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MSI 100/200

Configurable safety modules and  safe extension modules

2018/02 -700922

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USER MANUAL

User Manual

MSI 100/200: Configurable safety modules and safe extension modules

UM MSI 100/200, Revision 01 2018-02-01

This user manual is valid for:

Designation Revision 

from HW/FW

MSI 100 MSI101 10/1636 547802

MSI102 10/1636 547812

MSI 200 MSI201 10/2033 547803

MSI202 10/2033 547813

MSI-EM200-8I4IO MSI-EM201-8I4IO 10/1021 547804

MSI-EM202-8I4IO 10/1021 547814

MSI-EM200-4RO MSI-EM201-4RO 02/1002 547805

MSI-EM202-4RO 02/1002 547815

The following designations are used in this manual:

Safety modules: 

designation for modules MSI 100 and MSI 200

Safe extension modules:

designation for modules MSI-EM200-8I4IO and MSI-EM200-4RO



Part no.

Leuze electronic MSI 100/200 2

Table of contents

1 For your safety ...................................................................................................................................................... 7

1.1 Labeling of the warning notices ............................................................................ 7

1.2 Qualification of the users ...................................................................................... 7

1.3 Range of application of the product ...................................................................... 8

1.3.1 Intended use ......................................................................................... 8

1.3.2 Changes to the product ......................................................................... 9

1.4 Safety notices ....................................................................................................... 9

1.4.1 General safety notices .......................................................................... 9

1.4.2 Electrical safety .................................................................................. 11

1.4.3 Safety of machines or systems ........................................................... 12

1.4.4 Safety when starting applications ........................................................ 13

1.5 Directives and standards .................................................................................... 13

1.6 Documentation.................................................................................................... 14

1.7 Safety hotline ...................................................................................................... 14

2 System description ............................................................................................................................................ 15

2.1 MSI 100/200 safety system: design and functionality ......................................... 15

2.2 Using the system ................................................................................................ 18

2.3 Safe state............................................................................................................ 19

2.4 System start-up and restart behavior .................................................................. 19

2.5 Error detection .................................................................................................... 21

2.6 Error state ........................................................................................................... 21

2.7 Diagnostic tools................................................................................................... 22

2.8 Password protection ........................................................................................... 22

3 MSI 100 and MSI 200 safety modules ........................................................................................................ 23

3.1 Product description ............................................................................................. 23

3.1.1 Connection of extension devices ........................................................ 25

3.2 Operating modes (status) of the safety modules ................................................ 26

3.3 Operating and indication elements ..................................................................... 27

3.3.1 Diagnostic and status indicators ......................................................... 27

3.3.2 Confirm button ..................................................................................... 28

3.3.3 USB interface ...................................................................................... 28

3.3.4 AC-MSI-CFG1 ..................................................................................... 30

3.4 Signal connections.............................................................................................. 31

3.4.1 Safe inputs .......................................................................................... 31

3.4.2 Safe outputs ........................................................................................ 32

3.4.3 Signal outputs ..................................................................................... 33

3.4.4 Clock outputs ...................................................................................... 33

3.4.5 Ground-switching outputs ................................................................... 34

3.4.6 Supply connections ............................................................................. 34

4 MSI-EM200-8I4IO safe extension module ................................................................................................. 36

4.1 Product description ............................................................................................. 36

4.2 Diagnostic and status indicators ......................................................................... 37

4.3 Signal connections.............................................................................................. 38

4.3.1 Safe inputs .......................................................................................... 38

4.3.2 Safe outputs ........................................................................................ 38

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Table of contents

4.3.3 Clock/signal outputs ............................................................................ 39

4.3.4 Supply connections ............................................................................. 41

5 MSI-EM200-4RO safe extension module .................................................................................................. 42

5.1 Product description ............................................................................................. 42

5.2 Diagnostic and status indicators ......................................................................... 44

5.3 Signal connections.............................................................................................. 45

5.3.1 Safe relay outputs ............................................................................... 45

5.3.2 Signal outputs ..................................................................................... 47

5.3.3 Supply connections ............................................................................. 47

6 Wiring examples ................................................................................................................................................. 49

6.1 Information on the wiring examples .................................................................... 49

6.2 Single-channel assignment of the safe digital inputs .......................................... 49

6.2.1 Cross circuit monitoring switched on ................................................... 49

6.2.2 Cross circuit monitoring switched off, external supply ........................ 50

6.2.3 External supply (OSSD) ...................................................................... 51

6.3 Two-channel equivalent assignment of the safe digital inputs............................ 52

6.3.1 Cross circuit monitoring switched on, supplied by T0 and T1 ............. 52

6.3.2 Cross circuit monitoring switched off, external supply ........................ 53

6.3.3 External supply (OSSD) ...................................................................... 54

6.4 Two-channel antivalent assignment of the safe digital inputs............................. 55

6.4.1 Cross circuit monitoring switched on, supplied by T0 and T1 ............. 55

6.4.2 Cross circuit monitoring switched off, external supply ........................ 56

6.5 Safe digital outputs ............................................................................................. 57

6.5.1 Information on the protective circuitry of external relays/contactors 

(freewheeling circuit) ........................................................................... 57

6.5.2 Single-channel assignment of the safe digital outputs ........................ 58

6.5.3 Two-channel assignment of the safe digital outputs ........................... 59

6.6 Safe relay outputs ............................................................................................... 60

6.6.1 Information on the protective circuitry of external relays/contactors 

(freewheeling circuit) ........................................................................... 60

6.6.2 Single-channel assignment of the safe relay outputs .......................... 60

6.6.3 Single-channel assignment of the safe relay outputs .......................... 61

7 Mounting, removal and electrical installation ............................................................................................ 62

7.1 Safety notices for mounting, removal and electrical installation ......................... 62

7.2 Mounting ............................................................................................................. 63

7.2.1 Mounting instructions .......................................................................... 63

7.2.2 Mounting location ................................................................................ 63

7.2.3 Mounting ............................................................................................. 64

7.3 Removal.............................................................................................................. 65

7.4 Electrical installation ........................................................................................... 66

7.4.1 Connecting signal lines ....................................................................... 67

7.4.2 Connecting the supply voltage ............................................................ 69

7.4.3 Example connection of an MSI 100/200 system ................................. 72

8 Firmware update ................................................................................................................................................ 73

8.1 Safety notices for the firmware update ............................................................... 73

8.2 Requirement for firmware update ....................................................................... 74

8.3 Running a firmware update................................................................................. 74

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Table of contents

9 MSIsafesoft configuration software .............................................................................................................. 75

9.1 Installing software ............................................................................................... 75

9.2 Opening the software help system...................................................................... 76

10 Configuration and commissioning ................................................................................................................ 77

10.1 Example for configuration and commissioning ................................................... 77

10.2 Downloading configuration from the MSIsafesoft configuration software ........... 80

10.3 Loading the configuration using the AC-MSI-CFG1 memory module................. 84

10.4 Uploading the configuration from the safety module .......................................... 86

10.5 Function Test ...................................................................................................... 87

10.5.1 Performing function test with the help of online mode ........................ 87

11 Diagnosis .............................................................................................................................................................. 89

11.1 Diagnosis via LED indicators on the module ...................................................... 89

11.1.1 MSI 100 and MSI 200 ......................................................................... 90

11.1.2 MSI-EM200-8I4IO ............................................................................... 93

11.1.3 MSI-EM200-4RO ................................................................................. 94

12 Problems and solutions ................................................................................................................................... 95

12.1 General ............................................................................................................... 95

12.2 Graphical connection editor ................................................................................ 96

12.3 Configuration editor............................................................................................. 96

12.4 Online communication between MSIsafesoft and the safety module ................ 97

12.5 Communication between the safety module and the safe extension module ..... 99

12.6 Safety module messages.................................................................................... 99

13 Maintenance, repair, decommissioning and disposal .......................................................................... 100

13.1 Maintenance ..................................................................................................... 100

13.2 Repair ............................................................................................................... 100

13.3 Decommissioning and disposal ........................................................................ 100

14 Technical data and ordering data ............................................................................................................... 101

14.1 Technical data MSI 100 and MSI 200 .............................................................. 101

14.2 Technical data MSI-EM200-8I4IO .................................................................... 107

14.3 Technical data MSI-EM200-4RO ..................................................................... 112

14.4 Certifications ..................................................................................................... 117

14.5 Conformity with EMC directive.......................................................................... 117

14.6 System requirements for the MSIsafesoft configuration software .................... 117

14.7 Ordering data.................................................................................................... 118

14.7.1 MSI 100/200 modules ....................................................................... 118

14.7.2 Software ............................................................................................ 118

14.7.3 Accessories ....................................................................................... 118

14.7.4 Gateways .......................................................................................... 118

14.8 Documentation.................................................................................................. 119

A Technical appendix ................................................................................................................. 120

A 1 Calculation of the power loss ............................................................................ 120

A 2 Switch-off time of the MSI 100/200 system....................................................... 124

A 3 Use of MSI 100/200 modules at altitudes above 2000 m above sea level ....... 125

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Table of contents

B List of appendices ................................................................................................................... 127

B.1 Figures.............................................................................................................. 127

B.2 Tables ............................................................................................................... 130

B.3 Index ................................................................................................................. 132

C Revision history....................................................................................................................... 135

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1 For your safety

Read this manual thoroughly and store it for future reference.

1.1 Labeling of the warning notices

For your safety

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. There are three signal words for the severity of the possible injury.

DANGER

This indicates a danger with high degree of risk. If the danger is not avoided, it will result in death or a severe injury.

WARNING

This indicates a danger with moderate degree of risk. If the danger is not avoided, it may result in death or a severe injury.

CAUTION

This indicates a danger with low degree of risk. If the danger is not avoided, it may result in a minor or moderate injury.

This icon with the ATTENTION signal word warns of actions that could result in

property damage or a malfunction.

Here, you can find additional information or other sources of information.

1.2 Qualification of the users

The use of products described in this manual is oriented exclusively to – Certified electricians or persons instructed by certified electricians. The users must be

familiar with the relevant safety concepts of automation technology as well as with the applicable standards and other regulations.

– Qualified application programmers and software engineers. The users must be familiar

with the relevant safety concepts of automation technology as well as with the applicable standards and other regulations.

Leuze electronic MSI 100/200 7

For your safety

1.3 Range of application of the product

Only use the MSI 100/200 system in accordance with the range of application described in this chapter.

1.3.1 Intended use

Only use the safety modules and safe extension modules of the MSI 100/200 system according to the information provided in this section.

MSI 100/200 system The intended use of the MSI 100/200 system is safe shutdowns. Safe switch-on is not an

intended use.

All modules of the MSI 100/200 system are intended for use in the industrial sector.

The safety modules and safe extension modules can only perform their safety-relevant tasks if they have been integrated in the execution process correctly and in such a way as to avoid errors.

You must observe all information in this user manual as well as in the user manuals and online help listed in "Documentation" on page 14.

Only use the modules of the MSI 100/200 system according to the provided technical data.  See chapter 14 „Technical data and ordering data“ from page 101.

You can find further information on the use of the MSI 100/200 system under "Using the system" on page 18.

MSI 100 and  MSI 200

MSI-EM200-8I4IO The MSI-EM200-8I4IO safe extension module is an extension to the MSI 200 safety module.

MSI-EM200-4RO The MSI-EM200-4RO safe extension module is an extension to the MSI 200 safety module.

The MSI 100 and MSI 200 modules are configurable safety modules with 20 safe inputs and four safe outputs. The inputs are used for the evaluation of safety-relevant transducers, such as E-Stop buttons or safety doors. The circuits are interrupted in a safe manner via the outputs. In addition, four signal outputs, two clock outputs and two ground-switching outputs are avail able.

The MSI 100 safety module is a stand-alone device and cannot be extended with safe extension modules.

The MSI 200 safety module can be extended with safe inputs and outputs using safe extension modules of the MSI 100/200 system.

You can connect one gateway to both safety modules for transferring diagnostic data.

An additional four configurable inputs or outputs, two configurable clock or signal outputs as well as eight safe inputs are thereby made available.

An additional four safe relay outputs and four signal outputs are thereby made available.

Leuze electronic MSI 100/200 8

For your safety

MSIsafesoft The MSIsafesoft safe configuration software is designed for the configuration of the safety

modules as well as connected extension modules.

Safe function blocks and functions in MSIsafesoft

The MSIsafesoft configuration software provides safe function blocks and functions for creating the safety logic. These are designed solely for use within the safety module and support specific safety functions here.

The safe function blocks and functions can only perform their safety-related tasks within the safe control system if they have been integrated into the execution process correctly and in such a way as to avoid errors.

1.3.2 Changes to the product

Modifications to the hardware and firmware of the device are not permitted.

Improper work or changes to the device could endanger your safety or damage the device. You may not repair the device. If the device is defective, contact Leuze electronic.

1.4 Safety notices

1.4.1 General safety notices

WARNING: Serious danger through improper use

Depending on the application, improper use of the MSI 100/200 system can place the user in serious danger.

• Observe the safety notices in this chapter.

• Observe the warning notices at other locations in this document.

Documentation

Safety of  personnel and equipment

You must observe all information in this manual and other applicable documents.  See chapter "Documentation" on page 14.

The safety of personnel and equipment can only be assured if the modules and safe function blocks are used correctly. See chapter "Intended use" on page 8.



Leuze electronic MSI 100/200 9

For your safety

Qualified personnel Qualified personnel are, in the context of this manual, persons who, because of their educa-

tion, experience, and instruction, and their knowledge of relevant standards, regulations, accident prevention, and service conditions, have been authorized to carry out any required operations, and who are able to recognize and avoid any possible dangers.

In the context of the use of the MSI 100/200 system with the MSIsafesoft configuration software and safe function blocks, the following operations may only be carried out by qualified personnel:

– Planning, configuration (development of safety logic) – Installation, commissioning, servicing – Maintenance, decommissioning

Requirements Knowledge of the following topics and products is required:

– The safety and safe extension modules used in the MSI 100/200 system – The used peripherals (extension devices, sensors, actuators) – Operating the MSIsafesoft configuration software – Standards of safety technology – Safety regulations in the area of application

Error detection Depending on the wiring and the configuration, the safety modules and safe extension mod-

ules of the MSI 100/200 system detect errors within the safety-related equipment.

Do not open the housing It is prohibited to open the housing of the modules. If the housing is opened, the function of the

MSI 100/200 modules is no longer guaranteed.

Misconnection and incorrect polarity of the connections

Take measures to protect against misconnection, polarity reversal and tampering at the connections.

The individual terminal blocks of all MSI 100/200 modules are mechanically coded to prevent incorrect connection.

Leuze electronic MSI 100/200 10

For your safety

1.4.2 Electrical safety

WARNING: Loss of the safety function / hazardous body currents

Incorrect installation can result in loss of the safety function as well as in hazardous body currents. Depending on the application, the user may be exposed to severe dangers.

• Observe the notices for electrical safety.

• Observe the warning notices at other locations in this document.

• Dimension the used devices and design their installation in the system according to the

specific requirements.

• Retest the equipment and systems that are retrofitted with the safety relay.

• Observe the information in the user documentation for other used devices

sensors, actuators or extension devices).

(e.g.,

Direct / indirect contact Protection against direct and indirect contact according to VDE 100 part 410 must be ensured

for all components connected to the system. In the event of an error, no hazardous parasitic voltages may occur (single-fault tolerance).

Mandatory measures: – Use power supply units with safe insulation (PELV) – Decoupling of circuits that are not PELV systems 

With the following components: optical couplers, relays or other components that satisfy the requirements for safe insulation

Safe insulation Only use devices with safe insulation if hazardous contact voltages can occur at their connec-

tions.

Power supply units for  24-V supply

Ground connection Ensure that all inputs and outputs of the system are connected to the same ground.

Insulation dimensioning When selecting the equipment, take into account the contamination and overvoltages that

Installation space and  installation position

ESD note

Only use power supply units with safe insulation and PELV in accordance with EN 50178 /

0160. These units prevent short circuits between primary and secondary sides.

VDE

Connect the output-side GND connection of the power supply unit to the functional earth (FE) of the system.

occur during operation. If necessary, take appropriate measures for voltage limitation.

