MSR300 Safety System Manual
Instruction Manual
MSR300 Modular Safety Control System
Summarized Table of Contents
Topic Page
- Detailed Table of Contents 2
1 Important User Information 4
2 About This Manual 6
3 MSR300 System: Product and Applications Overview 8
4 MSR300 Modules: Details 20
5 Special Functions: Robot Safety and Combination Logic 41
6 Faults / Errors: Detection and Response 49
7 Installation, Start-Up, Operation, Maintenance 52
8 Application Examples 59
9 Serial Data Communication Protocols 69
Annexure 84
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Detailed Table of Contents
1 Important User Information
1.1 Intended Product Applications
1.2 Authorized Personnel
1.3 General Safety Precautions
1.4 Product Warranty and Disclaimer
1.5 Technical Support
2 About This Manual
2.1 Content Guidance
2.2 Annotation Symbols
2.3 Document Disclaimer
3 MSR300 System: Product and Applications Overview
3.1 Safety Standards and Safety Relay Functions
3.1.1 Safety Standards
3.1.1.1 EN 954 - 1
3.1.1.2 EN 61508
3.1.2 MSR300 Safety Relay Functions
3.1.2.1 One-Channel Emergency Stop
3.1.2.2 Two-Channel Emergency Stop
3.1.2.3 Three-Channel Emergency Stop
3.1.2.4 Two-Channel Safety Gates
3.1.2.5 Two-Channel Light Curtain
3.1.2.6 Two-Hand Control
3.1.2.7 Reset Action
3.1.2.8 Muting (for Robot Cell Applications)
3.2 MSR300 System: Overview
3.3 MSR300 Modules: Summary
3.4 MSR300 Modules: Specifications
3.4.1 MSR310
3.4.2 MSR320
3.4.3 MSR330
3.4.4 MSR329
4 MSR300 Modules: Details
4.1 MSR310 Base Module
4.1.1 Terminals
4.1.2 LED Indicators
4.1.3 Settings and Wiring
4.1.4 Auxiliary Outputs (On-Off, Solid-State)
4.1.5 External Device Connections
4.1.6 Input Fault Logging
4.1.7 Serial Data Interface Connections
[continued.....]
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4.2 MSR320 Input Module
4.2.1 Terminals
4.2.2 LED Indicators
4.2.3 Settings and Wiring
4.2.3.1 1-Channel Emergency Stop
4.2.3.2 2-Channel Emergency Stop
4.2.3.3 3-Channel Emergency Stop
4.2.3.4 Safety Mats
4.2.3.5 Safety Gate
4.2.3.6 Light Curtain
4.2.3.7 Two-hand Control
4.2.3.8 2-Channel Emergency Stop and Light Curtain
4.2.3.9 Safety Gate and Light Curtain
4.3 MSR330 Output Module
4.3.1 Terminals
4.3.2 LED Indicators
4.4 MSR329 Muting Lamp Module
4.4.1 Terminals
4.4.2 LED Indicators
5 Special Functions: Robot Safety and Combination Logic
5.1 Robot Safety Control
5.1.1 General
5.1.2 Two Areas
5.1.3 Additional Safe Area
5.2 Special Logic Functions
6 Faults / Errors: Detection and Response
6.1 Major Faults
6.2 Recoverable Faults During Start-Up or Operation
6.3 Recoverable Start-Up and Operation
7 Installation, Start-Up, Operation, Maintenance
7.1 Safety Precautions and Practices
7.2 Installation
7.2.1 General and Safety Considerations
7.2.2 Environmental Considerations
7.2.3 Mechanical
7.2.4 Electrical
7.3 Set-Up
7.4 Operation
7.5 Maintenance
8 Application Examples
9 Serial Data Communication Protocols
9.1 RS232 Bidirectional
9.2 RS232 Unidirectional
9.3 CRC Generation (Code Examples)
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Annexure: Product Warranty and Disclaimer
1 User Information
The meanings of the following words used in this document should be understood:
"Standard" can mean a named / numbered industry standard, EU / IEC directive,
technical statute or regulation.
"Product" can refer to an MSR300 System consisting of a combination of MSR300 Series
Modules or any one of these modules.
1.1 Intended Product Applications
The MSR300 Safety System is a modular, intelligent safety control system for monitoring
of
• 1, 2, or 3 - channel emergency stops
• Safety gates
• Light curtains
• Safety mats
• Two-hand controls
The MSR300 is particularly suitable where multiple safety loops and hazardous areas are
to be monitored, or where users require flexibility and possible future expansion and
reconfiguration of the safety monitoring and control system.
