Lueze MSI-m/R, MSI-mE/R operating instructions

Original operating instructions

MSI-m/R
MSI-mE/R

Modular safety interface

We reserve the right to make technical changes

EN • 2020-07-22 • 603501

© 2020
Leuze electronic GmbH & Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone: [phone]
Fax: [phone]
http://www.leuze.com
[e-mail]

Leuze electronic GmbH + Co. KG MSI-m(E)/R 2

1 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 System overview and range of applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3 Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4 Nomenclature MSI-m(E)/R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1 Intended use and foreseeable misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2 Competent personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.3 Responsibility for safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.4 Exemption of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.5 Connection of E-STOP buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.6 Additional safety notices for the special function "Muting" . . . . . . . . . . . . . . . . . . . . . . . . 11

4 System design and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.1 System design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.2 DIP switch settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.2.1 MSI-m module DIP switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.2.2 I/O-m module DIP switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.3 Operating modes and functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.3.1 Operating modes – interlocking and contactor monitoring functions. . . . . . . . . . . . . . . 13

4.3.1.1 Operating mode: with start/restart interlock – with dynamic contactor monitoring. . . . . 14

4.3.1.2 Operating mode: with start/restart interlock – with static contactor monitoring . . . . . . . 14

4.3.1.3 Operating mode: with start/restart interlock – without contactor monitoring . . . . . . . . . 14

4.3.1.4 Operating mode: without start/restart interlock – without contactor monitoring. . . . . . . 15

4.3.1.5 Operating mode: with start/without restart interlock – without contactor monitoring . . . 15

4.3.2 Muting function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.3.2.1 Sequential muting, connections at M1 to M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.3.2.2 Parallel muting (2.5 s), connections M2 and M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.3.2.3 Parallel double muting – with extended version MSI-mx(E)/Rx only . . . . . . . . . . . . . . . 16

4.3.2.4 Testable and non-testable muting sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.3.2.5 Muting display function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.3.2.6 Muting restart while transport material is located in the muting area . . . . . . . . . . . . . . 17

4.3.2.7 Muting time limit - 10 minutes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.3.2.8 Example: Sequential muting, non-testable muting sensors. . . . . . . . . . . . . . . . . . . . . . 18

4.3.2.9 Example: Sequential muting, testable muting sensors . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.3.2.10 Example: Parallel muting, non-testable muting sensors . . . . . . . . . . . . . . . . . . . . . . . . 20

4.3.2.11 Example: Parallel muting, testable muting sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.4 Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.5 Signal outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.6 Diagnostics function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.1 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.2 Power supply requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.3 Connecting AOPDs, type 4 or type 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.4 Connecting to the machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6 Connection examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Leuze electronic GmbH + Co. KG MSI-m(E)/R 3

7 Technical data and order guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7.1 MSI-m(E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7.2 /R output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.3 Dimensioned drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.4 Order guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8 EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Leuze electronic GmbH + Co. KG MSI-m(E)/R 4

About this document

1 About this document

These connecting and operating instructions contain information on the approved purpose and use of MSI
safety interfaces.

ATTENTION!

All information provided in the connecting and operating instructions, especially the Safety
Notices, must be observed.

Safety and warning notices are marked with the symbol.
These connecting and operating instructions must be kept in a safe place. It must be available during the

mission time of the MSI safety interfaces.
Leuze electronic GmbH + Co. KG is not liable for damages caused by improper use. Knowledge of these

connecting and operating instructions is considered an element of proper use.

Leuze electronic GmbH + Co. KG MSI-m(E)/R 5

System overview and range of applications

2 System overview and range of applications

2.1 General information

The Modular Safety Interface (MSI) serves as a link between one or more active optoelectronic protective
devices (AOPD), type 2, type 3 or type 4, and the machine control. All MSI safety components include start/
restart interlock and contactor monitoring functions that can be activated and deactivated. They are also
equipped with a series of signal outputs and LED indicators as well as a diagnostic interface to a PC.

In addition, MSI-m(E)/R offers a muting function to suppress the protective function of an AOPD, e.g. when
transporting materials through the protective field. Special safety regulations for muting are described in
chapter 3.6 below.

Leuze electronic offers a range of additional MSI safety interfaces with standard and special function, e.g.
muting (intentional suppression of the safety function) or cycle control (single cycle, two cycle).

All MSI safety modules are equipped with relay outputs.
All information also applies to UL compliant version MSI-mE/R, provided that nothing to the contrary is

stated.

2.2 Certifications

Europe

EC Type Examination
TÜV SÜD

2.3 Terminology

AOPD Active Optoelectronic Protective Device

Diagn. Diagnosis Function

EDM External Device Monitoring

ESPE Electro-sensitive Protective Equipment

Fault Relay error

I/O-m module Input/Output module

Lamp Warn. Muting Indicator Failure Warning

Locked Start/Restart Interlock active

MSI Fault MSI error

Muting
Fault/Failure

Contactor monitoring

Muting error

M1 - M4 Muting Input 1 - 4

Muting Indicators Muting indicators

Muting Sensors Muting sensors

N.O. Normally Open Contact

OSSD Safety-related switching output

Reset Start/Restart Interlock Initiator

RS 232 Interface RS 232

S1, S2 Safety input 1, 2

Leuze electronic GmbH + Co. KG MSI-m(E)/R 6

System overview and range of applications

S1 & S2 Indication protective fields free/interrupted

Safety Switches Safety Switches

State Status

Test Test Signal Outputs

T1, T2 Test signal output 1, 2

Warn.

