Rockwell Automation Allen-Bradley MicroLogix 1100, Allen-Bradley GuardShield Micro 400, Allen-Bradley MSR42 Quick Start Manual

Bidirectional (4-sensor, T-type) Muting
With MSR42 Relay
Connected Components Building Block

Catalog Numbers MSR42, MicroLogix 1100, GuardShield Micro 400
Light Curtains

Quick Start

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines
for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
Automation sales office or online at http://www.rockwellautomation.com/literature/
between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the
wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that
each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING

Identifies 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.

available from your local Rockwell

) describes some important differences

IMPORTANT

ATTENTION

SHOCK HAZARD

BURN HAZARD

Allen-Bradley, Rockwell Automation, TechConnect, MicroLogix, PanelView, Rockwell Software, and GuardShield are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Identifies information that is critical for successful application and understanding of the product.

Identifies 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 consequence

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may
be present.

Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach
dangerous temperatures.

Connected Components Building Block Outline

Follow the path below to complete your connected components building block.

Connected Components

Building Blocks, publication

CC-QS001

Where to Start

Chapter 1 Product

Integration

Chapter 2 System

Validation and Application

Tips

ESC OK

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Where to Start

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Product Integration

System Validation and Application
Tips

Table of Contents

Preface

About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Understand the Safety Function . . . . . . . . . . . . . . . . . . . . . . 10

Set Up the Configuration and Diagnostic Software . . . . . . . . 12

Configure the MSR42 Safety Relay . . . . . . . . . . . . . . . . . . . . 13

Download the Configuration . . . . . . . . . . . . . . . . . . . . . . . . 19

Confirm the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chapter 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Follow These Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Validate Proper Operation of the Safety Systems. . . . . . . . . . 26

Validate Proper Operation of the PanelView Screens . . . . . . 31

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Table of Contents

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Preface

About This Publication

This quick start illustrates one way of combining a set of Micro 400 Light Curtains, an MSR42
safety relay, an MSR45E expansion module, an MSR127 safety relay, an E-stop, and two
contactors into an integrated safety system providing both a bidirectional, four-sensor, T-type
muting function and an E-stop function.

A MicroLogix 1100 controller and a PanelView HMI are included to provide a convenient and
graphical way to monitor the operation of the safety systems and provide basic diagnostic
information and corrective action suggestions when appropriate. The MicroLogix controller and
PanelView terminal only monitor the safety systems. They are not safety components and they
have no safety control or function. The safety systems operate independently from the
MicroLogix controller and PanelView terminal.

IMPORTANT

To assist in the design and installation of your system, application files and other information are
provided on the Connected Components Building Blocks Overview CD, publication CC-QR001.
The CD provides bills of materials (BOM), CAD drawings for panel layout and wiring, control
programs, Human Machine Interface (HMI) screens, and more. With these tools and the built-in
best-practices design, the system designer is free to focus on the design of their machine control
and not on design overhead tasks.

Read these sections carefully before beginning work in each chapter. The beginning of each
chapter contains the following information:

• Before You Begin - This section lists the steps that must be completed and decisions that

must be made before starting that chapter.

• What You Need - This section lists the tools that are required to complete the steps in the

current chapter. This includes, but is not limited to, hardware and software.

• Follow These Steps - This illustrates the steps in the current chapter and identifies which

steps are required to complete the examples.

Use this Simple Machine Safety Connected Components Building Block Quick Start in conjunction
with the Connected Components Building Blocks Quick Start, publication CC-QS001.

Refer to Additional Resources on page 8 for a listing of quick starts.

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Preface

Conventions

Convention Meaning Example

Check or uncheck To activate or deactivate a checkbox. Check Disable Keying.

Click

Double-click

Expand Click the + to the left of a given item /folder to show its contents. Expand 1768 Bus under I/O Configuration.

Right-click

Select Using the mouse to highlight a specific option. Select the New Module folder.
Press Pressing a specific key on the keyboard or button on a touchscreen. Press Enter.
> Use this symbol to indicate the sub-menu name. Choose File
‘Project’ Refers to the application on both the controller side and the PanelView component side.

Click the left mouse button once while the cursor is positioned on
object or selection to initiate an action.

Click the left mouse button twice in quick succession while the cursor
is positioned on object or selection to initiate an action.

Click the right mouse button once while the cursor is positioned on
object or selection.

Click Browse.

Double-click the application icon.

Right-click the 1768 Bus icon.

>Menu>Options.

Additional Resources

Resource Description

Connected Components Building Blocks Quick Start,
publication CC-QS001

Connected Components Building Blocks Overview CD,
publication CC-QR001

Position Control Connected Components Building
Block Quick Start, publication CC-QS003

MicroLogix 1100 Controller User Manual, publication

176

3-UM001

MSR42 Safety Base Module Operating Manual,
publication 440R-IN017

MSR45E Safety Expander Module, Operation Manual,
publication 440R-IN018

GuardShield Micro 400 Safety Light Curtain Operation
Manual, publication 445L-IN001

Configuration Tool for MSR42, GuardShield Micro 400
and Safe 2/4 Light Curtains Software Description

http://www.ab.com
http://www.rockwellautomation.com/knowledgebase
http://www.rockwellautomation.com/components/

connected/blocks.html

Provides information on how to select products and gain access to panel and
wiring information

