AGI CMC MRS Series User manual
Read this manual before using product. Failure to
follow instructions and safety precautions can
result in serious injury, death, or property
damage. Keep manual for future reference.
Part Number: 10678 Rev. G
Revised: November 2023
Original Instructions
MRS Series
MRS001-EK Rotation Sensor
Technical Manual
New in this Manual
The following revisions have been made to this manual:
Rev Description Date
First Release First release January 21 2005
Rev. A Miscellaneous text changes and updated dimensions drawing. May 11 2005
Rev. B Updated mechanical installation details to include grommet
mounting system.
May 20 2005
Rev. C Updated illustration showing new code wheel. May 20 2005
Rev. D Added the MRS001-EK to the manual. April 17 2008
Rev. E Updated exploded view drawing 11031. December 17 2010
Rev. F Updated parts list drawing 11031. January 24 2012
Rev. G • Changed company logo and refresh changing name to reflect
complete assembly.
• Rewrite for enclosure assembled at factory instead of fabricated
bracket installation.
• Updated specifications to reflect higher current draw and
housing dimensions.
• Revised drawing 11031 changing name to Assembly/Installation.
• Updated to new AGI manual format.
March 4 2023
Manual updated to standard AGI format. September 2023
MRS SERIES –
10678 REV. G 3
CONTENTS
1. Introduction ............................................................................................................................................ 4
2. Safety....................................................................................................................................................... 5
2.1 Safety Alert Symbol and Signal Words...................................................................................... 5
2.2 General Safety Information....................................................................................................... 5
2.3 HAZMON Safety......................................................................................................................... 5
2.4 Drives and Lockout/Tagout Safety ............................................................................................ 6
2.5 Safety Equipment and Procedures............................................................................................ 6
2.6 Personal Protective Equipment................................................................................................. 7
3. Indicators ................................................................................................................................................ 8
4. Installation .............................................................................................................................................. 9
4.1 Mounting the MRS001–EK ........................................................................................................ 9
4.2 Mounting Using a Fabricated Bracket — Deprecated ............................................................ 11
5. Communications ................................................................................................................................... 13
6. Assembly ............................................................................................................................................... 14
6.1 Assembly Drawings ................................................................................................................. 16
7. Specifications ........................................................................................................................................ 19
8. Form of Limited Warranty.................................................................................................................... 20
4 10678 REV. G
1. Introduction
The MRS001-EK Rotation Sensor is designed to determine the shaft speed of rotating equipment.
Measurements from 1 to 1000 RPM are possible. Internally, the device uses a magnetic code wheel
that attaches to the shaft with threaded coupling. FOLLOW ALL SAFETY PROTOCOLS. Before working
on equipment, use Lockout/Tagout procedure to shutdown Hazardous Energy sources including but
not limited to powered circuits, moving
Always operate machines with guards in place to avoid the risk of injury or loss of life.
Always operate the plant with hazardous monitoring systems fully operational to avoid
risks of injury or loss of life. Follow all safety protocols. Follow all safety instructions
throughout this manual.The sensors are intended for installation as part of a complete
HAZMON system where components are specified by CMC for operation in hazardous
locations. This includes:
• MIP001 Inductive Proximity Sensors
• MBC081/3 IS Bus Converters acting as Intrinsic Safety Barrier
• MTB0X6 Field Interconnect Boxes (FIB)
• Operator/PLC Interface
Cable materials are pre-specified to meet the Control Drawing requirements.
The rugged shaft mounted housing facilitates mounting to a machine’s output shaft using 1/2”-13NC
male thread. The housing is free hanging and does not require any brackets. Alternately a high force
magnet assembly is available to attach the code wheel to the machine’s output shaft. This version
comes with a protective shroud that guards the threaded attachment point. Otherwise, suitable
guarding is always to be used to protect personnel from contact with rotating equipment.
Each sensor has a unique digital serial number automatically recognized by the associated system
components. Communication utilizes a Single-Wire bus protocol that also provides power to the
sensor. It is considered Intrinsically Safe when used with MBC081/3 IS Bus Converter.
