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 —

Rockwell Automation Publication 440R-UM004C-EN-P - October 2021 11
Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
Resource Description
Guardmaster MSR57P Speed Monitoring Safety Relay Installation Instructions,
publication
440R-IN016
Provides information on installation of the MSR57P safety relay.
HIM Quick Reference, publication
20HIM-QR001 A quick reference for using the HIM keypad.
PowerFlex 1203-USB Converter User Manual, publication DRIVES-UM001
Provides detailed information on installation, configuration, and troubleshooting the
1203-USB converter.
PowerFlex Smart Self-powered Serial Converter User Manual, publication
20COMM-UM001
Provides detailed information on installation, configuration, and troubleshooting the
1203-SSS Series B serial converter.
PowerFlex 700S Phase II Drive User Manual, publication
20D-UM006
Provides detailed information on installation, wiring, programming, and troubleshooting
PowerFlex® 700S Phase II drives.
PowerFlex 700 AC Drives – Series A, Frames 0…6 User Manual, publication
20B-UM001
Provides detailed information on installation, wiring, programming, and troubleshooting
PowerFlex 700 Series A drives.
PowerFlex 700 AC Drives – Frames 0…10 User Manual, publication
20B-UM002
Provides detailed information on installation, wiring, programming, and troubleshooting
PowerFlex 700 Series B drives.
PowerFlex 70 Adjustable Frequency AC Drives User Manual, publication
20A-UM001
Provides detailed information on installation, wiring, programming, and troubleshooting
PowerFlex 70 drives.
PowerFlex 70/700 Adjustable Frequency AC Drives Reference Manual,
publication PFLEX-RM001
Provides specifications and dimensions, and detailed information about drive operation.
DriveGuard Safe Torque Off Option (Series B) for PowerFlex 40P and
PowerFlex 70 User Manual, publication
PFLEX-UM003
Provides detailed information installation, wiring, and operating PowerFlex 70 AC drives with
the Safe Torque Off option. The manual also includes certification information for the
Safe-Off option.
Kinetix 6000 Multi-axis Servo Drive User Manual, publication
2094-UM001
Provides detailed information on installation, connection, configuration, and
troubleshooting a Kinetix® 6000 drive. The manual also includes specifications and
dimensions.
Kinetix Safe Torque Off Feature Reference Manual, publication
GMC-RM002
Provides detailed information on the safety requirements, and connector and wiring
diagrams for the Safe Torque Off feature.
Kinetix Motion Control Selection Guide, publication GMC-SG001
Provides features, specifications, and dimensions for selecting Kinetix Motion Control servo
drives, motors, actuators, and accessory components.
Ultra3000 Digital Servo Drives Installation Manual, publication
2098-IN003 Provides information on installation and wiring for the Ultra™ 3000 Digital Servo Drives.
Ultra3000 Digital Servo Drives Integration Manual, publication
2098-IN005
Provides power-up procedures, system integration, and troubleshooting tables for the
Ultra 3000 Digital Servo Drives.
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-State Control, publication SGI-1.1
Describes important differences between solid-state control and hard-wired
electromechanical devices.
EtherNet/IP Network Devices User Manual, publication ENET-UM006 Describes how to configure and use EtherNet/IP™ devices to communicate on the
EtherNet/IP network.
Ethernet Reference Manual, publication ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
System Security Design Guidelines Reference Manual, publication SECURE-
RM001
Provides guidance on how to conduct security assessments, implement Rockwell
Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
UL Standards Listing for Industrial Control Products,
publication CMPNTS-SR002 Assists original equipment manufacturers (OEMs) with construction of panels, to help
confirm that they conform to the requirements of Underwriters Laboratories.
American Standards, Configurations, and Ratings: Introduction to
Motor Circuit Design, publication IC-AT001 Provides an overview of American motor circuit design that is based on methods that are
outlined in the NEC.
