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MSR300 Safety System Manual   

 

 
Rockwell Automation  

 

MSR300 Manual.doc 

Pg 1 of 85 

 

 

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 

Serial Data Communication Protocols 

69 

 Annexure 

84 

 
 
 

Summary of Contents for MSR300

Page 1: ...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 Combinati...

Page 2: ...2 EN 61508 3 1 2 MSR300 Safety Relay Functions 3 1 2 1 One Channel Emergency Stop 3 1 2 2 Two Channel Emergency Stop 3 1 2 3 Three Channel Emergency Stop 3 1 2 4 Two Channel Safety Gates 3 1 2 5 Two C...

Page 3: ...Terminals 4 4 2 LED Indicators 5 Special Functions Robot Safety and Combination Logic 5 1 Robot Safety Control 5 1 1 General 5 1 2 Two Areas 5 1 3 Additional Safe Area 5 2 Special Logic Functions 6 F...

Page 4: ...uture expansion and reconfiguration of the safety monitoring and control system The MSR300 Safety System is intended for applications requiring safety monitoring of machinery in accordance with the fo...

Page 5: ...MSR300 Safety System Manual Rockwell Automation MSR300 Manual doc Pg 5 of 85...

Page 6: ...he proper selection and co ordination of the safety controls with the machinery the safety system design and proper installation practices are all necessary to meet the objectives of overall safety Ca...

Page 7: ...hapter 1 contains preliminary user information this must be read and understood before proceeding to Chapters 3 onward Chapter 2 this chapter has information about this manual Sections 2 1 this sectio...

Page 8: ...y damage or economic loss Identifies information that is critical for successful application and understanding of the product Identifies information that could help in completing a task or achieving a...

Page 9: ...ropriate safety standards and good practices The safety functions may not operate properly or at all if this equipment is not used for the intended purposes This product the equipment on which it is i...

Page 10: ...y function If the detection of certain faults is not possible at least during the next check up after the occurrence of the fault for reasons of technology or circuit engineering the occurrence of fur...

Page 11: ...ted subsystems Type B use of programmable complex Components Hardware Fault Tolerance HFT 1 two channel system Safe Failure Fraction SFF 90 to 99 61508 2 table3 Calculations for MSR300 MSR310 Base Mod...

Page 12: ...trical ground or 24V will be detected 3 1 2 2 Two Channel Emergency Stop Safety output contacts are opened if at least one input loop is open Stop category 0 Short circuiting of the input loop to elec...

Page 13: ...the three Output Groups of the system can be configured for one of the following modes Automatic reset The Output Group is active as soon as all input circuits and feedback loop are closed Manual moni...

Page 14: ...gured for the robot function MSR320 and MSR329 Modules are daisy chain connected to the left bus interface connector of the MSR310 Base Module Up to ten MSR 320 Input Modules can be included in an MSR...

Page 15: ...mary Brief descriptions of the MSR300 Series Modules are given in this section followed by the specifications of the modules in tabular format in the next section Details of the Modules are given in C...

Page 16: ...ts System maximum 3 x 6 18 N C plus 1 x 6 6 N O auxiliary contacts A minimum of one and a maximum of six Output Modules can be included in a single MSR300 System MSR330 Output Modules are available in...

Page 17: ...nominal 50 mA short circuit protected Serial data interface RS232 Unidirectional 4800 baud Birectional 2400 4800 9600 or 19200 baud Bus connectors Flat cable type with gold plated pins sockets Power...

Page 18: ...y detection 3 secs or disabled infinite time limit Two Hand Operation Mode 0 5s between both Inputs LED indicators Input status 2 Green input closed Red input open Output switch group assignment 3 Inp...

Page 19: ...expectancy Electrical 220VAC 4A 880VA cos 0 35 100 000 operations 220VAC 1 7A 375VA cos 0 6 500 000 operations 30VDC 2A 60W 1 000 000 operations 10VDC 0 01A 0 1W 2 000 000 operations Mechanical 2 000...

Page 20: ...each Outputs 2 x muting lamps plus 2 x reserve muting lamps LED indicators State of muting lamps Bus connectors Flat cable type with gold plated pins sockets Pollution degree 2 Operating temperature...

Page 21: ...or automatic The MSR310 has independent feedback loops for each output group There are no safety inputs or outputs on this module The MSR310 Base Module has three microprocessors for redundancy and su...

Page 22: ...power up 2 flashes red Configuration change during operation 3 flashes red Current configuration not as stored on EEPROM 4 flashes red At least one muting lamp and one reserve lamp defective 5 flashes...

