Micronor MR380 Series User manual

MICRONOR INC.
900 Calle Plano, Suite K
Camarillo, CA 93012
USA
Tel [phone]
Fax [phone]
[e-mail]
www.micronor.com
For Support in Europe:
MICRONOR AG
Pumpwerkstrasse 32
CH-8105 Regensdorf
Switzerland
Tel [phone]
Fax [phone]
[e-mail]
www.micronor.ch
Notice of Proprietary Rights
The design concepts and engineering details embodied in this manual, which are the property of
MICRONOR INC., are to be maintained in strict confidence; no element or detail of this manual is to
be spuriously used, nor disclosed, without the express written permission of MICRONOR INC. All
rights are reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, without prior written permission from MICRONOR INC.
© Copyright 2013-2015, Micronor Inc., USA
MR380 Series
Fiber Optic Emergency Stop System
Instruction Manual
Doc No: 98-0380-01
Revision C, Released 10-15-2015

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Revision History
Revision
Date
Notes
A
12/11/2013
Initial release
B
7/13/2015
•Added 50/125 fiber pigtail option
•Controller design upgraded to Universal and will
work with both 50/125 and 62.5/125
multimode fiber
C
10/15/2015
Update with new Camarillo address and tel/fax
numbers

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Table of Contents
1. Product Description ................................................................5
1.1. Fiber Optic Emergency Stop Switch ..................................................................................5
1.2. Fields of Application ...........................................................................................................6
1.3. Features..............................................................................................................................6
2. Standard Contents...................................................................7
3. Installation and Operation ......................................................8
3.1. Mounting the Emergency Switch.......................................................................................8
3.2. Mounting the Controller Module .......................................................................................9
3.3. Connecting the Controller ................................................................................................10
3.4. System Start-Up & Performance Check..........................................................................11
4. Troubleshooting ....................................................................12
4.1. Potential Issues & Solutions............................................................................................12
4.1.1. ‘Power’ not illuminated when controller powered ..................................................12
4.1.2. ‘Emergency ON’ illuminated w/Emergency Switch Connected..............................12
4.1.3. No +24V Digital Out ..................................................................................................12
4.1.4. No +5V Digital Out ....................................................................................................12
4.1.5. Relay Switching Failure.............................................................................................13
4.1.6. Damaged Emergency Switch (Fiber)........................................................................13
4.2. Damaged In Shipment .....................................................................................................14
5. Warranty Information ............................................................15
6. Specifications ........................................................................16
6.1. E-STOP Sensor ..................................................................................................................16
6.2. E-STOP Controller Module................................................................................................18
7. Theory of Operation ..............................................................20
8. Application Notes ..................................................................21
8.1. Determining System Loss Budget For Chaining Multiple Switches ..............................21
9. Mechanical Reference Drawings..........................................23
9.1. MR380-1 Controller .........................................................................................................23
9.2. MR382-2 Sensor ..............................................................................................................23

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Table of Figures
Figure 1. MR380 Series Fiber Optic Emergency Switch & MR380 Series Controller
5
Figure 2. Complete Functional System Overview
......................................................... 6
Figure 3. Panel Cut Out Dimensions and Assembly Hierarchy of Emergency Switch
8
Figure 4. Emergency Switch Orientation when Mounting into Optical Block
.............. 8
Figure 5. DIN Rail Mount
................................................................................................ 9
Figure 6. Mounting Clip Mount
....................................................................................... 9
Figure 7. Front Panel Outputs of MR380-1 Series Controller
....................................10
Figure 8. Properly Functioning Controller with Switch Connected and Not Depressed
11
Figure 9. Properly Powered Controller with Depressed Switch, Broken Fiber Link, or High Loss
................................................................................................................................11
Figure 10. LC Loopback MR380-2,-8 Check
...............................................................13
Figure 11 Block Diagram of Basic Theory of Operation for MR380 Fiber Optic E-STOP
20
Figure 12 Example System Using Three MR380-2 Switches at 500m Length
........21

