Leuze electronic MSI-SR5B Series User manual

SAFE IMPLEMENTATION AND OPERATION
Original operating instructions
EN 2013/10 - 50124428 We reserve the right to make technical changes

Leuze electronic MSI-SR5B 2
© 2013
Leuze electronic GmbH + Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone: [phone]
Fax: [phone]
http://www.leuze.com
[email protected]

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1.1 Used symbols and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Approved purpose and foreseeable improper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1.2 Using E-Stop buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.3 Using reset buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.4 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Competent persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Responsibility for safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
9
3.1 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.1 Terminal assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2 Sensor wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2.1 Selecting the operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7.2.2 Acceptance of pending sensor signals (S1 and S2), for both channel 1 (Sx1) and channel 2 (Sx2) .
19
7.2.3 Acceptance of the RES manual release signal via the start button at (RES-I) . . . . . . . . . . . . . . . . 19
7.3 Circuit diagram examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.4 Connecting to the machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.2 Start/restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.2.1 Unlocking start/restart interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.1 Before the initial start-up and following modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.1.1 Checklist  initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2 To be performed periodically by a competent person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.3 To be performed daily by the operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.3.1 Check list  daily or at change of shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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13.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Table 1.1: Warning symbols and signal words
Table 1.2: Other symbols
Table 1.3: Terms and abbreviations
The checklists (see chapter 9 Testing) serve as a reference for the machine manufacturer or supplier.
They replace neither testing of the complete machine or system prior to the initial start-up nor their periodic
testing by a competent person. The checklists contain minimum testing requirements. Depending on the
application, other tests may be necessary.
Symbol for dangers
NOTICE Signal word for property damage
Indicates dangers that may result in property damage if the measures for danger
avoidance are not followed.
CAUTION Signal word for minor injury
Indicates dangers that may result in minor injury if the measures for danger avoid-
ance are not followed.
WARNING Signal word for serious injury
Indicates dangers that may result in severe or fatal injury if the measures for dan-
ger avoidance are not followed.
DANGER Signal word for life-threatening danger
Indicates dangers with which serious or fatal injury is imminent if the measures for
danger avoidance are not followed.
Symbol for tips
Text passages with this symbol provide you with further information.
Symbols for action steps
Text passages with this symbol instruct you to perform actions.
AOPD Active Optoelectronic Protective Device
Active Optoelectronic Protective Device
OSSD Output Safety Switching Device
ESPE Electro-Sensitive Protective Equipment
(AOPD)
EDM External Device Monitoring
RES Start/restart interlock (reset)
PFHDProbability of a dangerous failure per hour
MTTFdMean time to a dangerous failure
(Mean Time To dangerous Failure)
PL Performance Level

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Before using the safety relay, a risk evaluation must be performed according to valid standards (e.g.
EN ISO 12100, ISO 13849-1, EN/IEC 61508, EN/IEC 62061). The result of the risk assessment deter-
mines the required safety level of the safety relay (see table 13.1). For mounting, operating and testing,
this document as well as all applicable national and international standards, regulations, rules and direc-
tives must be observed. Relevant and supplied documents must be observed and handed to the affected
personnel.
Before working with the safety relay, completely read and understand the documents applicable to your
task.
In particular, the following national and international legal regulations apply for the start-up, technical
inspections and work with safety relays:
 Machinery directive 2006/42/EC
 Low voltage directive 2006/95/EC
 Electromagnetic compatibility 2004/108/EC
 Use of Work Equipment Directive 89/655/EEC supplemented by Directive 2009/104/EC
 OSHA 1910 Subpart 0
 Safety regulations
 Accident-prevention regulations and safety rules
 Industrial safety regulation and employment protection act
 Product Safety Act
For safety-related information you may also contact the local authorities (e.g., industrial inspec-
torate, employer's liability insurance association, labor inspectorate, occupational safety and
health authority).
During all conversions, maintenance work and inspections, make certain that the voltage supply is
interrupted and protected against being restarted again.
Only have work on the electrical system and electronics performed by a competent person.
Make certain that the safety relay is correctly connected and that the protective function of the protec-
tive device is ensured.
Make certain that, during all conversions, maintenance work and inspections, the system is securely
shut down and protected against being restarted.

