Phoenix Contact PSR-MM35 User manual

Original operating instructions
PSR-MM35 sensorless over-speed safety relay
with PSRmotion configuration software

2022-03-03
PHOENIX CONTACT GmbH & Co. KG • Flachsmarktstraße 8 • 32825 Blomberg • Germany
phoenixcontact.com
110272_en_01
PSR-MM35 sensorless over-speed safety relay
with PSRmotion configuration software
Designation Revision Article No.
PSR-MM35-1NO-1DO-24DC-SC 00/100 1249515
PSR-MM35-1NO-1DO-24DC-SP 00/100 1249516
The items listed are all referred to in this user manual by the designation PSR-MM35.
Original operating instructions
This manual is valid for:
UM EN PSR-MM35, Revision 01

Table of contents
110272_en_01 PHOENIX CONTACT 3 / 86
Table of contents
1 For your safety............................................................................................................................6
1.1 Identification of warning notes ............................................................................... 6
1.2 Qualification of users ............................................................................................. 6
1.3 Field of application of the product.......................................................................... 7
1.3.1 Intended use .......................................................................................... 7
1.3.2 Foreseeable misuse ............................................................................... 8
1.3.3 Product changes .................................................................................... 8
1.4 Safety notes .......................................................................................................... 9
1.4.1 General safety notes ............................................................................. 9
1.4.2 Electrical safety .................................................................................... 10
1.4.3 Safety of machines or systems ............................................................ 12
1.4.4 Safety when starting applications ......................................................... 13
1.5 Directives and standards..................................................................................... 13
1.6 Documentation .................................................................................................... 13
1.7 Safety hotline....................................................................................................... 13
2 Product description and method of operation ...........................................................................14
2.1 Product features .................................................................................................. 14
2.2 Structure.............................................................................................................. 14
2.2.1 Connection assignment ....................................................................... 16
2.3 Inputs and outputs............................................................................................... 17
2.3.1 24 V supply connection ........................................................................ 17
2.3.2 Acknowledgment input .........................................................................17
2.3.3 Enabling current path ........................................................................... 17
2.3.4 Signal output ........................................................................................ 18
2.3.5 Micro USB port .................................................................................... 18
2.4 Function description ............................................................................................ 19
2.4.1 Acknowledgment function .................................................................... 19
2.4.2 Speed monitoring ................................................................................. 20
2.4.3 Without startup monitoring ................................................................... 21
2.4.4 Startup monitoring ................................................................................ 22
2.4.5 Switch-on and switch-off delay ............................................................ 24
2.4.6 Operating states .................................................................................. 25
2.4.7 Diagnostic functions ............................................................................. 26
2.4.8 Safe state ............................................................................................. 26
2.4.9 Behavior in the event of an error .......................................................... 26

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3 Mounting and removal ..............................................................................................................27
3.1 Assembly notes ................................................................................................... 27
3.2 Mounting work..................................................................................................... 28
3.3 Removal work...................................................................................................... 28
4 Electrical connection.................................................................................................................29
4.1 Connection notes ................................................................................................ 29
4.2 Wiring of the connection terminal blocks .............................................................30
4.3 Arrangement of the measuring cables................................................................. 31
5 Configuration and startup..........................................................................................................32
5.1 System requirements........................................................................................... 32
5.2 Installing the configuration software..................................................................... 33
5.3 Connection to the PC........................................................................................... 33
5.4 User interfaces ....................................................................................................34
5.4.1 Start screen ......................................................................................... 34
5.4.2 Layout of the user interface .................................................................. 35
5.5 Creating a project ................................................................................................ 37
5.6 Saving the project................................................................................................ 38
5.7 Reading a project ................................................................................................ 40
5.8 Device configuration............................................................................................ 41
5.8.1 Configuration ....................................................................................... 41
5.8.2 Parameterization .................................................................................. 42
5.8.3 Advanced settings ............................................................................... 46
5.8.4 Parameterization of machine data ........................................................ 49
5.8.5 Password settings ................................................................................ 50
5.9 Diagnosis............................................................................................................. 51
5.9.1 Latch data ............................................................................................ 52
5.9.2 System data ......................................................................................... 53
5.9.3 Validation ............................................................................................. 54
6 Function test .............................................................................................................................55
6.1 Performing the function test................................................................................. 55
6.1.1 Function test A: Shutdown in the event of over-speed ......................... 56
6.1.2 Function test B: Shutdown in the event of under-speed ....................... 56
7 Maintenance, repair, decommissioning, and disposal ..............................................................57
7.1 Maintenance........................................................................................................ 57
7.2 Repairs ................................................................................................................ 57
7.3 Decommissioning and disposal........................................................................... 57