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1.
Product Description
1.1.
Fiber Optic Emergency Stop Switch
Figure 1. MR380 Series Fiber Optic Emergency Switch & MR380 Series Controller
The MR380-2 Emergency Stop Switch paired with MR380-1 series Controller provides a new,
innovative emergency signaling detection that can be deployed in hazardous environments
and over very long distances. The Fiber Optic E-Stop switch employs a photo interrupt scheme
operating over a duplex 50/125µm or 62.5/125µm optical link that allows for reliable signal
detection and implements a known default failure state.
The optical signal levels are rated inherently safe Ex op is, allowing the system to be safely
deployed in any type of explosive atmosphere or hazardous location. The entire fiber optic
sensor system has a generous system loss budget, allowing for long distance, complex
routing, and daisy chaining of multiple switches.
Depressing the switch interrupts the optical signal and the Controller provides both Double
Pole Double Throw (DPDT) relay contacts and digital outputs for signal and control. The
controller will indicate if there is a broken fiber connection or depressed switch in the system
which provides increased safety margin over electrical emergency switches. The controller will
always default to the emergency state when: the switch is depressed, in case of a broken
fiber, in case of a fiber being disconnected or loss of power to the controller unit.
Figure 2 provides a complete functional overview of the emergency switch system.

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1.2.
Fields of Application
•Hazardous Environments: Oil & gas mining/extracting, refining
•Medical: MRI environment
•Energy Distribution: E-Switch maybe deployed next to high voltage lines
1.3.
Features
EMI/RFI Immune
Wide System Loss Budget
Complex Routing Capability
Long Distance Signaling without Interference
Multiple Switches in Series
Immune to High Voltage Lines
Immune to Lightening
Inherently Safe Mechanical Apparatus
Multiple E-STOP Switches Can Be Daisy Chained
Double Pole Double Throw Relay Output
Digital Signal Out
ESTOP sensor available with either 50/125µm or 62.5/125µm pigtails
Universal DIN Rail Mountable Controller, works with both 50/125 µm and
62.5/125 µm multimode fiber links
Emergency Switch
Optional Switches
in Series
24V Out
5V Out
NC2
CM2
NO2
NC1
NO1
CM1
MR380-1 Controller
Module
‘POWER’
‘EMERGENCY ON’
Figure 2. Complete Functional System Overview

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2.
Standard Contents
MR380-X ESTOP Sensor:
•MR380-X-YY with multimode fiber size and pigtail length as ordered by customer,
terminated with LC duplex connector.
•2-56 x 1/8 Pan Head Phillips Screws, Qty 2
•Instruction Manual (this document, one soft copy supplied with each shipment)
MR380-1 Controller Module:
•MR380-1 Universal Controller Module
•Phoenix Terminal Block(1879599) inserted as part of unit
•Instruction Manual (this document, one soft copy supplied with each shipment)

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3.
Installation and Operation
3.1.
Mounting the Emergency Switch
For mounting the sensor switch into a panel, please provide a cut-out as dimensionally shown
in
Figure 3
and Mechanical Reference Drawing. Refer to
Figure 4
for switch orientation.
Secure panel-mount switch with all appropriate designations and requirements.
Mushroom Push Button
Mounting Nut
Panel Lock Washer
Gasket
2-56 x 1/8
Panhead Philips
Screws
Figure 3. Panel Cut Out Dimensions and Assembly Hierarchy of Emergency Switch
Figure 4. Emergency Switch Orientation when Mounting into Optical Block

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3.2.
Mounting the Controller Module
The controller unit mounts on DIN rails as well as a single mounting clip. Both mounting
schemes are shown below in Figures 5 and 6.
Figure 5. DIN Rail Mount
Figure 6. Mounting Clip Mount