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Only if the safety relay is correctly connected and correctly started up is the protective function of the
protective device ensured. To prevent misuse and resulting dangers, the following must be observed:
 These operating instructions are included in the documentation of the system on which the protective
device is mounted and are available to the operating personnel at all times.
 The safety relay is used as a safety monitoring device in combination with safety sensors, switches
and command devices for guarding danger zones or points of operation in machines and systems.
 The safety relay must 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, connected, checked and commissioned by a -
.
 The safety relay must only be connected and commissioned in accordance with its specifications
(technical data, environmental conditions, etc.).
 The Reset acknowledgment button for unlocking the start/restart interlock must be located outside
of the danger zone.
 The entire danger zone must be visible from the installation site of the acknowledgment button.
 The safety relay must be selected so that its safety-related capability meets or exceeds the required
Performance Level PL ascertained in the risk assessment (see table 13.1).
 The machine or system control must be electrically influenceable so that a switch command sent by
the safety relay results in the immediate shutdown of the dangerous movement.
 The construction of the safety relay must not be altered. When manipulating the safety relay, the pro-
tective function is no longer guaranteed. Manipulating the safety relay also voids all warranty claims
against the manufacturer of the safety relay.
 The safety relay must be tested regularly by a competent person (see chapter 9 Testing).
 The safety relay must be exchanged after a maximum of 20 years. Repairs or the exchange of parts
subject to wear and tear do not extend the service life.
It must be ensured that the E-Stop function always acts directly and immediately. An example for the
connection of a two-channel E-Stop button (see chapter 7.2.2 Acceptance of pending sensor signals (S1
and S2), for both channel 1 (Sx1) and channel 2 (Sx2)).
E-Stop buttons connected to the safety relay act only on the safety circuit to which the AOPD or the safety
switch is assigned. Thus, it can be considered to be an area E-Stop. The limited sphere of action of the
button is to be clearly marked for the operating personnel. E-Stop buttons must only be used for safety-
related STOP signaling.
The Reset reset button for unlocking the start/restart interlock (RES)
 must be located outside of the danger zone.
 must be mounted so that the entire danger zone can be viewed from the installation site.
 must not be accessible from within the danger zone.
If the overview of the situation is not ensured in the case of two danger zones, two reset buttons (e.g.,
connection at the local socket of the AOPD) are to be used. The assignment of the buttons for the respec-
tive danger zone is to be clearly labeled for the operating personnel.
Any use other than that defined under the Approved purpose or which goes beyond that use is consid-
ered improper use.
Alone, the safety relay is not a complete protective device. It is not suitable for use in the following cases:
 in explosive or easily flammable atmospheres.
 on machines or systems with long stopping times.

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Prerequisites for competent persons:
 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 relay and the machine.
 They have been instructed by the responsible person on the mounting and operation of the machine
and of the safety relay.
Manufacturer and operating company must ensure that the machine and implemented safety relay func-
tion 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 relay
 Imparting all relevant information to the operating company
 Adhering to all regulations and directives for the safe starting-up 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 persons
Leuze electronic GmbH + Co. KG is not liable in the following cases:
 Safety relay 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 (see chapter 9 Testing).
 Changes (e.g., constructional) are made to the safety relay

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The safety relay serves as a link between one or more safety-related sensors and the machine control.
These sensors may be
 type 4, type 3 or type 2 (self-testing) optoelectronic protective devices (AOPD)
 safety switches,
 safety locking devices,
 E-Stop buttons,
 safety rope switches or
 combinations of these sensors.
The safety relay includes a start/restart interlock that can be activated via the connection terminals, a
contactor monitoring function (EDM) and features two safety-related relay outputs (OSSDs) and LED
displays for status control.
Two terminal groups allow the safety relay to connect the sensors and signals their aggregate data via the
OSSDs. Only if the sensors are switched-on on both channels and on both terminal groups is it possible
to switch through - taking into account RES and EDM.
If one of the sensors switches off, this results in the immediate shutdown of the OSSDs of the safety relay.
With appropriate bridging (see table 7.1), the evaluation can be reduced to just one sensor.
The safety system consists of the safety relay and the safety components connected to it. It enables
machines or systems to achieve a safe state before persons can be endangered. Through the flexible eval-
uation of two - even different - sensors, the safety relay makes available a compact, economical safety
relay which, with Performance Level PL e in accordance with EN ISO 13849-1 and SIL 3 in accordance
with EN 61508:2001, satisfies the highest safety level.
Figure 3.1: MSI-SR5B with screw terminals Figure 3.2: MSI-SR5B with spring-cage terminals

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Figure 3.3: Internal circuit diagram
 Double sensor evaluation at two terminal groups
 1- or 2-channel E-Stop circuit
 Cross-circuit recognition
 Monitoring of external contactors in the reset circuit
 Monitored reset button (cross connections between the button contacts and earth faults in the button
circuit are detected.)
 Automatic or manual start/restart
 Stop category 0 (EN 60204-1:2006)
 2 release circuits
 LED displays Power, K1 and K2, reset
 Operating voltage 24 V AC/DC
 Housing width, 22.5 mm
 Removable connection terminal blocks (screw terminals, spring-cage terminals)
Four LEDs indicate the operating state of the safety relay.
N.O.
N.O.
29 31
30 32
14
K2
K1
5
CH1
CH2
~
=
+
24 16 713
MSI- SR5
21
22 23
15 8
&
(+24V)
(+S12)
(+S11)
(-S12)
(-S22)
(+S22)
(+S21)
(IV-O)
(RES-I)
(RES-O)
(0V-O)
(0V)
6