Installation Instructions

GuardMaster MSR57P Speed Monitoring Safety Relay Catalog Number 440R-S845AER-NNL

Dimensions S32 S42 S52 S62 S11 S21 S12 S22

13 14 34 44

P

Encoder 1

99 mm (3.9 in.)

24 A1 51 52

67.5 mm (2.66 in.)

Config Lock Stop

Inputs

DPI

Limited Speed Standstill

Status

Safe Speed Motion Power Door

Encoder 2 S72 S82 X32 X42 Y31 Y32 Y33 Y30

Y1 Y2 S34 Y37 68 78 Y35 A2

114.5 mm (4.51 in.)

PWR/Fault

Additional Resources Resource

Description

GuardMaster MSR57P Speed Monitoring Safety Relay User Manual, publication 440R-UM004

Detailed information on wiring, configuring, and operating an MSR57P relay, including safety requirements.

You can view or download publications at http://literature.rockwellautomation.com. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative.

Publication 440R-IN016B-EN-P - November 2008

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GuardMaster MSR57P Speed Monitoring Safety Relay

Installation Instructions in Other Languages English

This instruction sheet is available in multiple languages at http://rockwellautomation.com/literature. Select publication language and type “MSR57P” in the search field.

Deutsch

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Publication 440R-IN016B-EN-P - November 2008

GuardMaster MSR57P Speed Monitoring Safety Relay

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General Safety Information Retain these instructions for future reference. Rockwell Automation cannot accept responsibility or liability for a failure of this device if the product is used outside the recommended specifications in this document.

ATTENTION This device is intended to be part of the safety-related control system of a machine. Before

installation, a risk assessment should be performed to determine whether the specifications of this device are suitable for all foreseeable operational and environmental characteristics for the machine to which it is to be fitted. At regular intervals during the life of the machine, check whether the characteristics foreseen remain valid.

ATTENTION Safety Programmable Electronic Systems (PES) Personnel responsible for the installation and application of safety-related programmable electronic systems (PES) shall be aware of the safety requirements in the application of the system and shall be trained in using the system.

Spacing Requirements Adequate air space must be provided around the system (module cluster). Minimum recommended clearances:

• 15 mm (0.6 in.) above • 15 mm (0.6 in.) below • 2…3 mm (0.08…0.12 in.) between modules at ambient temperatures higher than 40 °C (104 °F).

Mount the MSR57P Relay Follow these steps to mount the MSR57P relay to an EN50022 -35 x 7.5 DIN rail. 1. Hook the top slot over the DIN rail. 2. Snap the bottom of the device into position while pressing the device down against the top of the rail.

Slot DIN Rail

3. Attach end plates on each end of the DIN rail. To remove the device from the DIN rail, use a flathead screwdriver to pull down the latch and lift the device from the rail.

Latch

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GuardMaster MSR57P Speed Monitoring Safety Relay

S72 S82

S32 S42

X32 X42

Pulse Test Outputs

Safe Stop (SS_In)

Safe Limited Speed (SLS_In)

Enabling Switch (ESM_In)

Door Monitor (DM_In)

Lock Monitor (LM_In)

SLS_Status

Fault_Status

Y31

Y32

Y33

Y30 Y35

Y37

Door Lock Control SS_Out SLS_Out (DC_Out) (Cascade) (Cascade) bipolar 2 OSSD 2 OSSD

34

44

68

78

Lo

GND

Y2

SLS_Command

S34

Stop_Command

Y1

Diag. Out

24V dc

Reset_In Feedback (RL_In)

DPI

24V dc

Isolated Outputs

13

A1

51

52

Motion Power (MP_Out) 2 OSSD

A2

14

24

Door Lock Control (DC_Out) Cascade Hi

S52 S62

Hi

S12 S22

Hi

RJ45-1

Mini-DIN

HIM

Monitor Encoder PS

S11 S21

RJ45-2

Encoder 2

Encoder 1

Circuit Diagram

51

52

Terminal Connections Terminal A1 A2 S11, S21 S12, S22 S72, S82 S52, S62 S32, S42 X32, X42 Y1 S34 Y2 Y35 Y37 13 14, 24 68, 78 51

Function +24V dc, user supply Common, user supply Test_Out_0, Test_Out_1, pulse test outputs for safety functions SS_In_Ch0, SS_In_Ch1, Safe Stop (SS) dual-channel input ESM_In_Ch0, ESM_In_Ch1, Enabling Switch Monitor (ESM) dual-channel input SLS_In_Ch0, SLS_In_Ch1, Safe Limited Speed (SLS) dual-channel input DM_In_Ch0, DM_In_Ch1, Door Monitor (DM) dual-channel input LM_In_Ch0, LM_In_Ch1, Lock Monitor (LM) dual-channel input, solenoid position 24V dc output for reset (S34) and for feedback (Y2) Reset_In RL_In, feedback input SLS_Status output Fault_Status output Supply power for Motion Power (MP) safety outputs 14 and 24 MP_Out_Ch0, MP_Out_Ch1, Motion Power (MP) outputs SLS_Out_Ch0, SLS_Out_Ch1, Safe Limited Speed (SLS) outputs