Observe the requirements listed in the technical data regarding the installation space and the installation position.

ATTENTION: Electrostatic discharge

Electrostatic discharge can damage or destroy components. When handling, take the necessary safety precautions against electrostatic discharge (ESD) according to EN 61340-5-1 and IEC 61340-5-1.

Leuze electronic MSI 100/200 11

For your safety

1.4.3 Safety of machines or systems

The safety of the machine or system and of the application in which the machine or system is used is the responsibility of the machine/system manufacturer and of the operating company.

Draw up and implement a safety concept

Safety-related equipment For the sensible use of the MSI 100/200 system, provide the machine with safety-related

Testing hardware and configuration

In order to use the system described in this document with the associated safe function blocks, you must have drawn up an appropriate safety concept for your machine or system. This includes the hazard and risk analysis, among others, according to the directives and standards listed in chapter

The target safety integrity level is ascertained on the basis of the risk analysis. – SIL acc. to IEC 61508 – SILCL acc. to EN 62061 – Cat./PL acc. to EN ISO 13849-1

The following are dependent on the ascertained safety integrity: – The wiring of safe sensors, command devices and actuators within the overall safety func-

tion

– The use of safe function blocks in the safety logic. 

The safety logic is created using the MSIsafesoft configuration software.

equipment.

This includes, for example: – E-Stop buttons – Protection hood switches – Enabling switches – Light barriers

Carry out a validation every time you make a safety-related modification to your overall system.

Use the relevant checklists when carrying out the validation. Enter the details requested in the "Project Information" dialog box in the MSIsafesoft safe configuration software.

Use your test report to satisfy yourself that: – The safe sensors and actuators are connected correctly in the MSI 100/200 safety appli-

cation. To do this, use the "Wiring check" function in the MSIsafesoft configuration software.

– The inputs and outputs of the safety modules and the safe extension modules are cor-

rectly configured.

– The signals have been connected to the safe sensors and actuators correctly (single-

channel or two-channel). – Cross-circuit detection is implemented in your application, if required (see page 22). – All safe function blocks and functions in the MSIsafesoft configuration software are con-

nected correctly.

"Directives and standards" on page 13.

Leuze electronic MSI 100/200 12

For your safety

Disconnecting the USB connection

For the safe operation of the machine or system, there must be no USB connection to the safety modules.

For further information, refer to Chapter "USB interface" on page 28.

1.4.4 Safety when starting applications

Take the following into account when defining the start conditions for your machine or system: – The machine or system may only be started if it is ensured that no persons are located in

the danger zone. – Comply with the requirements of EN ISO 13849-1 with regard to the manual reset func-

tion.

This applies for: – The switching on of safe participants – The acknowledgment of device error messages – The canceling of start interlocks for safety functions

Observe start-up behavior Some of the safe function blocks in the MSIsafesoft configuration software have parameters

for specifying a start interlock and/or a restart interlock.

For further information, refer to Chapter "System start-up and restart behavior" on page 19.

1.5 Directives and standards

The standards with which the MSI 100/200 system complies can be found in the certificate of the approval body and the EC Declaration of Conformity.

You can find these documents on the Internet.  See www.leuze.com.

Leuze electronic MSI 100/200 13

For your safety

1.6 Documentation

Latest documentation Always use the latest documentation. You can find changes or additions on the Internet.

See www.leuze.com.

You must observe all information from the following sources: – Technical description of the safety modules – Technical description of the safe extension modules – User documentation for peripheral devices (e.g., sensors/actuators) that are connected to

the MSI

(MSIsafesoft configuration software) – Documentation for the supplementary standard technology – Help system for the MSIsafesoft safe configuration software and for each of the safe func-

tion blocks (see "Opening the software help system" on page 76)

Additional information and detailed step-by-step instructions for the MSIsafesoft configuration software can be found in the help system of the software.

100/200 modules and are connected to safe function blocks in the safety logic

1.7 Safety hotline

If you have technical questions, please use our 24-hour hotline.

Phone: +49 7021 573-123

E-mail: service.protect@leuze.de

Leuze electronic MSI 100/200 14

2System description

Upload online values during the function test

Download configuration and control parameters

Reset button for  removing active  start/restart interlocks

Control signals for the contactors at the safety module outputs

Readback signal from the monitoring contacts of the contactor

Single-channel or two-channel connection to safety module

Safe command devices or sensors

MSIsafesoft  on configuration computer

Indicator lamp

Check valve

Motor

USB

MSI 200

Contactor or  relay

MSI-EM200-8I4IO

2.1 MSI 100/200 safety system: design and functionality

System description

Overall system:  Hardware and software

The MSI 100/200 safety system consists of the following components:

When using the MSI 100 safety module:

–MSI 100 safety module – MSIsafesoft configuration software – Safe command devices, sensors, and actuators (depending on the application)

When using the MSI 200 safety module:

–MSI 200 safety module – Optional safe extension modules MSI-EM200-8I4IO / MSI-EM200-4RO – MSIsafesoft configuration software – Safe command devices, sensors, and actuators (depending on the application)

The diagram below illustrates the overall system in an application example with the MSI 200.

Leuze electronic MSI 100/200 15

Figure 2-1 Typical structure of a safety system with MSI 200

System description

Communication via USB Communication between the MSI 100 or MSI 200 safety modules and the configuration soft-

ware takes place via a USB interface.

WARNING: Non-safe operation

The USB interface is not protected against ESD. If a there is a USB connection in place, the safety module is in non-safe operation. The safety function cannot be properly executed.

• Only use the USB connection for commissioning.

• Disconnect the USB connection for regular operation.

Communication between the safety module and the configuration software on the PC takes place in both directions:

PC  safety module

The configuration data and device parameters are downloaded from the configuration PC to the safety module. Configuration data refers to the application logic, which you created using the MSIsafesoft configuration software.

The configuration can also be downloaded using the AC-MSI-CFG1 pluggable memory module. Please refer to "Downloading configuration from the MSIsafesoft configuration software" on page 80 and "Loading the configuration using the AC-MSI-CFG1 memory module" on page 84.

Safety module  PC

For diagnostic purposes, online values can be read from the safety module via the USB interface and displayed "live" in the software. For more detailed information, please refer to "Function Test" on page 87.

Communication via the DIN rail connector

The MSI 100 safety module is equipped with an interface for the yellow MSI-TBUS DIN rail connector. The MSI 200 safety module is equipped with two interfaces for the yellow MSI-TBUS.

In combination with the green TBUS DIN rail connector, connect a maximum of one non-safe extension device (gateway) to the MSI

100 or MSI 200 safety module.

Leuze electronic MSI 100/200 16

System description

AC-MSI-TCS

Art.-Nr. 547821

MSI 200

MSI-EM200

8I4I0/4RO

MSI-EM200

8I4I0/4RO

TBUS

GATEWAY

AC-MSI-TC

Art.-Nr. 547823

MSI-TBUS

MSI-TB

Safe  communication area

Non-safe  communication area

Use additional yellow MSI-TBUS DIN rail connectors to connect up to ten safe extension modules to the MSI 200 safety module.

Figure 2-2 Extension of the MSI 200 safety module

Other standard bus participants are possible. For further information, refer to the user documentation of the used gateway at www.leuze.com.

Communication between the safe modules and the non-safe or safe extension modules takes place automatically via the connectors of the DIN rail connectors. See also chapter "Mounting" on page 63.

ATTENTION: Connector wear

The modules may be connected to the DIN rail connectors a maximum of eight mating cycles.

Note the maximum permissible continuous current for extension modules supplied via the MSI-TBUS as well as the technical data of the MSI 100/200 system. See Chapter "Technical data and ordering data" on page 101.

Leuze electronic MSI 100/200 17

System description

2.2 Using the system

Safety circuits The safety modules of the MSI 100/200 system can be flexibly configured. For the creation of

the safety logic, the system is equipped with safe function blocks. You can thereby use the

100/200 system to implement various safety functions in different safety circuits. Just

MSI some of the most important options are listed below:

– E-Stop monitoring – Safety door monitoring (with and without locking device) – Two-hand control units (types II and III) – External device monitoring (EDM) – Monitoring and checking electro-sensitive protective equipment – Operating mode selector switch (evaluation of an operating mode selector switch and an

enabling switch) – Muting applications (light grid monitoring with parallel muting)

Application examples:

In the help system of the MSIsafesoft configuration software, you can find application examples for the safe function blocks with typical application for each function block.

The safety logic configured in the configuration software as well as the wiring of the safety modules and the safe extension modules is displayed in the form of schematic views.

The online help also includes typical signal sequence diagrams, which illustrate the behavior of each function block.

The following application examples are included in the online help for the function blocks: – Single-channel and two-channel E-Stop circuits – Single-channel and two-channel safety door monitoring, with and without locking – Operating mode selection with locking of the set operating mode and manual operating

mode acknowledgment

– Evaluation of a three-position enabling switch with confirmation of the selected safe

operating mode – Parallel muting with two sensors – Evaluation of a light curtain connected via a single channel – Type II and type III two-hand control devices

Leuze electronic MSI 100/200 18

System description

2.3 Safe state

The safe state of an output terminal block is defined as the power off mode (signal value "0").

The safe state can be assumed by the MSI 100/200 system in the following cases:

1. Operating state (by triggering the safety function)

2. Error detection in the peripherals

3. Device error

4. Configuration error

5. Error detection in safe communication

2.4 System start-up and restart behavior

WARNING: Unintended machine start-up

Start/restart after switching on voltage as well as the discontinued demand for the safety function can result in undesired machine start-up.

• Note the following:

– The module starts up immediately after completing the configuration.

– The module restarts immediately if the trigger of the safety function is reset.

• If automatic start/restart is not desired, configure automatic start/restart accordingly in

the safety logic.

Start-up Start-up refers to the behavior of the MSI 100 and MSI 200 safety modules and the optional

safe extension modules after switching on (or applying the supply voltage) and after configuring via USB interface or AC-MSI-CFG1.

Unless a start interlock is configured, the safety module starts up immediately following successful configuration (i.e., after pressing the "Confirm" button). The safe inputs are evaluated and the outputs controlled accordingly.

Restart Restart refers to the behavior of the safety modules and the optional safe extension modules

after the safety function is triggered and the subsequent return to normal operation. Normal operation is restored, e.g., by unlocking the E-Stop command device, after which safe opera tion is again possible.

With an active start/restart interlock, the corresponding safe module output remains in the safe state. This prevents an undesired start/restart of a machine controlled by the relevant output.

Leuze electronic MSI 100/200 19

Reset button

System description

WARNING: Unintended machine start-up

Acknowledgment of an error results in the safe input or output being immediately returned to the operating state.

• Before acknowledging an error, make certain that acknowledgment cannot result in a

dangerous machine state.

• When planning the machine or system, make certain that acknowledgment is possible

only if the danger zone is visible.

In accordance with EN ISO 13849-1, the manual reset function must not trigger a machine start.

An active start/restart interlock can be released by actuating a reset button that is connected and appropriately wired to the safety module or to the safe extension modules.

The reset signal is used at the same time to exit the error state once the error cause has been removed.

Implementation using  safe function blocks

To implement a start/restart interlock, use the safe function blocks in the MSIsafesoft configuration software which have the relevant parameters for activating the start/restart interlock.

To configure a start interlock for a specific safe output, for example, this output must be

directly connected in the safety logic to the output of a safe function block, for which a start

interlock is set via the parameters.

You can find further information on the implementation of a start/restart interlock in the help system of the MSIsafesoft configuration software.

Leuze electronic MSI 100/200 20

Stop category 1 only in the error-free state

Operating duration in faulty state

System description

2.5 Error detection

Depending on the wiring and the configuration, the safety modules and safe extension modules of the MSI 100/200 system detect the following errors at the safe inputs and outputs:

– Short circuit of the outputs – Cross-circuit of the inputs or outputs – Overload at the outputs

2.6 Error state

ATTENTION: Property damage through immediate shutdown

The device ensures stop category 1 only in error free operation. If the supply voltage is lost

or in the case of an internal error, the device behaves acc. to stop category 0.

• Do not use the device in applications in which stop category 1 must be maintained even

in case of failure.

WARNING: Loss of the safe state in the error state

While in the error state, no module-internal tests run and, due to an accumulation of errors, the safe state may be exited.

• If the module takes on a faulty state, examine, acknowledge or rectify the error within 72

hours.

Leuze electronic MSI 100/200 21

System description

MSIsafesoft

You can find further information on password protection in the help system of the MSIsafesoft configuration software.

2.7 Diagnostic tools

MSIsafesoft diagnosis Depending on the device, the modules of the MSI 100/200 system together with the

MSIsafesoft configuration software provide various tools that can be used to diagnose the cur rent configuration on the safety module:

– Hardware diagnosis in the event of a safe function block error – Wiring check – Tool tips in the connection editor – Diagnostic and status indicators on the module – Further diagnostic options via gateways

Information on hardware diagnosis, wiring checks and tool tips can be found in the help system of the MSIsafesoft configuration software.

Diagnostic and status indicators

An overview of the diagnosis and status displays of the individual modules can be found in the respective chapter.

–MSI 100 and MSI 200: see "Diagnostic and status indicators" on page 27. – MSI-EM200-8I4IO: see "Diagnostic and status indicators" on page 37. – MSI-EM200-4RO: see "Diagnostic and status indicators" on page 44.

Diagnosis via gateways You can connect your MSI 100/200 system with gateways to a primary control. The reading

out of the diagnosis is bus-specific.

Information on diagnosis via gateways can be found in the respective user manuals of the gateway.  See www.leuze.com.

You can find suitable gateways for use with the MSI 100/200 system in the accessories chapter "Gateways" on page 118.

2.8 Password protection

The MSI 100/200 system and MSIsafesoft use two passwords to offer dual protection against unauthorized modifications to the configuration and the project in the configuration software.

Leuze electronic MSI 100/200 22

3 MSI 100 and MSI 200 safety modules

The MSI 100 and MSI 200 safety modules are, with respect to their functionality and basic design, largely identical.

Both of the safety modules are described together in this chapter.

Also note the additional information provided for the MSI 200 and the safe extension modules.

MSI 100 and MSI 200 safety modules

Difference between MSI 100 and MSI 200

The difference between the two safety modules lies in the following properties: – MSIsafesoft diagnosis – Connection option for safe extension modules of the MSI 100/200 system

3.1 Product description

Observe the technical data for the safety modules.  See "Technical data and ordering data" on page 101.

Safe digital inputs MSI 100 and MSI 200 are configurable safety modules with 20 safe digital inputs. The inputs

are used to connect safe sensors or command devices. The maximum number of sen sors/command devices is dependent on the wiring:

– Single-channel wiring: maximum 20 safe sensors/command devices – Two-channel wiring: maximum 10 safe sensors/command devices

Safe digital outputs The safety modules have four safe digital outputs. The outputs are actuated after evaluating

the incoming signals according to the configuration.

Ground-switching outputs The safety modules have two ground-switching outputs. The ground-switching outputs are

used, for example, to switch off a contactor that is connected to the safety module. The contactor can be switched off here via either the safe 24 V output or via ground. Use of the groundswitching outputs increases the shutdown protection and cross-circuit protection of the safety circuit.

Digital signal outputs The safety modules have four non-safe digital signal outputs. The signal outputs are used to

control, e.g., a non-safe PLC or signal units.

Safe clock outputs The safety modules have two clock outputs. The asynchronous test pulses enable safe cross-

circuit detection at the inputs of the safety modules that is dependent on the configuration.

Connection technology The safety modules are available with either screw connections or with spring-cage connec-

tions. All connection terminals are pluggable. The individual terminal blocks are mechanically coded to prevent swapping or skewed plug in.