The MSR300 Safety System is intended for applications requiring safety monitoring of
machinery in accordance with the following standards:
• EN954-1: Safety-Related Parts Of Control Systems; up to Category 4.
• IEC 61508: Functional Safety of Electrical / Electronic / Programmable Electronic
Safety-Related Systems, Parts 1-7, 1998; level SIL 3.
This equipment must not be used for unintended applications, or
in ways that do not conform to applicable safety standards. The
safety functions may not operate properly (or at all) if this
equipment is not used for the intended purposes.
1.2 Authorized Personnel
This equipment is to be installed, started up, and operated only
by technical personnel
who have been trained and made familiar with:
• The product/s for which this document exists
• Directives, regulations and practices relating to machine safety
• Instrumentation and automation components, equipment and systems
• Industrial electrical practices
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1.3 General Safety Precautions
This product, the equipment on which it installed, persons handling the product and
equipment, and/or the immediate environment can be harmed if this equipment is
operated outside the specified limits of any of its technical parameters.
Observe all electrical safety regulations stipulated by the appropriate technical authorities.
The latest version of user documentation that includes instructions for installation,
operation and maintenance of this product must be readily available with personnel
involved in any of these tasks.
Machine safety applications make it necessary for hazardous areas and dangerous
operating modes to be carefully identified, and adequate measures taken to ensure that
failure or tampering does not allow automated equipment to be of risk to personnel.
It must be understood that the use of safety monitoring and control devices such as this
product is not sufficient to ensure that the equipment on which it is installed will meet the
relevant stipulated regulations and directives. The design and reliability of the machinery
on which this product is used, the proper selection and co-ordination of the safety controls
with the machinery, the safety system design, and proper installation practices are all
necessary to meet the objectives of overall safety.
Careful attention must be paid to safety instructions in other parts of this document,
particularly regarding installation, start-up and operation.
1.4 Product Warranty and Disclaimer
A partial statement of the product warranty and disclaimer is annexed at the end of this
manual, and is subject to the warranty terms and disclaimer included in the detailed
standard terms of sale/contract of the Seller.
1.5 Technical Support
Technical information related to this product and its application is available in product
literature, manuals, and other documentation available from the following sources:
• Rockwell Automation / Allen Bradley web sites:
http://shop.rockwellautomation.com/
http://www.ab.com/
> Literature library > Safety > Safety control relays
• The Rockwell Automation / Allen Bradley reseller from whom the product was
purchased or the distributor nearest to you. This information is available at:
http://www.rockwellautomation.com/distributor/index.html
[Presently only for USA and Canada. Information for other zones expected here in the
near future]
• The Rockwell Automation / Allen Bradley sales / customer support office nearest to
you. This information is available at:
http://www.rockwellautomation.com/locations/
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2 About This Manual
This manual contains detailed information about the product, and instructions for its
installation, operation and maintenance.
Operators and other technical personnel responsible for the equipment must read this
manual thoroughly before attempting to install or operate this equipment.
The latest version of this manual must be readily available with personnel involved
installation, operation or replacement of this product.
Product documentation that accompanies the product in its packing must be considered
to have precedence over corresponding contents of this manual
Note: The meanings of the following words used in this document should be understood:
"Standard" can mean a named / numbered industry standard, EU / IEC directive,
technical statute or regulation.
"Product" can refer to an MSR300 System consisting of a combination of MSR300 Series
Modules, or to any one of these modules.
2.1 Content Guidance
Chapter 1 contains preliminary user information: this must be read and understood before
proceeding to Chapters 3 onward.
Chapter 2 (this chapter) has information about this manual. Sections 2.1 (this section)
and 2.2 must be read before proceeding to remaining chapters. Sections 2.3 and 2.4 are
for incidental reference.
Chapter 3 provides information about the relevant safety directives and standards
applicable to the safety of automatic machinery, the safety functions that can be
implemented by the use of MSR300 Systems, an overview of the MSR300 System, a
summary of the individual modules, and their technical specifications.
Chapter 4 has detailed information about each of the MSR300 Series Modules and how
they are used for specific applications.
Chapter 5 describes the special applications of safety control of industrial robots and
related automatic machines. This chapter also includes information about the special
logic functions available in the MSR300 System.
Chapter 6 describes possible faults and error conditions, and how the MSR300 System
handles these.
Chapter 7 contains instructions about installation, start-up, operation and maintenance.
Application examples are described in Chapter 8.
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Chapter 9 has detailed information about the serial data communication protocols.