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3.3.
Connecting the Controller
An LC Duplex optical cable is used to interconnect the sensor and controller. The sensor
incorporates a 3m optical pigtail (or alternate length as specified by customer). If a longer
connection to the controller is required, then an extension cable having LC duplex connector
may be used.
Remove LC Duplex connector's dust cap(s) and open the external shutter of the controller.
When inserting the LC Duplex connector, there should be a positive click when the connector
is engaged properly. Avoid repeated fiber optic disconnects to reduce likelihood of surface
contamination.
Electrical Connections MR380-1 Controller
The contact on the controller module uses a Phoenix Contact screw terminal. For more
information, consult Controller specifications given in Section 6.2 . If connectors are lost or
damaged, contact Micronor Sales for replacement details.
MR380-1 Fiber Optic E-STOP Controller Module
Terminal
Description
For Typical Emergency Stop Operation
Connect to Terminals 5 & 6 or 8 & 9
1 +24VDC Power Supply
STATE TABLE
2 Ground Input
Module
Powered
Module Not
Powered
Switch
ON
Switch
OFF
Switch
ON/OFF
3 Digital 24V Normally High LOW HIGH -
4 Digital 5V Normally High LOW HIGH -
5 Normally Closed Relay Contact 2 OPEN CLOSED OPEN
6 Common Relay Contact 2 - - -
7 Normally Open Relay Contact 2 CLOSED OPEN CLOSED
8 Normally Closed Relay Contact 1 OPEN CLOSED OPEN
9 Common Relay Contact 1 - - -
10 Normally Open Relay Contact 1 CLOSED OPEN CLOSED
Camarillo, CA USA
T [phone]
F [phone]
www.micronor.com
MADE IN USA
Product conforms to 21 CFR 1040 and
IEC 60825-1:2004 at date of manufacture:
DEPENDENT ON PART NUMBER
Figure 7. Front Panel Outputs of MR380-1 Series Controller
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3.4.
System Start-Up & Performance Check
Connect +24VDC supply and ground to the designated terminals on the controller module.
Verify that the ‘POWER’ LED (green) is illuminated. If the emergency switch is not connected,
do so at this time and also verify that the ‘EMERGENCY ON’ LED (red) turns off as the switch is
connected.
E-Stop Switch
‘Power’
LED
‘Emergency
ON’ LED
24V Digital
Out
5V Digital
Out
Relay Contacts
Not Depressed
ON
OFF
> +20V
> + 4V
No Change
Depressed
ON
OFF
< +1V
< +0.5V
Polarization
Change
If the switch is connected and not depressed with both LEDs illuminated, see Section 4
Troubleshooting for additional help.
Figure 8. Properly Functioning Controller with Switch Connected and Not Depressed
Figure 9. Properly Powered Controller with Depressed Switch, Broken Fiber Link, or High Loss

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4.
Troubleshooting
The following are potential issues and recommended solutions when troubleshooting the
MR380 fiber optic emergency stop switch system. For issues not listed, please contact
Micronor Sales.
4.1.
Potential Issues & Solutions
4.1.1. ‘Power’ not illuminated when controller powered
•Verify solid electrical connection between wires and screw terminal for both +24VDC
and GND.
•Verify controller module power supply is +24VDC with a current output of at least
80mA.
•Contact Micronor Sales for further assistance.
4.1.2. ‘Emergency ON’ illuminated w/Emergency Switch Connected
•Check if emergency switch is ‘On’ when depressed. If so, reset switch and verify
‘Emergency ON’ is now off.
•Verify optical link cabling is properly connected and undamaged.
•Verify that the entire fiber optic system does not exceed system loss margin
specifications, using either an optical power meter or OTDR.
•Clean all fiber optic connector surfaces using appropriate cleaning materials.
•Contact Micronor Sales for further assistance.
4.1.3. No +24V Digital Out
•Verify solid electrical connection between wires and screw terminal for +24V Digital
Out and GND.
•Verify that the controller module is properly powered with +24VDC and grounded.
•Verify emergency switch is connected and 'Emergency ON’ is off.
•Contact Micronor Sales for further assistance.
4.1.4. No +5V Digital Out
•Verify solid electrical connection between wires and screw terminal for +5V Digital Out
and GND.
•Verify that the controller module is properly powered with +24VDC and grounded.
•Verify emergency switch is connected and 'Emergency ON’ is off.
•Contact Micronor Sales for further assistance.