The enclosure is industrial grade UHMW-PE plastic housing utilizing a fully potted sensor module
which is field replaceable. Each sensor comes complete with 6’6” (2 m) of flexible UV resistant UL 2517
TPE cable. The cable is meant to be protected with LFNC for heavy industrial environments. This cable
is terminated with an RJ-11 connector for modular connection to Field Interconnect Box (FIB)
backplane.
Figure 1. Direct Coupled Threaded Shaft Attachment
1. INTRODUCTION MRS SERIES –
10678 REV. G 5
2. Safety
2.1. Safety Alert Symbol and Signal Words
This safety alert symbol indicates important safety messages in this manual. When you see
this symbol, be alert to the possibility of injury or death, carefully read the message that
follows, and inform others.
Signal Words: Note the use of the signal words DANGER,WARNING,CAUTION, and NOTICE with the safety
messages. The appropriate signal word for each message has been selected using the definitions below as a
guideline.
Indicates an imminently hazardous situation that, if not avoided, will result in serious injury or
death.
Indicates a hazardous situation that, if not avoided, could result in serious injury or death.
Indicates a hazardous situation that, if not avoided, may result in minor or moderate injury.
Indicates a potentially hazardous situation that, if not avoided, may result in property damage.
2.2. General Safety Information
Read and understand all safety instructions, safety decals, and manuals and follow them when operating or
maintaining the equipment.
• Owners must give instructions and review the information initially and annually with
all personnel before allowing them in the work area. Untrained users/operators
expose themselves and bystanders to possible serious injury or death.
• Use for intended purposes only.
• Modification of the rotation sensor in any way without written permission from the manufacturer is not
covered by the warranty.
• Follow a health and safety program for your worksite. Contact your local occupational health and safety
organization for information.
• Follow applicable local codes and regulations.
2.3. HAZMON Safety
Do not operate plant or equipment with compromised system. Follow safety procedures while
starting and stopping the Hazard Monitoring system including notification, permits, etc.
• To prevent exposure to potential ignition source, DO NOT OPEN IS Bus Converter cover in dust explosive
atmosphere while energized. Field Interconnect Boxes may be opened for troubleshooting purposes with
power applied – see next warning:
• Remove dust and condensation away from enclosure seals before opening to prevent contamination.
MRS SERIES – 2. SAFETY
6 10678 REV. G
• Always operate system without bypassing alarm controls. Otherwise, follow safety protocols to verify there
are no actual hazards including but not limited to heat sources, blockages, lack of guarding, etc.
• Validate sensor positions before first operating, after regular system maintenance, immediately after
installing replacement parts, and before operating machines. Always test interlocks during commissioning
and on a periodic basis recording their functionality.
• Inspect sensors, associated wiring and enclosures for damage and proper installation on regular interval.
• Follow all other manufactures’ instructions, safety labels and placards.
2.4. Drives and Lockout/Tagout Safety
Inspect the power source(s) before using and know how to shut down in an emergency.
Whenever servicing or adjusting the equipment, make sure to shut down the power
source and follow lockout and tagout procedures to prevent inadvertent start-up and
hazardous energy release. Know the procedure(s) that applies to the equipment from the
following power sources.
For example:
WARNING
• De-energize, block, and dissipate all sources of hazardous energy.
• Lock out and tag out all forms of hazardous energy.
• Ensure that only 1 key exists for each assigned lock, and that you are the only one that holds that key.
• After verifying all energy sources are de-energized, service or maintenance may be performed.
• Ensure that all personnel are clear before turning on power to equipment.
For more information on occupational safety practices, contact your local health and safety organization.
2.5. Safety Equipment and Procedures
Fire Extinguisher
Provide a fire extinguisher for use in case of an accident. Store in a highly visible and accessible
place.
First-Aid Kit
Have a properly-stocked first-aid kit available for use should the need arise, and know how to use it.
•Emergency Egress
Locate the shortest path to the nearest exit(s) and know how to sound alarm in case of accident. Be
aware of closest muster station and alternate in case of evacuation.
2. SAFETY MRS SERIES –
10678 REV. G 7
•Confined Space
Use personal carbon monoxide detector when entering Boot Pit and follow safety protocols for
determining whether safe to enter enclosed spaces using necessary equipment.
2.6. Personal Protective Equipment
The following Personal Protective Equipment (PPE) should be worn when assembling, operating or maintaining
the equipment.