Page 23: ...the dangerous area can be visual monitored Automatic reset is only allowed if the start of the machine cannot lead to a hazard or a restart interlock must be accomplished by other means of control pe...

Page 24: ...odule has three LEDs and three auxiliary solid state switch outputs that indicate the states of the three Output Groups respectively Condition Y31 Y32 Y33 Group 1 active 24V Group 1 inactive 0V Group...

Page 25: ...ts 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...

Page 26: ...the circuits of all channels of one input simultaneously If the faults are not cleared the MSR310 indicates this on the next power up The faults can even then be cleared by opening and closing the ci...

Page 27: ...tch on off signal input from a light curtain and an on off signal input from safety contacts switch or electromechanical relay input can be given as inputs to the same Input Module Rotary switches on...

Page 28: ...toring The same terminal acts as the third input when an Input Module is configured for 3 channel monitoring 4 2 1 Terminals Name Function S12 Input channel for Input 1 S22 Input channel for Input 1 S...

Page 29: ...3 command if at least one of the conditions occur Input 1 of this Input Module is active OR Input 2 of this Input Module is active OR Group 1 output is active Switch setting 1 Group 1 Output Module is...

Page 30: ...cted configuration does not match that stored in the EEPROM Input 1 LED flashes red alternately with Input 2 LED Input 2 LED flashes red alternately with Input 1 LED 8 Redundant rotary switches are no...

Page 31: ...te auxiliary output Input 2 S11 S12 N C S21 S22 N C S11 S42 N C S21 S52 N C S32 S62 With simultaneity monitoring 3 second time limit to close channels per input Input 1 Input 2 Solid state auxiliary o...

Page 32: ...liary output Input 1 Solid state auxiliary output Input 2 S11 S22 N C S21 S12 N C S31 S32 N C S11 S52 N C S21 S42 N C S31 S62 N C Not available Not available 4 2 3 4 Safety Mats Switch setting 2 Witho...

Page 33: ...itoring Input 1 Input 2 Solid state auxiliary output Input 1 Solid state auxiliary output Input 2 S11 S12 N C S11 S22 N O S11 S42 N C S11 S52 N O S32 S62 With simultaneity monitoring 3 second limit In...

Page 34: ...ut 2 Solid state auxiliary output Input 1 Solid state auxiliary output Input 2 OSSD1 S12 OSSD2 S22 OSSD1 S42 OSSD2 S52 S32 S62 4 2 3 7 Two hand Control Switch setting 7 With simultaneity monitoring 0...

Page 35: ...itoring of Input 1 and Input 2 Input 1 Input 2 Solid state auxiliary output Input 1 Solid state auxiliary output Input 2 S11 S12 N C S21 S22 N C OSSD1 S42 OSSD2 S52 S32 S62 With simultaneity monitorin...

Page 36: ...ary output Input 1 Solid state auxiliary output Input 2 S11 S12 N C S11 S22 N O OSSD1 S42 OSSD2 S52 S32 S62 With simultaneity monitoring 3 second limit of Input 1 and without simultaneity monitoring o...

Page 37: ...up to a maximum of six Output Modules can be included in a single MSR300 System MSR330 Output Modules are available in three distinct versions each specific for one of three output groups i e Group 1...

Page 38: ...muting lamps Capacity 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...

Page 39: ...cally If the defective lamp is replaced the normal muting lamp will light up when the next muting condition occurs and the spare lamp will remain off If a muting lamp and its spare lamp are both defec...

Page 40: ...ion Diagnostics H1 H2 Muting lamp 1 off Off Muting lamp 1 on Green Muting lamp 1 faulty but reserve lamp 1 OK Red Muting lamp 1 and reserve lamp 1 faulty Flashes red Muting lamp 2 off Off Muting lamp...

Page 41: ...be prevented or monitored via safety mats For implementing this function one Input Module has to be set up for robot safety control function by setting its rotary switch to 8 5 1 2 Robot Cell with Tw...

Page 42: ...A robot cell can be safety controlled for an additional safe area by a combination of two Input Modules in an MSR300 System One Input Module is set up for robot safety control function switch setting...

Page 43: ...0 1 1 0 1 1 0 1 0 1 1 1 0 1 0 1 0 1 1 1 1 1 0 1 1 0 0 0 0 0 1 0 1 0 0 0 1 0 1 0 1 0 0 1 0 1 1 0 1 0 0 1 1 1 1 0 1 1 0 0 0 0 1 0 1 1 0 0 1 0 1 0 1 1 0 1 0 1 1 0 1 1 0 1 1 1 1 0 1 0 1 0 0 0 0 0 1 0 1 0...