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4.1.5. Relay Switching Failure
•Verify solid electrical connection between wires and screw terminal for NO2,NC2, CM2,
NO1,NC2,CM1
•Verify that the controller module is properly powered with +24VDC and grounded.
•Verify emergency switch is connected and “Emergency ON’ is off
•Verify when switch is depressed, the controller will electro-mechanically switch the
state of the relay resulting in a faint ‘click’ sound.
•Contact Micronor Sales for further assistance.
4.1.6. Damaged Emergency Switch (Fiber)
•Verify controller module outputs optical power by connecting LC loopback directly from
one LC connector to the other, shown in Figure 10. ‘Power’ should be illuminated and
‘Emergency ON’ should be off.
•Verify undamaged fiber with visual fault finder.
•Verify that the switch has a loss of < 1dB, using optical power meter.
•Clean fiber optic surfaces on the emergency switch using the appropriate cleaning
materials.
•Contact Micronor Sales for further assistance.
Figure 10. LC Loopback MR380-2,-8 Check

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4.2.
Damaged In Shipment
In the event of a damaged instrument, write or call your nearest MICRONOR office in the U.S. A.
Please retain the shipping container in case reshipment is required for any reason.
If you receive a damaged instrument you should:
1) Report the damage to your shipper immediately.
2) Inform MICRONOR
3) Save all shipping cartons.
Failure to follow this procedure may affect your claim for compensation.

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5.
Warranty Information
Warranty
MICRONOR INC. warrants this product to be free from defects in material and workmanship
for a period of 1 (one) year from date of shipment. During the warranty period we will, at our
option, either repair or replace any product that proves to be defective.
To exercise this warranty, write or call your local MICRONOR INC. representative, or contact
MICRONOR INC. headquarters. You will be given prompt assistance and return instructions.
Send the instrument, transportation prepaid, to the indicated service facility. Repairs will be
made and the instrument returned transportation prepaid. Repaired products are warranted
for the balance of the original warranty period, or at least 90 days.
Limitations of Warranty
This warranty does not apply to defects resulting from unauthorized modification or misuse of
any product or part. This warranty also does not apply to Fiber Optic Connector interfaces,
fuses or AC line cords. This warranty is in lieu of all other warranties, expressed or implied,
including any implied warranty of merchantability of fitness for a particular use. MICRONOR
INC. shall not be liable for any indirect, special or consequent damages.
Contact Information:
Micronor Inc. Phone [phone]
900 Calle Plano, Suite K Fax [phone]
Camarillo, CA 93012 Email sales@micronor,com
USA URL www.micronor.com
For Europe:
Micronor AG Phone [phone]
Pumpwerkstrasse 32 Phone [phone]
CH-8015 Regensdorf Email [e-mail]
SWITZERLAND URL www.micronor.ch

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6.
Specifications
For additional clarification of parameters related to Functional Safety, Laser Safety, Explosive
Atmospheres and CE Marking, consult the following additional Micronor documents:
•93-0380-01, Declaration of Conformity - Summary. This document is the short form
version of the Declaration of Conformity and is posted on the Micronor.com website.
•93-0380-02, Declaration of Conformity - Detailed Report. This Document is the long
form version of the Declaration of Conformity with supporting detail and risk
assessments in support of CE marking.Contact Micronor Sales for a copy.
6.1.
E-STOP Sensor
Functional Specification:
Description
MR380-X-YY
Specification
Optical Insertion Loss
MR380-2-YY (62.5/125)
MR380-5-YY (50/125)
Insertion Loss
<2.5 dB (2 dB typical)
<3.5 dB (3 dB typical)
To determine maximum distance, consult Optical
specifications for the Controller Module.
Mechanical
Optical Housing Aluminum, Anodized Finish
Durability
100,000 Operations min.
Environmental & Safety Specifications:
Description
MR380-X-YY
Specification
Temperature Range
-40° C to +65° C (-40° F to +150°F)
Humidity
0% to 90% RH (non-condensing)
Ingress Protection
IP61
Laser Safety
Under Normal Installation and Operating Conditions, the
Operator has no access or exposure to unsafe optical
radiation.
Explosive Atmospheres
Sensor can be installed and operated in Hazardous Areas
Inherently Safe Optical Radiation op is
Per IEC 60079-28
USA (NEC)
Zone 0/Zone 20
EU (ATEX)
 Ex Op is I/II/III 65°C/T6 Ga/Ma/Da
Functional Safety Rating
(Consult Controller specifications for all information)