•Safety Glasses
Wear safety glasses at all times to
protect eyes from debris.
•Steel-Toe Boots
Wear steel-toe boots to protect feet from
falling debris.
•Coveralls
Wear coveralls to protect skin.
•Work Gloves
Wear work gloves to protect your hands
from sharp and rough edges.
MRS SERIES – 2. SAFETY
8 10678 REV. G
3. Indicators
The following indicator description is used for troubleshooting sensors outside of the enclosure, and is
not meant to be for field diagnostics. Use the EZTest handheld Diagnostic Troubleshooter to test
communication and read RPM (Revolutions Per Minute).
Figure 2. Indicator Illustration
The sensor requires no settings. There are two indicator lamps:
Description Color Flash Rate Operation
Status Green 1
2
3
4
5
6
OK, no communications
OK, communications active
Power on self test fault
Calibration parameter fault
Firmware fault
Serial number fault
Rotation Red -Flashes whenever a code wheel
magnet crossing is detected.
3. INDICATORS MRS SERIES –
10678 REV. G 9
4. Installation
The rotation sensor comes assembled in MRS001-EK enclosure kits. The housing is free-standing as it is
mounted to the drive shaft of the machine at single attachment point. No brackets are required.
The optional magnet used to attach the Rotation Sensor to the machine shaft has an
extremely strong attractive force and will move suddenly and rapidly towards any
ferrous or magnetic material which may cause injury.
4.1. Mounting the MRS001–EK
Before installation:
1. When directly coupled, drill and tap the shaft of the rotating device with a 1/2”-13NC threaded hole to a
depth of at least 1.5” (38 mm).
Note
It is important to ensure this hole is centered and parallel to the shaft – excessive deviation will
cause bearing wear damaging the device.
2. Unpack the respective MRS001 and check the supplied parts are complete:
a. 11486 Assembled c/w 1/2”-13 Nut
b. 11486PS Assembled c/w 1/2”-13 Nut, Magnet and Protective Shroud
3. Install the coupling onto the machine’s drive shaft. For threaded attachment, screw the shaft as far as
possible into the shaft. Secure the shaft with a 7/16” open end wrench and tighten the jam nut to secure
the shaft. For the magnetic coupling, center it on the end of the shaft sliding it as necessary into place.
4. Install LFNC (Liquid-tight Flexible Non-metallic Conduit) using 1/2” (16mm) fittings as supplied in the
HAZMON In-A-Box kit.
5. With guards in place, start the machine and observe the shaft and housing.
Note
There should be a minimum of wobble due to being un-centered (eccentricity) keeping the housing
stationary and no noticeable vibration.
6. Verify the sensor’s output speed with a tachometer if otherwise unknown.
7. Determine the direction of rotation of the shaft. For standard configuration as supplied by the factory, set
the span value in the system to 1 (positive one) for counterclockwise, and to -1 (minus one) for clockwise.
MRS SERIES – 4. INSTALLATION
10678 REV. G 11
4.2. Mounting Using a Fabricated Bracket — Deprecated
Safety guards are required to protect from personal injury due to pinch point or the
disengagement of components. The mounting bracket for sensor must be rigid and able to
withstand loads from unexpected sources. The mounting surface for the code wheel must be
flat and perpendicular to the shaft. It is the sole responsibility of the installer to ensure the
mounting method and protective guards meet site safety requirements in accordance with
regulations.
It is possible to mount the MRS001 Rotational Speed sensor and Magnetic Code wheel without the purpose
made enclosure assembly. Follow the instructions below for this mounting method.
To install using a fabricated bracket:
1. Mount the sensor to the bracket using the supplied 4-40 x 1” screws with flat washers and nylon locking nut
as shown in the diagram below.
Note
The encoder wheel target is located on the sensors face.
2. Tighten screws to compress the grommet 1/16”. Do not over tighten the screws.
3. Install the sensor so the code wheel magnets pass over the sensor’s target mark with an average distance
from the code wheel of 0.25” to 0.40”.
Note
The direction the magnets move across the sensor face sensor determines the rotation direction.
