Because of the variety of uses for the products described in this publication, those responsible for the
application and use of this control equipment must satisfy themselves that all necessary steps have been
taken to assure that each application and use meets all performance and safety requirements, including
any applicable laws, regulations, codes and standards.
Reproduction of the contents of this copyrighted publication, in whole or part, without written permission
of Rockwell Automation, is prohibited.
Throughout this manual we use notes to make you aware of safety considerations:
The illustrations, charts, sample programs and layout examples shown in the guide are intended solely for
purposes of example. Since there are many variables and requirements associated with any particular
installation, Rockwell Automation does not assume responsibility or liability (to include intellectual property
liability) for actual use based upon the examples shown in this publication.
Rockwell Automation publication SGI-1.1, Safety Guidelines for the Application, Installation and
Maintenance of Solid-State Control (available from your local Rockwell Automation sales oce), describes
some important dierences between solid-state equipment and electromechanical devices that should be
taken into consideration when applying products such as those described in this publication.
It is recommended that you save this user manual for future use.
Identies information about practices or circumstances that can cause an explosion in
a hazardous environment, which may lead to personal injury or death, property
damage, or economic loss.
Identies information that is critical for successful application and understanding of
the product.
Identies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss. Attentions help you identify a
hazard, avoid a hazard, and recognize the consequences.
SHOCK HAZARD
Labels may be on or inside the equipment (for example, drive or motor) to alert people
that dangerous voltage may be present.
BURN HAZARD
Labels may be on or inside the equipment (for example, drive or motor) to alert people
that surfaces may reach dangerous temperatures.
MSR41 units can only achieve their
function as a safety controller module, if
the instructions given in this instruction
manual and the within mentioned
documents are exactly followed, as well
as consulting the valid laws and
regulations at the time of installation.
Should these instructions not be carefully
followed, serious injury or death may
occur. The installer or system integrator
will be fully responsible for a safe
integration of this product.
This instruction manual is to be used in
conjunction with the MSR41 base
module. It must be kept accessible
together with the other machine
documentation during its entire life cycle
for all personnel responsible for assembly,
installation, operation and maintenance.
Introduction
MSR41 is a extremely compact safety module. This main controlling
module allows the connection and the control of the compact
GuardShield Micro400 safety light curtain systems (Figure 1).
The safety approval, performed by TÜV Rheinland. The actual list of
relevant safety data and applied standards are given in this document.
Figure 1: MSR41 controller and GuardShield Micro400 Safety Light curtain
The base module offers two safety PNP outputs (OSSD). Additional
expansion modules (MSR45E) can be applied for applications, which
require more outputs and/or dry contacts to switch loads
Special features
The outstanding characteristics of the MSR41 controller:
• Category 4, PL e according EN ISO 13849-1
• Type 4 according EN 61496-1/-2
• SIL 3 according IEC 61508
• SIL CL 3 according EN 62061
• Short response times
•Modular expansible
• Up to 3 expansion modules per main module
• Different start modes by hardware selectable
Original instructions
1
Page 4
MSR41 Safety Module User Manual
Applications
Typical applications
MSR41 controller modules are developed and conceived for typical
applications like:
• Robotic cells
•Assembly lines
• Indexing tables
• Conveyor systems
• Automatic storage facilities
Application restrictions
MSR41 modules are not intended for application in explosive (EX) or in
radioactive environments.
Dimensions
The dimensions of the housing for MSR41 are illustrated in Figure 2.
Te rminal connection diagram
The following figures shows the connection possibilities for the MSR41
base module:
Figure 3: MSR41 Base module, Micro 400 LightCurtain, automatic start, no output
monitoring
Figure 2: Base module dimensions are the same for expansion modules
Figure 4: MSR41 Base module, Micro 400 LightCurtain, manual start, no output monitoring
Table 2 gives information about the LED on the front side of a MSR41
base module with the basic configuration:
LEDSignal / Color / StatusSignal / Color / Status
OSSD2
OSSD1
Info2 (LED)See page 3See p age 3
Info1 (LED)See page 3See p age 3
IN2
IN1not used / greennot used / green
0 V--
+24 V
+24 V / green /
Light curtain not activated
(free)
+24 V / green /
Light curtain not activated
(free)
+24 V / green /
start release okay
+24 V / green /
power connected
Table 2: LED description
0 V / red / Safe400
Light curtain activated
(interrupted)
0 V / red / Safe400
Light curtain activated
(interrupted)
0 V / red /
no start release signal
0 V / off /
no power con nected
Figure 7: MSR41 Base module and MSR45E expander module, Micro 400 Light Curtain,
automatic start, output monitoring
Status outputs
The MSR41 base module has two status outputs (“Info1” and “Info2”).