2.2 Annotation Symbols
The following symbols have prominently inserted at appropriate places in this document
to draw the reader's attention to important points:
Symbol Meaning
This symbol is intended to draw the reader's attention to
important safety points that help in one or more of these
ways:
• Identify a hazard
• Avoid a hazard
• Recognize the consequence
Identifies information about practices or circumstances that
can 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 that could help in completing a task or
achieving a result more efficiently or quickly.
2.3 Document Disclaimer
The contents of this manual have been compiled with the utmost care, and diligence has
been used to present all the information clearly and accurately. However, the
manufacturer cannot accept any liability for any residual errors or omissions that may be
found in this document. If users find any errors, omissions or other deficiencies, please
inform the manufacturer immediately. Corrections will be made in the next edition of this
document.
Nothing in this document can be interpreted to create new conditions or modify existing
conditions of the product warranty.
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3 MSR300 System: Product and Applications Overview
3.1 Safety Standards and Safety Relay Functions
Note: In this document, the word "standard" can mean a defined industry standard, EU
directive, technical statute or regulation.
The safety standards relevant to this product and its application are outlined in brief in
Section 3.1.2 below.
General
The MSR300 Safety System is intended for applications requiring safety monitoring of
machinery in accordance with the following directives / standards:
• EN954-1: Safety-Related Parts Of Control Systems; up to Category 4.
• IEC 61508: Functional Safety of Electrical / Electronic / Programmable Electronic
Safety-Related Systems, Parts 1-7, 1998; level SIL 3.
An MSR300 System will conform to these standards provided external devices connected
to it, overall system and safety design, and installation practices conform to appropriate
standards.
This equipment must not be used for unintended applications, nor in
ways that do not conform to appropriate safety standards and good
practices. The safety functions may not operate properly (or at all) if
this equipment is not used for the intended purposes.
This product, the equipment on which it is installed, persons handling
the product and equipment, and/or the immediate environment can
be harmed if this equipment is operated outside the specified limits of
any of its technical parameters.
Electrical safety regulations stipulated by the appropriate technical
authorities must be observed.
Machine safety applications make it necessary for hazardous areas
and dangerous operating modes to be carefully identified, and
adequate measures taken to ensure that failure or tampering does
not allow automated equipment to be of risk to personnel.
It must be understood that use of safety monitoring and control
devices such as this product is not sufficient to ensure that the
equipment on which it is installed will meet the relevant stipulated
regulations and directives. The design and reliability of the machinery
on which this product is used, the proper selection and co-ordination
of the safety controls with the machinery, the safety system design,
and proper installation practices are all necessary to meet the
objectives of overall safety.
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3.1.1 Safety Standards
MSR300 Series Modules conform to the Essential Health & Safety Requirements
(EHSR's) of the European Machinery Directive (98/37/EC), the relevant requirements of
the Low Voltage Directive (73/23/EEC as amended by 93/68 EEC) and the essential
protection requirements of the EMC Directive (89/336/EEC as amended by 92/31 EEC).
The MSR310P also conforms to EN 292, EN 60204-1, EN61508, EN 954-1, and UL 508.
3.1.1.1 EN 954-1
This product conforms to Category 4 of EN954-1: Safety-Related Parts Of Control
Systems.
The main stipulations of this standard are:
Safety-related parts of control systems conforming to Category 4 shall be designed so
that:
• A single fault in any of these safety-related parts does not lead to a loss of the
safety function.
• The single fault is detected at or before the next demand upon the safety functions,
e.g. immediately at switch on, at end of a machine operating cycle. If this detection
is not possible, then an accumulation of faults shall not lead to a loss of the safety
function.
If the detection of certain faults is not possible, at least during the next check-up after the
occurrence of the fault, for reasons of technology or circuit engineering, the occurrence of
further faults shall be assumed. In this situation the accumulation of faults shall not lead
to the loss of the safety function.
Fault review may be stopped when the probability of occurrence of further faults is
considered to be sufficiently low. In this case the number of faults in combination, which
need to be taken into consideration, will depend upon the technology, structure and
application but shall be sufficient to meet the detection criteria.
3.1.1.2 IEC/EN 61508
This product has been designed to conform to SIL 3 of IEC/EN 61508: Functional Safety
of Electrical / Electronic / Programmable Electronic Safety-Related Systems, Parts 1-7,
1998.
