Rockwell Automation Allen-Bradley MicroLogix 1100 User 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 available from your local Rockwell
Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences
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.
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.
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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
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
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.

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Where to Start
Connected Components Building Block Outline
Follow the path below to complete your connected components building block.
ESC OK
Chapter 1 Product
Integration
Chapter 2 System
Validation and Application
Tips
Connected Components
Building Blocks, publication
CC-QS001

4Publication CC-QS015A-EN-P - November 2009
Where to Start

5Publication CC-QS015A-EN-P - November 2009 5
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Product Integration 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
SystemValidationandApplication
Tips
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

6Publication CC-QS015A-EN-P - November 2009
Table of Contents

7Publication CC-QS015A-EN-P - November 2009 7
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.
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.
IMPORTANT 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.

8Publication CC-QS015A-EN-P - November 2009
Preface
Conventions
Additional Resources
Convention Meaning Example
Check or uncheck To activate or deactivate a checkbox. Check Disable Keying.
Click Click the left mouse button once while the cursor is positioned on
object or selection to initiate an action. Click Browse.
Double-click Click the left mouse button twice in quick succession while the cursor
is positioned on object or selection to initiate an action. Double-click the application icon.
Expand Click the + to the left of a given item /folder to show its contents. Expand 1768 Bus under I/O Configuration.
Right-click Click the right mouse button once while the cursor is positioned on
object or selection. Right-click the 1768 Bus icon.
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>Menu>Options.
‘Project’ Refers to the application on both the controller side and the PanelView component side.
Resource Description
Connected Components Building Blocks Quick Start,
publication CC-QS001 Provides information on how to select products and gain access to panel and
wiring information
Connected Components Building Blocks Overview CD,
publication CC-QR001 Provides files for the Connected Components Building Blocks
Position Control Connected Components Building
Block Quick Start, publication CC-QS003 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
MicroLogix 1100 Controller User Manual, publication
1763-UM001 Provides information on using the MicroLogix 1100 Programmable Controller
MSR42 Safety Base Module Operating Manual,
publication 440R-IN017 Provides information wiring and operating the MSR42 safety controller
MSR45E Safety Expander Module, Operation Manual,
publication 440R-IN018 Provides information on using the MSR45E expander module
GuardShield Micro 400 Safety Light Curtain Operation
Manual, publication 445L-IN001 Provides information on mounting, wiring, and using safety light curtains
Configuration Tool for MSR42, GuardShield Micro 400
and Safe 2/4 Light Curtains Software Description Provides information on configuring and programming an MSR42 safety controller with Configuration Tool software
http://www.ab.com Provides access to the Allen-Bradley website
http://www.rockwellautomation.com/knowledgebase Provides access to self-service support
http://www.rockwellautomation.com/components/
connected/blocks.html 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.
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
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.

10 Publication CC-QS015A-EN-P - November 2009
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
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.
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