Leuze electronic MSI 100/200 23

Connection variants

PWR

EXT

ERR

24V

O0-

01-

NFIRM

CFG

STICK

SI10

I12

I13

I10

I14

I11

I15

I16

I17

I18

I19

.leuze.de

PWR

EXT

ERR

24V

O0-

01-

STICK

I12

I13

I10

I14

I11

I15

I16

I17

I18

I19

SI1

.le

uze

.de/M

A1 A2 T0

24V 0V O0 O1 O2 O3 O0- O1-

T0 T1 T1 I0 I1 I19 M0 M1 M2 M3

TBUS

NON-SAFE

POWER

24V DC

POWER 24V DC

TEST PULSE MONITORING

OUTPUT OUTPUTSAFE INPUT

LOGIC

SAFE OUTPUT

USB

CONF STICK

Figure 3-1 Screw terminals (left) and spring-cage terminals (right)

Block diagrams MSI 100:

MSI 100 and MSI 200 safety modules

Figure 3-2 MSI 100 block diagram

MSI 200:

A1 A2 T0

POWER 24V DC

TBUS

NON-SAFE

POWER 24V DC

24V 0V O0 O1 O2 O3 O0- O1-

T0 T1 T1 I0 I1 I19 M0 M1 M2 M3

TEST PULSE MONITORING

OUTPUT OUTPUTSAFE INPUT

LOGIC

SAFE OUTPUT

Figure 3-3 MSI 200 block diagram

USB

CONF STICK

TBUS

MSI-

AFE S

Leuze electronic MSI 100/200 24

MSI 100 and MSI 200 safety modules

Configuration The configuration of the safety modules is created with the MSIsafesoft configuration software.

You then load the configuration into the safety module via the USB interface.

WARNING: Non-safe operation

The USB interface is not protected against ESD. If a there is a USB connection in place, the safety module is in non-safe operation. The safety function cannot be properly executed.

• Only use the USB connection for commissioning.

• Disconnect the USB connection for regular operation.

Difference in MSIsafesoft For the MSI 100 safety module, there are 16 external signals available in the MSIsafesoft con-

figuration software.

For the MSI 200 safety module, there are 64 external signals available. The use of diagnostic addresses is also possible for function block diagnosis.

Further information on the MSIsafesoft configuration software can be found in Chapter "MSIsafesoft configuration software" on page 75 or the help system of the software.

3.1.1 Connection of extension devices

Also read "Communication via the DIN rail connector" on page 16.

Non-safe extension:

MSI 100/200

Safe extension:  only MSI 200

Connection of non-safe extension devices (gateways):

You can connect a maximum of one gateway to both safety modules for transferring diagnostic data. Install the gateway to the left of the safety module.

Information on diagnosis via gateways can be found in the respective user manual of the gateway.  See www.leuze.com.

You can find suitable gateways for use with the MSI 100/200 system in the accessories chapter "Gateways" on page 118.

Connection of safe extension modules:

Only the MSI 200 safety module can be extended with the safe extension modules of the  MSI 100/200 system. Install a maximum of ten safe extension modules to the right of the

200 safety module.

MSI

Additional information on the safe extension modules can be found in chapters "MSI-EM200-8I4IO safe extension module" on page 36 and "MSI-EM200-4RO safe extension module" on page 42.

Leuze electronic MSI 100/200 25

MSI 100 and MSI 200 safety modules

PLC: Connected

PLC: Error

The Safety controller and PC

are connected via USB,

the safety controller is switched on

Download project Execution will start after confirmation (Confirm button on controller)

Change from safe online mode to non-safe commissioning mode

ilu

tio

ilu

rin

tio

Connection editor

Online or offline

USB connection (PC – controller) may not be interrupted and the project in MSIsafesoft may not be changed. If this happens, the controller will stop and switch to a safe condition after 10 minutes.

PLC: No project

PLC: Commissioning

Commissioning

PLC: Timeout

Temporary condition during:

- Saving (during download)

- Initialization

- Self-test of the controller

Yes

Temporary condition during:

- Communication

- Initialization

- Self-test

Initial setup?

PLC: Timeout

3.2 Operating modes (status) of the safety modules

The following diagram illustrates the possible operating modes (status) of the MSI 100 and

200 safety modules as well as the possible status transitions. When there is a USB con-

MSI nection to the PC, the module status is indicated on the far right in the status line of the MSIsafesoft configuration software.

WARNING: Non-safe operation

The USB interface is not protected against ESD. If a there is a USB connection in place, the safety module is in non-safe operation. The safety function cannot be properly executed.

• Only use the USB connection for commissioning.

• Disconnect the USB connection for regular operation.

Leuze electronic MSI 100/200 26

Figure 3-4 Possible operating modes (status) of MSI 100/200

MSI 100 and MSI 200 safety modules

Diagnostic indicators

AC-MSI-CFG1

Confirm button

Status indicators

for safe

inputs and outputs

USB interface

3.3 Operating and indication elements

All controls and indicators for the MSI 100 and MSI 200 safety modules are located on the front side of the device.

Figure 3-5 MSI 100/200 operating and display elements

3.3.1 Diagnostic and status indicators

Diagnostic indicators The four diagnostic indicators on the front side show the operating status of the safety mod-

ules. The following LEDs are present on the devices (from left to right).

Table 3-1 MSI 100/200 LED diagnostic indicators

LED Color Description

PWR Green Indicator for the voltage supply of the safety module

DATA Green Only MSI 200: 

Indicator for communication with safe extension modules via MSI-TBUS. This LED is only on if an MSI-TBUS participant is connected.

ERR Red Error display / indicator for safety-critical system errors

CONF Green Indicator for the configuration status and communication via the USB

interface / AC-MSI-CFG1

Status indicators The state of each of the 20 safe digital inputs and four safe digital outputs is indicated by one

LED for each on the front side of the device. The display corresponds to the actually applied signal at the terminals (not the process image).

A detailed list of possible indicator combinations for diagnostic and status indicators and their meanings can be found in

Chapter "Diagnosis" on page 89.



Leuze electronic MSI 100/200 27

3.3.2 Confirm button

MSI 100 and MSI 200 safety modules

Confirming the new configuration

Resetting errors Use the "Confirm" button to reset displayed errors. Depending on the error type, the "Confirm"

Restart To initiate a restart of the device, press the "Confirm" button on the device for at least 15 sec-

Replacing AC-MSI-CFG1 If you load a new configuration by replacing the AC-MSI-CFG1, press and hold down the "Con-

The "Confirm" button is on the right-hand side on the front of the safety modules, above the USB interface. Briefly press this button using a pen to confirm a new configuration loaded via the USB interface. It is then accepted by the safety module.

See also "Downloading configuration from the MSIsafesoft configuration software" on page 80.

button must be pressed briefly (3 s) or for a prolonged period of time (min. 15 s).

onds. As part of the warm start process, all outputs are initially set to the safe state. Pending error messages are now reset as long as the cause of the error no longer exists. The device then enters the initialization phase.

firm" button while removing and inserting the AC-MSI-CFG1 according to the specified procedure.

For the precise procedure, please refer to Chapter "Loading the configuration using the AC-MSI-CFG1 memory module" on page 84.

3.3.3 USB interface

WARNING: Non-safe operation

The USB interface is not protected against ESD. If a there is a USB connection in place, the safety module is in non-safe operation. The safety function cannot be properly executed.

• Only use the USB connection for commissioning.

• Disconnect the USB connection for regular operation.

ATTENTION: Electrostatic discharge

The safety modules contain components that can be damaged or destroyed by electrostatic discharge. When handling the USB interface, observe the necessary safety measures against electrostatic discharge (ESD) according to EN

Communication between the safety module and the MSIsafesoft configuration software takes place via the USB interface (standard USB 2.0). The communication includes the following events:

– Downloading of the configuration data (i.e., for the MSIsafesoft project) – Optional: uploading of the configuration to open it as a project in MSIsafesoft and edit it

as required

– Reading of values from the safety module during operation and "live" display in the con-

nection editor of MSIsafesoft (online mode)

– Forcing of signals on the running safety module for commissioning purposes (non-safe

commissioning mode)

61340-5-1 and EN 61340-5-1.

Leuze electronic MSI 100/200 28

MSI 100 and MSI 200 safety modules

Before connecting the safety module to the configuration PC, install the MSIsafesoft config-

uration software along with the associated USB drivers for the module.

Installing the USB drivers:

The first time a MSI 100/200 safety module is connected to the configuration PC, the "Found New Hardware Wizard" appears. To install the drivers, proceed as follows:

1. When asked "Do you want to establish a connection with Windows Update?", select the "No, not this time" option.

2. Now follow the USB driver installation for MSI 100/200: confirm with "Next". a) When asked "Do you want to install this device software?", confirm your trust in the

software manufacturer by selecting the "Install" button.

3. In the "Completing the Found New Hardware Wizard" window, complete the process by pressing the Finish button.

If the USB drivers are already installed, the appropriately configured PC detects the safety module automatically after the USB connection cable is connected.

If the MSIsafesoft configuration software is already running, the software detects the status of the safety module and indicates it at the bottom right in the status line.

Figure 3-6 Status line in the MSIsafesoft safe configuration software (safety module al-

ready contains a configuration project)

Leuze electronic MSI 100/200 29

MSI 100 and MSI 200 safety modules

EXT

ERR

24V

O0-

01-

CONFIRM

CFG

STICK

MSI100

I12

I13

I10

I14

I11

I15

I16

I17

I18

I19

www.leuze.de/MSI

3.3.4 AC-MSI-CFG1

The safety modules are equipped with a pluggable AC-MSI-CFG1 memory module.

Figure 3-7 AC-MSI-CFG1 with MSI 100/200 safety module

After downloading the configuration from MSIsafesoft to the safety module, the configuration is stored in the AC-MSI-CFG1 memory module.

The AC-MSI-CFG1 must be inserted in the safety module both during normal operation and

for downloading configuration data from MSIsafesoft via the USB interface.

As an alternative to downloading the configuration via the USB interface, it can also be loaded on the safety module using the AC-MSI-CFG1. See "Loading the configuration using the AC-MSI-CFG1 memory module" on page 84.



Behavior without 

AC-MSI-CFG1

If no AC-MSI-CFG1 is plugged into the safety module or if it is pulled out, the safety module behaves as follows.

Table 3-2 Module behavior in case of missing AC-MSI-CFG1

AC-MSI-CFG1 status Module behavior

Stick is not plugged in while downloading the configuration data.

Stick is not plugged in when the safety module is started.

Configuration cannot be loaded. MSIsafesoft outputs an error message.

All outputs remain switched off. Safety module outputs an error state. Safety module performs no functions.

Stick is pulled out during running operation. Safety module switches off all outputs and

outputs an error state. Safety module exe

cutes no further functions.

Stick is pulled out and plugged in according to the instructions for loading the configura tion.

See "Loading the configuration using the

The safety module switches off all outputs

and executes no functions until the stick is plugged in again correctly. The safety mod

ule does not indicate an error state

AC-MSI-CFG1 memory module" on page 84

Leuze electronic MSI 100/200 30

MSI 100 and MSI 200 safety modules

Supply for logic, clock

and signal outputs

(A1/A2)

Clock outputs  (T0, T1)

Supply for

safe outputs

(24V/0V)

Safe inputs  (I0 - I19)

Safe outputs

(O0, O3)

Non-safe signal outputs  (M0 - M3)

Ground-switching out-

puts

(O0-, O1-)

3.4 Signal connections

All input and output connections, with the exception of the USB interface, are made via pluggable and coded connection terminals.

Figure 3-8 Signal connections MSI 100/200

3.4.1 Safe inputs

I0 to I19 The 20 safe digital inputs I0 to I19 are used for the direct connection of safe command devices

or safety sensors.

The safe inputs are linked to the safety logic in the connection editor of the MSIsafesoft configuration software.

You can find further information on linking the safe inputs in the connection editor in the help system of the MSIsafesoft configuration software.

There, you will also find information on the topics of signal redundancy due to dual signals, two-channel sensors and cross-circuit detection.

Leuze electronic MSI 100/200 31

MSI 100 and MSI 200 safety modules

3.4.2 Safe outputs

O0 to O3 The safety-related outputs O0 to O3 are designed as digital semiconductor outputs.

ATTENTION: Module defect

Inductive loads can destroy the outputs.

• Use a suitable and effective protective circuit.

• The protective circuit is to be parallel to the load, not parallel to the switching contact.

• Prevent feedback to the outputs.

The outputs are controlled according to the configured safety logic.

The safe outputs are linked to the safety logic in the connection editor of the MSIsafesoft configuration software.

You can find further information on linking the safe outputs in the connection editor in the help system of the MSIsafesoft configuration software.

Increasing cross-circuit protection  (optional)

Test pulses The safe output signals are clocked with a test pulse.

To increase shutdown protection and cross-circuit protection, use outputs O0 and O1 in combination with ground-switching outputs O0- and O1-.  See chapter "Ground-switching outputs" on page 34.

Reduced availability through test pulses

Test pulses can reduce the availability of the machine or system.

• Make certain that the connected load does not react to the test pulses.

• Use an appropriate filter terminal block if necessary.

Test behavior at the ground-switching output

The first dynamic test on the ground-switching output occurs up to 60 s after system restart. Not all errors in the peripherals or in the internal electronics of the outputs are therefore detected at the switch-on time.

If the switch-on time of the ground-switching outputs is < 60 s, the test takes place after an accumulated switch-on time of 60 s.

Leuze electronic MSI 100/200 32

MSI 100 and MSI 200 safety modules

3.4.3 Signal outputs

M0 to M3 The non-safety-relevant signal outputs M0 to M3 are designed as digital semiconductor out-

puts.

ATTENTION: Module defect

The signal outputs can be destroyed by incorrect wiring.

• Do not connect the signal outputs in parallel.

• Prevent feedback to the signal outputs.

The signal outputs are used to control, e.g., a non-safe PLC or signal units.

Make certain that the GND potential of the signal receiver is the same as the GND potential of the safety module.

The signal outputs are linked in the connection editor of the MSIsafesoft configuration software.

You can find further information on linking the signal outputs in the connection editor in the help system of the MSIsafesoft configuration software.

3.4.4 Clock outputs

T0 and T1 The test pulses output at outputs T0 and T1 are used for cross-circuit detection at the inputs.

Each output is available twice. The output test pulses T0 and T1 are phase-shifted.

The clock outputs are permanently assigned to the inputs. If this assignment is violated, the safety module detects a cross-circuit.

Cross-circuit detection can take place between T0 and T1 as well as between a test pulse and

No cross-circuit detection takes place between inputs with the same test pulse.

Cross-circuit detection  with MSIsafesoft

To implement cross-circuit detection, the relevant safe inputs must be configured accordingly using the configuration editor in MSIsafesoft.

The MSIsafesoft configuration software specifies the clock signals to be used as follows: – For the "even" inputs (I0, I2, I4 … I18), cross-circuit detection is realized with the test pulse

on T0.

– For the "odd" inputs (I1, I3, I5 … I19), cross-circuit detection is realized with the test pulse

on T1.

To use cross-circuit detection for two-channel sensors, "even" inputs must therefore always be combined with "odd" inputs.

Further information on configuring cross-circuit detection via the clock outputs can be found in the help system of the MSIsafesoft configuration software.

Leuze electronic MSI 100/200 33

MSI 100 and MSI 200 safety modules

3.4.5 Ground-switching outputs

O0- and O1- The ground-switching outputs O0- and O1- increase the shutdown protection and cross-circuit

protection of the safety system. For example, these outputs can be used to disconnect a contactor connected to the safety module both via the safe 24 V output and via ground.

The ground-switching outputs are assigned to the safe outputs as follows and can only be used in the respective combination:

– Ground-switching output O0- to output O0 – Ground-switching output O1- to output O1

In order to use the ground-switching outputs, perform the corresponding configuration for outputs O0 and O1 in the MSIsafesoft configuration software.

For more detailed information, please see topic "Configuring the I/Os of the safety module" in the help system.

3.4.6 Supply connections

WARNING: Loss of the safety function

The use of unsuitable voltage supplies and the incorrect connection of the voltage supply can result in the loss of the safety function.

• Only supply the supply voltage at connections A1/A2 and 24/0V on the base device of

a MSI 100/200 system via the same voltage supply.

• Likewise, supply the supply voltage for all other devices participating in the system via

the same voltage supply.

• Only use power supply units with safe insulation and SELV/PELV in accordance with

EN 50178 / VDE 0160.

WARNING: Loss of the safety function through interference

EMC interference can lead to the loss of the safety function.

• Connect the output-side GND connection of the power supply unit to the functional earth

(FE) of the system.

Connect the two supply connections (A1/A2 and 24V/0V) for an intended function of the safety module.