Industrial Components Preventive Maintenance, Enclosures, and Contact
Ratings Specifications, publication IC-TD002 Provides a quick reference tool for Allen-Bradley® industrial automation controls and assemblies.
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-State Control, publication SGI-1.1
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
general guidelines for the application, installation, and maintenance of solid-state control in
the form of individual devices or packaged assemblies that incorporate solid-state
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.

12 Rockwell Automation Publication 440R-UM004C-EN-P - October 2021
Preface
Notes:

Rockwell Automation Publication 440R-UM004C-EN-P - October 2021 13
Chapter 1
Safety Concept
Introduction This chapter describes the safety performance level concept and how the
MSR57P speed monitoring safety relay can meet the requirements for SIL CL 3,
PLe, or CAT 4 applications.
Safety Certification The MSR57P speed monitoring safety relay is certified for use in safety
applications up to and including SIL CL 3 according to IEC 61508 and EN
62061, Performance Level PLe, and CAT 4 according to ISO 13849-1. Safety
requirements are based on the standards current at the time of certification.
The TÜV Rheinland group has approved the MSR57P speed monitoring safety
relay for use in safety-related applications where the de-energized state is
considered to be the safe state. All examples related to I/O included in this
manual are based on achieving de-energization as the safe state for typical
Machine Safety and Emergency Shutdown (ESD) systems.
Important Safety Considerations
As a user, you must:
• Set-up, rate for safety, and validate any sensors or actuators that are
connected to the system.
• Complete a system-level risk assessment and reassess the system
anytime a change is made.
• Certify the system to the desired safety performance level.
• Project management and proof tests.
• Program the application software and the device configurations in
accordance with the information in this manual.
• Access control to the system, including handling passwords. Analyze all
configuration settings and choose the proper setting to achieve the
required safety rating.
IMPORTANT When applying functional safety, restrict access to qualified, authorized
personnel who are trained and experienced.
ATTENTION: When designing your system, consider how personnel exit the
machine if the door locks while they are in the machine. Additional safeguard
devices can be required for your specific application.
ATTENTION: An HIM can be used to configure and monitor the MSR57P speed
monitoring safety relay. However, the stop button on the HIM does not have
safety integrity and must not be used to execute a Safe Stop.
The stop button setting is not maintained through a power cycle. Do not use
the stop button with an automatic reset configuration. Unintended motion
could result.

14 Rockwell Automation Publication 440R-UM004C-EN-P - October 2021
Chapter 1 Safety Concept
Safety Category 4 Performance Definition
To achieve Safety Category 4 according to ISO 13849-1:2015, the safety-related
parts must be designed such that:
• The safety-related parts of machine control systems and/or their
protective equipment, and their components, must be designed,
constructed, selected, assembled, and combined in accordance with
relevant standards so that they can withstand expected conditions.
• You must apply basic safety principles.
• A fault in any of its parts does not lead to a loss of safety function.
• A fault is detected at or before the next demand of the safety function, or,
if this detection is not possible, then an accumulation of faults must not
lead to a loss of the safety function.
• The average diagnostic coverage of the safety-related parts of the control
system must be high, including the accumulation of faults.
• The mean time to dangerous failure of each of the redundant channels
must be high.
• You must apply measures against common cause failure.
Stop Category Definitions
You must perform a risk assessment to determine the selection of a stop
category for each stop function.
• Stop Category 0 is achieved with immediate removal of power to the
actuator, which results in an uncontrolled coast-to-stop. Safe Torque Off
accomplishes a Stop Category 0 stop.
• Stop Category 1 is achieved with power available to the machine
actuators to achieve the stop. Power is removed from the actuators when
the stop is achieved.
• Stop Category 2 is a controlled stop with power available to the machine
actuators. The stop is followed by a holding position under power.