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8 Errors: Messages and removal .................................................................................................58
8.1 Status indicator.................................................................................................... 58
8.2 Error message and LED error codes ................................................................... 59
8.3 Remedy in the event of an error........................................................................... 61
9 Application examples................................................................................................................62
9.1 Application information ........................................................................................ 62
9.1.1 General information ............................................................................. 62
9.2 Speed monitoring of a 3-phase motor.................................................................. 62
9.3 Speed monitoring of a 1-phase motor.................................................................. 64
9.4 Zero-speed and speed monitoring of a
3-phase motor ..................................................................................................... 66
10 Technical data and ordering data .............................................................................................68
10.1 Technical data..................................................................................................... 68
10.1.1 Derating ............................................................................................... 72
10.1.2 Load curve ........................................................................................... 73
10.1.3 Insulation coordination ......................................................................... 74
10.1.4 Electrical service life ............................................................................ 75
10.1.5 Interface types according to ZVEI classification ................................... 76
10.2 Approvals ............................................................................................................ 78
10.3 Ordering data ...................................................................................................... 78
A Technical appendix...................................................................................................................79
A 1 Calculating the power dissipation ....................................................................... 79
A 2 Shutdown time of the safety function .................................................................. 80
B Revision history ........................................................................................................................84

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1 For your safety
Read this user manual carefully and keep it for future reference.
1.1 Identification of warning notes
1.2 Qualification of users
The use of products described in this user manual is oriented exclusively to:
– Qualified personnel who plan and design safety equipment for machines and systems
and are familiar with regulations governing occupational safety and accident
prevention.
– Qualified personnel who install and operate safety equipment in machines and
systems.
Qualified personnel Qualified personnel are people who, because of their education, experience, and
instruction and their knowledge of relevant standards, regulations, accident prevention, and
service conditions, have been authorized by those responsible for the safety of the system
to carry out any required operations and who are able to recognize and avoid any possible
dangers.
Requirements Knowledge of the following topics is required:
– Handling of safety components
– Applicable EMC regulations
– Applicable regulations governing occupational safety and accident prevention
This symbol indicates hazards that could lead to personal injury.
There are three signal words indicating the severity of a potential injury.
DANGER
Indicates a hazard with a high risk level. If this hazardous situation is not
avoided, it will result in death or serious injury.
WARNING
Indicates a hazard with a medium risk level. If this hazardous situation is not
avoided, it could result in death or serious injury.
CAUTION
Indicates a hazard with a low risk level. If this hazardous situation is not avoided,
it could result in minor or moderate injury.
This symbol together with the NOTE signal word warns the reader of actions
that might cause property damage or a malfunction.
Here you will find additional information or detailed sources of information.

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1.3 Field of application of the product
Only use the safety relay module in accordance with the area of application described in this
section.
1.3.1 Intended use
PSR-MM35 is a safety relay module for sensorless speed monitoring on 3- and 1-phase
motors. PSR-MM35 detects and monitors a minimum speed, a maximum speed, or a speed
range.
Safety functions The safety relay module can perform various safety functions:
– Monitoring of a minimum speed
– Monitoring of a maximum speed
– Monitoring of a speed range
Possible signal
generators
An external signal generator does not need to be connected. The safety relay module is
connected parallel to the motor phases.
Safe shutdown The safety relay module safely interrupts circuits.
 See “Safe state” on page 26.
Safety functions in
accordance with
EN 61800-5-2
With the appropriate wiring and suitable additional components (sensors and actuators),
the safety relay module supports the following safety functions in accordance with
EN 61800-5-2:
– STO (safe torque off)
– SLS (safe limited speed)
– SSM (safe speed monitor)
– SSR (safe speed range)
Achievable safety
integrity
Within a system, the PSR-MM35 safety relay module can be used to achieve the following
safety integrity depending on the conditions of use:
– Up to SIL 3 in accordance with IEC 61508 and EN 62061
– Up to Cat. 4/PL e in accordance with EN ISO 13849
To ensure that the safety relay module is able to perform its safety-related tasks within the
system, integrate the safety relay module into the execution process in a correct and failsafe
manner.
Configuration software The safety relay module is configured using the PSRmotion configuration software.
 See “Configuration and startup” on page 32.
DANGER: The technology is not suitable for every application
–You must ensure, on an application-specific basis, that motion is
stopped when the motor is shut down (STO). Applications in which
motion continues or is accelerated when the motor is shut down (STO),
e.g., suspended loads, are not suitable for sensorless measurement
technology.
–The frequency measurement process will not detect a mechanically
blocked motor or overloaded motor.