24V/0V The 24V/0V supply connection is used to supply the safe outputs of the safety module as well

as the ground-switching outputs with voltage.

Leuze electronic MSI 100/200 34

MSI 100 and MSI 200 safety modules

A1/A2 Supply connection A1/A2 is used to supply the logic of the safety module as well as the clock

and signal outputs with voltage.

Double terminal contacts A1/A1 and A2/A2

The double terminal contacts A1/A1 and A2/A2 are looped through and can be used to supply other modules or sensors.

ATTENTION: Module defect

The module can be permanently destroyed by an excessive current load.

• Observe the maximum permissible continuous current for devices connected to termi-

nals A1 and A2

Limiting continuous current for looped-through current paths A1/A1 and A2/A2: see "Limiting continuous current" on page 101.

At the double terminal contacts, 2 and 3-conductor sensors and command devices can be supplied directly by the safety module (UN = 24 V DC).

WARNING: Loss of the safety function through parasitic voltages

With 3-conductor sensors, make certain that the GND potential of the sensor/command device is the same as the GND potential of the safety module.

Leuze electronic MSI 100/200 35

MSI-EM200-8I4IO safe extension module

4 MSI-EM200-8I4IO safe extension module

4.1 Product description

Observe the technical data of the safe extension module.  See "Technical data MSI-EM200-8I4IO" on page 107.

Extension module for

MSI 200

The MSI-EM200-8I4IO safe extension module makes additional configurable inputs and outputs available for the MSI 200 safety module. Depending on the configuration, the inputs and outputs are used for connecting safe command devices and sensors or actuators.

Safe digital  inputs/outputs

The extension module has eight safe digital inputs.

You can configure another four signals as either safe digital inputs or outputs. The signal direction (input or output) can only be changed over block by block, i.e., for all four signals at once.

The outputs are actuated depending on the safety logic, which is executed in the MSI 200 safety module.

Digital  clock/signal outputs  (configurable)

The extension module has two digital clock/signal outputs, which are configurable.

If you configure the outputs as clock outputs, they will support cross-circuit detection at the inputs of the safe extension module.

If you configure the outputs as signal outputs, you thereby control, e.g., a non-safe PLC or signal units. The signal outputs are not safety-oriented.

Connection technology The extension module is available with either screw connections or with spring-cage connec-

tions. All connection terminals are pluggable. The individual terminal blocks are mechanically coded to prevent swapping or skewed plug in.

Connection variants

TM0

MSI-EM200-8I4IO

TM1

IO3

PWR

ERR

I11

I4 I5

I6 I7

I8 I9

0I11

I10

MSI-EM200-8I4IO

PWR

IO0 IO1 IO2 IO

IO0

IO1

TM1

IO3

ERR

Figure 4-1 Screw terminals (left) and spring-cage terminals (right)

Leuze electronic MSI 100/200 36

Block diagram

TM0 TM1

A1 A2 IO0 IO1 IO2 IO3

I4 I5 I11

MSI-TBUS

EFAS

EF AS

POWER 24V DC

TEST PULSE/ MONITORING

OUTPUT

SAFE INPUT

LOGIC

SAFE INPUT/

OUTPUT

Status indicators  IO0 to IO3

Diagnostic indicators

Status indicators

I0 to I11

MSI-EM200-8I4IO safe extension module

Figure 4-2 MSI-EM200-8I4IO block diagram

4.2 Diagnostic and status indicators

Figure 4-3 Diagnostic and status indicators MSI-EM200-8I4IO

Diagnostic indicators The two diagnostic indicators on the front side display the operating status of the extension

module.

Table 4-1 MSI-EM200-8I4IO LED diagnostic indicators

LED Color Description

PWR Green Indicator for the voltage supply of the extension module

ERR Red Error display

Status indicators The state of each of the eight safe inputs and the four configurable safe inputs/outputs is indi-

cated by a separate LED on the front side of the device.

A detailed list of possible indicator combinations for diagnostic and status indicators and their meanings can be found in Chapter "Diagnosis" on page 89.

Leuze electronic MSI 100/200 37

MSI-EM200-8I4IO safe extension module

Outputs, configurable as clock outputs or as non-safe signal outputs  (TM0, TM1)

Supply connection for

clock/signal outputs and

inputs/outputs (A1/A2)

Safe inputs (I4-I11)

Signals, configurable block by

block as safe inputs or as safe

outputs (IO0 -IO3)

Supply connection for the module via MSI-TBUS on the rear side

4.3 Signal connections

All of the inputs and outputs are connected using pluggable and coded connection terminals.

Figure 4-4 Signal connections MSI-EM200-8I4IO

4.3.1 Safe inputs

 The safe digital inputs are used for the direct connection of safe command devices or safety

sensors.

I4 to I11 IO0 to IO3 as inputs

The safe extension module has eight permanent safe digital inputs I4 to I11. Another four safe digital inputs IO0 to IO3 can be obtained through appropriate configuration.

The inputs/outputs are configured with the help of the configuration editor of the MSIsafesoft configuration software. The safe inputs are linked to the safety logic in the connection editor of the configuration software.

The signal direction (input or output) can only be selected for IO0 to IO3 block by block, i.e., for all four signals at once.

Conditions for IO0 to IO3 as inputs:

If you use configurable inputs/outputs IO0 to IO3 as inputs, it is mandatory that cross-circuit detection be implemented with the extension module. To do this, power the affected inputs via clock outputs TM0 or TM1 of the extension module. See also chapter "Clock/signal outputs" on page 39.

You can find further information on configuring and linking the safe inputs in the help system of the MSIsafesoft configuration software.

There, you will also find information on the topics relevant to the safe inputs: signal redundancy due to dual signals, two-channel sensors and cross-circuit detection.



IO0 to IO3 as outputs Signals IO0 to IO3 can be configured as safety-related outputs and implemented as digital

Leuze electronic MSI 100/200 38

4.3.2 Safe outputs

semiconductor outputs.

ATTENTION: Module defect

Inductive loads can destroy the outputs.

• Use a suitable and effective protective circuit.

• The protective circuit is to be parallel to the load, not parallel to the switching contact.

• Prevent feedback to the outputs.

The outputs are actuated depending on the safety logic, which is executed in the MSI 200 safety module.

MSI-EM200-8I4IO safe extension module

The safe outputs are linked to the safety logic in the connection editor of the MSIsafesoft configuration software.

You can find further information on configuring and linking the safe outputs in the help system of the MSIsafesoft configuration software.

Test pulses The safe output signals are clocked with a test pulse.

Reduced availability through test pulses

Test pulses can reduce the availability of the machine or system.

• Make certain that the connected load does not react to the test pulses.

• Use an appropriate filter terminal block if necessary.

4.3.3 Clock/signal outputs

TM0 and TM1 You can configure outputs TM0 and TM1 of the extension module as either non-safety-rele-

vant digital signal outputs or as safe clock outputs.

The outputs are configured with the help of the configuration editor of the MSIsafesoft configuration software.

You can find further information on configuring and linking the clock/signal outputs in the configuration editor in the help system of the MSIsafesoft configuration software.

Leuze electronic MSI 100/200 39

MSI-EM200-8I4IO safe extension module

TM0 and TM1 as  signal outputs

TM0 and TM1 as  clock outputs

If you configure outputs TM0 and TM1 as signal outputs, you thereby control, e.g., a non-safe PLC or signal units.

Make certain that the GND potential of the signal receiver is the same as the GND potential of the safety module.

The non-safety-relevant signal outputs are designed as digital semiconductor outputs.

ATTENTION: Module defect

The signal outputs can be destroyed by incorrect wiring.

• Do not connect the signal outputs in parallel.

• Prevent feedback to the signal outputs.

Configure the two outputs TM0 and TM1 as signal outputs by making the following settings in the configuration editor in MSIsafesoft. The signal outputs can only be configured together.

• For TM0 to TM1, set the "Configuration" parameter to the value "Signal output - M0 to M1".

The signal outputs are linked in the connection editor of the MSIsafesoft configuration software.

You can find further information on linking the signal outputs in the connection editor in the help system of the MSIsafesoft configuration software.

If you configure outputs TM0 and TM1 as clock outputs, they will support cross-circuit detection at the inputs of the safe extension module. See chapter "Error detection" on page 21.

If you use configurable inputs/outputs IO0 to IO3 as inputs, it is mandatory that cross-circuit detection be implemented with the extension module, i.e., the affected inputs must be supplied via clock outputs TM0 or TM1 of the extension module. See Chapter "Safe inputs" on page 38.

If you use configurable inputs/outputs IO0 to IO3 as outputs, configuring TM0 and TM1 as clock outputs results in an error.

Configure the two outputs TM0 or TM1 as clock outputs by making the following settings in the safe configuration editor. The clock outputs can only be configured together.

• For IO0 to IO3, set the "Signal configuration" parameter to the value "Configured as safe

inputs with test pulse"

• For TM0 to TM1, set the "Configuration" parameter to the value "Clock T0 to T1"

The test pulses output at outputs TM0 and TM1 (if the configuration settings have been made accordingly) are used for cross-circuit detection at the inputs of the extension module. The out put test pulses T0 and T1 are phase-shifted with respect to one another.

To implement cross-circuit detection, the relevant safe inputs must be configured accordingly using the configuration editor in MSIsafesoft.

Leuze electronic MSI 100/200 40

MSI-EM200-8I4IO safe extension module

The MSIsafesoft configuration software specifies the clock signals to be used as follows: – For the "even" inputs (IO0 and IO2 as well as I4 … I10), cross-circuit detection is realized

with the test pulse on TM0.

– For the "odd" inputs (IO1 and IO3 as well as I5 … I11), cross-circuit detection is realized

with the test pulse on TM1.

4.3.4 Supply connections

WARNING: Loss of the safety function

The use of unsuitable voltage supplies and the incorrect connection of the voltage supply can result in the loss of the safety function.

• Only supply the supply voltage at connections A1/A2 and 24/0V on the base device of

100/200 system via the same voltage supply.

a MSI

• Likewise, supply the supply voltage for all other devices participating in the system via

the same voltage supply.

• Only use power supply units with safe insulation and SELV/PELV in accordance with

50178 / VDE 0160.

WARNING: Loss of the safety function through interference

EMC interference can lead to the loss of the safety function.

• Connect the output-side GND connection of the power supply unit to the functional earth

(FE) of the system.

Connect the two supply connections (A1/A2 and MSI-TBUS) for an intended function of the safe extension module.

Yellow MSI-TBUS The logic of the MSI-EM200-8I4IO safe extension module is supplied with voltage via the yel-

low MSI-TBUS DIN rail connector.

ATTENTION: Module defect

The use of an incorrect DIN rail connector or of a terminating plug can result in a module defect.

• Only use the yellow MSI-TBUS DIN rail connector.

• Never use the green TBUS DIN rail connector.

A1/A2 Supply connection A1/A2 is used to supply the configurable inputs/outputs as well as the con-

figurable clock/signal outputs with voltage.

Leuze electronic MSI 100/200 41

MSI-EM200-4RO safe extension module

M0 M1 M2 M3

PWR

ERR

14 24

33 43

13 23

PWR

ERR

MSI-EM200-4RO

5 MSI-EM200-4RO safe extension module

5.1 Product description

Observe the technical data of the safe extension module, see "Technical data and ordering data" on page 101.

Extension module for

MSI 200

The MSI-EM200-4RO safe extension module makes additional relay outputs available to the MSI 200 safety module that you can connect to the actuator.

Safe relay outputs The extension module has four safe relay outputs. The outputs are actuated depending on the

safety logic, which is executed in the MSI 200 safety module.

Digital signal outputs The extension module has four non-safe digital signal outputs. The signal outputs are used to

control, e.g., a non-safe PLC or signal units.

Connection technology The extension module is available with either screw connections or with spring-cage connec-

tions. All connection terminals are pluggable. The individual terminal blocks are mechanically coded to prevent swapping or skewed plug in.

Connection variants

Figure 5-1 Screw terminals (left) and spring-cage terminals (right)

Leuze electronic MSI 100/200 42

MSI-EM200-4RO safe extension module

Logic

TBUS

SAFE

TBUS

SAFE

Monitoring

Outputs

A1 M0 M1 M2 M3A2

13 23 33

14 24 34

Power

24V DC

Block diagram

Figure 5-2 MSI-EM200-4RO block diagram

Insulation coordination The following table shows the insulation of the relay outputs between one another and for the

logic area of the device.

Table 5-1 Insulation coordination

A1A2

13/14 23/24 33/34 43/44

24V/0V

A1A2

- 6 kV ST 6 kV ST 6 kV ST 6 kV ST

24V/0V 13/14 - - 4 kV BI 4 kV BI 4 kV BI 23/24 - - - 4 kV BI 4 kV BI 33/34 - - - - 4 kV BI 43/44 - - - - -

Legend:

BI Basic insulation ST Safe insulation

Basic insulation

(Rated surge voltage 4 kV)

A mix of safe extra-low voltage and low voltage is not permitted.

Safe insulation / reinforced insulation

(Rated surge voltage 6 kV)

Reinforced insulation (e.g., through larger clearances and creepage distances of the conductor tracks) is designed to a higher overvoltage category than the basic insulation. It is, therefore, not possible to mix safe extra-low voltage circuits U

 25 V AC or U  60 V DC

and circuits with higher voltage.

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MSI-EM200-4RO safe extension module

Status indicators for safe

outputs

Diagnostic indicators

5.2 Diagnostic and status indicators

Figure 5-3 Diagnostic and status indicators MSI-EM200-4RO

Diagnostic indicators The two diagnostic indicators on the front side display the operating status of the extension

module.

Table 5-2 MSI-EM200-4RO LED diagnostic indicators

LED Color Description

PWR Green Indicator for the voltage supply of the extension module

ERR Red Error display

Status indicators The state of each of the four safe relay outputs is indicated by a separate LED on the front side

of the device.

A detailed list of possible indicator combinations for diagnostic and status indicators and their meanings can be found in

Chapter "Diagnosis" on page 89.

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MSI-EM200-4RO safe extension module

Supply connection for

signal outputs (A1/A2)

Safe relay outputs

(O0 - O3, corresponds to

13/14 - 43/44)

Non-safe

signal outputs (M0 - M3)

Supply connection for the module via MSI-TBUS on the rear side

5.3 Signal connections

All of the outputs are connected using pluggable and coded connection terminals.

Figure 5-4 Signal connections MSI-EM200-4RO

5.3.1 Safe relay outputs

O0 to O3 Outputs O0 to O3 are designed as safety-related relay outputs.

Table 5-3 Relay outputs

Output Relay contacts Output Relay contacts

O0 13/14 O2 33/34

O1 23/24 O3 43/44

WARNING: Loss of the safety function / hazardous body currents

Mixing different voltages (e.g., SELV/PELV with mains voltage) can destroy the relay contacts. The safety function can be lost and dangerous body currents may occur.

• Observe the information in Table 5-1 „Insulation coordination“ on page 43.

ATTENTION: Module defect

Inductive loads can destroy the outputs.

• Use a suitable and effective protective circuit.

• The protective circuit is to be parallel to the load, not parallel to the switching contact.

• Prevent feedback to the outputs.

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MSI-EM200-4RO safe extension module

You can use the relay outputs as follows: – Single-channel assignment – Two-channel assignment

More detailed information on the assignment can be found in the following table.

Table 5-4 Assignment of the relay outputs

Assignment Number of outpu t s Comment

Two-channel 2 two-channel relay outputs

(wired in pairs)

Pair 1: 13/14 and 23/24 

(bridge between contacts 13/23)

Pair 2: 33/34 and 43/44 

(bridge between contacts 33/43)

One-channel 4 single-channel relay out-

puts – 13/14 – 23/24 – 33/34 – 43/44

Prerequisite: The bridges between con-

tacts 13/23 and 33/43 are plugged-in and the configuration has been performed accordingly.

Info: The pairwise wiring of the relay out-

puts corresponds to the factory settings.

Prerequisite: The bridges between con-

tacts 13/23 and 33/43 are removed and the configuration has been performed accord ingly.

Note for cat. 4 applications:

To achieve cat. 4 acc. to EN ISO 13849-1, wire the relay outputs in pairs (two-channel assignment).

The outputs are actuated depending on the safety logic, which is executed in the MSI 200 safety module.