4. Observe the direction arrow on the face of the sensor for positive RPM orientation.
MRS SERIES – 4. INSTALLATION
10678 REV. G 13
5. Communications
The MRS001–EK Rotation Sensor uses a single-wire communication protocol. The sensor is supplied
with 6’6” (2 m) cable terminated with a RJ-11 plug. The sensor connects to the wiring system through
an IS barrier powered Field Interconnect Box.
The output of the sensor is a single signed 16 bit word. The resolution is 1 RPM and the range is 1 to
1000 RPM. The reading is averaged and updated once per second for values greater than 10. For rates
less than 10, the magnetic sensor on and off transitions determine the update rate.
The sensor detects the direction of rotation and will provide a negative value for reverse rotations. The
arrow next to the target on the sensor is the positive rotation direction.
The sensor requires a Bus Converter to convert the signaling system to the industrial Field Bus
Modbus485 RTU protocol. The RPM is represented as a single signed word in the Bus Converter’s
Modbus register map. A unique serial number is automatically Acquired by the Bus Converter on
request.
As a 1-Wire®compatible device, the sensor value is returned using the read scratch function as 3
bytes, the first 2 bytes is signed word containing the RPM and the 3rd byte is an 8-bit CRC. The family
code for the sensor is 160 decimal or A0 Hex. The sensor responds to the following Dallas function
codes:
Code Decimal Code Hex Function
240 F0 Search ROM
85 55 Match ROM
15 0F Read ROM
51 33 Read ROM
204 CC Skip ROM
190 BE Read Scratch, 3 bytes, low byte + high byte +
Dallas 8–bit CRC
1-Wire®is a registered trademark of Analog Devices.
MRS SERIES – 5. COMMUNICATIONS
14 10678 REV. G
6. Assembly
Over tightening the shaft screw will permanently damage the plastic code wheel. Use a
torque wrench to tighten the screw to the required torque and be certain to use
removable thread locking compound on the screw threads. Failure to observe these
requirements may result in the speed sensor separating from the machine.
See Section 6.1 – Assembly Drawings on page 16 for standard assembly configuration (Drawings 11031
and MRS001–EK Parts List). Some legacy MRS001-EK may be assembled with changes to the span
value corresponding to the direction of rotation – note the non-standard configuration uses span value
of 1 (positive one) for clockwise rotation (Drawing 11031 B).
To assemble the MRS001–EK:
1. Disassemble by removing the lid and if necessary, remove the magnetic code wheel by unscrewing
the button head screw (legacy hex cap screw) retainer using 7/16” open end wrench and hex key.
2. Install the MRS001–EK sensor by passing the cable through the conduit opening in the base of the
enclosure and place the sensor in position.
Note
The rubber grommets should be against the inside of the housing. Use the 4-40 x 1” screws
supplied with the rotation sensor to mount the sensor.
3. Install the screws from the outside of the main housing using the flat washer and finally the nylon
lock nut to compress the rubber grommets 1/16”.
Note
Use the 4-40 x 3/4” screws and nylon lock nuts to plug the 2 small holes in the enclosures
lid.
Note
Do not clamp, hold or damage the drive shaft seal area shown below. Damaging these
surfaces will destroy the shaft seal.
4. Inspect the code wheel shaft and housing seal for damage, if either is damaged do not install the
housing.
6. ASSEMBLY MRS SERIES –
10678 REV. G 15
5. Carefully push the housing on the drive shaft. Be careful not to damage the rubber seal in the
housing.
6. Rock the housing back and forth to ensure the seal is free and not pinched by the shaft as you are
pressing the shaft into the seal and bearing.
7. Apply removable thread locking compound to the threads of the code wheel screw and thread it
into the drive shaft using fender and star lock washers.
Note
Ensure the bearing and seal have not been damaged and that the drive shaft and bushing
are fully engaged in the bearing.
8. Tighten the screw to 50 inch-pounds of torque. The enclosure should rotate freely back and forth
on the drive shaft.
9. Align the gasket to the lid using the #8 x 1” self-tapping screws to hold the gasket in place and
fasten the lid to the main housing.
10. Tighten the screws alternately to compress the gasket. Do not over tighten the screws.
11. Examine the gap between enclosure body and lid to ensure the gasket remained in place and is
compressed evenly.