IEC/EN 61508 relates to the functional safety of electrical, electronic, and programmable
electronic safety-related systems. These are referred to as Safety Instrumented Systems
(SIS). IEC/EN 61508 is an umbrella standard applicable to all industries. Safety Integrity
Level (SIL) is a statistical representation of the reliability of the SIS. Four SIL levels are
defined: SIL 1 through SIL 4. The higher the SIL number, the more reliable or effective
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the system is. SILs are correlated to the probability of failure of demand (PFD), which is
equivalent to the unavailability of a system at the time of a process demand.
IEC/EN 61508 is approximately equivalent to ANSI/ISA-S84.0: Application of Safety
Instrumented Systems for the Process Industries," Instrument Society of America
Standards and Practices, 1996.
IEC/EN 61508 SIL 3 summary for the MSR300 System:
Safety Integrity Level: SIL 3
10
10
-4
≤ PFD ≤ 10-3 (whole safety function)
-8 h-1
≤ PFH ≤ 10
-7 h-1
SIL – part of logic unit: 15%
PFD ≤ 0,15 x 10
PFH ≤ 0,15 x 10
-3
-7
Mode of operation: low demand mode (Ú PFD)
High demand mode (Ú PFH)
Safety related subsystems: Type B (use of programmable / complex
Components)
Hardware Fault Tolerance: HFT = 1 (two channel system)
Safe Failure Fraction: SFF = 90% to 99% (61508-2, table3)
Calculations for MSR300:
MSR310 Base Module
PFDav(T1)≈ 5,9E-10 *t PFDav(T1)≈ 6,92E-11 *t
PFH(T1)≈ 1,2E-09 [1/h] PFH(T1)≈ 1,38E-10 [1/h]
MSR320 Input Module
1-Channel Wiring
PFDav(T1)≈ 3,19E-11 *t PFH(T1)≈ 5,00E-09 [1/h] 1 contact
PFH(T1)≈ 6,39E-11 [1/h]
2-Channel Wiring
PFDav(T1)≈ 1,19E-11 *t PFH(T1)≈ 1,00E-08 [1/h] 2 contacts
PFH(T1)≈ 2,39E-11 [1/h]
3-Channel Wiring
PFDav(T1)≈ 1,43E-11 *t PFH(T1)≈ 1,50E-08 [1/h] 3 contacts
PFH(T1)≈ 2,86E-11 [1/h]
Standard configuration:
MSR300 System consisting of: 1 MSR310, 4 MSR320, 1 MSR330, 1 MSR329
PFD
avSystem(T1
PFH(T
1
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)= 8,17E-09 *t T1(15% PFD
)= 1,63E-08 [1/h]
MSR329 Muting Lamp Module
MSR330 Output Module
PFDav(T1)≈ 2,50E-09 *t
PFDav(T1)≈ 5,00E-09 *t
PFDav(T1)≈ 7,50E-09 *t
(Each MSR320 configured for two single channel inputs)
) Test interval: 2,1 Years
zul
MSR300 Safety System Manual
3.1.2 MSR300 Safety Relay Functions
MSR300 Systems can be used for various safety relay functions outlined below, when
appropriately configured for the respective function.
Simultaneity monitoring (sometimes referred to as synchronization monitoring or
coincidence gating) is often necessary for many of these safety applications. This means
that 2 (sometimes even 3) input contacts must be closed (or reset) simultaneously to
clear this set of inputs (simultaneity between all channels of one input). For these
applications, the allowable time window is 3 seconds. Another common application that
involves simultaneity monitoring (0.5 seconds window) is two-hand safety control.
(simultaneity activation of both inputs of one module).
3.1.2.1 One-Channel Emergency Stop
• Safety output contacts are opened if the input loop is open.
• Stop category: 0.
• Short-circuiting of the input loop to electrical ground or 24V will be detected.
3.1.2.2 Two-Channel Emergency Stop
• Safety output contacts are opened if at least one input loop is open.
• Stop category: 0.
• Short-circuiting of the input loop to electrical ground or 24V will be detected.
• Cross loops will be detected.
• Suitable for use with safety mats.
• Can be configured for simultaneity detection: 3 seconds limit.
3.1.2.3 Three-Channel Emergency Stop
• Safety output contacts are opened if at least one input loop is open.
• Stop category: 0.
• Short-circuiting of the input loop to electrical ground or 24V will be detected.
• Cross loops will be detected.
• Can be configured for simultaneity detection: 3 seconds limit.
3.1.2.4 Two-Channel Safety Gates
• Safety output contacts are opened if the N/O input is closed or the N/C input is
open
• Stop category: 0.
• Short-circuiting of the input loop to electrical ground or 24V will be detected.
