Rockwell Automation Guardmaster MSR57P User manual

User Manual Original Instructions
MSR57P Guardmaster Speed
Monitoring Safety
Catalog Number 440R-S845AER-NNL

2Rockwell Automation Publication 440R-UM004C-EN-P - October 2021
MSR57P Guardmaster Speed Monitoring Safety User Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
These labels may also be on or inside the equipment to provide specific precautions.
The following icon may appear in the text of this document.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation Publication 440R-UM004C-EN-P - October 2021 3
Table of Contents
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 1
Safety Concept Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Category 4 Performance Definition . . . . . . . . . . . . . . . . . . . . . 14
Stop Category Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Performance Level and Safety Integrity Level (SIL) 3 . . . . . . . . . . . . 14
Functional Proof Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PFD and PFH Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PFD and PFH Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safe State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety Reaction Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Considerations for Safety Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Output Pulse Test Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Considerations for Single-encoder Applications . . . . . . . . . . . . . . . . 17
Contact Information if Device Failure Occurs. . . . . . . . . . . . . . . . . . . . . . 18
Chapter 2
About the MSR57P Speed
Monitoring Safety Relay
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Safety Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disabled Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lock Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safe Maximum Speed, Safe Maximum Acceleration, and Safe
Direction Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hardware Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chapter 3
Installation and Wiring Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Environment and Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Considerations for Reducing Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mount the MSR57P Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removable Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4Rockwell Automation Publication 440R-UM004C-EN-P - October 2021
Table of Contents
Terminal Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Compatible Encoders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connect an Encoder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Encoder Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Feedback Cable Connections for Motion Control Applications. . . . . . . 33
Flying Lead Feedback Cable Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Wiring Low-profile Connector Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Feedback Connections for PowerFlex 70 Drives . . . . . . . . . . . . . . . . . . . . 39
Safe Torque Off Terminal Block (Enhanced Control Only) . . . . . . . 40
Encoder Interface Terminal Block (Enhanced Control Only) . . . . . 40
Feedback Connections for PowerFlex 700S Drives. . . . . . . . . . . . . . . . . . 41
Connect a Configuration Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chapter 4
Speed Monitoring I/O Signals Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Safe Stop Input (SS_In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Safely-limited Speed Input (SLS_In). . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Door Monitor Input (DM_In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Enabling Switch Monitor Input (ESM_In) . . . . . . . . . . . . . . . . . . . . . 45
Lock Monitor Input (LM_In). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Reset Input (Reset_In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Reset Loop Input (RL_In). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Safety Control Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Diagnostic Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 5
General Safety Relay and
Feedback Monitoring
Configuration
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Cascaded Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Safety Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Reset Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Reset Qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Overspeed Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Speed Resolution Accuracy for Rotary Systems . . . . . . . . . . . . . . . . . 56
Speed Resolution Accuracy for Linear Systems . . . . . . . . . . . . . . . . . 58
Language Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Max Display Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
General Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Feedback Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Feedback Polarity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Single Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Dual Encoders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Feedback Voltage Monitor Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Feedback Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Feedback Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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Table of Contents
Chapter 6
Safe Stop and Safe Stop with
Door Monitoring Modes
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Safe Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Safe Stop Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Standstill Speed and Position Tolerance . . . . . . . . . . . . . . . . . . . . . . . 70
Deceleration Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Safe Stop Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Door Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Lock Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Safe Stop Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Safe Stop Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Safe Stop with Door Monitoring Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Lock Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SS Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Safe Stop with Door Monitoring Parameter List. . . . . . . . . . . . . . . . . . . . 77
Safe Stop with Door Monitoring Wiring Example . . . . . . . . . . . . . . . . . . 78
Chapter 7
Safely-limited Speed (SLS)
Modes
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Safely-limited Speed (SLS) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Safely-limited Speed Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Safely-limited Speed Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Safely-limited Speed Wiring Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Safely-limited Speed with Door Monitoring Mode. . . . . . . . . . . . . . . . . . 82
Safely-limited Speed Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SLS with Door Monitoring Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . 83
SLS with Door Monitoring Wiring Example . . . . . . . . . . . . . . . . . . . . . . . 84
Safely-limited Speed with Enabling Switch Monitoring Mode . . . . . . . 84
Safe Stop Reset (SS Reset) and Safely-limited Speed Reset
(SLS Reset). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SLS with Enabling Switch Monitoring Parameter List . . . . . . . . . . . . . . 85
SLS with Enabling Switch Monitoring Wiring Example. . . . . . . . . . . . . 86
Safely-limited Speed with Door Monitoring and Enabling Switch
Monitoring Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Behavior During SLS Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Behavior While SLS Monitoring is Inactive. . . . . . . . . . . . . . . . . . . . . 87
Behavior During SLS Monitoring Delay. . . . . . . . . . . . . . . . . . . . . . . . 88
Safe Stop Reset (SS Reset) and Safely-limited Speed Reset
(SLS Reset). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
SLS with Door Monitoring and Enabling Switch Monitoring
Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
SLS with Door Monitoring and Enabling Switch Monitoring Wiring
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Safely-limited Speed Status Only Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Speed Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
SLS Status Only Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
SLS Status Only Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