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Technical data and
environmental conditions
Only use the device in accordance with the defined technical data and environmental
conditions.
 See “Technical data” on page 68.
Application examples The safety relay module is used for the following applications, for example:
– Use in safety circuits in accordance with EN 60204 Part 1
– Applications for the safe shutdown of electrical loads, e.g., contactors or valves
1.3.2 Foreseeable misuse
1.3.3 Product changes
Modifications to hardware and firmware of the device are not permitted.
Incorrect operation or modifications to the device can endanger your safety or damage the
device. Do not repair the device yourself. If the device is defective, please contact
Phoenix Contact.
WARNING: Serious risks for the user
• Make sure that the safety relay module is always used properly.
• Only use the safety relay module for its intended purpose.
• Prevent any tampering on the safety relay module.

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1.4 Safety notes
1.4.1 General safety notes
Documentation
Safety of personnel and
property
The safety of personnel and property can only be assured if the safety relay module is used
correctly.
 See “Intended use” on page 7.
Startup, mounting, and
modifications
Startup, mounting, modifications, and upgrades may only be carried out by qualified
personnel.
Defective devices The devices may be damaged following an error. Correct operation can no longer be
ensured.
• In the event of an error, replace the device.
Do not open the housing Only the manufacturer or their authorized representative may perform the following
activities. Otherwise, the warranty is invalidated.
– Repairs to the device
– Opening the housing
Decommissioning and
disposal
• Dispose of the device in accordance with environmental regulations.
• Make sure that the device can never be reused.
WARNING: Serious risks due to improper use
Depending on the application, improper use of the safety relay module
may pose serious risks for the user.
• Observe the safety notes in this section.
• Observe the warning instructions provided elsewhere in this document.
Observe all information in this user manual and the accompanying documents.
See “Documentation” on page 13.

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1.4.2 Electrical safety
Electrical connection Electrical connection may only be performed by qualified personnel.
Mismatching and polarity
reversal of connections
• Take measures to prevent mismatching, polarity reversal, and manipulation of
connections.
PELV power supply Insulate all electrical connections from the mains using suitable measures.
• Observe the requirements of EN 60204-1, Section 6.4.
• Only use power supply units with safe isolation and SELV/PELV.
• Use the same power source for all devices that are electrically connected to the safety
relay module.
• Make sure that the output voltage of the power supply does not exceed 32 V, even in
the event of an error.
Ground connection • Use the same ground for all devices that are electrically connected to the safety relay
module.
Fuse protection for the
power supply
• Protect the power supply with a suitable external fuse.
• Make sure that the power supply unit is able to supply four times the nominal current
of the external fuse. This ensures safe tripping in the event of an error.
Direct / indirect contact • Protection against direct and indirect contact in accordance with VDE 0100 Part 410
must be ensured for all components connected to the system.
In the event of an error, parasitic voltages must not occur (single-fault tolerance).
Do not remove protective
covers
During operation, parts of the electrical switching devices may carry hazardous voltages.
• Protective covers must not be removed when operating electrical switching devices.
WARNING: Loss of safety function and hazardous shock currents
Incorrect installation can result in the loss of the safety function as well as
hazardous shock currents. Depending on the application, there may be
serious risks for the user.
• Observe the notes on electrical safety.
• Observe the warning instructions provided elsewhere in this document.
• Plan the devices used and their installation in the system according to the
specific requirements.
• Recheck plants and systems that have been retrofitted with the safety relay
module.