Page 44: ...bject to the following system configuration rules An MSR300 System cannot have a Muting Module and a Logic Module Input Module set up for logic function i e the system can have either one or the other...

Page 45: ...g 45 of 85 Example 1 Door closed Pendant enable Hydraulic power Output Group 3 Hydraulic power Group 3 2 channel Door closed Group 1 Safety gate Pendant enable Logic function 2 channel Logic function...

Page 46: ...ual doc Pg 46 of 85 Example 2 Door closed Light curtain clear Pendant enable CNC E stop Output Group3 Output Group2 Group1 CNC E stop Group2 3 2 channel Door closed Group 1 2 Safety gate Pendant enabl...

Page 47: ...Pg 47 of 85 Example 3 Door closed Light curtain clear Pendant enable 2 CNC E stop Output Group 3 Output Group 2 Pendant enable 1 CNC E stop Group2 3 2 channel Door closed Group 1 2 Safety gate Pendan...

Page 48: ...of 85 Example 4 Zoning application without OR logic function Door closed Light curtain clear Front gate CNC E stop Output Group 1 Output Group 2 CNC E stop Group 1 2 2 channel Door closed Group 1 2 Sa...

Page 49: ...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 These...

Page 50: ...orrective Action Input switch fault if switch monitoring is enabled Status LED flashes 2 x LED of the faulty input flashes red Unlock the faulty input The reset pushbutton momentary switch is pressed...

Page 51: ...atus LED flashes 6 x Modify modules configuration More than one Robot Module installed in system Status LED flashes 6 x Modify modules configuration More than one Additional Safe Area Module installed...

Page 52: ...rsonnel who have been trained and made familiar with The product s for which this document exists Directives regulations and practices relating to machine safety Instrumentation and automation compone...

Page 53: ...tion is made impossible Examples of such conditions are Visible damage to the equipment Loss of electrical function s Exposure to temperatures higher the specified operating limit Visible indication o...

Page 54: ...nels cabinets appropriate for the environmental conditions of the industrial location The protection class of the panel cabinet should preferably be IP 54 or higher The environmental protection rating...

Page 55: ...ting and removal The modules are mounted on standard DIN 35 mm rails To mount the module first engage its bottom lips with the upper flange of the DIN rail then rotate and press the module down until...

Page 56: ...rough them to the modules particularly the terminals Tighten all terminal screws firmly and re check all after connections have been made Recommended screw tightening torque 0 6 to 0 8 Nm or 5 to 7 lb...

Page 57: ...fault response is immediately generated with appropriate diagnostic indication and output The Base Module is set up in auto detection mode as default If it is powered up the first time it will automat...

Page 58: ...d replaced before attempting to operate the machinery under the control of this safety system It is recommended that the integrity of all electrical connections tightness of terminal screws firm seati...

Page 59: ...ces 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 out...

Page 60: ...90 area 90 Station 90O Input 1 1 Input 2 0 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 Lam...

Page 61: ...ing 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 M...

Page 62: ...Muting 90 Station 90 O Input 1 1 Input 2 0 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 Lam...

Page 63: ...ger 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 station 0 0 1 1 0 0 1...

Page 64: ...ger 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 station 1 1 0 0 0 1 0...

Page 65: ...ation MSR310 Base Module 1 MSR320 Input Modules 3 MSR330 Output Module 1 MSR329 Muting Lamp Module 1 I O A I Light curtain inputs C H Safety mat inputs D F Robot cam switch inputs B G Muting lamp cont...

Page 66: ...Status Group 1 270 station Input 2 Danger Zone 2 90 area Input Status Group 2 90 station Add Safe Area Output Group 3 Robot Muting Lamp1 270 station Muting Lamp2 90 station Pos 1 1 0 0 1 0 1 1 0 Pos 2...

Page 67: ...Input 1 Input 2 Gr 13 23 14 24 MSR330P 1 2 41 33 34 44 Group 3 Channel S12 S22 S32 S42 S52 S62 1 2 3 MSR320P Input 1 2 Input 1 Input 2 Gr S12 S22 S32 S42 S52 S62 1 2 3 MSR320P Input 1 2 Input 1 Input...

Page 68: ...ut 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...