The safe relay outputs are linked to the safety logic in the connection editor of the MSIsafesoft configuration software.

You can find further information on configuring and linking the safe outputs in the help system of the MSIsafesoft configuration software.

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MSI-EM200-4RO safe extension module

5.3.2 Signal outputs

M0 to M3 The non-safety-relevant signal outputs M0 to M3 are designed as digital semiconductor out-

puts.

ATTENTION: Module defect

The signal outputs can be destroyed by incorrect wiring.

• Do not connect the signal outputs in parallel.

• Prevent feedback to the signal outputs.

The signal outputs are used to control, e.g., a non-safe PLC or signal units.

Make certain that the GND potential of the signal receiver is the same as the GND potential of the safety module.

The signal outputs are linked in the connection editor of the MSIsafesoft configuration software.

You can find further information on linking the signal outputs in the connection editor in the help system of the MSIsafesoft configuration software.

5.3.3 Supply connections

WARNING: Loss of the safety function

The use of unsuitable voltage supplies and the incorrect connection of the voltage supply can result in the loss of the safety function.

• Only supply the supply voltage at connections A1/A2 and 24/0V on the base device of

a MSI 100/200 system via the same voltage supply.

• Likewise, supply the supply voltage for all other devices participating in the system via

the same voltage supply.

• Only use power supply units with safe insulation and SELV/PELV in accordance with

EN 50178 / VDE 0160.

Connect the two supply connections (A1/A2 and MSI-TBUS) for an intended function of the safe extension module.

Yellow MSI-TBUS The logic of the MSI-EM200-4RO safe extension module is supplied with voltage via the yellow

MSI-TBUS DIN rail connector.

ATTENTION: Module defect

The use of an incorrect DIN rail connector or of a terminating plug can result in a module defect.

• Only use the yellow MSI-TBUS DIN rail connector.

• Never use the green TBUS DIN rail connector.

Leuze electronic MSI 100/200 47

MSI-EM200-4RO safe extension module

A1/A2 Supply connection A1/A2 is used to supply the signal outputs of the safe extension module

with power.

Double terminal contacts A1/A1 and A2/A2

The double terminal contacts A1/A1 and A2/A2 are looped through and can be used to supply other modules or sensors.

ATTENTION: Module defect

The module can be permanently destroyed by an excessive current load.

• Observe the maximum permissible continuous current for devices connected to termi-

nals A1 and A2

Limiting continuous current for looped-through current paths A1/A1 and A2/A2: see "Limiting continuous current" on page 101.

At the double terminal contacts, 2 and 3-conductor sensors and command devices can be supplied directly by the safety module (UN = 24 V DC).

WARNING: Loss of the safety function through parasitic voltages

With 3-conductor sensors, make certain that the GND potential of the sensor/command device is the same as the GND potential of the safety module.

Leuze electronic MSI 100/200 48

6 Wiring examples

6.1 Information on the wiring examples

In the following examples, clock outputs T0 and T1 are used.

With safe extension module MSI-EM200-8I4IO, these correspond to clock outputs TM0 and TM1 if they are configured as clock outputs.

Terminals IO0 to IO3 of safe extension module MSI-EM200-8I4IO function as inputs if they are appropriately configured as inputs.

6.2 Single-channel assignment of the safe digital inputs

With the single-channel assignment of the safe digital inputs, the inputs function independent of one another.

6.2.1 Cross circuit monitoring switched on

Wiring examples

If an input pair is configured single-channel with cross circuit monitoring, the following permanent assignment applies:

– – All "even" inputs I0, I2, … are permanently assigned to clock output T0. – – All "odd" inputs I1, I3, … are permanently assigned to clock output T1.

Figure 6-1 Single-channel assignment of the inputs

Key dates

Sensor Sensor supply Attainable safety integrity

Configuration Configured as Input xx channel 1/channel 2

Cross circuit monitoring Yes, with test pulse T0 for all "even" inputs I0, I2, …

One-channel

Internally through clock output T0 (clocked) or T1 (clocked)

SIL 1/SILCL 1/Cat. 1/PL c

Example configuration

Yes, with test pulse T1 for all "odd" inputs I1, I3, …

Legend:

S1 Safety switches I0 Input T0 Clock output

Leuze electronic MSI 100/200 49

Wiring examples

6.2.2 Cross circuit monitoring switched off, external supply

+24 V

Figure 6-2 Single-channel assignment of the inputs: external supply

Key dates

Sensor Sensor supply Attainable safety integrity

Configuration Configured as Input xx channel 1/channel 2

Cross circuit monitoring No

Single-channel switch

External (24 V, note potential reference)

SIL 1/SILCL 1/Cat. 1/PL c

WARNING: Loss of the safety function

Cross circuits can lead to the loss of the safety function.

• Exclude the possibility of cross circuits in order to be able to achieve the specified safety

integrity.

Example configuration

Legend:

S1 Safety switches I0 Input +24 V Supplied by external 24 V (note

potential reference)

Leuze electronic MSI 100/200 50

6.2.3 External supply (OSSD)

Wiring examples

Sensor Sensor supply Attainable safety integrity

+24 V

OSSD

Figure 6-3 Single-channel assignment of the inputs: external supply (OSSD)

WARNING: Loss of the safety function

Parasitic voltages can lead to the loss of the safety function.

• Exclude the possibility of parasitic voltages through appropriate wiring.

Key dates

Single-channel OSSD output (with internal testing)

External (OSSD sensor)

SIL 1/SILCL 1/Cat. 1/PL c

WARNING: Loss of the safety function

Cross circuits can lead to the loss of the safety function.

• Exclude the possibility of cross circuits in order to be able to achieve the specified safety

integrity.

Legend:

OSSD OSSD sensor I0 Input +24 V Supplied by external 24 V 0 V External 0 V (note potential refer-

ence)

Example configuration

Configuration Configured as Input xx channel 1/channel 2

Cross circuit monitoring No

Leuze electronic MSI 100/200 51

Wiring examples

6.3 Two-channel equivalent assignment of the safe digi-

tal inputs

With the two-channel assignment of the inputs, two adjacent inputs of the same connector are used.

For two-channel equivalent assignment of the inputs, use the "equivalent" function module in the MSIsafesoft configuration software.

The function description of the module can be found in the help system of the software.

6.3.1 Cross circuit monitoring switched on, supplied by T0 and T1

Possible wiring variants:

Figure 6-4 Two-channel equivalent assignment of the inputs, supplied by T0 and T1 (both

clocked)

Key dates

Sensor Sensor supply Attainable safety integrity

Configuration Configured as Input xx channel 1/channel 2

Cross circuit monitoring Yes, with test pulse T0 at I0

Two-channel equivalent with cross circuit monitoring

Internal by clock outputs T0 and T1 (both clocked)

SIL 3/SILCL 3/Cat. 4/PL e

Example configuration

Yes, with test pulse T1 at I1

Legend:

S1, S2 Switching elements I0, I1 Inputs T0, T1 Supplied by T0 and T1

Leuze electronic MSI 100/200 52

Wiring examples

+24 V

6.3.2 Cross circuit monitoring switched off, external supply

Legend:

S1, S2 Switching elements I0, I1 Inputs +24 V Supplied by external 24 V (note

potential reference)

Figure 6-5 Two-channel equivalent assignment of the inputs, external supply, cross cir-

cuit monitoring switched off

Key dates

Sensor Sensor supply Attainable safety integrity

Configuration Configured as Input xx channel 1/channel 2

Cross circuit monitoring No

Two-channel equivalent

External (24 V, note potential reference)

SIL 3/SILCL 3/Cat. 3/PL d

WARNING: Loss of the safety function

An accumulation of errors can lead to the loss of the safety function.

• Test the safety function at appropriate time intervals to detect errors in good time.

Example configuration

Leuze electronic MSI 100/200 53

Wiring examples

OSSD

+24 V

6.3.3 External supply (OSSD)

Legend:

OSSD OSSD sensor I0, I1 Inputs +24 V Supplied by external 24 V

0 V External 0 V (note potential refer-

ence)

Figure 6-6 Two-channel equivalent assignment of the inputs, external supply (OSSD)

WARNING: Loss of the safety function

Parasitic voltages can lead to the loss of the safety function.

• Exclude the possibility of parasitic voltages through appropriate wiring.

Key dates

Sensor Sensor supply Attainable safety integrity

Configuration Configured as Input xx channel 1/channel 2

Cross circuit monitoring No

Two-channel OSSD output (with internal testing)

External (OSSD sensor)

SIL 3/SILCL 3/Cat. 4/PL e

Example configuration

Leuze electronic MSI 100/200 54

Wiring examples

6.4 Two-channel antivalent assignment of the safe digital

inputs

With the two-channel assignment of the inputs, two adjacent inputs of the same connector are used.

For two-channel antivalent assignment of the inputs, use the "antivalent" function module in the MSIsafesoft configuration software.

The function description of the module can be found in the help system of the software.

6.4.1 Cross circuit monitoring switched on, supplied by T0 and T1

Possible wiring variants:

Figure 6-7 Two-channel antivalent assignment of the inputs, supplied by T0 and T1, cross

circuit monitoring switched on

Key dates

Sensor Sensor supply Attainable safety integrity

Configuration Configured as Input xx channel 1/channel 2

Cross circuit monitoring Yes, with test pulse T0 at I0

Two-channel antivalent

Internal by clock output T0 and T1, cross circuit monitoring switched on

SIL 3/SILCL 3/Cat. 4/PL e

WARNING: Loss of the safety function

An accumulation of errors can lead to the loss of the safety function.

• Test the safety function at appropriate time intervals to detect errors in good time.

Example configuration

Yes, with test pulse T1 at I1

Legend:

S1, S2 Switching elements I0, I1 Inputs T0, T1 Supplied by T0 and T1

Leuze electronic MSI 100/200 55

Wiring examples

6.4.2 Cross circuit monitoring switched off, external supply

+24 V

Figure 6-8 Two-channel antivalent assignment of the inputs, external supply

Key dates

Sensor Sensor supply Attainable safety integrity

Configuration Configured as Input xx channel 1/channel 2

Cross circuit monitoring No

Two-channel antivalent

External (24 V, note potential reference)

SIL 3/SILCL 3/Cat. 3/PL d

WARNING: Loss of the safety function

An accumulation of errors can lead to the loss of the safety function.

• Test the safety function at appropriate time intervals to detect errors in good time.

Example configuration

Legend:

S1, S2 Switching elements I0, I1 Inputs +24 V Supplied by external 24 V (note

potential reference)

Leuze electronic MSI 100/200 56

Wiring examples

6.5 Safe digital outputs

6.5.1 Information on the protective circuitry of external relays/con-

tactors (freewheeling circuit)

Possible wiring variants:

Figure 6-9 Example for the freewheeling circuit of an external relay

Observe the following measures:

• Limit the inductive cut-off voltage to < –15 V (e.g, with RC elements, suppressor diodes

or varistors).

• Note that the freewheeling circuit affects the decay time and the life expectancy of the con-

tactor.

• When dimensioning the protective circuit of the relay, take into account the information

provided by the relay manufacturer.

Leuze electronic MSI 100/200 57

Wiring examples

K2 (R)

K1 (R)

0V (O0-)

6.5.2 Single-channel assignment of the safe digital outputs

Legend:

O0, 0V, O0-

K1, K2 External relays/contactors K1(R),

K2(R)

Figure 6-10 Single-channel assignment of the outputs

K1 (R) and, where applicable, K2 (R) represent the forced normally closed contacts for state monitoring of the relays (readback contacts).

• Connect these contacts via safe digital inputs.

• Evaluate the readback and, thus, the state of the switching elements in the safe applica-

tion program.

Outputs

Forced normally closed contacts

Actuator Attainable safety integrity

WARNING: Loss of the safety function

Parasitic voltages can lead to the loss of the safety function.

• Exclude the possibility of parasitic voltages through appropriate wiring.

Key dates

One-channel Two-channel

SIL 1/SILCL 1/Cat. 1/PL c SIL 3/SILCL 3/Cat. 4/PL e

Leuze electronic MSI 100/200 58

Wiring examples

K2 (R

K1 (R

0V (O0-)

0V (O1-)

6.5.3 Two-channel assignment of the safe digital outputs

Legend:

O0, 01, O0-, O1-, 0V

K1, K2 External relays/contactors K1(R),

K2(R)

Figure 6-11 Two-channel assignment of the outputs

K1 (R) and K2 (R) represent the forced normally closed contacts for state monitoring of the relays (readback contacts).

• Connect these contacts via safe digital inputs.

• Evaluate the readback and, thus, the state of the switching elements in the safe applica-

tion program.

Outputs

Forced normally closed contacts

Actuator Attainable safety integrity

WARNING: Loss of the safety function

Parasitic voltages can lead to the loss of the safety function.

• Exclude the possibility of parasitic voltages through appropriate wiring.

Key dates

Two-channel

SIL 3/SILCL 3/Cat. 4/PL e

Leuze electronic MSI 100/200 59

Wiring examples

O0_13

O0_14

+24 V

400 V

6.6 Safe relay outputs

6.6.1 Information on the protective circuitry of external relays/con-

tactors (freewheeling circuit)

Figure 6-12 Example for the freewheeling circuit of an external relay

A protective circuit via the relay contacts is not permissible.

6.6.2 Single-channel assignment of the safe relay outputs

With single-channel assignment, the safety relays operate independent of one another. They are actuated individually.

Actuator Attainable safety integrity

Legend:

O0_xx Relay outputs +24 V Switching voltage (external) 400 V Actuator voltage



Figure 6-13 Single-channel assignment of the relay outputs

Optional readback of the actuator is possible via the safe inputs of the MSI 100/200 system.

Information on switching other voltages: see chapter 14 „Technical data and ordering data“.

Key dates

One-channel

SILCL 1/Cat. 1/PL c

Example configuration

Possible readback

Configuration Configured as

Signal configuration Single-channel (O0 and O1 switch independently)

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Wiring examples

6.6.3 Single-channel assignment of the safe relay outputs

With two-channel assignment, the safety relays of both channels work together. This assignment is permanent and cannot be configured.

+24 V

O0_13

Legend:

O0_xx,

Relay outputs

O1_xx

O0_14

400 V

K1 (R)

+24 V Switching voltage (external) 400 V Actuator voltage K1, K2 External relays/contactors

O1_23

O1_24

+24 V

K2 (R)

K1(R), K2(R)



Forced normally closed contacts

Possible readback

Figure 6-14 Two-channel assignment of the relay outputs

A possible readback of the actuator is possible via the safe inputs of the MSI 100/200 system.

Information on switching other voltages: see chapter 14.3 „Technical data MSI-EM2004RO“.

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Mounting, removal and electrical installation

7 Mounting, removal and electrical installation

7.1 Safety notices for mounting, removal and electrical

installation

Qualified personnel Mounting, removal and electrical installation of the MSI 100/200 system may only be per-

formed by qualified personnel. See "Qualified personnel" on page 10.

WARNING: Serious personal injury or material damage

Disregarding this warning may result in damage to equipment and/or serious personal injury.

WARNING: Dangerous voltage

Mounting, removal and electrical installation without ensuring that the system is free of voltage can result in dangerous electric shocks.

• Perform mounting, removal and electrical installation of the safety modules and safe

extension modules only in a voltage-free state.

• De-energize the entire system before performing installation work and secure the sys-

tem against unintentional switching-on of the voltage.

• Only switch voltage on after completing the setting and the system can no longer pose

a hazard.

WARNING: Unintended machine start-up

Mounting, removal and electrical installation without ensuring that the system is free of voltage can result in unintended machine start-up.

• Perform mounting, removal and electrical installation of the safety modules and safe

extension modules only in a voltage-free state.

• De-energize the entire system before performing installation work and secure the sys-

tem against unintentional switching-on of the voltage.

• Only switch voltage on after completing the setting and the system can no longer pose

a hazard.

ATTENTION: Electrostatic discharge

The modules contain components that can be damaged or destroyed by electrostatic discharge. When handling the modules, take the necessary safety precautions against electrostatic discharge (ESD) according to EN 61340-5-1 and IEC 61340-5-1.

Leuze electronic MSI 100/200 62

Mounting, removal and electrical installation

7.2 Mounting

7.2.1 Mounting instructions

ATTENTION: Property damage

Improper mounting can result in property damage.