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Optical Cabling:
Description
MR380-X-YY
Specification
Fiber Optic Interface
LC Duplex Plug
Fiber Optic Cable
MR380-2-YY
MR380-5-YY
Where YY is pigtail length in meter
Duplex 62.5/125µm OM-1 Multimode Fiber
Duplex 50/125µm OM-2 Multimode Fiber
Physical Specifications:
Description
MR380-X-YY
Specification
Mounting
Consult Mechanical Reference Drawing
Housing
Consult Mechanical Reference Drawing
Weight
Sensor with 5 meter pigtail
240 g (6.5 oz)
Specifications subject to change without notice

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6.2.
E-STOP Controller Module
Functional Specification:
Description
MR380-1-1
Specification
Digital Outputs
Voltage Output(5V):
Voltage Output(24V):
5VDC/2k& Load
24VDC/2k& Load
(Short Circuit Protected)
Relay Contacts
Switching Power Rating
Current Rating
Contact Material
DC Rating
AC Rating
2x Form C (CO)
60W/62.5VA
2A
AgNi, Gold Covered
75 V @ 0.75A; 24 V @ 2A
50 V @ 1A; 24 V @ 2A
Optical
Transmitter Power
Receiver Sensitivity
System Loss Budget
Maximum Distance
850nm, ~0.1 mW (-10 dBm)
High>-15dB; Low<-21dB
15 dB-
Lesser of 15dB or 2500 meters
(See Application Notes)
Interface
Electrical
Optical
10-pin Screw Terminal, 30-14 AWG
(Phoenix Mating Plug, 1803659)
NOTE: Electrical connections shall not exceed 3m
LC Duplex, 50/125µm OM-2 or 62.5/125µm OM-1
Multimode Fiber, same as MR380 ESTOP sensor ordered
Power Supply Specifications:
Description
Specification
Power Supply Input
+24VDC, <80mA

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Environmental and Safety Specifications:
Description
MR380-1-1
Specification
Temperature Range
-5° to +55° C
(23° F to +131°F)
Humidity
0-90% RH (non-condensing)
Ingress Protection
IP50 per IEC 60529
Laser Safety
Per IEC 60825-1
850nm, VCSEL
Class 1 (Safe)
Explosive Environments
Controller shall be installed in non-hazardous locations only
EX Classification contained within Brackets [...]
Inherently Safe Optical Radiation op is
Per IEC 60079-28
USA (NEC)
[Zone 0/Zone 20]
EU (ATEX)
 [Ex Op is I/II/III 55° C/T6 Ga/Ma/Da]
Functional Safety
Category
For MR380 System:
Category 2 per ISO 13849-1
MTTF
d
6.20 E+05 hours (70.8 years)
Performance Level (PL)
PL=c
Safety Integrity Level (SIL)
SIL=1
Physical Specifications:
Description
MR380-1-1
Specification
Mounting
35mm DIN Rail
(See Drawing)
Housing
11.4 x 8.9 x 3.2 cm
(4.50” x 3.50” x 1.25 inches)
Weight
230 g (8.1 oz)
Specifications subject to change without notice

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7.
Theory of Operation
A functional block diagram is shown in Figure 11, showing the Switch Sensor, Optical Link
and Controller Module. The switch is connected by a duplex fiber optic cable of readily
available 50/125µm or 62.5/125µm multi-mode fiber. The transmit fiber guides steady
optical power from a near-IR light source to the optical switch. A second receive fiber returns
the light relaying if the switch is closed or open.
Controller
The light source power is held constant under normal operating conditions allowing for a
known system loss budget when designing a system. The optics within the switch itself are
designed to couple maximum light back into the receive fiber allowing for long distance and
chaining multiple switches.
The optical power is then detected by the Schmitt Trigger Photodetector and translated into a
logic signal depending on the power level. The photodetector operates with an active low
signal scheme allowing for a known failure state. If a fiber were to break, poor connection,
high loss, or depressed switch the controller would interpret those events as a failure or
‘EMERGENCY ON.’
The photo detector outputs a logic signal to the remaining logic circuitry which then interprets
high or low levels for the +24V and +5V digital outputs.
Switch
Digital Out
Logic
Circuitry
Relay
Contacts
Light
Source
Photodetector
850nm
1300nm
635nm
Figure 11 Block Diagram of Basic Theory of Operation for MR380 Fiber Optic E-STOP