Page 69: ...l 9 2 RS232 Bi directional Bi directional RS232 features automatic baud rate detection and can handle baud rates of 2400 4800 9600 or 19200 baud 9 2 1 Protocol Supported exception codes Code Name Mean...

Page 70: ...f registers High byte 0x00 Number of registers Low byte 0x02 CRC High byte 0x65 CRC Low byte 0xCB Response Fieldname Example Slave Address 0x01 Function Code 0x03 Byte Count 0x04 Data High byte 0x1F D...

Page 71: ...0x03 Data High byte 0x00 Data Low byte 0x02 CRC High byte 0xF8 CRC Low byte 0x0B Response Fieldname Example Slave Address 0x01 Function Code 0x03 Start Address High byte 0x00 Start Address Low byte 0x...

Page 72: ...s 0x0000 0xFFFF 0x0009 11 R Configuration status EM 8 2 bytes 0x0000 0xFFFF 0x000A 12 R Configuration status EM 9 2 bytes 0x0000 0xFFFF 0x000B 13 R Configuration status EM 10 2 bytes 0x0000 0xFFFF 0x0...

Page 73: ...module 6 Input 1 interrupted 1 Extension module 5 Input 2 interrupted 0 Extension module 5 Input 1 interrupted Low Byte Bit Function 7 Extension module 4 Input 2 interrupted 6 Extension module 4 Input...

Page 74: ...2 1 Switch settings of group bit 1 0 Switch settings of group bit 0 Low Byte Bit Function 7 Stored EEPROM settings of function bit 3 6 Stored EEPROM settings of function bit 2 5 Stored EEPROM setting...

Page 75: ...Reserved 5 Reserved 4 Reserved 3 Reserved 2 Reserved 1 Reserved 0 Reserved Low Byte Bit Function 7 Reserved 6 Reserved 5 Reserved 4 Reserved 3 Input error monitoring extension module 10 input 2 2 Inpu...

Page 76: ...witch extension module 10 input 2 6 Faulty input switch extension module 10 input 1 5 Faulty input switch extension module 9 input 2 4 Faulty input switch extension module 9 input 1 3 Internal fault 2...

Page 77: ...DM loop closed Bit 0 Group 1 EDM loop closed 0x00 0xFF 4 Input status 1 Bit 7 Extension module 4 Input 2 interrupted Bit 6 Extension module 4 Input 1 interrupted Bit 5 Extension module 3 Input 2 inter...

Page 78: ...Input 1 interrupted 0x00 0x0F 7 Muting lamp status Bit 7 reserved Bit 6 reserved Bit 5 reserved Bit 4 Fault Reserve Muting lamp 1 Bit 3 Fault Muting lamp 2 Bit 2 Fault Reserve Muting lamp 1 Bit 1 Fau...

Page 79: ...ration 12 EEPROM value extension module 1 13 Configuration 13 EEPROM value extension module 2 14 Configuration 14 EEPROM value extension module 3 15 Configuration 15 EEPROM value extension module 4 16...

Page 80: ...sage After all bytes of the message have been applied the final content of the register is the CRC value Step by Step 1 Load a 16 bit register with 0xFFFF all 1 s Call this the CRC register 2 XOR the...

Page 81: ...essage A pointer to the message buffer containing binary data to be used for generating the CRC UINT16 iLength The quantity of bytes in the message buffer Typedefs UINT8 Unsigned 8 bit e g unsigned ch...

Page 82: ...message buffer Typedefs UINT8 Unsigned 8 bit e g unsigned char UINT16 Unsigned 16 bit e g unsigned short Source Code UINT16 GenerateCrc UINT8 pabMessage UINT16 iLength static UINT8 abCrcHi 0x00 0xC1 0...

Page 83: ...0x3B 0xFB 0x39 0xF9 0xF8 0x38 0x28 0xE8 0xE9 0x29 0xEB 0x2B 0x2A 0xEA 0xEE 0x2E 0x2F 0xEF 0x2D 0xED 0xEC 0x2C 0xE4 0x24 0x25 0xE5 0x27 0xE7 0xE6 0x26 0x22 0xE2 0xE3 0x23 0xE1 0x21 0x20 0xE0 0xA0 0x60...

Page 84: ...Products will be uninterrupted or error free or that the functions contained therein will meet or satisfy Buyer s intended use or requirements c Remedies Remedies under the above warranties will be li...

Page 85: ...cost of the product s giving rise to the claim or liability Seller disclaims all liability relative to gratuitous information or assistance provided by but not required of seller hereunder Any action...

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