-in electronic motor overload protection

Terminal Block Relay (700-HL)• Designed for a variety of high-density isolation and interposing applications• Slim build of only 14mm wide that meets the demand for panel space-savings• C-UL-US listed relay and socket combinations• 10 Amp Contact Rating

t

g

MSR127 Safety RelayM

LOGIC CONTRO

MSR• Cat 61

CAD Drawing

Publication CC-AP009A-EN-P – October 2009 Copyright ©2009 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Applications Guarding Palletizer Systems•Guarding Wrapping Systems•Guarding ASRS Pick Up/Drop Off Stations•Guarding Conveyor Pass Through Sections•

Connected Components SolutionThe following sample bill of materials lists core products. For a complete solution bill of materials (includes power circuit components, control circuit components, sensors and pushbuttons) order the Connected Components Building Blocks DVD, CC-QR001_-MU -C.

CCBB Light Curtain Muting Control BasicsQuantity Catalog Number Description

1 1763-L16BBB MicroLogix 1100, 24V DC power, (10) 24V DC digital inputs, (2) 10V analog inputs, (2) relay outputs, (4) 24V DC FET outputs

1 445L-P4E1200FP Micro 400 Safety Light Curtain, Res 30 mm, Pt Ht 1200 mm

1 440R-P226AGS-NNR MSR42 Multi function Controller for GuardShield Light Curtains

1 440R-N23132 Minotaur, MSR127TP, 24V AC/DC, 3 NO + 1 NC, 22.5 mm case

1 2711C-T6C PanelView Component 6" color touchscreen terminal

1 2711P-CBL-EX04 Ethernet CAT5 crossover cable (industrial grade) 4.3 m (14 ft)

1 1606-XLP90E-2 AC/DC DINrail mount compact power supply, standard module 90 W, 2 phase, 480V AC input voltage

1763-NC01 Cable: MicroLogix 1100 Channel 0 (8-pin DIN) to RS-485 (6-pin Phoenix)

CCBB Light Curtain Muting Control Products for ProgrammingQuantity Catalog Number Description

1 9324-RLM0100ENE RSLogix Micro Starter (English) CD-ROM

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