• Cross loops will be detected.
• Can be configured for simultaneity detection: 3 seconds limit.
• Can be configured to execute a start-up test of the input loops.
3.1.2.5 Two-Channel Light Curtain
• Safety output contacts are opened if one or more inputs have has no signal.
• Stop category: 0.
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3.1.2.6 Two-Hand Control
• Two-hand control type IIIC (
EN 574)
• Simultaneity detection: 0.5 seconds limit.
The two-hand control function ensures that operators keep their hands clear of a
hazardous area of a machine. It is meant for use with machines such as mechanical and
hydraulic presses. A machine cycle can only be initiated by pressing two momentary
pushbutton switches simultaneously. Switches must fulfill the requirements of EN574 type
IIIC. Releasing one or both pushbutton switches open the output contacts to interrupt the
cycle and stop the machine. The output contacts can be closed again only after the inputs
have released and the pushbutton switches actuated again.
If a machine is operated by more than one person simultaneously, separate two-hand
controls are required for each operator station.
The two-hand operator station should be located far enough from the hazardous area so
that the latter cannot be reached by the operator before the machine stops (after a stop
command is given).
Typical applications of two-hand safety controls are: presses, shears, plastic-molding
machines, etc.
3.1.2.7 Reset Action
The reset logic of the three Output Groups of the system can be configured for one of the
following modes:
• Automatic reset: The Output Group is active as soon as all input circuits and
feedback loop are closed.
• Manual monitored reset: The Output Group is not active until the reset button has
been operated and then released (and feedback loop closed). This eliminates the
possibility of triggering automatic activation if the reset switch is overridden.
• Manual (non-monitored) reset: The Output Group can be set up for automatic reset
and yet have a reset contact connected in series with the feedback loop. In this
case manual reset is not monitored.
3.1.2.8 Muting (for Robot cell applications)
Muting is the safe, automatic and temporary suspension of an electrosensitive protective
device, in accordance with EN 61496-1 A.7. Muting is typically applied to allow material in
process to be moved into and out of a hazardous area. The presence / movement of such
material can be detected by muting sensors. Typically, muting causes the signal inputs
from safety barriers such as opto-switches or light curtains to be temporarily ignored, only as long as the muting sensors detect material in process approaching entry to, or
exit from a machine. MSR300 muting does not monitor material flow but is especially
designed and limited to applications as explained in the Robot cell examples later in this
document (safe position monitoring of the Robot arm).
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Muting lamps are deployed to indicate that muting is existent. Special safety controls are
necessary to ensure that muting lamps operate correctly and safely. The MSR329 Muting
Lamp Controller is expressly designed for this purpose. Details of this module are given
later in this document.
3.2 MSR300 System: Overview
The MSR300 System is a modular safety control system with extended functions, and is
intended for monitoring and safety control of:
• 1-, 2-, or 3-channel emergency stops
• Safety gates and doors
• Light curtains
• Safety mats
• Two-hand control
An MSR300 System is made up of a combination of the following MSR300 Series
Modules:
• MSR310 Base Module
• MSR320 Input Module
• MSR330 Output Module
• MSR329 Muting Lamp Module:
An MSR300 System is constituted as follows:
• One MSR310 Base Module
• At least one MSR320 Input Module
• At least one MSR330 Output Module
• One MSR329 Muting Modules may be optionally included if needed (provided one
MSR320 Input Module is configured for the robot function).
MSR320 and MSR329 Modules are daisy-chain connected to the left
bus interface
connector of the MSR310 Base Module. Up to ten MSR 320 Input Modules can be
included in an MSR300 System, for a maximum of 20 input circuits.
MSR330 Output Modules are daisy-chain connected to the right
bus interface connector
of the MSR310 Base Module. Up to six MSR330 Output Modules can be included in an
MSR300 System, for a maximum of 18 N/O safety outputs plus 6 N/C auxiliary outputs.
The integrity of all safety inputs are constantly checked by means of feedback of the
safety loops. Dynamic (pulse frequency) excitation signals are generated by the MSR310
Base Module. These signals are fed (as a star-connected bus) to monitor the contact(s)
of every safety sensing device connected to the MSR 300 System. The signals are then
feed back to the Input Module to which each corresponding safety contact input is
connected. If a safety-sensing device is defective the system will detect non-valid signals
or signal sequences on the Inputs. This causes a fail-safe fault response by the MSR300
System.
Every input can be connected to a separate input switching circuit.
Input modules can be freely assigned to any output group module.