A description of these outputs is given below.
The following table shows the logic of the two status outputs. The state
of the status outputs will also be displayed through LED, visible on the
front side of the main module.
Term ina l
(LED)
Info1 (LED)Start ok (green)No start possible (red)
These outputs may not perform any
safety relevant functions. They serve only
to communicate the status to a machine
controller.
Response time
General
• The response time of a MSR41 base module depends on the
connected GuradShield Micro400 Light Curtain length and
resolution.
• The response time for the MSR41 base module [t(totLCOSSD)]
with respect to the Micro400 light curtain is the sum of the base
module response time t(C) + the response time of the light curtain
t(LC):
t(totLCOSSD)= t(C) + t(LC)
• The response time for the MSR45E expander module (relay safety
output) [t(totLCEXT)] with respect to the Micro400 light
curtain is the sum of the base module response time
t(totLCOSSD) + the response time of the expander module
t(em):
t(totLCEXT)= t(totLCOSSD) + t(em)
=t(C) + t(LC) + t(em)
The total response time of a system is the sum of each response time:
Response time MSR41
Response time first,
2nd and 3rd expander
module
Max. OSSD response time for Micro400
light curtain
Max. relay extension module response
time for Micro400 light curtain
Table 3: Calculation for the total response time of the Micro400 safety light curtain
t(totLCOSSD) = 9.10ms(t(c)) + t(LC)
from the Micro400 label
t(totLCEXT) = 9.10ms(t(c)) +
6.00ms(t(em)) + t(LC) from the
Micro400 label
Original instructions
3
Page 6
MSR41 Safety Module User Manual
Explanation of the terminology
SymbolMeaning
t(C)Response time for the MSR41 base module (evaluation time)
t(LC) Response time of the light curtain on the label of the light curtain)
t(em)Response time for the MSR45E expander module
t(totLCOSSD)Maximum OSSD response time triggered by the light curtain
t(totLCEXT)Maximum relay extension module response time for the light curtain
The maximum response time for the MSR41 base module t(C) are given
in chapter 14.
Installation
For the professional installation and connection, please consult the
relevant laws and regulations. The safety officer of the manufacturing
facilities, the local authorities (OSHA in USA, HSE in GB).
The requirements of the safety regulations of electrical engineering, the
local employer’s liability insurance association and the international
standard IEC 60204 are to be taken into full consideration.
Mounting location
The MSR41 modules must be mounted in a control cabinet which is
sealed to at least IP54. The units must be snapped onto a 35 mm
mounting rail, which is grounded. If it is used outside of a control cabinet
a housing with a protection category of IP54 and a mounting rail
capability is recommend.
Cable and wires
The wires from the MSR41 base module must be securely separated and
guided away from the wires of the relay section (MSR45E expansion
modules).
Supply voltage
To safeguard the controller, the +24 V terminal should be protected with
an external 5 A fuse. The controller and the machine should be offline
before beginning the installation.
The supply voltage must conform to the requirements of EN 60204-1, it
must bridge a 20 ms interruption of the supply network. When
considering the supply voltage, it must be one of the following: SELV
(Safety-Extra-Low-Voltage) or PELV (Protective-Extra-Low-Voltage) in
accordance with IEC 364-4-41.
Earth connection
The earth of each MSR4x module is realized through the connection to
the mounting rail. Consequently it is important to ensure, that the
mounting rail has a good earth connection.
Micro400 light curtain
The two RJ45 sockets on the lower portion of the base module are for
the connection of Allen-Bradley GuardShield Micro400 (white = E =
emitter; blue = R = receiver). To protect the RJ45 connectors the cables
have to be snapped into the provided cable holders.
Start mode
The following start modes are supported by the MSR41:
• automatic start or
• manual start
Manual start
Depressing the start button will cause the two safety OSSD outputs to
change from low to high and if connected the MSR45E relay expander
modules will close (= manual start).
The start function is not monitored (no
edge detection). Further additional
measures must be done to fulfill the
requirements of a manual monitored
reset according to the saftey standards
(e.g. use of an additional MSR127 safety
relay).