• When mounting the MSI 100/200 system, observe the following instructions.

Table 7-1 Important mounting instructions

Connection via DIN rail connectors

MSI-TBUS To connect the MSI 100 and MSI 200 safety modules as well as the MSI-EM200-8I4IO and

MSI-EM200-4RO safe extension modules, use only the yellow MSI-TBUS DIN rail connec tor.

Connection with another DIN rail connector is not permitted.

TBUS For the connection of non-safe extension devices (gateways), use only the green TBUS

DIN rail connector.

Connection with another DIN rail connector is not permitted.

Mounting direction for extensions

Non-safe extension: left

Safe extension: right

Maximum number of extension devices

Non-safe extension Connect a maximum of one non-safe extension device (gateway) to the MSI 100 or

Safe extension Connect a maximum of ten safe extension modules to the MSI 200 safety module.

Mount a non-safe extension module (gateway) to the left of the MSI 100 or MSI 200 safety module.

Mount the MSI-EM200-8I4IO and/or MSI-EM200-4RO safe extension modules to the right of the MSI 200 safety module.

200 safety module.

MSI

You can find a graphical depiction of an MSI 100/200 system extended with MSI-TBUS and TBUS in Figure 2-2 on page 17.

7.2.2 Mounting location

• Mount the module in a dust- and humidity-protected switch cabinet or terminal box (IP54

or higher).

• Secure the switch cabinet/terminal box against opening by unauthorized persons.

Leuze electronic MSI 100/200 63

Mounting, removal and electrical installation

DIN rail connector

7.2.3 Mounting

35 mm DIN rail The modules of the MSI 100/200 system are intended only for mounting on 35 mm DIN rails

acc. to EN 60715. To avoid contact resistance, only use clean and corrosion-free DIN rails.

TBUS / MSI-TBUS DIN rail connectors (optional)

Mounting the MSI 100/200 module

1. Optional: If you would like to use the DIN rail connectors to create a connection station

with extension units, proceed as follows. b) Connect the required number of DIN rail connectors for the connection station (see

Figure 7-1, A).

c) Snap this group of DIN rail connectors onto the DIN rail (see steps B and C).

Figure 7-1 Mounting DIN rail connectors

2. Place the module onto the DIN rail from above so that the upper retaining groove of the module is hooked onto the top edge of the DIN rail (see

ATTENTION: Module defect

The use of an incorrect DIN rail connector or of a terminating plug can result in a module defect.

• Use only the yellow MSI-TBUS DIN rail connector for safe extension modules.

• For non-safe extension devices, use the green TBUS DIN rail connector.

Figure 7-2).

ATTENTION: Damage to the connectors

When using DIN rail connectors, ensure that the contact opening in the base of the module is aligned correctly over the contact block of the DIN rail connector.

ATTENTION: Connector wear

The modules may be connected to the DIN rail connectors a maximum of eight mating cycles.

Leuze electronic MSI 100/200 64

Mounting, removal and electrical installation

Figure 7-2 Mounting a MSI 100/200 module on the DIN rail

3. Push the lower part of the module that is furthest from the DIN rail towards the DIN rail until it engages with a click.

4. Check that the module is fixed securely on the DIN rail.

5. When mounting additional modules on the DIN rail (e.g., gateways or power supply units), place them on the DIN rail with no spacing, i.e., in direct contact with the sides of the housing.

6. Mount a standard end clamp for 35 mm DIN rails (TS 35) on both sides of the module or module group. This prevents the modules from sliding and protects against faulty connection with other modules on the DIN rail. You thereby also avoid an accidental connection of other DIN rail connectors.

7.3 Removal

1. Pull the locking latch on the bottom of the module down using a screwdriver, for example, to release the module from the DIN rail.

2. Slightly lift the bottom of the module away from the DIN rail.

3. Pull the module diagonally upwards away from the DIN rail.

Leuze electronic MSI 100/200 65

Mounting, removal and electrical installation

7mm

I12

I13

I10

I14

I11

I15

I16

I17

I18

I19

www

.leuze.de/M

Screw  terminals

0,5-0,6 Nm 5-7 lb In

8mm

I12

I13

I10

I14

I11

I15

I16

I17

I18

I19

CON

w.leuze.de/MS

Spring-cage terminals

7.4 Electrical installation

For reliable and touch-safe contacts, isolate the connection ends for all modules of the

100/200 system as follows:

MSI

Figure 7-3 Connecting to screw terminals

Figure 7-4 Connecting to spring-cage terminals

Wire-end sleeves are recommended when using flexible cables.

To maintain UL approval, use copper cables that are designed for operating temperatures of > 75 °C.

Leuze electronic MSI 100/200 66

Mounting, removal and electrical installation

7.4.1 Connecting signal lines

Observe manufacturer's  specifications

Ensure signal  redundancy

Cable lengths Many applications use large numbers of sensors or command devices. Depending on the size

Connect the sensors and actuators according to your safety requirements and the respective manufacturer specifications.

Ensure signal redundancy when connecting the signal lines of two-channel command devices and sensors to the inputs of the safety modules.

WARNING: Loss of the safety function through cross circuits and short circuits

Cross circuits and short circuits can lead to the loss of the safety function.

• Prevent cross circuits and short circuits by using a suitable cable installation.

• Implement cross-circuit detection.

You can find further information on the topics of signal redundancy through dual signals, twochannel sensors and cross-circuit detection in the help system of the MSIsafesoft configuration software.

of the machine or system, a considerable amount of cabling may be required to wire the sensors.

WARNING: Loss of the safety function through interference

To avoid interference, always cover both cable ends at the inputs as well as the outputs.

ATTENTION: Reduced availability through excessively long cables

If the maximum permissible cable lengths are exceeded, the safety modules automatically trigger the safety function, even if it was not requested. Your system thereby suffers an unwanted reduction in availability.

• Do not exceed the maximum permissible cable lengths.

See "Maximum cable lengths" for the safe inputs of the MSI 100/200 modules on pages 101 and 101.

MSI 100 and MSI 200 Conne cting signal lines for the safety modules:

1. Connect the sensors to safe inputs I0 to I19.

2. Connect the actuators to safe outputs O0 to O3.

3. Optional: Also connect the actuators to ground-switching outputs O0- (assigned to O0) and O1- (assigned to O1) to increase the shutdown protection and cross-circuit protection.

4. Optional: Implement a signaling function by, e.g., connecting a non-safe PLC or a signal unit to signal outputs M0 to M3.

5. Optional: Implement cross-circuit detection for the "even" inputs I0, I2, I4, … I18 by wiring these to clock output T0. For the "odd" inputs I1, I3, I5, … I19, use clock output T1.



Leuze electronic MSI 100/200 67

Mounting, removal and electrical installation

Connecting signal lines for the MSI-EM200-8I4IO safe extension module:

MSI-EM200-8I4IO IO0 to IO3 as inputs:

1. Connect the sensors to safe inputs I4 to I11.

2. Connect the sensors to safe inputs IO0 to IO3.

3. Mandatory: Implement cross-circuit detection for inputs IO0 to IO3 by wiring these to clock outputs TM0 and TM1.

IO0 to IO3 as outputs:

1. Connect the sensors to safe inputs I4 to I11.

2. Connect the actuators to safe outputs IO0 to IO3.

3. Optional: Implement a signaling function by, e.g., connecting a non-safe PLC or a signal unit to the outputs configured as signal outputs TM0 and TM1.

4. Optional: Implement cross-circuit detection for inputs I4 to I11 by wiring these to the outputs configured as clock outputs TM0 and TM1.

Connecting signal lines for the MSI-EM200-4RO safe extension module:

MSI-EM200-4RO 1. Connect the actuators to safe relay outputs O0 to O3.

2. Optional: Implement a signaling function by, e.g., connecting a non-safe PLC or a signal unit to signal outputs M0 to M3.

Leuze electronic MSI 100/200 68

Mounting, removal and electrical installation

7.4.2 Connecting the supply voltage

Switching on

The modules of the MSI 100/200 system have no main switch. You switch them on by applying the supply voltage.

Once the supply voltage has been applied, the modules execute an initialization routine (all LEDs illuminate). Once the "PWR" status indicator lights up permanently, the respective

100/200 module is ready to operate.

MSI

MSI 100 and MSI 200 Connecting the supply voltage for the safety modules:

1. Connect the supply voltage to terminal points A1 (24 V DC) and A2 (0 V).

Connections A1/A2 supply the logic as well as the clock and signal outputs of the safety modules.

2. Connect the supply voltage to terminal points 24V and 0V.

Connections 24V/0V supply the safe outputs and the ground-switching outputs of the safety modules.

WARNING: Loss of the safety function

The use of unsuitable voltage supplies and the incorrect connection of the voltage supply can result in the loss of the safety function.

• Only supply the supply voltage at connections A1/A2 and 24/0V on the base device of

100/200 system via the same voltage supply.

a MSI

• Likewise, supply the supply voltage for all other devices participating in the system via

the same voltage supply.

• Only use power supply units with safe insulation and SELV/PELV in accordance with

50178 / VDE 0160.

Connect the two supply connections (A1/A2 and 24V/0V) for an intended function of the safety module.

Leuze electronic MSI 100/200 69

Mounting, removal and electrical installation

Connections

24 V DC / 0 V

"PWR" diagnostic

indicator

Connections A2 (2 terminals each)A1

Figure 7-5 Connecting the MSI 100/200 supply voltage

Double terminal contacts A1 and A2 provide the supply voltage for supplying other sensors and command devices.

Also read chapter "Ground-switching outputs" on page 34.

Leuze electronic MSI 100/200 70

Mounting, removal and electrical installation

Connections

A1 (24 V DC)

and A2 (0 V)

"PWR" diagnostic indicator

Supply connection for the

module via MSI-TBUS on the

rear side

MSI-EM200-8I4IO and MSI-EM200-4RO

Connecting the supply voltage for the safe extension modules:

1. Connect the supply voltage to terminal points A1 (24 V DC) and A2 (0 V) of the respective

safe extension module.

Connections A1/A2 supply the clock/signal outputs as well as the inputs and outputs (MSI-EM200-8I4IO) or the signal outputs (MSI-EM200-4RO).

The logic of the safe extension modules is supplied with voltage via the yellow MSI-TBUS DIN rail connector.

WARNING: Loss of the safety function

The use of unsuitable voltage supplies and the incorrect connection of the voltage supply can result in the loss of the safety function.

• Only supply the supply voltage at connections A1/A2 and 24/0V on the base device of

a MSI 100/200 system via the same voltage supply.

• Likewise, supply the supply voltage for all other devices participating in the system via

the same voltage supply.

• Only use power supply units with safe insulation and SELV/PELV in accordance with

50178 / VDE 0160.

Connect the two supply connections (A1/A2 and MSI-TBUS) for an intended function of the safe extension modules.

Figure 7-6 Connecting the supply voltage 

MSI-EM200-8I4IO and MSI-EM200-4RO

Also read: – MSI-EM200-8I4IO: "Supply connections" on page 41 – MSI-EM200-4RO: "Supply connections" on page 47

Leuze electronic MSI 100/200 71

Mounting, removal and electrical installation

1A0I

0OI

2A1

1OI

0MT2

6I2OI

1MT3I

7I3OI

EFA

1A0I

V4 24I

0T8I

0M21I

61I

0 O

V 0

0 T9

1 M31

71 I

2 A

0O6I

1T01I

2 M41I

8 1

1O7

1 T1

3 M5

91I

MSI 200

S UB

EF A

E FA

SI-TBUS

1A3

410M

1A3

1 M

4 32M

2 A34

MSI‐EM200‐4RO

EFAS

EF AS

MSI‐EM200‐

8I4IO

230 V

24 V

7.4.3 Example connection of an MSI 100/200 system

Note the following points when connecting your MSI 100/200 system to the various participants:

Voltage supply and ground reference

• Supply the supply voltage for all other devices participating in the system via the same

voltage supply.

• Only use power supply units with safe insulation and SELV/PELV in accordance with

EN 50178 / VDE 0160.

• Safeguard the voltage supply externally with a suitable fuse.

• Connect the output-side GND connection of the power supply unit to the functional earth

(FE) of the system.

• Ensure that all inputs and outputs of the system are connected to the same ground.

Other participants

• For the connection of safe extension modules, use only the yellow MSI-TBUS DIN rail con-

nector.

• For the connection of non-safe extension devices (gateways), use only the green TBUS

DIN rail connector.

The following figure shows the correct connection of the voltage supply for an MSI 100/200 system with various participants.

Figure 7-7 MSI 100/200 system voltage supply

Legend:

F1 External fuse

Functional earth (FE)

Leuze electronic MSI 100/200 72

8 Firmware update

Update the firmware of the MSI 100/200 system with the help of the MSIsafesoft safe config-

uration software.

8.1 Safety notices for the firmware update

The following safety notices must be observed during and after the firmware update:

WARNING: Non-safe operation

While the firmware update is running, the MSI 100/200 operates in the non-safe mode. Reliable detection of the safety demand is not guaranteed while in this operating state.

• Therefore, make sure that running the firmware update will not lead to any hazardous

situations.

• Take action to prevent the machine from being started up unintentionally (by, e.g., dis-

connecting the terminals on the output side from the MSI 100/200 system, and disconnecting the drives from the power supply).

ATTENTION: Module defect

Interrupting the connection between the PC and safety module during the firmware update can damage the device.

A faulty or incomplete firmware installation can render communication between the PC and safety module impossible. In this case, the faulty installation cannot be corrected with the assistance of MSIsafesoft.

• Do not disconnect the USB cable during the update process.

• Do not switch off the safety module during the update process.

Firmware update

Validation /  verification

Once the firmware update has concluded, validate and verify the safety application.

Leuze electronic MSI 100/200 73

Firmware update

8.2 Requirement for firmware update

Before running the firmware-update, ensure the following points: – The MSI 100 or MSI 200 safety module is connected to the PC via the USB cable and

switched on.

– The AC-MSI-CFG1 memory module is plugged into the safety module. – A project for the safety module is loaded in the MSIsafesoft configuration software. – Simulation mode for the MSIsafesoft configuration software is switched off. – Displayed in the status line of the MSIsafesoft configuration software is: 

"Control: Connected" and "Control: Logged off".

– Displayed in the status line of the MSIsafesoft configuration software is:

"Project: Write protected".

8.3 Running a firmware update

1. To start the firmware update in the MSIsafesoft configuration software, select the "Safe control > Firmware update" menu item.

The wizard, which will guide you through the update, is displayed.

2. Proceed as described in detail in the help system.

You will find the topic "Firmware update" listed in the contents of the MSIsafesoft configuration software help system.  See also "Opening the software help system" on page 9-76.

Leuze electronic MSI 100/200 74

MSIsafesoft configuration software

9 MSIsafesoft configuration software

9.1 Installing software

Installation The installation routine for the configuration software includes the installation of the driver for

the USB interface. The driver enables communication between the PC and the modules of the

100/200 system.

MSI

To ensure that the safety modules are automatically and correctly detected by the configu-

ration software, the software must be fully installed before the device is connected to the PC

the first time.

Proceed as follows:

1. If you have downloaded the configuration software: 

Extract the downloaded file and start the installation program (setup file).

If you purchased the configuration software on CD: 

Insert the CD in the drive. A menu opens automatically. Start the installation program via menu item "Install software".

If you have deactivated the auto start option on your computer, open the "MSIsafesoft" folder on the CD-ROM and execute the setup file.

2. Select the desired language for the installation routine.

This selection also sets the language for the MSIsafesoft user interface, which is set when the software is started for the first time.

The installation program now guides you through the installation step by step.

3. Follow the instructions on the screen.

Once MSIsafesoft is installed, you will be prompted to install the drivers for the safety module.

4. Follow the instructions on the screen.

5. In the Windows dialog box for driver installation, select "Install the software automatically (recommended)".

Finally, a message appears indicating that the configuration software and drivers for the safety module have been fully installed.

Leuze electronic MSI 100/200 75

MSIsafesoft configuration software

Start page for  the help system

Help page for the object

Help page for the  dialog box or area

9.2 Opening the software help system

You will find a description of the comprehensive functions of MSIsafesoft in the help system for the software.