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Unintended modifications to MSR300 Systems are prevented by design. The system
configuration is automatically checked when it is first started up, and this information is
stored in non-volatile memory (EEPROM) in the Base Module. Whenever the system is
started up (or restarted) thereafter, the current system configuration is checked against
the stored configuration. If a discrepancy is detected, a fault response is immediately
generated, with appropriate diagnostic indication and output (see setup details in Chapter
7.3).
The MSR300 System is suitable for safety monitoring and control of robot cells, with or
without additional safe areas. The special MSR329 Muting Lamp Module is available for
this.
Special logic functions can be implemented in MSR300 Systems (see Section 5.2 and
Chapter 8).
3.3 MSR300 Modules: Summary
Brief descriptions of the MSR300 Series Modules are given in this section, followed by
the specifications of the modules in tabular format in the next section. Details of the
Modules are given in Chapter 4.
MSR310 Base Module:
Functions:
System control, safety and auxiliary output contacts,
supervision of bus-connected input and output modules,
monitoring of reset and feedback loops
Auxiliary outputs:
3 solid-state switch outputs for signaling the states of output
groups
Serial data interfaces:
Two RS232 ports (bi-directional and uni-directional)
The MSR310 Base Module has two microprocessors for redundancy and supervision of
I/O modules and one for interface and diagnostic operations. Comprehensive diagnostic
information is available through LED indicators, auxiliary solid-state switch outputs and a
serial data interface.
MSR320 Input Module:
Functions:
Processing inputs from various safety sensing devices,
assignment of sensing inputs to output switching groups by
means of rotary coded switches.
Inputs:
2 safety inputs (each module)
2 auxiliary outputs (if third channel is not used)
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Rotary switches on the side of the MSR320 Input Module are used to set the assignment
of inputs to specific output switching groups: each group has a designated Output Module
(Output Groups 1, 2 and 3).
MSR330 Output Module:
Functions:
Safety contact outputs.
Outputs:
Each module: 3 x N/C outputs plus 1 x N/O safety contact
outputs.
System maximum:
3 x 6 = 18 N/C plus 1 x 6 = 6 N/O auxiliary contacts.
A minimum of one and a maximum of six Output Modules
can be included in a single MSR300 System.
MSR330 Output Modules are available in three versions, each specific for one of three
output groups: i.e., Group 1, Group 2, Group 3, respectively. The group number must be
specified when ordering these modules.
MSR329 Muting Lamp Module:
Functions:
Connection and control of muting lamps.
Capacity:
2 x main muting lamps plus 2 x reserve muting lamps
One Muting Lamp Module can be optionally included in an
MSR300 System in lieu of one MSR320 Input.
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3.4 MSR300 Modules: Specifications
3.4.1 MSR310 Specifications
Standards IEC/EN60204-1, ISOTR12100, ISO13849-1
Approvals CE marked for all applicable directives
Power supply Nominal: 24 VDC. Range: 0.8 to 1.1 x rated voltage
Power consumption 5W
Reset Monitored manual and / or automatic
System inputs capacity 1 to 10 Input Modules, each with 2 inputs
System outputs
capacity
1 to 6 Output Modules, each with 3 N/C and 1 N/O safety
contacts, 3 Group indicating auxiliary solid-state outputs plus
2 optional aux. Outputs on each connected Input Module
Solid-state output rating 24 VDC (nominal); 50 mA; short-circuit protected
Serial data interface RS232. Unidirectional: 4800 baud. Birectional: 2400, 4800,
9600, or 19200 baud.
Bus connectors Flat cable type, with gold plated pins/sockets
Power on delay 3 sec.
Response time 26ms + (6ms x number of input extension modules)
Recovery time 26ms + (6ms x number of input extension modules)
Pollution degree 2
Operating temperature -5°C to +55°C (+23°F to 131°F)
Relative humidity (RH) 90%
Enclosure protection IP40
Terminals protection IP20
Short circuit protected
S11, S21, S31, S41, S51, Y40, Y10, Y31, Y32, Y33
output terminals
Connecting wire Copper conductor. Temperature rating: 60/75 °C
Conductor size 0.2 to 2.5 mm² (24-12 AWG)
Terminal screw torque 0.6 to 0.8 Nm (5 to 7 lb-in)
Housing material Polyamide PA 6.6
Mounting 35mm DIN rail
Weight 210g (0.46 lbs)
Vibration 10 – 55 Hz, 0.35 mm
Mechanical shock 10g, 16 msec, 100 shocks
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MSR300 Safety System Manual
3.4.2 MSR320 Specifications
Standards IEC/EN60204-1, ISOTR12100, ISO13849-1
Approvals CE marked for all applicable directives
Power supply Nominal: 24 VDC. Range: 0.8 to 1.1 x rated voltage
Power consumption approx. 3W
Safety inputs 1 N/C, 2 N/C, 3 N/C, safety mat, light curtain, N/C-N/O, two-
hand control
Solid-state switch
24 VDC (nominal); 20 mA; short-circuit protected
output rating
Input simultaneity
detection
3 secs. or disabled (infinite time limit)
Two Hand Operation Mode: 0.5s between both Inputs
LED indicators Input status (2): Green = input closed. Red = input open
Output switch group assignment (3)
Input load impedance 900 ohms (max.)