52

DC_Out_Ch1 (Low Side), Door Control output [door switch solenoid, bipolar or cascading(1)]

34, 44

SS_Out_Ch0, SS_Out_Ch1, cascading Safe Stop outputs

Y31

24V dc power for isolated outputs

Y32

Stop_Command, isolated output

DC_Out_Ch0 (High Side), Door Control output [door switch solenoid, bipolar or cascading(1)]

Y33

SLS_Command, isolated output

Y30

GND for isolated outputs

(1)

The DC_Out output may also be configured as cascading (2 Channel Source). For information on using this configuration in limited applications, refer to the GuardMaster Speed Monitoring Safety Relay User Manual, publication 440R-UM004.

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GuardMaster MSR57P Speed Monitoring Safety Relay

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Status Indicators Indicator PWR/Fault

(1)

Status

Description

Green/On

The device is operating normally and is in Run mode.

Red/Flashing

A recoverable fault has occurred.

Red/On

A nonrecoverable fault has occurred.

Red/Green Flashing

The configuration is being downloaded or a firmware upgrade is in progress.

Config Lock(1) Yellow/On Yellow/Flashing

The device’s configuration is unlocked.

Stop

Green/On

The Safe Stop (SS) input is closed.

Red/On

The SS input is open or pressed.

Red/Flashing

The SS input has a fault.

Green/On

The Safe Limited Speed (SLS) input is closed for normal Run operation.

Green/Flashing

The SLS input is open for a safe speed request to allow access to the machine (Maintenance operation).

Limited Speed

Off

The SLS function is not configured.

Red/Flashing

The SLS input has a fault.

Motion Power Green/On

Door

Safe Speed

Standstill

(1)

The device’s configuration is locked.

The Motion Power (MP) output is ON.

Off

The MP output is OFF.

Red/Flashing

The MP output has a fault.

Green/On

The door is closed.

Red/On

The door is open.

Red/Flashing

Door Monitor or Lock Monitor input switch has a fault.

Off

Door monitoring is not configured.

Green/On

Safe Limited Speed is being actively monitored and is below the configured Safe Limited Speed value after an SLS request has been made.

Off

Safe Limited Speed is not being monitored.

Red/Flashing

An SLS Speed Fault has occurred.

Green/On

Standstill Speed has been detected.

Off

Speed is greater than the configured Standstill Speed.

Red/Flashing

Motion has been detected after stopped condition or a Stop Speed Fault has occurred.

PWR/Fault green indicator and Config Lock indicator flash in synch when the device is in Program mode.

When you apply power to the device, the red/green indicators flash alternate colors twice and the Config Lock indicator flashes on and off twice before all indicators except for the PWR/Fault indicator turn off. The PWR/Fault indicator remains flashing until the device enters Run or Program mode.

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GuardMaster MSR57P Speed Monitoring Safety Relay

Specifications GuardMaster MSR57P Speed Monitoring Safety Relay – 440R-S845AER-NNL Attribute

Value

Standards

IEC/EN60204-1, ISO12100, IEC 61800-5-2

Safety category

Cat. 4 and PL e per EN ISO 13849-1; SIL CL1 to CL3 per IEC 61508/EN62061

Power supply

24V dc, 0.8…1.1 x rated voltage(3) PELV/SELV

Aggregate current of MSR57P

10.4 A max. @ terminal A1 + 13

Power consumption

5W

Outputs 14, 24, 68, 78 24V dc, 2 A, short-circuit protected Outputs 34, 44

24V dc, 100 mA, short-circuit protected

Outputs Y35, Y37

24V dc, 50 mA, short-circuit protected

Door switches 51, 52(1) 24V dc, short-circuit protected • 1.5 A, bipolar (Power to Release/Power to Lock) configuration • 20 mA, cascading (2 Channel Source) configuration Outputs Y32, Y33

24V dc, 100 mA, short-circuit protected

Output Y1

24V dc, 20 mA, short-circuit protected

Pulse outputs S11, S21 24V dc, 100 mA, short-circuit protected Pulse inputs S12, S22, 11 mA per input, max S32, S42, S52, S62, S72, S82, X32, X42 Inputs S34, Y2

11 mA per input, max

Power-on delay, max

3s

Response time

User-configurable.(4)

Pollution degree

2

Enclosure protection

IP40

Terminal protection

IP20

Wire Type

Use copper that will withstand 60/75 °C (140/167 °F)

Conductor size(2)

0.2…2.5 mm2 (12…24 AWG)

Terminal screw torque 0.6…0.8 Nm (5…7 lb-in) Case material

Polyamide PA 6.6

Mounting

35 mm DIN rail

Weight, approx.