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Protective circuit in the
case of inductive loads
All electrical outputs require an adequate protective circuit in the case of inductive loads.
• Connect a suitable and effective protective circuit.
• Implement the protective circuit parallel to the load.
Sources of interference
from magnetic fields
Magnetic fields can influence the device. The magnetic field strength of the environment
must not exceed 30 A/m.
• Do not use the device in the vicinity of strong magnetic fields (e.g., caused by
transformers or magnetic iron).
Electromagnetic
interference
The device is a Class A product.
• Observe the requirements for noise emission for electrical and electronic equipment
(EN 61000-6-4).
• Implement appropriate protective measures against noise emission.
Installation space and
mounting position
Reliable operation is only ensured if the device is installed in housing protected from dust
and humidity.
• Observe the requirements for the installation space and mounting position as specified
in the technical data.
Insulation rating The safety relay module is designed for overvoltage category II (600 V) or III (300 V) in
accordance with EN 60664-1.
• When selecting the equipment, please take into consideration the dirt and overvoltages
which may occur during operation.
• If you expect overvoltages in the system that exceed the values defined for the relevant
overvoltage category, take additional measures for voltage limitation.
ESD information
NOTE: Electrostatic discharge
Electrostatic discharge can damage or destroy components. When
handling the device, observe the necessary safety precautions against
electrostatic discharge (ESD) in accordance with EN 61340-5-1 and
IEC 61340-5-1.

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1.4.3 Safety of machines or systems
Draw up and implement a
safety concept
The machine/system manufacturer and the operator are responsible for the safety of the
machine or system and the application in which the machine or system is used. In order to
use the device described in this document, you must have drawn up an appropriate safety
concept for your machine or system. This includes a hazard and risk analysis in accordance
with the directives and standards specified in section “Directives and standards”
on page 13.
Risk assessment,
validation, and function
test
• Before using the device, perform a risk assessment for the machine or system.
• Validate your entire safety system.
• Carry out a new validation every time you make a safety-related modification.
• Perform function tests on a regular basis.
Achievable safety
integrity
Functional safety is guaranteed for the device as a single component. However, this does
not guarantee functional safety for the entire machine or system. In order to achieve the
desired safety level for the entire machine or system, define the safety requirements for the
machine or system as well as how to implement them from both a technological and
organizational perspective.
Target safety integrity The target safety integrity is ascertained on the basis of the risk analysis.
– SIL in accordance with IEC 61508 and EN 62061
– Cat./PL in accordance with EN ISO 13849-1
The safety integrity ascertained determines how to connect and parameterize the safety
relay module within the overall safety function.
Safety-related equipment In order to use the safety relay module properly, safety-related equipment must be provided
on the machine.
This includes the following:
– Safety switch
– Enable switch
– Mode selector switch
Checking hardware and
parameterization
You must carry out a validation every time you make a safety-related modification to your
overall system.
Use your test report to ensure that the following conditions are met:
– The safe devices are connected to the correct safe sensors and actuators.
–The safety functions have been wired correctly.

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1.4.4 Safety when starting applications
Start conditions Take the following into consideration when determining the start conditions for your
machine or system:
– The machine or system may only be started if nobody is present in the danger zone.
– If required: Meet the requirements of EN ISO 13849-1 with regar d to the manual reset
function.
Pressing a reset button must not cause automatic startup of a dangerous machine
function.
1.5 Directives and standards
The directives and standards complied with by the safety relay module can be found in the
certificate issued by the approval body and in the EC declaration of conformity.
These documents are available on the Internet.
See phoenixcontact.net/products.
1.6 Documentation
Latest documentation Always use the latest documentation. Changes or additions to documentation can be found
on the Internet.
See phoenixcontact.net/products.
Also observe the documentation for all other devices used together with the safety relay
module.
1.7 Safety hotline
Should you have any technical questions, contact our 24-hour hotline.
Phone: [phone]
E-mail: [e-mail]