There are various ways to open the help system:

a) In the "?" menu, select "Help topics". 

The table of contents for the help system appears.  Search for a help topic as described below.

b) In an active dialog box or window, press <F1>. 

The context-sensitive help for the active dialog box or window appears.

c) In the connection editor, select an object and press <F1> in order to view information

relating to that object.  For safe functions and function blocks, general information about the objects can be accessed in this way.

d) Use the "Help" context menu item of an applicable module or function to open the rel-

evant module information.

The diagram below illustrates the various options for opening the help system and searching for information via context-sensitive help or via the contents or index.

Figure 9-1 Opening the help system in the MSIsafesoft configuration software

Leuze electronic MSI 100/200 76

Configuration and commissioning

MSIsafesoft:

Configure inputs/outputs of the safety

module and the extension devices

Double-click on the device representation in the

hardware editor to open the safe configuration

editor for this device.

Develop safety logic in the connection editor

- Insert input/output signals from the hardware editor

- Enter signal information ("Project", "Assignment List" menu)

- Insert functions and function blocks from the toolbox

- Connect the objects

- Safety networks

MSIsafesoft: Check project

Errors in the project?

>> Message window in

MSIsafesoft

Yes

Continued (A) ...

(from B)

MSIsafesoft: Define bus configuration

Use drag & drop to move extension modules from the tool-

box ("Hardware" compartment) to the hardware editor

10 Configuration and commissioning

Qualified personnel The MSI 100/200 system may only be configured and commissioned by qualified personnel.

See "Qualified personnel" on page 10.

10.1 Example for configuration and commissioning

For detailed information, please refer to the sections cited and the help system of the MSIsafesoft configuration software.

Figure 10-1 Flow chart: Example configuration and commissioning (1 of 3)

Leuze electronic MSI 100/200 77

Configuration and commissioning

Alternative: Instead of using the safety module, check the function of

the safety logic using MSISIMsoft simulation. To do this, use the SIM

button in MSIsafesoft to switch to simulation mode. The project is

checked automatically. MSISIMsoft is minimized in the taskbar.

Download configuration project to the safety

module and acknowledge with the "Confirm"

button (see page 80)

The MSI 100/200 system starts in safe normal operation following acknowl-

edgment. Is a start interlock active? If so, remove with the reset button.

Display in the MSIsafesoft status line:

Display online values in the connection editor

... Continued (from A)

Continued (B) ...

Continued (C) ...

Switch on the MSI 100/200 system (apply supply voltage, see page 63) and

connect to the USB interface of the PC (see page 28).

Are you using MSISIMsoft simulation? If you are using the MSISIMsoft simulation instead of the safety module, download the configuration in the same way

with simulation active (see previous step).

Acknowledgment is not required.

Continued

(from D) ...

Optional: Lock safety networks to prevent editing

in the connection editor

Figure 10-2 Flow chart: Example configuration and commissioning (2 of 3)

Leuze electronic MSI 100/200 78

Configuration and commissioning

Switch the connection editor offline

Commissioning completed

Documentation in MSIsafesoft

Complete the project information:

"Project, Project Information" menu

... Continued (from C)

Optional: Certify safety networks in the

connection editor

Archive the project in MSIsafesoft

(zip and save to backup medium)

Print the project in MSIsafesoft

Function test

completed without errors?

Yes

Continued (D) ...

Carry out a function test

(see page 87)

- Trigger safety demand

via command devices/sensors

- Analyze system response

- Check device parameters

Non-safe

commissioning

mode

- Force signals

- Analyze

system response

Optional and only in addition to the function

test: In MSIsafesoft, switch to

non-safe commissioning mode

Switch connection editor

offline, unlock safety net-

works if required, make cor-

rections to the project

Are you using MSISIMsoft simulation? Use the I/O view and expert mode

to set the simulation inputs.

Figure 10-3 Flow chart: Example configuration and commissioning (3 of 3)

Leuze electronic MSI 100/200 79

Configuration and commissioning

10.2 Downloading configuration from the MSIsafesoft con-

figuration software

WARNING: Risk of injury or damage to equipment due to unintentional system states or incorrect responses

The safety module is in the commissioning phase, i.e., unintentional system states or incorrect responses cannot be ruled out. Operation is not safe.

• Make sure that the act of triggering the safety demand will not pose a risk for people or

materials.

• Do not enter any hazardous areas and ensure that no other persons can access the

danger zone either.

The configuration, including the device configuration, is created in the MSIsafesoft configuration software as a project. Once finished, load the configuration in the MSI 100 or MSI 200 safety module. This data is usually transmitted via the USB interface of the safety module.

Alternatively, the configuration can also be loaded by inserting a AC-MSI-CFG1 memory module that contains the relevant data.

For further information, please refer to "Loading the configuration using the AC-MSI-CFG1 memory module" on page 84.

The memory requirements of the MSI100/200 system are influenced mainly by the following factors:

• The number of digital I/O extension modules used

• The number of function modules used

• The type of function modules used

• The number of flags used

• The extent of user comments in the program

In the case of very complex logic programs, our service department can provide you with support in optimizing memory use (see

To download the configuration, proceed as follows:

1. Ensure the following: – The safety module is switched on.

– The MSIsafesoft configuration software is installed on the configuration computer

(this installation also includes the required drivers). – The MSIsafesoft configuration software is started. – A AC-MSI-CFG1 memory module is plugged into the safety module. The configura-

tion cannot otherwise be loaded.

2. Connect the USB cable to the safety module (Mini-USB connector, 5-pin, maximum cable length 3

ATTENTION: Electrostatic discharge

m) and to a USB port on the PC.

"Safety hotline" on page 14).

61340-5-1 and EN 61340-5-1.

Leuze electronic MSI 100/200 80

Configuration and commissioning

The "ERR" LED flashes during data transmission

Status indicator for

MSI 100/200 system

Once the interconnection cable has been connected, the correspondingly configured PC automatically detects the safety module and indicates its status at the bottom right of the status line.

Figure 10-4 USB connection between PC and safety module

Logging on with control password

The project can only be downloaded to the safety module if you have logged on in

MSIsafesoft with the correct control password.

3. In the "Safe control" menu, select "Log on", enter the control password in the dialog box, and click "OK".

4. Download the project created in MSIsafesoft to the safety module by clicking on the depicted icon in the toolbar.

Prerequisite for this is that the current project was first checked and deter-

mined to be free of errors (see MSIsafesoft help system).

Is there already a project on the safety module?

If the status line on the right has the yellow entry "Control: No project", the project is transmitted to the safety module without any further prompts.

If another project or another version of the same project is already available on the safety module and is being executed, a corresponding dialog box appears, indicating this fact.

• Click "Yes" in this dialog box to overwrite the current control configuration on the safety

module.

Data transmission Durin g data transmission

– A progress indicator is displayed in the status line of MSIsafesoft. – The "CONF" status display flashes quickly on the safety module (approximately 6 Hz).

If data transmission is interrupted during the download, you can find assistance in chapter "Problems and solutions" starting on page 95.

Leuze electronic MSI 100/200 81

Configuration and commissioning

First acknowledge the configuration on the safety module  (see step 5).

Please note:

... before clicking "OK".

PWR

EXT

ERR

CFG

24V

O0-

01-

CONFIR

CFG

STICK

MSI100

I12

I13

I14

www.leuze.de/MSI

Following successful data transmission

– The "CONF" status display flashes slowly on the safety module (approx. 1.5 Hz). – A corresponding dialog 

"Sending successful" appears in the configuration software.

If the "Sending successful" dialog is displayed, perform the next steps in the following order.

Figure 10-5 Dialog box following successful data transmission

5. Confirm the new configuration by pressing the "Confirm" button using a pen (see Figure 10-6).

WARNING: Danger due to activated outputs

Following acknowledgment, the safety module starts running immediately. Provided that no start interlock is active, which must be canceled manually, outputs may be activated immediately after start-up.

• Make sure that the start-up of the safety module cannot lead to any hazardous situa-

tions.

Figure 10-6 Confirming the configuration with the "Confirm" button

Initialization The safety module is then reinitialized (all diagnostic indicators illuminate briefly) and then

switches to safe normal operation (only "PWR" LED on).

Ending 

6. Exit the dialog in the configuration software and click on "OK".

data transmission

Leuze electronic MSI 100/200 82

Start interlock Start interlock active ?

WARNING: Unintended machine start-up

Canceling the start interlock can result in unintended machine start-up.

• Before canceling the start interlock, make certain that canceling cannot result in a dan-

gerous machine state.

• When planning the machine or system, make certain that canceling the start interlock is

possible only if the danger zone is visible.

If a start interlock has been predefined in the configuration, it will be active following start-up. An active start interlock must be canceled by pressing a reset button which is connected to the safety module according to the configuration.

For further information, please refer to "System start-up and restart behavior" on page 19.

If the safety module is not initialized correctly, proceed as described in chapter "Problems and solutions" on page 95.

Next steps Next, continue with the function test.

See chapter "Function Test" on page 87.

Check values (CRC)

To ensure that any distortions to the configuration data during transmission to the safety module can be reliably detected, a check value (CRC) is calculated in the configuration soft ware when the project is checked.

The safety module also determines the check value for the downloaded data.

If the check values on the safety module and in the configuration software are identical, all data has been saved on the safety module without distortion. If the check values differ, a corresponding error message is output.

Deviating check values through subsequent changes

The check value (CRC) will also differ if subsequent modifications have been made to the project in the configuration software, but have not yet been downloaded to the safety mod ule.

Note

For example, the following tasks are evaluated as changes in the project: – Moving an object – Making a change to the project documentation

Recommendation

Record the check value (CRC) after commissioning and subsequent validation in the machine protocol to understand subsequent project changes.

Configuration and commissioning

Leuze electronic MSI 100/200 83

Configuration and commissioning

10.3 Loading the configuration using the AC-MSI-CFG1

memory module

WARNING: Risk of injury or damage to equipment due to unintentional system states or incorrect responses

The safety module is in the commissioning phase, i.e., unintentional system states or incorrect responses cannot be ruled out. Operation is not safe.

• Make sure that the act of triggering the safety demand will not pose a risk for people or

materials.

• Do not enter any hazardous areas and ensure that no other persons can access the

danger zone either.

Configurations can be downloaded not only via the USB interface but also with the help of the AC-MSI-CFG1 memory module. In this way, the configuration of one device can be transferred to other safety modules. This is useful if no configuration computer is available at an installa tion location or for transferring the configuration to a new device on device replacement.

To replace the AC-MSI-CFG1 memory module, proceed as follows. This sequence ensures that the active configuration is not overwritten by accidental insertion of an AC-MSI-CFG1.

Removing the  AC-MSI-CFG1

Inserting the new  AC-MSI-CFG1

1. It is not permissible to replace the AC-MSI-CFG1 during running operation. If the safety module is already in operation, perform the following steps.

a) First, shut down the machine. b) Switch off the safety module. c) Remove the current AC-MSI-CFG1.

After the AC-MSI-CFG1 has been removed correctly, all outputs of the safety module are in a safe, de-energized state (FALSE). As long as the AC-MSI-CFG1 is removed, the safety module has no function.

If the AC-MSI-CFG1 is not removed correctly, the safety module also displays an error message.

WARNING: Danger due to activated outputs

After you have loaded the configuration by replacing the AC-MSI-CFG1, the safety module starts with program execution. Provided that no start interlock which must be cancelled man ually is active, outputs may be activated immediately.

• Make sure that the start-up of the safety module cannot lead to any hazardous situa-

tions.

2. Insert the new AC-MSI-CFG1 in the safety module, which is switched off. The AC-MSI-CFG1 is mechanically coded and cannot be inserted in the device incor-

rectly.

3. Switch the safety module on and wait until it has initialized. All four diagnostic indicators light up once during initialization. 

The safety module now detects the previously unknown AC-MSI-CFG1 and indicates this with a flashing "CONF" diagnostic indicator.

4. Remove the AC-MSI-CFG1 again.

Leuze electronic MSI 100/200 84

5. Press the "Confirm" button on the device and hold it down.

EXT

ERR

CFG

24V

O0-

01-

NFIRM

CFG

STICK

MSI100

I13

www.leuze.de/MSI

Hold down the "Confirm" button  while inserting the AC-MSI-CFG1

6. Reinsert the AC-MSI-CFG1 while holding down the "Confirm" button.

Figure 10-7 Insert AC-MSI-CFG1

7. Release the "Confirm" button once the AC-MSI-CFG1 is inserted correctly. The safety module now initializes with the new configuration.

Start interlock Start interlock active ?

WARNING: Unintended machine start-up

Canceling the start interlock can result in unintended machine start-up.

• Before canceling the start interlock, make certain that canceling cannot result in a dan-

gerous machine state.

• When planning the machine or system, make certain that canceling the start interlock is

possible only if the danger zone is visible.

Configuration and commissioning

For further information, please refer to "System start-up and restart behavior" on page 19.

If the safety module is not initialized correctly, proceed as described in chapter "Problems and solutions" on page 95.

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Configuration and commissioning

10.4 Uploading the configuration from the safety module

Projects downloaded to the safety module are saved there and can be uploaded to the PC and the configuration software again if required.

This may be required, for example, if a project has to be read from the safety module for diagnostic purposes.

It is possible to upload a project from the safety module to the configuration software without the control password. However, to edit the uploaded project you will need the correct project password.

To upload the project, proceed as follows:

1. If a project is currently open in the configuration software, save it before uploading the required project from the safety module.

2. Exit commissioning mode and the online mode of the configuration software.

The "Online values" icon must not be selected prior to starting the upload and the status line must show the control status "Control: Connected".

3. Click on the "Upload" icon in the toolbar.

4. Click "Yes" in the dialog box to confirm the upload. Transmission from the safety module to the PC starts and a progress indicator is displayed

in the MSIsafesoft configuration software status line.

5. If a project with the same name already exists on the PC, a prompt will appear where you must decide whether you want to overwrite the project which is already loaded or not.

In this dialog box, click on the corresponding buttons:

– "Yes" to overwrite the data of the existing project with that of the project which has

just been uploaded. Overwriting means that the current data will be lost and cannot be recovered.

– "No" to save the uploaded project under a different name or in a different directory. 

The "Save Project As" dialog box appears.  Here, select a directory, enter a file name, and click "Save".

6. You are now asked to enter the project password. Once you have entered the password you can edit and check the project, load it to the safety module, and start it up there as usual.

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Configuration and commissioning

10.5 Function Test

WARNING: Risk of injury or damage to equipment due to unintentional system states or incorrect responses

The safety module is in the commissioning phase, i.e., unintentional system states or incorrect responses cannot be ruled out. Operation is not safe.

• Make sure that the act of triggering the safety demand will not pose a risk for people or

materials.

• Do not enter any hazardous areas and ensure that no other persons can access the

danger zone either.

Validation Once the project has been uploaded to the safety module, it is executed there following man-

ual acknowledgment. You must perform a function test to ensure that the safety module and, thus, the safety logic and the entire wiring are functioning correctly.

Online mode in MSIsafesoft

Safety demand / monitoring signals

Connecting /  logging in

You can switch the MSIsafesoft configuration software to online mode for the function test. The online values are thereby read cyclically from the safety module and displayed in the connec tion editor and the hardware editor.

By activating the safe command devices, e.g., by pressing the E-Stop command device or opening the safety door, you trigger the safety demand. The behavior of the safety logic can now be analyzed precisely in the configuration software, as the connection editor displays the value of every signal "live" in online mode.

10.5.1 Performing function test with the help of online mode

1. Connect the switched-on safety module to the configuration computer via the USB interface.

2. Start the MSIsafesoft configuration software and log in to the safety module. The status line in the MSIsafesoft configuration software now displays the following entry

on the right-hand side.

The system can only display online values if the project in the safety module and the project in the configuration system are identical.

If you have made a change to a project after commissioning, you must check the project and download it to the safety module again.

Only then can you display online values.

Note

For example, the following tasks are evaluated as changes in the project: – Moving an object – Making a change to the project documentation

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Configuration and commissioning

E-Stop not pressed, no safety demand

Safety demand

3. Switch the MSIsafesoft configuration software to online mode by clicking on the "Display online values" icon in the toolbar.

