Leuze MSI-m/R User manual

MSI-m/R
MSI-mE/R
Modular safety interface
Original operating instructions
EN • 2020-07-22 • 603501
We reserve the right to make technical changes

Leuze electronic GmbH + Co. KG MSI-m(E)/R 2
© 2020
Leuze electronic GmbH & Co. KG

Leuze electronic GmbH + Co. KG MSI-m(E)/R 3
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 4
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

About this document
Leuze electronic GmbH + Co. KG MSI-m(E)/R 5
1About this document
These connecting and operating instructions contain information on the approved purpose and use of MSI
safety interfaces.
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.
ATTENTION!
All information provided in the connecting and operating instructions, especially the Safety
Notices, must be observed.

System overview and range of applications
Leuze electronic GmbH + Co. KG MSI-m(E)/R 6
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
2.3 Terminology
Europe
EC Type Examination
TÜV SÜD
AOPD Active Optoelectronic Protective Device
Diagn. Diagnosis Function
EDM External Device Monitoring
Contactor 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
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

System overview and range of applications
Leuze electronic GmbH + Co. KG MSI-m(E)/R 7
2.4 Nomenclature MSI-m(E)/R
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.
(I/O-m module)
Warning muting indicator defective
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

Safety
Leuze electronic GmbH + Co. KG MSI-m(E)/R 8
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, docu-
ment "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)
3.1 Intended use and foreseeable misuse
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 PLr ascertained in the risk assessment.
The following table shows the safety-related characteristic parameters of the MSI-m(E)/R modular safety
interfaces.
NOTE
Local agencies can also provide safety-relevant information (e.g. occupational safety and
health inspectorate, employer's liability insurance association, labor inspectorate, OSHA).
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.

Safety
Leuze electronic GmbH + Co. KG MSI-m(E)/R 9
• 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 addi-
tion 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
Type in accordance with EN 61496-1 Type 4
SIL in accordance with EN 61508 SIL 3
Performance Level (PL) in accordance with
EN ISO 13849-1:2015
PL e
Category in accordance with
EN ISO 13849-1:2015
Cat. 4
Mean probability of a dangerous failure per hour
(PFHd) as a function of the mean number of
annual switching cycles of the relay nop*
100% Load nop = 4,800: 1.5 x 10-08 1/h
60% Load nop = 4,800: 1.2 x 10-08 1/h
100% Load nop = 28,800: 3.1 x 10-08 1/h
60% Load nop = 28,800: 1.5 x 10-08 1/h
100% Load nop = 86,400: 7.4 x 10-08 1/h
60% Load nop = 86,400: 2.1 x 10-08 1/h
*nop = mean number of annual actuations, see C.4.2 and C.4.3 of EN ISO 13849-1:2015
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:
hop = mean operating time in hours per day
dop = mean operating time in days per year
tcycle = mean operating time between the start of two successive cycles of the component (e.g switch-
ing of a valve) in seconds per cycle
nop dop hop 3600 s/htZyklus =

Safety
Leuze electronic GmbH + Co. KG MSI-m(E)/R 10
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
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 prop-
erly 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.
ATTENTION!
Such instances can jeopardize the health and lives of the personnel operating the machinery
and/or may cause damage to property.