350 g (0.77 lb)

(1) (2) (3) (4)

For information on using these outputs in bipolar or cascading configurations, refer to the GuardMaster Speed Monitoring Safety Relay, publication 440R-UM004. Refer to Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1. Safety outputs need additional fuse for reverse voltage protection of the control circuit. Install a 6 A slow-blow or 10 A fast-acting fuse. Refer to the GuardMaster MSR57P Speed Monitoring Safety Relay User Manual, publication 440R-UM004 for details.

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GuardMaster MSR57P Speed Monitoring Safety Relay

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Environmental Specifications Attribute

Value

Temperature, operating -5…55 °C (23…131 °F) Relative humidity

90% RH noncondensing

Vibration

10…55 Hz, 0.35 mm displacement

Shock, operating

10 g, 16 ms, 100 shocks

ESD immunity

4 kV contact discharges; 8 kV air discharges

Radiated RF immunity

10 V/m from 80…1000 MHz; 3 V/m from 1.4…2.0 GHz; 1V/m from 2.0…2.7GHz

EFT/B immunity

Power, dc: ±2 kV I/O signal lines: ±1 kV

Surge transient immunity Power, dc: ±0.5 kV line-line and ±0.5 kV line-earth I/O signal lines: ±1 kV line-earth Conducted RF immunity 10V rms from 150 kHz…80 MHz

Certifications Certification(1)

Value

c-UL-us

UL Listed, certified for US and Canada.

CE

European Union 2004/108/EC EMC Directive, compliant with: • EN 61000-6-4; Industrial Emissions. • EN 61131-2 Programmable Controllers (Clause 8, Zone A & B). • EN 61326-3-1; Meas./Control/Lab., Industrial Requirements. • EN 61000-6-2; Industrial Immunity.

C-Tick

Australian Radiocommunications Act, compliant with: AS/NZS CISPR 11; Industrial Emissions.

TÜV

TÜV Certified for Functional Safety: SIL CL1 to CL3, according to IEC 61508/EN62061; Category 1 to 4 and Performance Level e, according to EN ISO 13849-1, when used as described in the GuardMaster MSR57P Speed Monitoring Safety Relay User Manual, publication 440R-UM004.

(1)

When product is marked. See the Product Certification link at http://ab.com for Declarations of Conformity, Certificates, and other certifications details.

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GuardMaster MSR57P Speed Monitoring Safety Relay

Application Example 1 This example is configured for Safe Stop 1. The control cabinet contains an MSR57P relay, a PowerFlex 70 AC Drive with Safe-Off function, as well as a PanelView terminal. The MSR57P relay monitors speed via a TTL encoder connected to the PowerFlex 70 drive.

E-Stop Reset Maintenance

Run Stopped Safe Speed Running

Mode

The control panel lets the operator select Run or Maintenance speeds. The door has an interlock switch with guardlocking to limit access to the machine when the machine is operating at normal Run speed. A towerlight indicates machine status.

Example 1: System Layout PowerFlex 70 Drive With Safe-Off Safe Stop SLS Request

Encoder Cable 1585J-M8RB-2M5

Configuration Tools

20-HIM-A3

S32 S42 S52 S62 S11 S21 S12 S22

13 14 34 44

P

Encoder 1

20-HIM-H10

24 A1 51 52 Config Lock

PC

PWR/Fault Stop

Inputs

DPI

Encoder Input 1

Limited Speed

-OR-

Standstill Status

Safe Speed

1203-USB or 1203-SSS(B)

Motion Power Door Encoder 2 S72 S82 X32 X42 Y31 Y32 Y33 Y30

Motor Power Cable Encoder Feedback Cable

M

Start/Stop Command and Motion Power Outputs

Y1 Y2 S34 Y37 68 78 Y35 A2

MSR57P Relay

Primary Encoder (Example, Catalog Number: 845T-HZ42EEN)

Publication 440R-IN016B-EN-P - November 2008

Guardlocking Switch TLS3-GD2

(1)

S22

Y35

Y37 34

44

SLS Fault Status Status SS Output

RJ45 Encoder Input 2

SS Input

S12

S82 51

52

Door Lock Control

S34

Y33

Y32

Reset 800FM-F6MX10

Y2

Aux. Signals to PLC

Y1

Y30

X42

Y31

24V dc

14

24

A1

A2

A1

S42 13

68

42 52

41 51

78

SLS Output

Door Monitor

S32

Power to Release

Motion Power Out

Lock Monitor

X32

Isolated Diagnostics and Power

MSR57P Relay

ESM Input

S72

RL Reset Feed- SLS Stop GND back Cmd Cmd Feed

DPI

S62

SLS Input

S52

SLS Request 800FM-KM23 800F-MX02V

Digital input 4. Proper configuration is required for inputs 1, 2, 4, and 6 on the PowerFlex 70 Drive.