Signal lines and function block connections are now displayed in the connection editor in different colors, according to their state (TRUE/FALSE), and together with the current values. The hardware editor also supports the function test through "lit" LEDs.

4. Trigger a safety demand via the safe command devices.

5. Monitor the response of the machine and the configuration via the online values in the connection editor.

Example:

Figure 10-8 Example of a function test for the safety system using the online mode of

MSIsafesoft

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Diagnosis

11 Diagnosis

MSIsafesoft diagnosis

Information on hardware diagnosis, wiring checks and tool tips can be found in the help system of the MSIsafesoft configuration software.

Diagnosis via gateways You can connect your MSI 100/200 system with gateways to a primary control. The reading

out of the diagnosis is bus-specific.

Information on diagnosis via gateways can be found in the respective user manual of the gateway. See www.leuze.com.

You can find suitable gateways for use with the MSI 100/200 system in the accessories chapter "Gateways" on page 118.

11.1 Diagnosis via LED indicators on the module

The following tables list the possible indicator combinations for the diagnostic and status indicators and their meanings. A distinction is made between slow flashing and fast flashing LEDs.



The LED symbols in the tables mean:

LED is off

LED is on

LED flashes: slowly ≈ 2 Hz / quickly ≈ 6 Hz

S If there is an S below an LED symbol, this LED indicator applies only for the

100.

MSI

M If there is an M below an LED symbol , this LED indicator applies only for the

MSI 200.

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11.1.1 MSI 100 and MSI 200

Table 11-1 Diagnostic indicators for MSI 100 and MSI 200

Diagnosis

PWR

(green)

DATA

(green)

ERR (red)

≈ 6 Hz

CONF

(green)

≈ 2 Hz

≈ 6 Hz

≈ 2 Hz

I0 … I19 O0 … O3 Meaning

Device is switched off  No voltage supply at A1 and A2

Initialization phase after switching on or after restarting after the "Confirm" button has been pressed  (maximum duration: 4 s)

Initial commissioning state  No configuration data present on the AC-MSI-CFG1

• Download project with MSIsafesoft

AC-MSI-CFG1 not present

• Insert AC-MSI-CFG1 and apply voltage supply

Acknowledgment of new configuration required after download

• Press the "Confirm" button on the device

Acknowledgment of a new configuration required after transfer via AC-MSI-CFG1 For sequence, see chapter 10.3 on page 84

Acknowledgment required after changing an extension device

• Press the "Confirm" button on the device MSI 100: Normal operation

Configuration data present on the AC-MSI-CFG1

MSI 200: Normal operation without connected extension devices (TBUS communication) Configuration data present on the AC-MSI-CFG1

MSI 200: Normal operation with connected exten-

sion units (TBUS communication)

Limited operation with error on at least one input/output

• Rectify the error

• Deactivate input/output

• Press the "Confirm" button on the device 

(duration: min. 15 s)

Error has occurred

• Read out error code with MSIsafesoft

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Table 11-1 Diagnostic indicators for MSI 100 and MSI 200

MSI 200: Only in combination with safe

extension module.

MSI 200: Only in combination with safe

extension module.

MSI 200: Only in combination with safe

extension module.

Diagnosis

PWR

(green)

DATA

(green)

ERR (red)

CONF

(green)

I0 … I19 O0 … O3 Meaning

Cross-circuit has occurred

• Check wiring of the peripherals

• Press the "Confirm" button (duration: 3 s)

≈ 6 Hz

Short-circuit at safe output (GND was connected to a safe output)

• Press the "Confirm" button on the device 

(duration: min. 15 s)

≈ 6 Hz

Short-circuit at clock output (GND was connected to a clock output).

• Rectify short circuit at clock output

• Press the "Confirm" button on the device 

≈ 6 Hz

(duration: min. 15 s)

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Diagnosis

Table 11-2 Status indicators of the safe inputs and outputs for MSI 100 and MSI 200

LED State Meaning

For each input ("I0" to "I19")

No switching signal at the relevant input

Switching signal active at the input

For each output ("O0" to "O3")

Long ON Short OFF

Long OFF Short ON

Long ON Short OFF

Long OFF Short ON

Wiring check at an active input or antivalent input

Wiring check at an inactive input or antivalent input

Output is not active

Output is active

Wiring check at an active output

Wiring check at an inactive output

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11.1.2 MSI-EM200-8I4IO

Table 11-3 Diagnostic indicators for MSI-EM200-8I4IO

Diagnosis

PWR

(green)

ERR (red)

Meaning

Device is switched off,  no voltage supply at 24 V/0 V or MSI-TBUS

Initialization phase after power up  (maximum duration: 4 s).

Normal operation

Limited operation with error on at least one input/output

• Rectify the error

• Deactivate input/output

• Press the "Confirm" button on the MSI 200 base device 

(duration: min. 15 s)

A flashing LED at an input or output signals an error affecting the corresponding signal (see

Table 11-4).

Error has occurred

≈ 6 Hz

• Read out error code with MSIsafesoft

Table 11-4 Status indicators for MSI-EM200-8I4IO safe inputs and outputs

LED State Meaning

For each input  ("I4" to "I11") and for "IO0" to "IO3", if these are configured as safe inputs

For "IO0" to "IO3", if these are configured as safe out

puts

Long ON Short OFF

No switching signal at the relevant input

Switching signal active at the input

Wiring check at an input or antivalent input

Output is not active

Output is active

Long ON Short OFF

Wiring check at an output

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11.1.3 MSI-EM200-4RO

Table 11-5 Diagnostic indicators for MSI-EM200-4RO

Diagnosis

PWR

(green)

ERR (red)

Meaning

Device is switched off,  no voltage supply at 24 V/0 V or MSI-TBUS

Initialization phase after power up  (maximum duration: 4 s).

Normal operation

Limited operation with error on at least one output

• Rectify the error

• Deactivate output

• Press the "Confirm" button on the MSI 200 base device 

(duration: min. 15 s)

A flashing LED at an output signals an error (see Table 11-6).

Error has occurred

≈ 6 Hz

• Read out error code with MSIsafesoft

Table 11-6 Status indicators of the safe outputs for MSI-EM200-4RO

LED State Meaning

For "O0" to "O3"

Output is not active

Long ON Short OFF

Output is active

Wiring check at an output

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12 Problems and solutions

This chapter contains a list of possible problems that may occur when working with the configuration software and the safety modules (MSI 100 and MSI 200) as well as with the safe extension modules (MSI-EM200-8I4IO and MSI-EM200-4RO). The following descriptions are divided into categories corresponding to the different sections of the configuration software.

12.1 General

Table 12-1 Solutions for general problems

Problem Solution

The user program cannot be downloaded from the configuration software to the control / the control hangs, whereby a system utilization < 100% is simultaneously displayed in the status bar in the lower right.

When the MSIsafesoft safe configuration software was launched, the installation check identified a faulty system file.

A corresponding message window is displayed.

The test routine for the operating system has determined that you are trying to launch the MSIsafesoft configuration software on an operating system that is not supported.

An error has occurred (accompanied by a corresponding message), which cannot be removed using any of the measures described here.

The safe MSIsafesoft configuration software or one of its functions is not behaving as described in the user documen tation or the help system.

Please contact Leuze electronic technical support. We can support you with the optimization of memory usage. See also "Downloading configuration from the MSIsafesoft configuration software" on page 80.

Uninstall the safe configuration software, then reinstall it by running the setup program from the installation CD.

Install an operating system supported by the MSIsafesoft configuration software (see "System requirements for the MSIsafesoft configuration software" on page 117) or consult with technical support to determine whether a newer version of MSIsafesoft is available that supports your current operating system.

Please contact Leuze electronic technical support.

Problems and solutions

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12.2 Graphical connection editor

Table 12-2 Solutions for problems with the graphical connection editor

Problem Solution

You have attempted to open a project, but the safety logic could not be loaded due to a checksum error.

A corresponding message window is displayed.

During editing, a message window appears where the connection editor reports damaged data, a sporadic error or a systematic error.

The project concerned is damaged and can no longer be used.

Use the latest backup copy of the project (as described in the help system under "Zipping and extracting projects").

If the problem persists, please contact Leuze electronic technical support.

The project is closed automatically. You do not have the opportunity to save the most recently made changes.

If the problem persists when the project is reopened, please contact Leuze electronic technical support.

12.3 Configuration editor

Table 12-3 Solutions for problems with the configuration editor

Problem Solution

You have attempted to open the configuration editor, but the data could not be loaded due to a checksum error.

A corresponding message window is displayed.

The configuration editor responds unexpectedly to an entry in the parameter table, e.g., by displaying something other than what has been entered or selected.

This may be traced back to a sporadic error or a systematic error.

During editing, a message window appears in which the configuration editor reports damaged data, a sporadic error or a systematic error.

The project can no longer be used, as the configuration data cannot be deleted.

Use the latest backup copy of the project (as described in the help system under "Zipping and extracting projects").

Undo the last entry (by pressing <Ctrl>+<Z>), then repeat the entry.

If the result is still incorrect, please contact Leuze electronic technical support.

The project is closed automatically. You do not have the opportunity to save the most recently made changes.

If the problem persists when the project is reopened, please contact Leuze

Problems and solutions

electronic technical support.

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Problems and solutions

Remove the USB connecting cable from the PC and safety controller, then reinsert it.

Yes

Is a module status

displayed

in the status bar *?

Try to establish a USB connection to another safety controller that is not currently in use.

Yes

The first USB connection used on the PC may be faulty. Use this port instead of the one used first.

Try to establish the connection using another USB cable.

Yes

Use the functioning cable.

Please contact our technical support team.

Communication with MSI 200 is

possible. No further action required.

* Possible module status on existing connection:

Temporary during initialization

Controller: Timeout

Controller: No project

Controller: Connected

Download project

Start function test

Yes

Insert the USB cable in a different USB connection on your PC.

Use this safety controller instead of the one used first.

Is a module status

displayed

in the status bar *?

Is a module status

displayed

in the status bar *?

Is a module status

displayed

in the status bar *?

12.4 Online communication between MSIsafesoft and the

safety module

Table 12-4 Solutions for communication problems between MSIsafesoft and the safety module

Problem Solution

A connection cannot be established to the safety module.

The status line does not display a status for the safety module ("Timeout", "No project" or "Connected"; see information under the diagram below).

The status line looks like this, for example:

Proceed as follows:

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Problems and solutions

Download the project to the safety againcontroller and acknowledge by pressing the "Confirm" button.

Yes

Checksum error

still indicated?

Download the project to another safety controller that is not currently in use.

No further action required. You can start the function test.

Use this safety controller instead of the one used first.

Please contact our technical support team.

Checksum error

still indicated?

Yes

Table 12-4 Solutions for communication problems between MSIsafesoft and the safety module

Problem Solution

Transmission has been interrupted during the download procedure.

Following successful project download, the MSIsafesoft safe configuration software identifies that the checksum of the project on the safety module does not match that of the project on the PC. A corresponding message window is displayed.

1. Start transmission again.

2. If the download fails once more, remove the USB connecting cable from the interface on the configuration computer and reinsert it.

3. Once the safety module has been detected correctly (see display in the status line), restart the download procedure.

Proceed as follows:

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Problems and solutions

12.5 Communication between the safety module and the safe extension module

Table 12-5 Solutions for communication problems between safety module and safe extension module

Problem Solution

Communication between the safety module and the safe extension module via the DIN rail connector (MSI-TBUS) has been interrupted.

The "Data" LED on the safety module does not illuminate.

Check whether all safe extension modules are correctly connected to the safety module. A connection is correct if there is a MSI-TBUS male connector under each extension module and the plug-in connection has been made properly (the module must snap into place).

Check whether the power supply at each extension module has been connected and switched on correctly.

12.6 Safety module messages

Table 12-6 Solutions for messages from the safety module

Problem Solution

Following acknowledgment of the newly loaded configuration, the safety module is not initialized correctly ("Control: Error" is displayed in the status line and flashing "ERR" status indicator on the safety module).

The safety module reports an internal error. Please contact Leuze electronic technical support.

1. Switch the safety module off and on again.

2. Download the project to the safety module again and acknowledge the new configuration by pressing the "Confirm" button on the device.

3. If the problem persists, please contact our technical support team

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Maintenance, repair, decommissioning and disposal

13 Maintenance, repair, decommissioning and disposal

13.1 Maintenance

The modules of the MSI 100/200 system are maintenance-free. Depending on the application and the connected peripherals, the function of the peripheral devices and the safety chain may need to be tested periodically.

Service the connected peripheral devices (e.g., light barriers) acc. to manufacturer's specifications.

The mission time and the proof test interval at high or low demand rate for the modules of the MSI 100/200 system can be found in the technical data. See "Technical data and ordering data" on page 101.

13.2 Repair

Repair work or changes by the user to the module are prohibited. The housing must not be opened. If the housing is opened, the function of the MSI 100/200 modules is no longer guaranteed.

In case of failure, send the module to Leuze electronic or immediately contact

electronicand request a member of service staff.

Leuze



13.3 Decommissioning and disposal

Decommission according to the requirements of the machine or system manufacturer.

When decommissioning the MSI 100/200 system or parts of the system, handle the used modules as follows:

Further use of the module Measure

The modules are still used as intended. Observe requirements on storage and

transport according to the technical data: see chapter 14 "Technical data and ordering data" on page 101.

Modules are no longer used. Dispose of the modules in accordance with

environmental regulations. Ensure that the modules cannot be used again.

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Leuze electronic MSI 100 Series, MSI-EM200-4PRO Series, MSI201, MSI202, MSI102 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

1 For your safety

1.1 Labeling of the warning notices

1.2 Qualification of the users

1.3 Range of application of the product

1.3.1 Intended use

1.3.2 Changes to the product

1.4 Safety notices

1.4.1 General safety notices

1.4.2 Electrical safety

1.4.3 Safety of machines or systems

1.4.4 Safety when starting applications

1.5 Directives and standards

1.6 Documentation

1.7 Safety hotline

2System description

2.1 MSI 100/200 safety system: design and functionality

2.2 Using the system

2.3 Safe state

2.4 System start-up and restart behavior

2.5 Error detection

2.6 Error state

2.7 Diagnostic tools

2.8 Password protection

3 MSI 100 and MSI 200 safety modules

3.1 Product description

3.1.1 Connection of extension devices

3.2 Operating modes (status) of the safety modules

3.3 Operating and indication elements

3.3.1 Diagnostic and status indicators

3.3.2 Confirm button

3.3.3 USB interface

3.3.4 AC-MSI-CFG1

3.4 Signal connections

3.4.1 Safe inputs

3.4.2 Safe outputs

3.4.3 Signal outputs

3.4.4 Clock outputs

3.4.5 Ground-switching outputs

3.4.6 Supply connections

4 MSI-EM200-8I4IO safe extension module

4.1 Product description

4.2 Diagnostic and status indicators

4.3 Signal connections

4.3.1 Safe inputs

4.3.2 Safe outputs

4.3.3 Clock/signal outputs

4.3.4 Supply connections

5 MSI-EM200-4RO safe extension module

5.1 Product description

5.2 Diagnostic and status indicators

5.3 Signal connections

5.3.1 Safe relay outputs

5.3.2 Signal outputs

5.3.3 Supply connections

6 Wiring examples

6.1 Information on the wiring examples

6.2 Single-channel assignment of the safe digital inputs

6.2.1 Cross circuit monitoring switched on

6.2.2 Cross circuit monitoring switched off, external supply

6.2.3 External supply (OSSD)

6.3.1 Cross circuit monitoring switched on, supplied by T0 and T1

6.3.2 Cross circuit monitoring switched off, external supply

6.3.3 External supply (OSSD)

6.4.1 Cross circuit monitoring switched on, supplied by T0 and T1

6.4.2 Cross circuit monitoring switched off, external supply

6.5 Safe digital outputs

6.5.2 Single-channel assignment of the safe digital outputs

6.5.3 Two-channel assignment of the safe digital outputs

6.6 Safe relay outputs

6.6.2 Single-channel assignment of the safe relay outputs

6.6.3 Single-channel assignment of the safe relay outputs

7 Mounting, removal and electrical installation

7.2 Mounting

7.2.1 Mounting instructions

7.2.2 Mounting location