6Rockwell Automation Publication 440R-UM004C-EN-P - October 2021
Table of Contents
Chapter 8
Slave Modes for Multi-axis
Cascaded Systems
Cascaded Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Slave, Safe Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Slave, Safe Stop Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Slave, Safe Stop Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Slave, Safely-limited Speed Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Slave, Safely-limited Speed Parameters List . . . . . . . . . . . . . . . . . . . . . . 100
Slave, Safely-limited Speed Wiring Examples . . . . . . . . . . . . . . . . . . . . . 100
Slave, Safely-limited Speed Status Only Mode. . . . . . . . . . . . . . . . . . . . . 102
Slave, Safely-limited Speed Status Only Parameter List . . . . . . . . . . . . 103
Slave, Safely-limited Speed Status Only Wiring Examples. . . . . . . . . . 103
Multi-axis Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Cascaded System Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Chapter 9
Safe Maximum Speed and
Direction Monitoring
Safe Maximum Speed (SMS) Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . 113
Safe Maximum Acceleration (SMA) Monitoring . . . . . . . . . . . . . . . . . . . 115
Safe Direction Monitoring (SDM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Max Speed, Max Accel, and Direction Monitoring Parameter List. . . 119
Chapter 10
Safety Configuration and
Verification
Safety Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Configuration Signature ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Safety-lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Set a Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Reset the Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Reset the Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Basics of Application Development and Testing. . . . . . . . . . . . . . . . . . . 123
Commissioning the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Specify the Safety Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Configure the Speed Monitoring Safety Relay . . . . . . . . . . . . . . . . . 124
Project Verification Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Confirm the Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Safety Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Verify the Signature and Lock at the Speed Monitoring
Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Editing the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Chapter 11
Configuration Examples Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Example Application 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Initial Security Group Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
General Group Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Feedback Group Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Stop Group Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Limited Speed Group Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Door Control Group Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Max Speed Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Rockwell Automation Publication 440R-UM004C-EN-P - October 2021 7
Table of Contents
Final Security Group Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Example Application 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Initial Security Group Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
General Group Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Feedback Group Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Stop Group Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Limited Speed Group Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Door Control Group Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Max Speed Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Final Security Group Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Chapter 12
Troubleshootthe MSR57P Safety
Relay
Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Nonrecoverable Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Fault Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Input and Output Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Fault Codes and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Fault Reactions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Safe State Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Stop Category Faults and Fault While Stopping Faults . . . . . . . . . 146
Status Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Guard Status Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
I/O Diagnostic Status Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Configuration Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Appendix A
Specifications General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Encoder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Appendix B
Parameter Data Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Parameters and Settings in a Linear List . . . . . . . . . . . . . . . . . . . . . . . . . 154
Appendix C
Using a HIM Connect a HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Setting Parameters with a HIM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Accessing the Fault History Queue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Appendix D
Use DriveExplorer or
DriveExecutive Software
Connect a Personal Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Using DriveExplorer Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Configure Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Edit Parameters in DriveExplorer Software . . . . . . . . . . . . . . . . . . . 164
Access the Fault History Queue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Using DriveExecutive Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