A2

S21

Pulse Test Outputs

S11

RJ45 Encoder Input 1

A1

E-Stop 800FM-MT44 800F-MX02V

SS Request

24V dc Com

Remove jumpers

6 Enable

4 2

1 3

Gate Control Circuit

Gate Control Power Supply

PowerFlex 70 AC Drive with DriveGuard

Remove two internal jumpers

4 SLS Input (1) Safe-Off Option

2 Start

1 Stop

9 24V dc 8 DC Comm 7 Dig Comm

TLS3-GD2 440G-T27260

12 22 34

11 21 33

Motor

L1 L2 L3

+24V dc

GuardMaster MSR57P Speed Monitoring Safety Relay 9

Example 1: System Wiring

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GuardMaster MSR57P Speed Monitoring Safety Relay

Application Example 2 This example is configured for Safe Stop 1. The control cabinet contains an MSR57P relay, a Kinetix 6000 drive with Safe-Off function, as well as a PanelView terminal. The MSR57P relay monitors speed via a Sin/Cos encoder connected to the Kinetix 6000 drive.

E-Stop Reset Run Maintenance Stopped Safe Speed Running

Mode

The control panel lets the operator select Run or Maintenance speeds. The door has an interlock switch with guardlocking to limit access to the machine when the machine is operating at normal Run speed. In addition, an enabling switch is required to be held in the middle position while operators are within the machine environment to keep the machine running at safe speed. A towerlight indicates machine status.

Example 2 System Layout Kinetix 6000 or Kinetix 7000 With Safe-Off Safe Stop Low Profile Connector 2090-K6CK-D15M

Enabling Switch SLS Request

Motion Power Outputs and Feedback Monitoring From the MSR57P Relay to Kinetix Safe-Off Interface Configuration Tools

Encoder Cable 1585J-M8RB-2M5

20-HIM-A3

S32 S42 S52 S62 S11 S21 S12 S22

20-HIM-H10

13 14 24 A1 34 44 51 52

P

Encoder 1

Config Lock

PWR/Fault Stop

Inputs

DPI

Encoder Input 1

Limited Speed

PC

-OR-

Standstill Status

Safe Speed

Encoder Feedback Cable

Motion Power Door Encoder 2 S72 S82 X32 X42 Y31 Y32 Y33 Y30

Motor Power Cable

Y1 Y2 S34 Y37 68 78 Y35 A2

1203-USB or 1203-SSS(B)

MSR57P Relay

Start/Stop Command to Logix Controller MP-Series Bulletin MPL Servo Motors

Publication 440R-IN016B-EN-P - November 2008

Guardlocking Switch TLS3-GD2

A2

Y35

Y37

SLS Fault Status Status

S22

SS Input

S12

Y2

Aux. Signals to Logix Controller

Reset 800FM-F6MX10

S34

Y33

Y1

44

34

MSR57P Relay

Door Lock Control

51

52

3

1

Y32

Stop Cmd

Y30

GND

Y31

24V dc

14

24

Motion Power Out

A1

A2

A1

13

68

42 52

41 51

FDBK2

FDBK1 FDBK2

FDBK1

R1

R2

R1 Safety Monitor

24V dc Com

R2

SAFETY EN2+

SAFETY EN-

SAFETY EN1+

Gate Control Enable

R1

Gate Control Circuit

R2

Motor

L1 L2 L3

+24V dc

Gate Control Power Supply

Remove two internal jumpers

Kinetix 6000 and 7000 AC Drive with GuardMotion

TLS3-GD2 440G-T27260

12 22 34

11 21 33

Aux.Signals to Logix Controller

78

SLS Output

S42

Door Monitor

S32

Power to Release

X42

Lock Monitor

X32

Isolated Diagnostics and Power

S82

ESM Input

S72

RL Reset Feed- SLS back Cmd Feed

DPI

S62

SLS Input

S52

4

2

440J-N21TNPM Enabling Switch

SS Output

RJ45 Encoder Input 2

S21

Pulse Test Outputs

S11

RJ45 Encoder Input 1

A1

E-Stop 800FM-MT44 800F-MX02V

SS Request

SLS Request 800FM-KM23 800F-MX02V

GuardMaster MSR57P Speed Monitoring Safety Relay 11

Example 2: System Wiring

Publication 440R-IN016B-EN-P - November 2008

Rockwell Automation, Allen-Bradley, GuardMaster, PowerFlex, Kinetix, PanelView, DriveExplorer, DriveGuard, GuardMotion, and MP-Series are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication 440R-IN016B-EN-P - November 2008

PN 95302398 Copyright © 2008 Rockwell Automation, Inc. All rights reserved. Printed in Germany.