Warning muting indicator defective

(I/O-m module)

2.4 Nomenclature MSI-m(E)/R

MSI Modular Safety Interface

m With muting function

This version offers the following standard functions for either 1 AOPD, type 4, or up to 2 AOPDs,
type 2:

• Start/restart interlock

• Contactor monitoring

• Diagnostics function

and the following special functions for 1 AOPD type 4 or 1 AOPD type 2:

• Sequential muting

• Parallel muting (2.5 s)

/R Relay output with the following functions:

• Two safety-related normally open contacts, OSSD 1 and OSSD 2

• Status indicators and signal outputs

(E) UL compliant version

• Additional empty housing for convection

Leuze electronic GmbH + Co. KG MSI-m(E)/R 7

Safety

3 Safety

Before using the safety interface, a risk assessment must be performed according to valid standards (e.g.
EN ISO 12100, EN ISO 13849-1, EN 62061). The result of the risk assessment determines the required
safety level of the safety interface (see table in chapter 3.1.1). For mounting, operating and testing, docu­ment "MSI-m(E)/R Modular Safety Interface" as well as all applicable national and international standards,
regulations, rules and directives must be observed. Relevant and supplied documents must be observed,
printed and handed to the affected personnel.

Before working with the safety interface, completely read and understand the documents applicable to
your task.

In particular, the current version of the following national and international legal regulations apply for
commissioning, technical tests and handling of safety sensors:

• Machinery Directive

• Low Voltage Directive

• Electromagnetic compatibility

• Use of Work Equipment Directive

• OSHA

• Safety regulations

• Accident-prevention regulations and safety rules

• Ordinance on Industrial Safety and Health and employment protection act

• Product Safety Law (ProdSG)

NOTE

Local agencies can also provide safety-relevant information (e.g. occupational safety and
health inspectorate, employer's liability insurance association, labor inspectorate, OSHA).

3.1 Intended use and foreseeable misuse

ATTENTION!

A running machine can cause severe injuries!
 Make certain that, during all conversions, maintenance work and inspections, the system is

securely shut down and protected against being restarted.

3.1.1 Intended use

• The safety interface may only be used after it has been selected in accordance with the respectively
applicable instructions and relevant standards, rules and regulations regarding labor protection and
safety at work, and after it has been installed on the machine, connected, commissioned, and
checked by a competent person.

• When selecting the safety interface it must be ensured that its safety-related capability meets or
exceeds the required Performance Level PL

The following table shows the safety-related characteristic parameters of the MSI-m(E)/R modular safety
interfaces.

ascertained in the risk assessment.

r

Leuze electronic GmbH + Co. KG MSI-m(E)/R 8

Safety

n

op

dophop3600 s/ht

Zyklus

=

Type in accordance with EN 61496-1 Type 4

SIL in accordance with EN 61508 SIL 3

Performance Level (PL) in accordance with

PL e

EN ISO 13849-1:2015

Category in accordance with

Cat. 4

EN ISO 13849-1:2015

Mean probability of a dangerous failure per hour
(PFH

) as a function of the mean number of

d

annual switching cycles of the relay n

op

*

100% Load n
60% Load n
100% Load n
60% Load n
100% Load n
60% Load n

*n

= mean number of annual actuations, see C.4.2 and C.4.3 of EN ISO 13849-1:2015

op

= 4,800: 1.5 x 10

op

= 4,800: 1.2 x 10

op

= 28,800: 3.1 x 10

op

= 28,800: 1.5 x 10

op

= 86,400: 7.4 x 10

op

= 86,400: 2.1 x 10

op

-08

-08

-08

-08

-08

-08

Use the following formula to calculate the mean number of annual actuations:

In doing so, make the following assumptions with regard to the use of the component:

= mean operating time in hours per day

h

op

d

= mean operating time in days per year

op

t

= mean operating time between the start of two successive cycles of the component (e.g switch-

cycle

ing of a valve) in seconds per cycle

1/h
1/h
1/h
1/h
1/h
1/h

• The safety interface is used in combination with one or more multiple light beam safety devices or
safety light curtains to safeguard points of operation or danger zones.

• The control of the machine or system that is to be safeguarded must be electrically influenceable. A
switch-off command initiated by an MSI must result in an immediate shutdown of the dangerous
movement.

• The "Reset" acknowledgment button for unlocking the start/restart interlock must be mounted in such
a way that the entire danger zone can be seen from its mounting location.

• Signal outputs (state output) must not be used for switching safety-relevant signals.

• The safety interface is designed for installation in a cabinet or a protective housing with a degree of
protection of at least IP 54.

