Rockwell Automation Allen-Bradley MSR42 User manual

User Manual Original Instructions
MSR42 Safety Module
Bulletin Number 440R

2Rockwell Automation Publication 440R-UM008B-EN-P - July 2022
MSR42 Safety Module User Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
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.
These labels may also be on or inside the equipment to provide specific precautions.
The following icon may appear in the text of this document.
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.
ATTENTION: 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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation Publication 440R-UM008B-EN-P - July 2022 3
Table of Contents
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Introduction General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Customer Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Application Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 2
System Configuration Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Basic Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Customer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Status Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Status Indicator Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Micro400 Safety Light Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Other Safety Components Connected to GPIO Terminals. . . . . . . . 15
MSR45E Extension Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Basic Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 3
Installation Mounting Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cable and Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Supply Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Earth Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Micro400 Safety Light Curtain Connection . . . . . . . . . . . . . . . . . . . . . . . . 17
Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Manual Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Automatic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Minimum Off Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
EDM or Start Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Safety Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safety Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OSSD Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Muting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Blanking Teach-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Single Scan Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Test the MSR42 Safety Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chapter 4
Maintenance Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4Rockwell Automation Publication 440R-UM008B-EN-P - July 2022
Table of Contents
External Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Internal Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Decommission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Appendix A
Specifications Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Product Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
UKCA Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Appendix B
Accessories Additional Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Interrupt Ignore Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Rockwell Automation Publication 440R-UM008B-EN-P - July 2022 5
Preface
About This Publication This manual covers the installation and operation of the Guardmaster® MSR42
Safety Module.
Summary of Changes This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
ATTENTION: MSR42 safety modules can only achieve functionality if the
instructions and additional documentation that are given in this instruction
manual are exactly followed. You must also consult the valid laws and
regulations at the time of installation. Serious injury or death can occur if you
do not follow these instructions carefully. The installer or system integrator is
fully responsible for a safe integration of this product. This instruction
manual is part of the MSR45E extension module. This instruction must be
accessible together with the other machine documentation during its entire
lifecycle for all personnel responsible for assembly, installation, operation,
and maintenance.
Topic Page
Added UKCA Approvals to Table 2 15
Updated Figure 13 31
Updated Declaration of Conformity 32
Resource Description
Light Curtains Configuration and Diagnostic Software Tool User Manual,
publication SAFETY-UM001 Provides information to configure and diagnose GuardShield™ safety light curtains and
MSR42 safety module products.
System Security Design Guidelines Reference Manual, SECURE-RM001 Provides guidance on how to conduct security assessments, implement Rockwell Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
UL Standards Listing for Industrial Control Products,
publication CMPNTS-SR002 Assists original equipment manufacturers (OEMs) with construction of panels, to help
confirm that they conform to the requirements of Underwriters Laboratories.
Industrial Components Preventive Maintenance, Enclosures, and Contact
Ratings Specifications, publication IC-TD002 Provides a quick reference tool for Allen-Bradley industrial automation controls and
assemblies.
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-state Control, publication SGI-1.1
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
general guidelines for the application, installation, and maintenance of solid-state control in
the form of individual devices or packaged assemblies incorporating solid-state
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.

6Rockwell Automation Publication 440R-UM008B-EN-P - July 2022
Preface
Notes:

Rockwell Automation Publication 440R-UM008B-EN-P - July 2022 7
Chapter 1
Introduction
General Description The MSR4xis a family of compact safety control modules. This main
controlling module allows the connection and the control of the compact
Allen-Bradley® GuardShield™ Micro400 Safety Light Curtain systems.
Depending on the configuration, other safety components can also be
connected and monitored simultaneously.
Figure 1 - MSR42 Safety Module and Safety Components
The MSR41 safety module or MSR42 safety module offer two safety PNP
outputs (OSSD). Additional MSR45E extension modules can be applied, which
require relay contact outputs.
You can attach up to three extension modules, which the base module controls.
We also offer models in special configurations, which are described in
Interrupt Ignore Time on page 36.
Special Features The characteristics of the MSR42 safety module:
• Category 4, PLe according to EN ISO 13849-1
• Type 4 according to EN 61496-1/-2
• SIL 3 according to IEC 61508
• SIL CL 3 according to EN 62061
•Shortresponsetimes
• Expandable
• Up to three extension modules per main safety module
• Adjustable stop delay time
• Different safety components suitable for connection
Safety Light Curtain
Main Safety Module
Extension Module

8Rockwell Automation Publication 440R-UM008B-EN-P - July 2022
Chapter 1 Introduction
•Blanking
• Muting
• Single scan selectable
Customer Configurations The configuration of an MSR42 safety module can adapt to the customer
requirements of an individual application with the use of the USB/optical
interface and the Allen-Bradley Guardmaster® software Configuration and
Diagnostic Tool. More information is in publication SAFETY-UM001. The
software generates a configuration control document that lists the
configurations and specifications of the controller and safety light curtain.
Typical Applications Typical MSR42 safety module applications are:
•Presses
• Robotic cells with automatic insertion
•Assemblylines
• Indexing tables
•Conveyorsystems
• Automatic storage facilities
Application Restrictions
MSR42 safety modules are not intended for application in explosive (EX) or in
radioactive environments.
WARNING: The resolution and the response time can increase due to the
download of other configuration settings for the Micro400 safety light curtain
and other safety sensors that are connected to an MSR42 safety module.
Consider the relevant resolution and the maximum response time when you
evaluate the safety distance. See Response Time on page 13. All relevant data of
the actual configuration are described in the configuration control document for
that controller. Always store the document near to the control unit.

Rockwell Automation Publication 440R-UM008B-EN-P - July 2022 9
Chapter 2
System Configuration
Wiring Diagrams Basic Configurations
Figure 2…Figure 6 on page 11 show the connection possibilities for the MSR42
safety module with basic configuration. The logic of this basic version is
exemplified in the configuration control document. See Blanking Teach-In on
page 23.
Figure 2 - Basic Configuration, Manual Start
Table 1 - Connection Configurations
Figure Safety Component Start Mode Start Release
Figure 2 Micro400 safety light curtain Manual No
Figure 3 on page 10 Micro400 safety light curtain Manual Yes
Figure 4 on page 10 Micro400 safety light curtain Automatic No
Figure 5 on page 11 Micro400 safety light curtain Automatic Yes
DIN Rail
Receiver
Emitter
Start

10 Rockwell Automation Publication 440R-UM008B-EN-P - July 2022
Chapter 2 System Configuration
Figure 3 - Basic Configuration, Manual Start, with Start Release
Figure 4 - Basic Configuration, Automatic Start
DIN Rail
Receiver
Emitter
Start
DIN Rail
Receiver
Emitter