8Rockwell Automation Publication 440R-UM004C-EN-P - October 2021
Table of Contents
Configure Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Edit Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Appendix E
Application Examples Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
PowerFlex 70 Drive with Safe Torque Off Application Example . . . . . 169
PowerFlex 700 Drive without Safe Torque Off. . . . . . . . . . . . . . . . . . . . . 172
Kinetix 6000 or Kinetix 7000 Drives with
Safe Torque Off Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Kinetix 2000 Drive without Safe Torque Off Example . . . . . . . . . . . . . 176
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Rockwell Automation Publication 440R-UM004C-EN-P - October 2021 9
Preface
About This Publication This manual explains how the Guardmaster MSR57P Speed Monitoring Safety
Relay can be used in Safety Integrity Level (SIL) 3, Performance Level (PLe), or
Category (CAT) 4 applications. It describes the safety requirements, including
PFD and PFH values and application verification information, and provides
information on how to install, configure, and troubleshoot the safety relay.
Summary of Changes This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.
Who Should Use This
Manual
Use this manual if you are responsible for design, installation, configuration,
or troubleshooting safety applications that use the MSR57P Speed Monitoring
Safety Relay.
You must have a basic understanding of electrical circuitry and familiarity
with relay logic. You must also be trained and experienced in the creation,
operation, and maintenance of safety systems.
Conventions This manual lists configuration parameters by number, followed by the name
in brackets. For example, P24 [OverSpd Response].
Topic Page
Updated certification information 14, 25

10 Rockwell Automation Publication 440R-UM004C-EN-P - October 2021
Preface
Terminology The following table defines terms that are used in this manual.
Abbreviation Full Term Definition
1oo2 One out of Two Refers to the behavioral design of a dual-channel safety system.
CAT Category —
DC Door Control —
DM Door Monitoring —
EN European Norm The official European Standard.
ESM Enabling Switch Monitoring —
ESPE Electro-sensitive Protective Equipment
An assembly of devices and/or components working together for protective tripping or
presence-sensing purposes and comprise as a minimum:
•Sensingdevice
• Controlling/monitoring devices
• Output signal-switching devices (OSSD).
FMEA Failure Mode and Effects Analysis Analysis of potential failure modes to determine the effect upon the system and identify ways
to mitigate those effects.
IEC International Electrotechnical Commission —
IGBT Insulated Gate Bipolar Transistor —
HFT Hardware Fault Tolerance The HFT equals n, where n+1 faults could cause the loss of the safety function. An HFT of 1
means that two faults are required before safety is lost.
HIM Human Interface Module A module used to configure a device.
LM Lock Monitoring —
MP Motion Power —
OSSD Output Signal Switching Device The component of the electro-sensitive protective equipment (ESPE) connected to the control system of a machine, which, when the sensing device is actuated during normal operation,
responds by going to the off state.
PC Personal Computer Computer used to interface with and program your safety system.
PFD Probability of a Dangerous Failure On
Demand The average probability of a system to fail to perform its design function on demand.
PFH Average Frequency of a Dangerous Failure
per Hour (Probability of Failure per Hour) The probability of a system to have a dangerous failure occur per hour.
PL Performance Level ISO 13849-1 safety rating
RL Reset Loop —
SDM Safe Direction Monitoring —
SFF Safe Failure Fraction The sum of safe failures plus the sum of dangerous detected failures that are divided by the
sum of all failures.
SIL Safety Integrity Level A measure of a products ability to lower the risk that a dangerous failure could occur.
SLS Safely-limited Speed —
SMA Safe Maximum Acceleration —
SMS Safe Maximum Speed —
SS Safe Stop —
STO State Torque Off —