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Safety Application Example Using the MSR57P Relay in a Safety Architecture to Monitor Machine Motor Speed TUIntroductionUT ..............................................................................................1 TUImportant User InformationUT .....................................................................2 TUGeneral Safety InformationUT .....................................................................2 TUControl of Hazardous EnergyUT .................................................................3 TUDescriptionUT ...............................................................................................3 TUExample Bill of MaterialUT ...........................................................................8 TUSetup and WiringUT .....................................................................................9 TUConfigurationUT .........................................................................................10 TUSmartGuard 600 Logic ...........................................................................14 TUAdditional ResourcesUT ............................................................................19 TIntroduction TThe MSR57P is a speed monitoring safety controller. This application example describes how to connect and configure the MSR57P Speed Monitoring Relay in an application where the MSR57P only monitors the speed of a motor. The safety functions are performed by another safety controller, the SmartGuard 600 controller.

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Page 1: Using the MSR57P Relay in a Safety Architeture to …...Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed 3 This application example is for advanced users and

Safety Application Example

Using the MSR57P Relay in a Safety Architecture to Monitor Machine Motor Speed

TUIntroduction UT ..............................................................................................1 TUImportant User Information UT.....................................................................2 TUGeneral Safety Information UT .....................................................................2 TUControl of Hazardous EnergyUT .................................................................3 TUDescriptionUT ...............................................................................................3 TUExample Bill of MaterialUT...........................................................................8 TUSetup and WiringUT .....................................................................................9 TUConfigurationUT .........................................................................................10 TUSmartGuard 600 Logic...........................................................................14 TUAdditional Resources UT ............................................................................19

TIntroduction TThe MSR57P is a speed monitoring safety controller. This application

example describes how to connect and configure the MSR57P Speed

Monitoring Relay in an application where the MSR57P only monitors the

speed of a motor. The safety functions are performed by another safety

controller, the SmartGuard 600 controller.

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2 Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed

TImportant User InformationT 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

HTUSGI-1.1 UTH available from your local Rockwell Automation sales office or

online at HTUhttp://literature.rockwellautomation.comUTH) 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.

TGeneral Safety InformatioTTnT Throughout this manual, when necessary, we use notes to make you

aware of safety considerations.

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.

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.

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Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed 3

This application example is for advanced users and assumes that you are trained and experienced in safety system requirements.

A risk assessment should be performed to make sure all task and hazard combinations have been identified and addressed. The risk assessment may require additional circuitry to reduce the risk to a tolerable level. Safety circuits must take into consideration safety distance calculations which are not part of the scope of this document.

Contact Rockwell Automation to find out more about our safety risk

assessment services.

TControl of Hazardous Energy T The primary method for the control of hazardous energy is

through a process known as lockout/tagout. Power is removed by

mechanical means and locked in the off state. The primary method

must be used when servicing and maintaining a machine. Refer to

the standards ANSI Z244.1, EN1037, or ISO 14118 for information on

lockout/tagout.

Users should always follow appropriate lockout/tagout standards when using this equipment.

The secondary method for the control of hazardous energy is through a

process known as safeguarding. Power is removed temporarily by

electromechanical or electronic means. Safeguarding can be used when

access to the hazard is integral to the production process. This

application example describes the safeguarding method for tasks that are

integral to the manufacturing process.T

Description

A machine, conveyor, or other type of hazard is enclosed with perimeter

guarding. Access to the machine is through one safety gate that has a

guardlocking interlock to control access. Personnel must perform certain

tasks periodically on the machine to assist in the manufacturing process.

During some of these tasks, the machine must be moving, and the speed

of the machine must be maintained within a specified, limited range.

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4 Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed

The machine can be placed in two modes of operation, assist and

production, by the means of a selector switch. Selection of the mode is

through a key-operated selector switch. If assist mode is selected, the

operator should remove the key to prevent someone else from returning

the machine to the production state.

In assist mode, personnel can access the machine. To verify the success

of the assist tasks, the motor can run at a limited speed provided the

operator uses an enabling device, such as a GripSwitch to start and stop

the machine.