Performance Level and Safety Integrity Level (SIL) 3
For safety-related control systems, PL, according to ISO 13849-1, and SIL levels,
according to IEC 61508 and EN 62061, include a rating of the system’s ability to
perform its safety functions. You must include all safety-related components
of the control system in both a risk assessment and the determination of the
achieved levels.
See the ISO 13849-1, EN 61508, and EN 62061 standards for complete
information on requirements for PL and SIL determination.
See Safety Configuration and Verification on page 121, for more information
on the requirements for the configuration and verification of a safety-related
system that contains the MSR57P speed monitoring safety relay.
IMPORTANT When you design the machine application, you must consider timing
and distance for a coast-to-stop (Stop Category 0 or Safe Torque Off).
For more information regarding stop categories, refer to EN 60204-1.

Rockwell Automation Publication 440R-UM004C-EN-P - October 2021 15
Chapter 1 Safety Concept
Functional Proof Tests The functional safety standards require that you perform functional proof
tests on the equipment that is used in the system. Proof tests are performed at
user-defined intervals and are dependent upon PFD and PFH values.
PFD and PFH Definitions Safety-related systems can be classified as operating in either a Low Demand
mode, or in a High Demand/Continuous mode.
• Low Demand mode: The frequency of demands for operation that are
made on a safety-related system is no greater than one per year or no
greater than twice the proof test frequency.
• High Demand/Continuous mode: The frequency of demands for
operation that are made on a safety-related system is greater than once
per year or greater than twice the proof test interval.
The SIL value for a low demand safety-related system is directly related to the
order-of-magnitude ranges of average probability of failure to perform its
safety function on demand. This value is also called average PFD. The SIL value
for a High Demand/Continuous mode safety-related system is directly related
to the probability of a PFH.
PFD and PFH Data These PFD and PFH calculations are based on the equations from Part6 of
EN 61508 and show worst-case values.
The following table provides data for a 20-year proof test interval and
demonstrates the worst-case effect of various configuration changes on the
data.
Safe State The safe state encompasses all operation that occurs outside of the other
monitoring and stopping behavior that is defined as part of the speed
monitoring safety relay. In addition, configuration takes place in the safe
state. While the safety relay is in the safe state, all safety control outputs,
except the Door Control (DC_Out) output, are in their safe state
(de-energized). The DC_Out output is in either the locked state or in the
de-energized state, depending upon the condition that resulted in the safe
state.
The diagnostic Fault_Status output can be on in the safe state.
When you cycle power, the safety relay enters the safe state for self-testing. If
the self-tests pass and there is a valid configuration, the safety relay remains in
the safe state until a successful request for safe speed monitoring occurs.
IMPORTANT Your specific application determines the time frame for the proof test
interval.
PFD and PFH for 20-year Proof Test Interval
Attribute Pulse Test ON Pulse Test OFF (1)
(1) The following parameters are used to configure pulse tests for outputs: P71 [MP Out Mode], P72 [SS Out Mode],
P73 [SLS Out Mode], P74 [Door Out Mode]. If you disable pulse tests on any of these outputs, the achievable SIL,
Category, and PL ratings of your entire MSR57P safety relay system are reduced. See Outputs on page 47.
Single Encoder Dual Encoder
PFD 1.23E - 04 5.93E-04 25.9E-04
PFH 7.04E-09 3.38E-09 14.8E-09
SFF 99.3% 99.2% 97.9%

16 Rockwell Automation Publication 440R-UM004C-EN-P - October 2021
Chapter 1 Safety Concept
If a Safe State fault is detected, the safety relay goes to the safe state. This state
includes faults that are related to integrity of hardware or firmware.
For more information on faults, see Troubleshoot the MSR57P Safety Relay on
page 143.
Safety Reaction Time The safety reaction time is the amount of time from when the system receives a
safety-related event input to when the system is in the safe state.
The safety reaction time is 20 ms (max) from an input signal condition that
triggers a Safe Stop, to the initiation of the configured Safe Stop type.