Provides files for the Connected Components Building Blocks

Provides information installing and setting up the PowerFlex 40P drive
parameters with the pre-configured RSLogix 500 program that controls you base
system including application tips, as well as implementing the drive parameter
backup and restore functionality

Provides information on using the MicroLogix 1100 Programmable Controller

Provides information wiring and operating the MSR42 safety controller

Provides information on using the MSR45E expander module

Provides information on mounting, wiring, and using safety light curtains

Provides information on configuring and programming an MSR42 safety controller
with Configuration Tool software

Provides access to the Allen-Bradley website
Provides access to self-service support
Provides access to the Connected Components website

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Chapter

1

Product Integration

Introduction

A bidirectional, four-sensor, T-type muting system lets valid loads or objects pass through its light
curtains in either direction without shutting down the machine or process, but will stop the
machine or process if anything or anyone attempts to move past the light curtain in any other
manner. This type of system is often used to guard the access point at a hazardous portion of a
machine or process where material must pass either into or out of the guarded area, such as an
automatic palletizing system or automatic assembly machine. This Connected Components
Building Block is intended to ease the installation, configuration, and implementation of such a
system.

Before You Begin

Review the Connected Components Building Blocks Quick Start, publication CC-QS001, verifying
that you have completed the hardware design and installation as well as software installation.

IMPORTANT

A safety risk assessment must be completed to make sure that all tasks and hazards are
considered and to confirm that the example circuit provides adequate risk reduction for your
specific application.

What You Need

• Personal computer

• Connected Components Building Blocks Overview CD, publication CC-QR001

• MicroLogix 1100 controller, catalog number 1763-L16BBB

• PanelView Component C600 terminal, catalog number 2711C-T6C

• Stratix 2000 Ethernet switch, catalog number 1783-US05T (or equivalent) to connect the

MicroLogix controller to the PanelView terminal

• Ethernet cables, catalog number 1585J-M8TBJM-2 or equivalent

• MSR127 safety relay, catalog number 440R-N231132

• MSR42 safety relay, catalog number 440R-P226AGS-NNR

• MSR45E expander module, catalog number 440R-P4NANS

• Optical Interface Tool, catalog number 445L-AF6150, which includes the Optical Interface

Tool-MSR42 Configuration and Diagnostic Software

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Chapter 1 Product Integration

• Optical Interface Tool Fastener, to attach the Optical Interface securely to the MSR42 relay

• 24V DC power supply, catalog number 1606-XL120D

• Safety components such as E-stops, GuardShield Micro 400 light curtains, as listed in the bill

of material on the Connected Components Building Blocks Overview CD, publication
CC-QR001

Follow These Steps

Start

Understand the Safety Function

on page 10

Set Up the Configuration and

Diagnostic Software on page 12

Configure the MSR42 Safety

Relay on page 13

Download the Configuration on

page 19

Confirm the Configuration on

page 22

Understand the Safety Function

Two separate safety functions are provided.

1. The GuardShield Micro 400 light curtains and MSR42 safety relay provide a bidirectional,

four-sensor, T-type muting function.

2. The E-stop and MSR127 safety relay provide an E-stop function.

These two safety functions are independent of one another. When set up properly, either safety
system is capable of stopping dangerous motion.

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Product Integration Chapter 1

The MicroLogix 1100 controller monitors the safety systems and, via the PanelView terminal,
provides a simple, graphical representation of the operation and status of the safety systems and
recommends corrective actions in response to system faults. The controller and the terminal
perform no safety or control functions.

If the PanelView terminal is mounted so that it provides the operator a clear and complete view
of the hazard area, and local safety regulations permit, the PanelView START RESET button may
be used to start or reset the safety systems, just like the Start – Reset push button.

IMPORTANT

If the operator stationed at the PanelView terminal’s location cannot see the guarded area well
enough to be certain that no one is in the guarded area, you must not use the START RESET
button.

The START RESET button can be disabled by removing three wires from the MicroLogix controller
I/O.

• Wire 6041

• Wire 10231

• Wire 10071

Safety Systems Diagram

800F

Start

Reset

MicroLogix 1100

Stratix

2000

PanelView

Component

Term in al

Personal

Computer

MSR45E

Expansion

Controller

MSR127

Safety

Relay

100S-C

100S-C

M

RightSight

Sensors

RightSight

Sensors

GuardShield Micro 400

Light Curtains

MSR42

Multi-

function

Safety

Relay

800FP

STOP

Publication CC-QS015A-EN-P - November 2009 11

Chapter 1 Product Integration

Set Up the Configuration and Diagnostic Software

Follow these steps to install and set up the Configuration and Diagnostic software.

1. If you do not have the Configuration and Diagnostic software, go to

http://www.ab.com/safety/logic/relays/msr4x/ to download the Configuration Tool for

MSR42 relay, GuardShield Micro 400 and Safe2/4 Light Curtains.

a. Go to Related Links on the right side of the page and choose ‘Safety Software [ZIP]’.
b. Save the zip file to your personal computer.
c. Unzip the file.
d. Run the SetupDiagnosticAndConfiguration_Vxxx.exe file to install the software.

2. Start the Configuration and Diagnostic software.

3. Click MSR42 and then OK.

4. If this is the first time you have used

the Configuration and Diagnostic
software, register the software.

a. From the Options menu, choose

User Registration.

b. Type in your information and

click OK.

TIP

It is not necessary to change the password for this building block. The default password is
ABGM.

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