In production mode, the safety gate must be closed and locked for the

motor to accelerate beyond a ‘standstill’ speed. Access to the machine is

allowed only when the motor is running below a ‘standstill’ speed. The

standstill speed is a speed greater than zero but slow enough to be

considered ‘safe’ while operators are present.

The user must perform a risk assessment to determine the standstill speed and the upper limit of the safe operating speed (safe limited speed) during assist mode.

The MSR57P speed monitoring safety relay is used to monitor the motor

speed. The MSR57P issues one safety output when the motor has

achieved a standstill speed and a second safety output when the motor

has exceeded the safe limited speed used during assist. The SmartGuard

600 controller receives the safety signals from the MSR57P relay and

determines when to use these signals to achieve the safety function.

The MSR57P is set to the operating mode called Safe Limited Speed –

Status Only. In this mode, the MSR57P plays a supporting role in that it

monitors the speed of a motor (or other device) and reports the status to

another controller. The status signals are safety-rated signals in that they

are redundant and designed to fail to a safe state in the presence of faults.

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Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed 5

Safety Function

The safety functions described below must apply.

Mode Selection

• Changing mode selection shall command the motor to stop if

running.

• Changing mode selection shall not command the motor to run if

stopped.

Production Mode

The Production/Assist switch is set to production. The following

conditions must exist:

• The safety gate must be closed and locked for the motor to run faster

than the standstill speed.

• When the safety gate closes, the motor does not start.

• The start and stop switches on the control panel are active and the

GripSwitch is inactive.

• The motor can run at any speed.

• When the motor speed drops below the standstill speed, the safety

gate lock release becomes enabled. The gate can be unlocked by the

rotary switch. The gate can then be opened.

Assist Mode

The Production/Assist switch is set to assist. The following conditions

must exist:

• The start and stop switches on the control panel are inactive.

• The safety gate lock release is enabled; the gate can be unlocked by

the rotary switch. The gate can be opened.

• The motor cannot be run at a speed faster than 600 revolutions per

minute.

• An audible warning shall be provided for 3 seconds before the motor

starts.

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6 Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed

Block Diagram

TThe block diagram below shows the components that make up this

application example. The MSR57P relay, operating in Status Only mode

reports the speed of the motor to the SmartGuard 600 controller. The

SmartGuard 600 controller receives inputs from the gate interlock, the

GripSwitch, and the start/stop controls. Under the proper conditions, the

SmartGuard controller enables the PowerFlex 70 drive to turn the motor

on under full production control or under a limited speed during assist

operations. The SmartGuard 600 controller also turns on the audio

warning just prior to the motor starting in assist mode.

An illuminated lock release switch is used to notify the user when the

gate can be unlocked.

T Note that this application does not describe the control function that

controls the speed of the motor under production conditions.T

T

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Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed 7

Timing Diagram

The MSR57P relay’s safety mode is set to Safe Limited Speed –Status

Only. To achieve the desired safety functionality, the MSR57P safety

status signals are used by the SmartGuard 600 slightly different than

illustrated in the MSR57P user manual, publication HTU440R-UM004UTH.

When the MSR57P relay plays a primary role in speed control, it can be

configured to use the GripSwitch while the speed is below the Safe

Limited Speed (SLS) value. In this application example, the SmartGuard

600 lets the GripSwitch be used when the speed exceeds the Safe

Limited Speed value. The Safe Limited Speed parameter is used to

indicate standstill, a condition that does not require a GripSwitch.

The MSR57P user manual describes the use of the Safe Maximum Speed

(SMS) parameter as a production maximum speed. In this application

example, it is used as the safe maximum assist speed.

The timing diagram shows the relation of the input and output signals of

the MSR57P relay as a function of the motor speed.

The motor starts at zero speed�. The Safe Limited Speed (SLS) and

Safe Speed (SS) outputs are both high – meaning it can be run in both

assist and production modes. When the speed exceeds 50 RPM�, the

SLS_Outputs go low, while the SS_Outputs remain high. In this case, if

the mode were set to assist, the GripSwitch would be required to run the

motor.