The safety reaction time from an overspeed event that triggers a Safe Stop, to
the actual initiation of the configured Safe Stop type, is equal to the value of
the P24 [OverSpd Response] parameter.
For more information on overspeed response time, see Overspeed Response
Time on page 56.
Considerations for Safety
Ratings
The achievable safety rating of an application that uses the MSR57 safety relay
is dependent upon many factors, including the encoder setup, drive options,
output pulse tests, and the type of motor.
When you use two independent encoders to monitor motion, and when
installed in a manner to avoid any common cause dangerous failure, the
MSR57P safety relay can be used in applications up to and including SIL CL 3,
PLe, and CAT 4.
When you use a drive with the STO option and one external contactor, or two
external contactors, the MSR57P safety relay can be used in applications up to
and including SIL CL 3, PLe, and CAT 4.
Output Pulse Test Considerations
If the pulse test of any safety output is disabled, the maximum safety rating is
up to and including SIL CL 2, PLd, and CAT 3 for any safety chain that
incorporates any input or output of the MSR57P safety relay.
You can disable pulse tests if the connected device does not support OSSD
inputs. See the product documentation for your connected device.
IMPORTANT Some of the diagnostics that are performed on the encoder signals
require motion to detect faults. You must verify that motion occurs at
least once every 6 months.
IMPORTANT If you set any of the P71 [MP_Out Mode], P72 [SS_Out Mode], P73
[SLS_Out Mode], or P74 [DC_Out Mode] parameters to 1 = No Pulse Test,
it disables internal diagnostics and external diagnostics that are
required to achieve higher safety ratings.
You must exercise the SS_In input at least once every 6 months.

Rockwell Automation Publication 440R-UM004C-EN-P - October 2021 17
Chapter 1 Safety Concept
Considerations for Single-encoder Applications
When configured correctly, the MSR57P safety relay performs these
diagnostics on the encoder:
•Sin
2+ Cos2diagnostic.
• Detection of open or short-circuit.
• Encoder supply voltage monitoring.
• Detection of illegal quadrature transitions of the sine and cosine signals.
A safety rating up to and including SIL CL 3, PLe, and CAT 4 can be achieved in
a single-encoder application with these requirements:
• The motor is a Permanent Magnet (PM) brushless AC motor.
• The motor controller must be configured as a closed-loop application
with field-oriented control that uses the single-encoder for
commutation.
• The motor-to-encoder coupling is designed to exclude shaft slippage as a
dangerous failure mechanism.
• The MSR57P safety relay is configured for Sin/Cos encoder type.
The encoder is of the Sin/Cos type and is suitable for the desired safety
rating of the application.
An encoder that is suitable for SIL CL 3 applications must:
- Use independent Sine/Cosine signals.
- Be incapable of producing simulated signals when under an error
condition.
- Use simple or discreet circuitry with no complex or programmable
internal devices.
• The controller is not configured for auto transition to encoderless
commutation if there is an encoder failure.
• The motor controller must use the same encoder signals as MSR57P
safety relay.
• Encoder voltage monitoring in the MSR57P safety relay must be enabled.
• The system design of the motor/encoder-to-load coupling excludes shaft
slippage and breakage as a dangerous failure mechanism.
Single-encoder with Kinetix Drive
A safety rating up to and including SIL CL 3, PLe, and CAT 4 can be achieved in
an MSR57P safety relay single-encoder application when the safety relay is
used with a properly configured Kinetix® Servo Drive with STO and any
motor/encoder combination that meets the single-encoder application
requirements listed in Considerations for Single-encoder Applications.
Single-encoder with PowerFlex Drive
A safety rating up to and including SIL CL 3, PLe, and CAT 4 can be achieved in
an MSR57P safety relay single-encoder application when the safety relay is
used with a properly configured PowerFlex® 700S or PowerFlex 755 drive and
any motor/encoder combination that meets the single-encoder application
requirements listed in Considerations for Single-encoder Applications.