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2 Product description and method of operation
2.1 Product features
The PSR-MM35 safety relay module offer the following features:
– Monitoring of a minimum and maximum speed and of a speed range
– Easy parameterization and online diagnostics using the PSRmotion software, which
can be downloaded free of charge
– Narrow overall width of 12.5 mm
– Force-guided relay contacts, start input, and signal output
– Standard USB port (micro USB type B)
– Suitable up to Cat. 4/PL e in accordance with EN ISO 13849-1 and SIL 3 in accordance
with EN 62061
2.2 Structure
Product image Figure 2-1 PSR-MM35 safety relay module
Key:
1COMBICON plug-in screw terminal block
2COMBICON plug-in spring-cage terminal
block
3Connection designations
4Operating and status indicators
5Micro USB port, type B
6Snap-on foot for fixing on the
DIN rail
PHOENIX CONTACTGmbH&CO.KG
32825 Blomberg, Germany
Docume n t at i o n
XX/XX
Docu me n t a t i o n
XX/ XX
PSR Safety Relays
PHOENI X CONT ACT GmbH & Co.KG
Flach sm a r k t s t r aß e 8
32825 Blo mb e r g , G er m a ny
1 2
3
4
5
6

Product description and method of operation
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Housing and terminal
blocks
The safety relay module consists of a 12.5 mm wide ME-MAX housing with COMBICON
plug-in connection terminal blocks.
The safety relay module is available in two different terminal block versions.
Connection assignment Information about the connection assignment of the terminal blocks can be found on the
front of the safety relay module.
Micro USB port A micro USB port, type B, can be accessed under the hinged front cover.
LED indicators The safety relay module has two LED indicators on the front.
The LED indicators show the general states and error messages of the safety relay module.
 See “Errors: Messages and removal” on page 58.
DIN rail mounting On the back of the safety relay module, there is a snap-in mechanism for DIN rail mounting
in the control cabinet.
Printing The printing on the side of the device provides the relevant device data and manufacturer’s
information.
Year of manufacture The device’s year of manufacture is located below the CE marking.
Plug-in screw terminal block PSR-MM35-...-SC
Plug-in spring-cage terminal block PSR-MM35-...-SP
For the exact housing dimensions for both terminal block versions, refer to the
technical data.
See “Technical data” on page 68.
PWR Operating voltage indicator
OUT Status indicator for enabling current path 13/14

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2.2.1 Connection assignment
For the assignment of the connections and LED indicators, please refer to the table below.
Front view Table 2-1 Connection designations and indicators
Block diagram Figure 2-2 Block diagram
L1/L2/L3 Measurement inputs
PWR LED Operating voltage indicator
OUT LED Status indicator for enabling current path 13/14
USB Micro USB port, type B, for connection to the PC for parameterization
A1 24 V DC power supply
A2 GND power supply
S34 Acknowledgment input
MO Signal output
13/14 Enabling current path (1 N/O contact)
L1
L2
L3
PS R-MM35
A1
S34
13
A2
MO
14
OUT
PWR
S34
A1
A2
OUT
K1
K2
24 VDC
PSR-MM35
PWR
MO
L1 L2 L3 13
14

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2.3 Inputs and outputs
This section contains information and notes regarding the function and wiring of the inputs
and outputs of the safety relay module.
2.3.1 24 V supply connection
Designation: A1, A2
Power supply Supply the safety relay module with appropriate voltage via connections A1 and A2.
• When doing so, observe the requirements for the power supply.
• Protect the power supply with a suitable external fuse.
 See “Electrical safety” on page 10.
2.3.2 Acknowledgment input
Designation: S34
Depending on the wiring and parameterization of acknowledgment input S34, enabling
current path 13/14 offers two possible types of startup behavior for speed monitoring:
– Automatic
– Manual, monitored
See Section “Acknowledgment function” on page 19.
2.3.3 Enabling current path
Designation: 13/14
The safety relay module has a safe enabling current path. The enabling current path
features a redundant internal design with safety relays. It is a 2-channel N/O contact.
Stop category 0 / 1 The enabling current path is configurable (with switch-on or switch-off delay) according to
stop category 0 and stop category 1 in accordance with EN 60204-1.
Protective circuit Please refer to “Protective circuit in the case of inductive loads” on page 11.
Observe the technical data for the inputs and outputs.
See “Technical data” on page 68.