When the motor speed exceeds the Safe Maximum Speed (SMS) set

value�, the SS_Outputs go low. In this case, if the mode were set to

assist, the motor would stop. While the speed exceeds the SMS value, a

pulse generator in the SmartGuard starts cycling the SS_Inputs� to try

to reset the MSR57P relay.

When the motor speed drops below the SMS value�, the MSR57P relay

resets and the SS_Outputs go high. As the motor speed drops and falls

below SLS�, the SLS_Outputs go high. The SLS signals indicate the

machine is at standstill, and the SmartGuard 600 controller enables the

safety gate to be unlocked. If the motor speed increases beyond SLS

(50RPM)�, the SLS signal goes low, and the SmartGuard controller

disables the lock on the safety gate.

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8 Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed

Example Bill of Material This application example uses these components Catalog Part Number Description Quantity

440R- S845AER-NNL MSR57P Speed Monitoring Safety Relay 1

1752-L24BBB SmartGuard 600 Safety Controller 1

20AB-2P2A3AYNNNG1 PowerFlex 70 AC Drive with Safe-off 1

1585J-M8R-2M5 RJ45 Encoder Cable to MSR57P 1

440J-N2NTMPC 889D-F4AC-10

GripSwitch with 4 Pin M12 Connector Cordset, 4 Pin, M12, 10m

1 1

440G-T27181

TLS3-GD2 Guardlocking Gate Interlock Switch with fully flexible actuator, 24VAC/DC solenoid

1

845T-DZ42PEN-1 Incremental Encoder, 3000PPR, 11-20VDC 1

800FM-LSM23 800F-MX02V

Two position, illuminated, green, rotary switch, with 2NC low voltage contacts for lock release

800FP-KM23 800F-MX02V

Two position eject key operated rotary switch with 2NC low voltage contacts for mode select

1

800FP-SM22 800F-PX11

Two position rotary switch, 1NC + 1NO for Fed/Rev

1

800FM-F3MQ10V

Push button, Flush, Metal, Green, 1NO, Low Voltage, Spring Clamp for Start Switch

1

800FM-E4MQ10V

Push button, Extended, Metal, Red, 1NO, Low Voltage, Spring Clamp for Stop Switch

1

855H-BD30AD Horn, 24VDC, Range B, Standard Base 1

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Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed 9

Setup and Wiring The following diagram shows the wiring required for this application.

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10 Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed

Configuration This section describes the configuration required for the MSR57P relay

and the SmartGuard 600 controller.

TMSR57P Parameter Settings T

The parameters of the MSR57P are set by using DriveExplorer or

DriveTools software or by using a HIM module. Refer to the

Guardmaster Speed Monitoring Safety Relay user manual, publication

HTU440R-UM004UTH for details. The table below shows the parameter settings

for this application example.

Parameter # Description Values

1 Password 0

2 Reserved 0

3 Reserved 0

4 Reserved 0

5 Lock State Unlock

6 Operating Mode Run

7 Reset Defaults No Action

8 Reserved 0

9 Reserved 0

10 Signature ID 3317762599

11 Reserved 0

12 Reserved 0

13 New Password 0

14 Reserved 0

15 Reserved 0

16 Reserved 0

17 Password Command No Action

18 Security Code 256

19 Vendor Password 0

20 Cascaded Config Single

21 Safety Mode Lim Spd Stat

22 Reset Type Automatic

23 Reset Loop Disable

24 OverSpd Response 42

25 Language Code English

26 Max Display Spd 1800

27 Fbk Mode Single Fbk

28 Fbk 1 Type Incremental

29 Fbk 1 Units Rev

30 Fbk 1 Polarity Normal

31 Fbk 1 Resolution 3000

32 Fbk 1 Volt Mon 0

33 Fbk 1 Speed 0.0

34 Fbk 2 Units Rev

35 Fbk 2 Polarity Normal

36 Fbk 2 Resolution 0

37 Fbk 2 Volt Mon 0

38 Fbk 2 Speed 0

39 Fbk Speed Ratio 0

40 Fbk Speed Tol 0

41 Fbk Pos Tol 0

42 Direction Mon Disable

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Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed 11