• The 24 V DC ±20% power supply must guarantee safe insulation from the mains voltage and be able
to bridge a power outage period of 20 ms.

• Depending on external wiring, dangerous voltages may be present at the switching outputs. In addi­tion to the power supply, these must be switched off and safeguarded against being switched back
on prior to all work on the MSI-m(E)/R.

• These operating instructions must be included with the documentation of the machine on which the
protective device is installed so that they are available to the operator at all times.

• In the event of changes to the MSI-m(E)/R, all warranty claims against the manufacturer of the safety
interface are rendered void.

• The safety distance between the AOPD and the point of operation is to be maintained. It is calculated
according to the formulas for machine-specific C standards or given in the general B1 standard
EN ISO 13855. Both the reaction time of the test monitoring unit and the braking time of the machine
must be taken into account.

• Two switching contacts must always be looped into the switch-off circuit of the machine. To prevent
welding, relay switching contacts must be fused/protected externally according to the technical data.

• The safety interface must be exchanged after a maximum of 20 years. Repairs or the exchange of
wear parts do not extend the mission time.

• The safety interface satisfies the requirements of safety category 4 acc. to EN ISO 13849-1:2015. If,
however, an AOPD of a lower safety category is connected, the total category for the given path of

Leuze electronic GmbH + Co. KG MSI-m(E)/R 9

Safety

the control cannot be higher than that of the connected AOPD.

• Cross-circuits between S1 and S2 are only detected by the MSI safety module if both time-delayed
test signal outputs, T1 and T2, are used for the connected protective device(s) with relay output.
AODPs of type 4 with safety-relevant transistor outputs and their own cross circuit monitoring can be
directly connected to S1 and S2.

3.1.2 Foreseeable misuse Any use other than that defined under the "approved purpose" or which goes beyond that use is consid-

ered improper use!
e.g.,

• Applications in explosive or easily flammable atmospheres

ATTENTION!

Such instances can jeopardize the health and lives of the personnel operating the machinery
and/or may cause damage to property.

3.2 Competent personnel

Prerequisites for competent personnel:

• They have a suitable technical education.

• They know the rules and regulations for labor protection, safety at work and safety technology and
can assess the safety of the machine.

• They know the instructions for the safety interface and the machine.

• They were instructed by the responsible individuals on the mounting and operation of the machine
and of the safety interface.

3.3 Responsibility for safety

Manufacturer and operator must ensure that the machine and implemented safety interface function prop­erly and that all affected persons are adequately informed and trained.

The type and content of all imparted information must not lead to unsafe actions by users.
The manufacturer of the machine is responsible for:

• Safe machine construction

• Safe implementation of the safety interface

• Imparting all relevant information to the operating company

• Adhering to all regulations and directives for the safe commissioning of the machine

The operator of the machine is responsible for:

• Instructing the operating personnel

• Maintaining the safe operation of the machine

• Adhering to all regulations and directives for labor protection and safety at work

• Regular testing by competent personnel (see chapters 3 and 3.2)

3.4 Exemption of liability

Leuze electronic GmbH + Co. KG is not liable in the following cases:

• Safety interface is not used as intended.

• Safety notices are not adhered to.

• Reasonably foreseeable misuse is not taken into account.

• Mounting and electrical connection are not properly performed.

• Proper function is not tested.

• Changes (e.g., constructional) are made to the safety interface.

Leuze electronic GmbH + Co. KG MSI-m(E)/R 10

Safety

3.5 Connection of E-STOP buttons

• It must be ensured that the EMERGENCY STOP function is always and immediately effective.

E-STOP buttons must not be connected at sensor inputs which provide for muting or cycle control functions!
Since the MSI-m(E)/R does not provide for additional sensor inputs without special functions, no E-STOP but­tons must be connected.

If an E-STOP button is needed, the use of the extended version MSI-mx(E)/

Rx is recommended.

3.6 Additional safety notices for the special function "Muting"

• Muting is the intentional suppression of the safety function of an AOPD. It is used, for instance, to
allow the material flow to pass through the protective field without triggering a switch-off signal.

• During the muting function the protective function of this AOPD is no longer active! For this reason
other measures must be taken to ensure that it is not possible to reach or go into the point of opera­tion. For instance, if the material transport completely fills the access area, or if there is no danger
while muting is active, such as during the return motion of a tool.

• The muting sensors must be positioned in such a way that it is impossible to manipulate them easily.
For example, optical sensors can be mounted so high or so far apart that the operating personnel
cannot cover them either simultaneously or at all. If switches are used, we recommend a concealed
installation.

• The operating personnel must be expressly informed that the protective device offers no protection in
the muting state. Any manipulations of or unauthorized entries into the system present immediate
danger to personnel.

• An additional sign should be put up stating that the safety light grid offers no protection when the
Muting indicator is lit and it is dangerous to reach or walk through the protective field. Muting indica­tors and sign should be placed in a clearly visible location near the muting area.

• The start button must be positioned so that it cannot be actuated by persons who are located in the
protective field.

Leuze electronic GmbH + Co. KG MSI-m(E)/R 11