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2.3.4 Signal output
Designation: MO
You can use the signal output to control a standard PLC or signaling units, for example.
The signal output has the following properties:
– Digital
– PNP
– Non-isolated
– Short-circuit-proof
– Non-safety-related
Signal output MO indicates the state of the enabling current path. It switches 24 V when the
enabling current path is closed.
2.3.5 Micro USB port
Connect the safety relay module to the PC via the micro USB port (standard USB 2.0).
The PC connection is required for the following actions:
– Downloading the configuration data
– Uploading the configuration as a project in the configuration software. You can open
and edit the project in the configuration software.
– Reading values from the safety relay module during operation, diagnostic display in the
configuration software (online mode)
Suitable cables The interface is suitable for standard micro USB type B cables.
 See “Ordering data” on page 78.
WARNING: Loss of the safety function due to incorrect wiring
The signal outputs are not safety-related.
• Do not use the signal output as a safety output.
NOTE: Module damage
Incorrect wiring can destroy the signal output.
• Prevent feedback at the signal output.
Make sure that the GND potential of the signal receiver is the same as the GND
potential of the safety module.
The USB interface is not intended for permanent connection to a PC.
NOTE: Electrostatic discharge
Electrostatic discharge can damage or destroy components. When handling
the device, observe the necessary safety precautions against electrostatic
discharge (ESD) in accordance with EN 61340-5-1 and IEC 61340-5-1.

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2.4 Function description
The 2-channel evaluation unit of the safety relay module measures the frequency of the
rotating field on the motor at measurement inputs L1, L2, and L3.
In the event of an underrange or overrange of the parameterized frequencies (fmin and fmax),
an internal error, or an external error, enabling current path 13/14 opens immediately. The
device is in the safe switching state.
The device has a standard micro USB port as the interface to the PC. The configuration
software provided enables easy parameterization and online diagnostics.
Start on machine
standstill
When the operating voltage (24 V DC) is applied at terminal blocks A1 and A2, the safety
relay module performs a self-test. The safety relay module is in the safe state for the
duration of the self-test. The enabling current path is open.
The device is ready to operate following a successful self-test. The PWR LED lights up
green.
2.4.1 Acknowledgment function
The acknowledgment function allows the module to be returned to operational readiness
following a shutdown due to under- or over-speed. If neither of the above states is present,
the reset is performed via input S34 on the module.
Automatic or manual acknowledgment is possible. In the case of automatic
acknowledgment, input S34 must be constantly connected to 24 V DC.
Autostart for enabling
current path 13/14
To implement the autostart for enabling current path 13/14, proceed as follows:
• Connect a constant 24 V DC voltage to acknowledgment input S34.
• Parameterize acknowledgment input S34 accordingly in the configuration software.
 See “Acknowledgment and startup monitoring” on page 45.
Manual start for enabling
current path 13/14
To implement the manual monitored start for enabling current path 13/14, proceed as
follows:
• Connect a start enable button (reset button) to acknowledgment input S34.
• Parameterize acknowledgment input S34 accordingly in the configuration software.
 See “Acknowledgment and startup monitoring” on page 45.
Start pulse
Manual monitored acknowledgment takes place on a falling edge of a 24 V signal (release
of the reset button). The acknowledgment signal is subject to time monitoring: The 24 V
signal must be applied at input S34 for min 200 ms and max. 10 s.
 See “Safe state” on page 26.

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2.4.2 Speed monitoring
The following monitoring functions are possible:
– Monitoring only for maximum speed
– Monitoring of a speed range with startup monitoring
– Monitoring of a speed range without startup monitoring
Parameterization The fmax (maximum frequency) and fmin (minimum frequency) parameters define the motor
speed limits that are to be monitored. The fmax and fmin cut-off frequencies are calculated
from speed n and the number of pole pairs of the motor:
f [Hz] = (n [rpm] / 60) x NumberPole pairs
Example: 5000 revolutions per minute x 3 pole pairs / 60 = 250 Hz
On asynchronous motors, load-dependent slippage occurs between the motor speed and
the rotating field frequency. This slippage must be taken into consideration for the
parameterization of the frequencies (fmax and fmin).
See Section “Frequencies” on page 43.
Minimum frequency (fmin)If fmin is not reached, the output contacts (13-14) switch off.
They are switched on again following acknowledgment via acknowledgment input S34.
The conditions for switching on again differ according to the type of acknowledgment. See
Section “Without startup monitoring” on page 21.
You can disable monitoring for a minimum frequency. The output contacts then remain
closed at standstill.
Maximum frequency (fmax)If fmax is exceeded, the output contacts (13-14) switch off.
They are switched on again following acknowledgment via acknowledgment input S34 and
when the value is below fmax-Hys.
NOTE
The frequency measurement process will not detect a mechanically blocked
motor or overloaded motor.