Parameter # Description Values

43 Direction Tol 10

44 Safe Stop Input 2 OSSD 3s

45 Safe Stop Type Torque Off

46 Stop Mon Delay 0

47 Max Stop Time 0

48 Standstill Speed 0.001

49 Standstill Pos 10

50 Decel Ref Speed 0

51 Stop Decel Tol 0

52 Lim Speed Input 2 OSSD 3s

53 LimSpd Mon Delay 0

54 Enable SW Input Not Used

55 Safe Speed Limit 50

56 Speed Hysteresis 80

57 Door Out Type 2Ch Sourcing

58 DM Input Not Used

59 Lock Mon Enable Disable

60 Lock Mon Input Not Used

61 Max Speed Enable Enable

62 Safe Max Speed 600

63 Max Spd Stop Typ Torque Off

64 Max Accel Enable Disable

65 Safe Accel Limit 0

66 Max Acc Stop Typ Torque Off

67 Fault Status –

68 Guard Status –

69 IO Diag Status –

70 Config Flt Code –

71 MP Out Mode No Pulse Test

72 SS Out Mode Pulse Test

73 SLS Out Mode Pulse Test

74 Door Out Mode Pulse Test

SmartGuard 600 Configuration

The SmartGuard 600 controller performs the primary safeguarding

functions. The following sections show the input, test output and output

settings.

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12 Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed

Local Input Settings

Test Output

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Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed 13

Local Output Settings

PowerFlex 70 Configuration

The PowerFlex 70 has several hundred parameters. The table below

shows the essential parameters for this application example.

Parameter #

Description Values Comment

1:0.93 Speed Ref B Sel Preset Spd1 Sets the safe limited speed

1:0.94 Speed Ref B Hi 60.0 Hz Sets the maximum level of the speed reference – must be greater than 10Hz

1:0.95 Speed Ref B Hi 0 Hz Sets the maximum level of the speed reference – must be less than 10Hz

1:0.101 Preset Speed 1 10 Hz Sets the safe limited speed, which must be determined by a risk assessment.

1:0.361 Digital In1 Sel 8 Run Forward

1:0.362 Digital In2 Sel 9 Run Reverse

1:0.363 Digital In3 Sel 15 Speed Sel 1 Terminal 3 is the input for Safe Limit Speed

1:0:366 Digital In6 Sel 1 Enable Terminal 6 is the Enable Signal

1:0.380 Digital Out1 Sel 4 Run Signal that Drive is running.

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14 Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed

SmartGuard 600 Logic This section shows the logic required for the various functions that make

up this application example.

Start/Stop Logic

The machine can be started in either production mode (P_Start) or assist

mode (A_Start).

The production start and stop push buttons have momentary operators

and normally open contacts. The production buttons are mounted on the

main control panel. The heart of this logic is the RS-Flip Flop logic block

[33]. Pressing the start button sets the flip-flop and turns the motor on.

Pressing the stop button resets the flip-flop and turns the motor off.

Blocks 6 and 7 are needed as an electrical interlock to turn the P_Start

signal on only when the mode is set to production. Block 32 turns P-Start

off when either the production stop button is pressed or when the

operator switches the mode selection to assist.

During assist, the motor can start only when all three conditions listed

below exist [25]:

• The mode must be set to assist.

• The operator must hold the 3-position GripSwitch in the center

position.

• The motor cannot be running too fast; that is, it may not exceed

the limited speed.

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Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed 15

Enable Drive Logic

In this application, a TLS3-GD2 guardlocking interlock is installed on

the safety gate. To check for potential shorts that would otherwise

compromise the integrity of the safety system, the gate and lock signals

are connected to pulsed outputs from the SmartGuard 600 controller.

Mode selection is accomplished by a key-operated, dual-channel, rotary

switch that is connected to pulsed outputs of the SmartGuard controller

(to check for potential shorts). The operator should place the machine in

assist mode and remove the key from the switch to prevent someone

from inadvertently placing the machine back into production mode

during the assist function.

The PowerFlex 70 drive is enabled by two signals: Safe-off and Drive

Enable. The drive is enabled by Block 22 in three cases.