Bus connectors Flat cable type, with gold plated pins/sockets
Pollution degree 2
Operating temperature -5°C to +55°C (+23°F to 131°F)
Relative humidity (RH) 90%
Enclosure protection IP40
Terminals protection IP20
Conductor size 0.2 to 2.5 mm² (24-12 AWG)
Terminal screw torque 0.6 to 0.8 Nm (5 to 7 lb-in)
Housing material Polyamide PA 6.6
Mounting 35mm DIN rail
Weight 110g (0.24 lbs)
Vibration 10 – 55 Hz, 0.35 mm
Mechanical shock 10g, 16 msec, 100 shocks
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3.4.3 MSR330 Specifications
Standards IEC/EN60204-1, ISOTR12100, ISO13849-1
Approvals CE marked for all applicable directives
Power supply 24 VDC from the MSR310 Base Module
Power consumption 1.5 W
Output fuses (external) 6 A slow blow, or 10 A quick blow.
Safety outputs 3 x N/O plus 1 x N/O (safety contacts)
Safety contact rating B300, AC-15, 6A / 250 VAC
DC-13, 3A / 24 VDC
Thermal Current rating 2x6A or 3x5A
Min. switched current /
10 mA / 10 V
voltage
Contacts material AgSnO2 ; 2 micron gold plated
Relay contacts life
expectancy
Electrical:
220VAC, 4A, 880VA, cos φ = 0.35: 100,000 operations
220VAC, 1.7A, 375VA, cos φ = 0.6: 500,000 operations
30VDC, 2A, 60W: 1,000,000 operations
10VDC, 0.01A, 0.1W: 2,000,000 operations
Mechanical: 2,000,000 operations
Impulse withstand
2500 V
voltage
LED indicators Relays state indication
Bus connectors Flat cable type, with gold plated pins/sockets
Pollution degree 2
Operating temperature -5°C to +55°C (+23°F to 131°F)
Relative humidity (RH) 90%
Enclosure protection IP40
Terminals protection IP20
Conductor size 0.2 to 2.5 mm² (24-12 AWG)
Connecting wire Copper conductor. Temperature rating: 60 / 75°C
Terminal screw torque 0.6 to 0.8 Nm (5 to 7 lb-in)
Housing material Polyamide PA 6.6
Mounting 35mm DIN rail
Weight 190g (0.42 lbs)
Vibration 10 – 55 Hz, 0.35 mm
Mechanical shock 10g, 16 msec, 100 shocks
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3.4.4 MSR329 Specifications
Standards IEC/EN60204-1, ISOTR12100, ISO13849-1
Approvals CE marked for all applicable directives
Power supply Nominal: 24 VDC. Range: 0.8 to 1.1 x rated voltage
Power consumption 1 W
Inputs Monitoring of 2 muting lamps, 30 mA - 200 mA each
Outputs 2 x muting lamps, plus 2 x reserve muting lamps
LED indicators State of muting lamps
Bus connectors Flat cable type, with gold plated pins/sockets
Pollution degree 2
Operating temperature -5°C to +55°C (+23°F to 131°F)
Relative humidity (RH) 90%
Enclosure protection IP40
Terminal protection IP20
Conductor size 0.2 to 2.5mm² (24-12 AWG)
Terminal screw torque 0.6 to 0.8 Nm (5 to 7 lb-in)
Housing material Polyamide PA 6.6
Mounting 35mm DIN rail
Weight 190g (0.42 lbs)
Vibration 10 – 55 Hz, 0.35 mm
Mechanical shock 10g, 16 msec, 100 shocks
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4 MSR300 Modules: Details
4.1 MSR310 Base Module
MSR310
Front View
MSR310 Internal Block Schematic Diagram
Functions: System control, safety and auxiliary output contacts, supervision of
bus-connected input and output modules.