MRS SERIES – 6. ASSEMBLY
10678 REV. G 19
7. Specifications
Description Characteristic
Sensor Bus
Voltage
Current
Communications
5 VDC
8 mA max
Single-wire Bus
Position
Resolution
Accuracy
Quadrature Magnetic Encoder
1–1000 RPM
1.0% full scale
6 divisions/revolutions
Environment
Temperature
Relative Humidity
-40 to 70° C (-40 to 158° F)
0 to 95% non-condensing
Housing Dimensions
Length
Width
Depth
Depth with protective shroud
6.0” (152 mm)
4.0” (102 mm)
2.3” (58 mm)
3.8” (96 mm)
MRS SERIES – 7. SPECIFICATIONS
20 10678 REV. G
8. Form of Limited Warranty
Ag Growth International Inc. warrants that the goods and/or services being supplied (the “Goods”) will
be free from defects in materials and workmanship under normal conditions, use, service, and
maintenance, for a period of twelve (12) months from the date of first operation of the Goods, but in
no event more than eighteen (18) months from the date of delivery of the Goods to the end-user (the
“Warranty Term”). If the Goods are being used for rental purposes, the Warranty Term for the subject
Goods shall be limited to 90 days.
Subject to AGI’s sole discretion, if the Goods, or a component thereof, are found to have a default in
materials and/or workmanship within the Warranty Term, AGI will, at its own option and expense,
repair or replace the subject Goods. Any warranty related expenses incurred on behalf of or by the
end-user without the prior written consent of AGI shall be the sole responsibility of the end-user.
Expenses relating to travel, freight, customs or import duties and tariffs, equipment rental, and any
costs associated with accessing the Goods are the sole responsibility of the customer. Any replacement
will be warranted for the remainder of the original warranty. AGI will not proceed with any repairs or
replacement unless first contacted and a Return Material Authorization (RMA) number issued.
Warranty shall be void in the event the Goods are returned or disposed of without the written consent
of AGI.
The customer shall not assert a claim that the Goods are defective unless the customer gives written
notice to AGI of such defect within forty-eight (48) hours of discovering such defect. In the event of a
warranty claim, the customer must complete any, and all information required by AGI to properly
assess or investigate the claim. AGI shall be given a reasonable opportunity to inspect and test the
Goods in question. Failure by the customer to notify AGI of such claim within 48 hours shall operate as
a waiver of any, and all such claims by the customer.
THIS IS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY AGI WITH RESPECT TO THE GOODS AND IS IN
LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY OPERATION OF
LAW OR OTHERWISE, INCLUDING WITHOUT LIMITATION, MERCHANTIBILITY OR FITNESS FOR A
PARTICULAR PURPOSE WHETHER OR NOT THE PURPOSE OR USE HAS BEEN DISCLOSED TO SELLER IN
SPECIFICATIONS, DRAWINGS, OR OTHERWISE, AND WHETHER OR NOT AGI’S GOODS ARE SPECIFICALLY
DESIGNED AND/OR MANUFACTURED BY AGI FOR BUYER’S USE OR PURPOSE.
This limited warranty extends solely to Goods manufactured by AGI and does not cover any third-party
parts, components, or materials. To the extent permitted by the manufacturer, AGI will pass on
applicable warranties on third-party parts, components or materials to the end-user. This warranty
does not extend to any losses or damages due to misuse, use of a kind and/or to a degree not
reasonably expected to be made of the Goods, any use of the Goods which is not an intended use as
specified in AGI’s published product literature or otherwise specified by AGI in writing, accident, acts
of God, abuse, neglect, normal wear and tear (including corrosion and cosmetic issues), any
equipment attached to or used in conjunction with the Goods, any field modifications or substitutions
to original Goods, component damage incurred during shipping and handling, unauthorized
modification or alteration, used beyond rated capacity, or improper installation, maintenance or
application.
THE SOLE AND EXCLUSIVE REMEDY FOR ANY CLAIM HEREUNDER SHALL BE LIMITED TO REPAIR OR
REPLACEMENT. AGI SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE AND IN
NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER BASED IN
CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT OR OTHERWISE), SHALL
8. FORM OF LIMITED WARRANTY MRS SERIES –
This manual suits for next models
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