• The gate interlock is closed and locked (during production

mode).

• The motor speed is at standstill (the gate can be opened).

• The mode is set to assist and the motor is not turning too fast

(faster than the allowed speed).

Under all of these conditions, the EDM block [23] requires the Safe-off

signal to be high (feedback circuit closed) before enabling the drive.

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16 Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed

MSR57P Reset Logic

The MSR57P relay monitors the speed of the motor. If the motor exceeds

the safe maximum speed, then its safety outputs (SS_Ch1 and SS_Ch2)

turn off, going from 24V to 0V. In order to turn these safety outputs back

on, the Safe Stop (SS) input must be cycled off and then back on. This is

accomplished in the SmartGuard controller by using a pulse generator

block [19]. The parameters of the pulse generator are set to

500 ms on and 500 ms off.

The pulse generator turns the To_SS_Input signals on and off

continuously until the MSR57P relay determines that the motor is

running below the safe maximum speed. With the MSR57P relay set for

automatic reset, it continuously tries to reset itself. Once the speed drops

below the safe maximum speed limit, the pulse generator turns off.

When the speed is below the safe maximum speed limit, a NotToFst (Not

Too Fast) signal is generated. This signal is used to enable the drive

during assist mode.

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Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed 17

Drive Start Power and Warning

In assist mode, we want an audible warning for 3 seconds before the

motor starts. If multiple people are performing assist tasks on the

conveyor, and one person wants to run the machine, the person starting

the machine must notify everyone else that the machine is going to start.

In case everyone is not informed, an audible signal announces that the

machine is going to start, and personnel can get out of harms way. In

production mode, the warning is not needed, as no one should be in the

cell.

Blocks 31 and 37 let the motor start in production mode with no delay. In

assist mode, the AsstStrt (assist start) signal sets an RS-FF [30] that turns

on the audible alarm. At the same time, it starts a delay timer [29] that

waits 3000 ms before starting the motor. After the motor starts, Digital

Output 1 of the PowerFlex 70 drive resets the

flip-flop and turns the audible alarm off.

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18 Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed

Motor Start

The application requires the motor to start in both production mode and

assist mode. By inverting the assist mode in block 9, a production mode

signal is created. This signal is ANDed in block 35 with the P_Start

(production start) signal. Similarly, the assist mode signal is ANDed with

the A_Start (assist start) signal in block 27. Both signals are ORed in

block 36 to create the MtrStrt (motor start) signal.

Standstill

The application requires access through the guardlocking gate when the

conveyor is at standstill (very low speed) or in assist mode.

The MSR57P relay generates the Safe Limited Speed (SLS) signals when

the speed of the motor is below the SLS limit. In this application

example, the SLS signals are 24V when the speed is below 50 rpm. This

is considered standstill for this application example and the gate can be

unlocked.

When the Assist/Prod switch is set to assist, the gate can also be opened.

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Using the MSR57 in a Safety Architecture to Monitor Machine Motor Speed 19

Additional Resources For more information about the products used in this example, refer to

these resources.

Resource Description

HTU440R-UM004UTH

Guardmaster MSR57P Speed Monitoring Safety Relay User Manual

HTU1752-UM001UTH SmartGuard 600 Controllers User Manual

HTU1752-RM001UTH SmartGuard 600 Controllers Safety Reference Manual

HTU20A-UM001UTH PowerFlex 70 AC Drives User Manual

HTUS116-CA001UTH

Safety Products Catalog provides information on TLS-GD2 Guardlocking Interlocks and Enabling Grip Switches

You can view or download publications at

HTUhttp://literature.rockwellautomation.comUTH. To order paper copies of

technical documentation, contact your local Rockwell Automation

distributor or sales representative.

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Rockwell Automation, Allen-Bradley, Guardmaster, DriveTools, DriveExplorer, PowerFlex, and SmartGuard are trademarks of Rockwell Automation, Inc.

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

Publication SAFETY-AT025A-EN-P – March 2010

Copyright © 2010 Rockwell Automation, Inc. All rights reserved. Printed in U.SA