18 Rockwell Automation Publication 440R-UM004C-EN-P - October 2021
Chapter 1 Safety Concept
For example, to configure a PowerFlex 700S drive properly to meet the single-
encoder application requirements listed in Considerations for Single-encoder
Applications on page 17, make these parameter settings.
You must verify that a Sin/Cos feedback option is installed in the drive. The
drive must be commissioned according to the normal startup procedure for
proper operation in your system.
The MSR57P safety relay is suitable for SIL CL 3, Cat 4 applications when
connected to drives that also support Cat 4 applications. Some applications can
require an external contactor to meet Cat 4 requirements. See your drive
manual for details on safety requirements.
See publication 20D-PM001 for detailed information on installation,
configuration, and operation of a PowerFlex 700S drive.
Commutation
Permanent Magnet (PM), brushless AC motors, like those listed previously, are
a class of synchronous motor that depends on electronic brushless
commutation to generate torque and motion. In PM brushless motors, the
permanent magnets on the rotor create an electromagnetic field. A number of
electromagnets that are commutated electronically with IGBTs at the right
speed, order, and times, create a rotating magnetic field. Switching the
currents in the coils of the stator winding creates movement of the
electromagnetic field. This process is called commutation. Interaction of the
two electromagnetic fields produces magnetic force or torque.
Excessive noise, broken encoder wires, and loss of the encoder power supply
are factors that can affect commutation while the motor is running. To help
prevent the motor from spinning, the drive can detect these conditions with
the use of safety monitoring circuits.
Contact Information if
Device Failure Occurs
If you experience a failure with any safety-certified device, contact your local
Allen-Bradley product distributor or Rockwell Automation sales office. With
this contact, you can:
• Return the device to Rockwell Automation so the failure is appropriately
logged for the affected catalog number and a record is made of the
failure.
• Request a failure analysis (if necessary) to determine the probable cause
of the failure.
Parameter
Number Parameter Name Required Drive Parameter Setting Addresses Single-encoder Requirement
P485 Motor Ctrl Mode 2 = Pmag Motor The motor controller must be
configured as a closed-loop application
with field-oriented control that uses
the single-encoder for commutation.
P222 Mtr Fdbk Sel Pri 5 = FB Opt Port0
P153, bit 16 Control options OFF = Auto Tach Sw
The controller is not configured for
auto transition to encoderless
commutation if there is an encoder
failure.

Rockwell Automation Publication 440R-UM004C-EN-P - October 2021 19
Chapter 2
About the MSR57P Speed Monitoring Safety Relay
Introduction This chapter describes the features of the MSR57P Speed Monitoring Safety
Relay.
Safety Functions The MSR57P Speed Monitoring Safety Relay features five inputs, three sets of
safety outputs, and one bipolar safety output. Each of the inputs supports a
specific safety function.
• Safe Stop (SS)
• Safely-limited Speed Monitoring (SLS)
• Door Monitoring (DM)
• Enabling Switch Monitoring (ESM)
• Lock Monitoring (LM)
An additional reset input provides for reset and monitoring of the safety
circuit.
The safety relay can be used in single-axis or multi-axis applications, and the
safety relay is configurable as a master or slave depending on its location in the
system.
Safety Modes
The safety relay can be configured to operate in one of 11 user-selectable Safety
modes, which are based on combinations of the safety functions listed
previously. The safety relay monitors motion for Safe Stop in every mode
except Disabled.