Auxiliary outputs: 3 solid-state switch outputs for signaling the states of output
groups.
Serial data interface: two RS232 ports (bi-directional and uni-directional).
Selectable start mode: Monitored (manual) or automatic.
The MSR310 has independent feedback loops for each output group.
There are no safety inputs or outputs on this module.
The MSR310 Base Module has three microprocessors: for redundancy and supervision of
I/O modules. Comprehensive diagnostic information is available via two-color LED
indicators, auxiliary solid-state switch outputs and the serial data interface.
4.1.1 Terminals
Name Function
A1 Supply +24 VDC
A2 Supply 0 V ; ground for solid-state switch outputs
GND, TxD1, RxD1 Bi-directional RS232
GND, TxD2 Uni-directional RS232
S11 – S51 Pulse train outputs (bus) to input devices
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Y40, Y41, Y42 Reset configuration
S34 Start button
Y31 – Y33 Solid-state auxiliary outputs for groups 1, 2 and 3
Y10 +24V for reset circuit and feedback loops
Y11 – Y13 Feedback loop inputs for Groups 1, 2 and 3
4.1.2 LED Indicators
Function Status LED Group 1-2-3 LEDs
Power up / normal operation Continuous on: green ---
Internal fault Continuous on: red ---
Entering configuration mode 1 flash: red ---
Input switch fault or reset switch
2 flashes; red ---
closed during power up
Configuration change during
3 flashes; red ---
operation
Current configuration not as stored
4 flashes; red ---
on EEPROM
At least one muting lamp and one
5 flashes; red ---
reserve lamp defective
Invalid switch settings of input
6 flashes; red ---
modules
Invalid reset configuration (Y41,
7 flashes; red ---
Y42, S34 terminal jumpers)
Input terminal block not (or
8 flashes; red ---
improperly) plugged in
Group output active --- Continuous on: green
Group ready --- Blinking: green
At least one input corresponding to
--- Continuous on: red
the output group is faulty
A feedback (EDM) loop of the
--- Off
output group is open, or no input is
assigned to the group
LEDs "TxD1" and "TxD2" indicate RS232 data communication activity when flashing.
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4.1.3 Settings, Connections, Start-Up
Reset mode selection (reset switch connection and jumper settings):
Reset button has to be installed at a place where the dangerous area can
be visual monitored. Automatic reset is only allowed if the start of the
machine cannot lead to a hazard or a restart interlock must be
accomplished by other means of control (per EN 60204-1)
Reset behavior Circuit
Group1 and 2: manual, monitored reset
Group3: automatic reset
Group 1 and 2: automatic reset
Group 3: manual, monitored reset
Groups1, 2 and 3: manual, monitored
reset
Groups 1, 2 and 3: automatic reset
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4.1.4 Auxiliary Outputs (Solid-State Switches)
The MSR310 Base Module has three LEDs and three auxiliary (solid-state switch)
outputs that indicate the states of the three Output Groups, respectively.
Condition Y31 Y32 Y33
Group 1 active 24V --- --Group 1 inactive 0V --- --Group 2 active --- 24V --Group 2 inactive --- 0V --Group 3 active --- --- 24V
Group 3 inactive --- --- 0V
Wiring
These outputs are short-circuit protected. Current limit: 50 mA.
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4.1.5 Output Groups Feedback
Every output group has its own feedback loop. This loop has to be closed for each group
before the respective group can be activated.
Function Wiring
External device for Group 1
External device for Group 2
External device for Group 3
No external device connected for Group 1
No external device connected for Group 2
No external device connected for Group 3
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4.1.6 Input Fault Logging
If inputs are wired for simultaneity monitoring, the following events are registered as faults
and stored in EEPROM:
• Simultaneity time limit is exceeded.
• Not all channels change state as required if input is cycled
• The reset switch is closed while not all channels of at least one input are in the
correct state for either “on” or “off”.
The faults can be cleared by opening and closing the circuits of all channels of one input
simultaneously. If the faults are not cleared, the MSR310 indicates this on the next power
up. The faults can even then be cleared by opening and closing the circuits of all
channels of the faulty input simultaneously.
4.1.7 Serial Communication Interface Connections
The MSR310 is equipped with two RS232 serial data interfaces: one for bi-directional and
one for uni-directional communication mode. The interface connections are illustrated
below.
TxD1
RxD1
GND
TxD2
GND
RS-232
Bi-
directional
RS-232
Unidirectional
Serial data communication protocol details (uni-directional and bi-directional) are given in
Chapter 9, at the end of this document.
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