It is fundamental that the start button be
mounted so that the danger area is clearly
visible. That is, when pressing the start
button it must be guaranteed that no one
is detained within the danger area.
Automatic start
If the MSR41 is connecte d for “automatic start”, then, af ter the activation
and the deactivation of the GuardShield Micro 400, the two OSSD
outputs will change automatically from low to high again and if
connected the MSR45E expander relay contacts will automatically
reclose.
According to EN 60204 article 9.2.4.4.2 a
system may not automatically restart,
even after the cause of the shutdown has
been eliminated and thereby another
danger may still exist to the operator. If
the MSR41 base module is configured
with an “automatic start”, this
requirement must be fulfilled by further
measures.
Output monitoring
Often a MSR41 module is connected to external relays. Reasons to do
this might be: The relays of the extension modules do not have enough
contacts or if the required switching capacity is more than the specified
capacity. These external relays can be connected:
a)to the two safety PNP outputs (OSSD) of the base module (e.g.
Figure 4)
and / or
b)to the contacts of an expander module, e.g. if the power of the two
OSSD outputs is not adequate.
In any case when using external relays the function of these external relays
must be monitored. For category 4 application, two external contactors,
each with force guided contacts must be inserted. For monitoring the
4
Original instructions
Page 7
MSR41 Safety Module User Manual
function of these contactors, each relay block must have at least one
normally closed contact which is fed back in series to the corresponding
terminal of the MSR41 base module.
Output monitoring: The signal at the corresponding input terminal
must be high before the start button is pressed (this means: the normally
closed contacts of the external relays must be closed before allowing a
start).
1. In cases where the MSR41 base module
is installed without expander modules
the function output monitoring must
always be realized, the only exceptions
are if the PNP outputs are connected with
another safety relay or a safety PLC.
2. Through the use of output monitoring,
it is possible to switch external “power”
contactors within the safety circuit. Such
contactors often deal with large inductive
loads, which during the switching off
phase can create large potential peaks.
For this reason surge suppressors are
highly recommended. Surge suppressors
must be connected parallel to the
external contactors (e.g. Figure 1). They
may never be connected parallel to the
contacts of a MSR45E expander module.
It must be noticed, that surge suppressors may drastically increase the off
delay time of the contactors. Diodes are not allowed to be used as surge
suppressors, for exactly this reason.
Recommended surge suppressors are:
Inspection and service
The MSR41 module has no serviceable components.
Inspections
The MSR41 module has to be tested periodically – in accordance with
valid regulations - by qualified and trained personnel to discover
prohibited manipulations or unauthorized modifications.
Decommissioning
The MSR41 Modules can only be removed, when the machine or the
equipment is shut down completely and can no longer be operated
without tools. If a controller has to be disposed, it can be simply
dismantled. The separated materials can be recycled according to state of
the art technology and corresponding regulations of the country it was
used in.
Product labels
All the necessary safety information can be found on the product labels,
which can be found on every controller module (example):
Supply voltage [ V]R esistor R [Ω]Condenser C [μF]
module (semi conductor outputs unloaded)
maximal: 1.7 A depending on attached load
Max. power consumption at max. supply voltage2.1 W (semiconductor outputs unloaded)
Controller protection (external)5 A slow
Control current into:
IN 1, IN 2
Minimum voltage at:
IN 1, IN 2
2 mA each (min.) (in accordance with EN 61131-2)
11 VDC at activated controller (EN 61131-2)
Start pulse duration
Min.50 ms
Maximum cable length for safety switches50 m out and back (total 100 m)
Info 1, Info 2 Status Outputs (PNP)
VoltageUN – 2 V
Current max100 mA (short-circuit protected)
Leakage currentI
MAX Off
= 0.05 mA (C
LOAD
= 4.7 μF)
OSSD semi conductor outputs (PNP)
VoltageUN – 2 V
Current max
Leakage currentI
400 mA short-circuit protected and with cross-fault
detection
MAX Off
= 0.1 mA (C
LOAD
= 3.3 μF)
6
Original instructions
Page 9
MSR41 Safety Module User Manual
Document Control Number: SEN-0394-B-EN 1 / 2
EC Declaration of Conformity
The undersigned, representing the manufacturer and the authorised representative established within the
Community
Rockwell Automation, Inc.