Safety Mode Page
Disabled – All safety functions are disabled. 20
Safe Stop – The safety relay activates the configured Safe Stop type upon deactivation of the Safe
Stop input or the occurrence of a Stop Category fault. 67
Safe Stop with Door Monitoring – The safety relay monitors for Safe Stop and the status of the door. 76
Safely-limited Speed – The safety relay monitors for Safe Stop and the feedback velocity. The
safety relay compares the feedback velocity to a configurable safe speed limit. If the velocity
exceeds the limit, the safety relay initiates the configured Safe Stop type. 79
Safely-limited Speed with Door Monitoring – The safety relay monitors for Safe Stop, Safely-limited
Speed, and the status of the door. 82
Safely-limited Speed with Enabling Switch Control – The safety relay monitors for Safe Stop,
Safely-limited Speed, and the status of the enabling switch input. 84
Safely-limited Speed with Door Monitor and Enabling Switch – The safety relay monitors for Safe
Stop, Safely-limited Speed, the status of the door, and the status of the enabling switch input. 86
Safely-limited Speed (status only) – The safety relay monitors for Safe Stop and the feedback
velocity. The safety relay compares the feedback velocity to a configurable safe speed limit. If the
velocity exceeds the limit, the system status is made available as a safe output, which is intended
for a safety programmable logic controller. No stopping action takes place.
90

20 Rockwell Automation Publication 440R-UM004C-EN-P - October 2021
Chapter 2 About the MSR57P Speed Monitoring Safety Relay
Disabled Mode
In Disabled mode, all safety functions are disabled. Input, output, or speed
monitoring diagnostics do not take place and all outputs are in their safe state.
Lock Monitoring
Lock monitoring helps prevent access to the hazard during motion. In many
applications, it is not sufficient for the machine to initiate a stop command
once the door is opened because a high inertia machine can take a long time to
stop. The safest condition is to prevent access to the hazard until a safe speed is
detected. The lock monitoring feature is used to verify the operation of the
door lock mechanism.
Lock monitoring can be enabled on single units or on the first unit in a
multi-axis system. If the Lock Monitor input (LM_In) indicates that the door is
unlocked when the Door Control output (DC_Out) is in the locked state, or if
the lock monitor input indicates locked when the Door Monitor input (DM_In)
transitions from closed to open, the configured Safe Stop type is initiated.
Safe Maximum Speed, Safe Maximum Acceleration, and Safe Direction
Monitoring
Three additional safety functions, Safe Maximum Speed (SMS), Safe
Maximum Acceleration (SMA) and Safe Direction Monitoring (SDM), operate
independent of the other modes and rely on the Safe Stop function. When you
configure the safety relay for Safe Maximum Speed, the feedback velocity is
monitored and compared against a user-configurable limit. If the measured
velocity is greater than or equal to the limit, the configured Safe Stop type is
executed.
When Safe Acceleration Monitoring is enabled, the safety relay monitors the
acceleration rate and compares it to a configured Safe Maximum Acceleration
Limit. If acceleration is detected as greater than or equal to the Safe Maximum
Acceleration Limit, an Acceleration fault occurs. If an Acceleration fault is
detected while the safety relay is actively monitoring motion, the configured
Safe Stop type is initiated.
Safe Direction Monitoring is also activated via device configuration. The safety
relay monitors the feedback direction and executes the configured Safe Stop
type when motion in the illegal direction is detected.
See Safe Maximum Speed and Direction Monitoring on page 113, for detailed
information on these functions.
Slave, Safe Stop – The safety relay performs the same functions as Safe Stop mode. However, the
safety relay regards the door monitor input as a door control output from an upstream axis, and
performs a logical AND with its internal door control signal to form the cascaded door control
output.
95
Slave, Safely-limited Speed – The safety relay performs the same functions as Safely-limited Speed
mode. However, the safety relay regards the door monitor input as a door control output from an
upstream axis, and performs a logical AND with its internal door control signal to form the
cascaded door control output.
100
Slave, Safely-limited Speed (status only) – The safety relay performs the same functions as Safely-
limited Speed Status Only mode. However, the safety relay regards the door monitor input as a door
control output from an upstream axis, and performs a logical AND with its internal door control
signal to form the cascaded door control output.
102
Safety Mode Page