2 Executive Dr.
Chelmsford, MA 01824
USA
Rockwell Automation BV
Rivium 1e Straat, 23
2909 LE Capelle aan den IJssel
Netherlands
Herewith declare that the Products:
MSR4x Safety Base / MSR4xE Expander Controller Modules
Product identification (brand and
catalogue number/part number):
Allen-Bradley 440R-P and 445L-1 Series
(reference the attached list of catalogue numbers)
Product Safety Function
The MSR4x safety base control devices and the MSR4xE extension modules
can be used in applications up to Safety Category 4 (EN 954-1)/ SIL3/SIL
CL3 (EN 61508 / EN 62061) and PL e (EN ISO 13849-1).
are in conformity with the essential requirements of the following EC Directive(s) when installed in accordance with
the installation instructions contained in the product documentation:
2006/42/EC Machinery Directive
2004/108/EC
EMC Directive
and that the standards and/or technical specifications referenced below have been applied:
EN 61496-1:2004 + A1:2008 Safety of machinery – Electro-sensitive protective equipment – Part 1: General
requirements and tests
IEC 61496-2:2006 Safety of machinery – Electro-sensitive protective equipment – Part 2:
Particular requirements for equipment using active opto-electronic protective
devices (AOPD’s)
EN ISO 13849-1:2008 Safety of machinery – Safety-related parts of control systems – Part 1: General
principles for design
EN 61508 Parts 1-7:1998-2000 Functional safety of electrical/electronic/programmable electronic safety-
related systems
EN 954-1:1997 Safety of machinery – Safety related parts of control systems – Part 1: General
principles for design
EN 50178:1997 Electronic equipment for use in power installations
EN 62061:2005 Safety of machinery – Functional safety of safety-related electrical, electronic
and programmable electronic control systems
EN 60204-1:2006 Safety of machinery – Electrical equipment of machines – General
requirements
EN 61000-6-4:2007 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards –
Emission standard for industrial environments (Class A)
EN 61000-6-2:2005 Electromagnetic Compatibility (EMC) – Part 6-2: Generic standards –
Immunity for industrial environments
Manufacturer:Authorised Representative in the Community:
ENGLISH Installation of this product must not take place until the installer has obtained a copy of the manufacturer’s instructions in a language which he can understand.
This instruction sheet is available in multiple languages at http://rockwellautomation.com/literature.
DEUTSCH Dieses Produkt darf erst installiert werden, wenn der Installateur eine Kopie der Instruktionen des Herstellers in der Sprache eingeholt hat, die er versteht.
Diese Instruktionen sind mehrsprachig erhältlich unter: http://rockwellautomation.com/literature.
FRANÇAIS Ce produit ne peut être installé avant l’obtention d’un duplicata des instructions du fabricant dans une langue compréhensible.
La che d’instructions est disponible en plusieurs langues depuis le lien http://rockwellautomation.com/literature.
ITALIANO Non si deve procedere all’installazione di questo prodotto n quando l’installatore non abbia ottenuto una copia delle istruzioni del produttore in una lingua che
l’installatore possa capire. La presente scheda di istruzioni è disponibile in linguaggi multipli sul sito web http://rockwellautomation.com/literature.
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En http://rockwellautomation.com/literature puede encontrar esta hoja de instrucciones en varios idiomas.
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Essa folha de instruções está disponível em diversas línguas em http://rockwellautomation.com/literature.
POLSKI Nie należy przeprowadzać instalacji tego produktu aż do otrzymania przez montera instrukcji producenta w języku, który on rozumie.
Te karty z instrukcjami są dostępne w wielu językach na: http://rockwellautomation.com/literature.
ČESKY Instalace tohoto výrobku nesmí proběhnout, dokud instalující osoba neobdrží pokyny výrobce v jazyce, kterému rozumí.
Tyto pokyny jsou k dispozici v několika jazycích na http://rockwellautomation.com/literature.
SVENSKA Denna produkt får inte installeras förrän installatören har ska at ett exemplar av tillverkarens instruktioner på ett språk som han/hon förstår.
Detta instruktionsblad nns på era språk på http://rockwellautomation.com/literature.
NEDERLANDS Het product mag pas worden geïnstalleerd wanneer de monteur beschikt over een exemplaar van de instructies van de fabrikant in een voor hem begrijpelijke
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Page 12
www.rockwellautomation.com
Power, Control and Information Solutions Headquarters
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe/Middle East/Africa : Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel : (32) 2 663 0600, Fax (32) 2 663 0640
Asia Pacic: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846
GuardShield is a trademark of Rockwell Automation, Inc.
Guardmaster is a registered trademark of Rockwell Automation, Inc.