Safety Relay Troubleshooting Guide

Troubleshooting Safety Relay Based Systems MSR131

MSR131 Toubleshooting Guide Rev C.doc

Page 1 of 22

December 27, 2005

Table of Contents
1) 2)
a)

Introduction......................................................................................................................................... 3 Power Supply ...................................................................................................................................... 4

FAQ: What is the inrush current on power-up?............................................................................................................5

3)
a)

Input Circuit 2NC ............................................................................................................................ 7

FAQ: How much inrush current is present at the inputs?...........................................................................................10

4) 5)
a) b)

Input Circuit Distribution Block .................................................................................................... 11 Input Circuit Light Curtain ............................................................................................................ 12
FAQ: Once the input circuit is opened, how long must it stay open?..........................................................................13 FAQ: Under what conditions is the order of input circuit closing important?.............................................................13

6)
a)

Safety Mat Input ............................................................................................................................... 14

FAQ: What causes only one output LED to turn on? ..................................................................................................15

7)
a)

Reset Circuit...................................................................................................................................... 15
FAQ: How soon after the inputs are closed can the reset button be pressed? ............................................................17

8) 9)

Monitoring Circuit ............................................................................................................................ 18 Output Circuits.................................................................................................................................. 20

10) Timing Requirements........................................................................................................................ 21 11) Single Point Lesson........................................................................................................................... 21

MSR131 Toubleshooting Guide Rev C.doc

Page 2 of 22

December 27, 2005

1) Introduction
The troubleshooting process for the MSR131 safety relay follows a straight forward process. The process starts with the power supply and follows the normal sequence of events that take place in the relay. The troubleshooting process is as follows: 1. Power 2. Inputs 3. Reset 4. Monitoring 5. Outputs The MSR131 safety relay goes into a lockout state when it detects a fault condition. The fault condition can be either external or internal to the MSR131, as the MSR131 monitors external devices as well as itself. This lockout state prevents the safety outputs from being energized, until the fault condition is corrected and the MSR131 is satisfied. If an external fault is corrected, the MSR131 is reset in one of two methods: 1. 2. Cycle an input device (the preferred method), or Cycle the power.

In many cases, the fault will be either an open-circuit or a short-circuit condition. In these cases, a digital multimeter can be used to accomplish the troubleshooting. An oscilloscope is needed when timing issues are suspected of causing lockouts. Note: The measurements in this document were taken on sample products. Actual measurements will vary from unit to unit, as well as with temperature. In this guide, the reader is asked to make measurements with a multimeter. An example of the terminology used is S12/S22, where one test lead is placed on terminal S12 and the other terminal is placed on terminal S22. FAQ = Frequently Asked Question EOT = End of Troubleshooting

Troubleshooting safety relay based systems sometimes requires the application of power. Troubleshooting must be performed by trained persons familiar with safety publications ANSI NFPA70E and ANSI Z244.1 and local applicable codes.

MSR131 Toubleshooting Guide Rev C.doc

Page 3 of 22

December 27, 2005

2) Power Supply
The power supply is protected by electronic current limiting. If a short circuit or overload occurs, the resistance goes up to prevent damage to the MSR131. When the fault is cleared, the resistance returns to normal, and the MSR131 begins to operate properly. See Safety Mat inputs for further details.

Step P1
Is power LED on? If not, go to Step P2. If blinking, go to Step P4 If yes, go to Input Circuits.

Step P2
Measure supply voltage at A1/A2 for 24VDC or 115VAC, depending on the model used.
DMM 24 Volts

Example for 24VDC

Example for 24VDC

DMM

+V

24 Amps A1 S11 S11 S21 Y31

440R-C23139 (24V AC/DC) 440R-C23137 (115V AC)

Circuit Protection AC (+) PWR 24VDC (-) Y30 Inputs Y35 Closed Output Y32 Active A2

-V

Reference Information: Power Supply Current The power supply current depends on the type of inputs used. Use an ammeter to measure the current. Values shown with safety outputs energized. Light Curtain 23mA DC @ 20.4V DC 28mA DC @ 24.0V DC 31mA DC @ 26.4V DC 19mA AC@ 98V AC 24mA AC@115V AC 26m A AC@126VAC 2 NC Contacts 70mA DC @ 20.4V DC 85mA DC @ 24.0V DC 95mA DC @ 26.4V DC 31mA AC @ 98V AC 38mA AC @ 115V AC 42mA AC @ 126V AC Safety Mat/Crossfault 115mA DC @ 24VDC 45mA AC @ 115VAC

X1 X2

Check Power Supply on Side Label

X3 X4 S22 S52

Start Logic

Start

Reset

S33 S34 Y2 Y1

CH2
&

CH2 CH2

S12

CH1 CH1

CH1 CH1
CH2

13

14 24 34 42 52

23 33 41 51

If OK, go to Step P3. If not, verify that the equipment power switch is set to ON. Is the equipment connected to the power source? Are the power supply fuses blown? Is the unit rated for the appropriate voltage see label on side of unit? Go to Step P1. As a reference, the current used by the MSR131, with its safety outputs energized, is shown in the side table. This table show the typical current when the MSR131 is functional and its safety outputs are energized.

MSR131 Toubleshooting Guide Rev C.doc

Page 4 of 22

December 27, 2005

a) FAQ: What is the inrush current on power-up? The worst case inrush occurs at the highest supply voltage with the MSR131. The inrush current is essentially the same regardless of whether or not the safety outputs energized on power up. At 26.4V DC, the inrush current of the power supply is 120mA. This pulse lasts for about 10ms. At 126VAC, the peak inrush is 150mA, and it decays exponentially to a steady state value within 3 cycles. 10ms

120mA

150mA

DC Power Inrush

AC Power Inrush

Step P3
Measure the internal supply voltage of the MSR131 - S11/S21 should be 17 to 40 VDC. The internal voltage is not tightly regulated and depends on the external power supply. If OK, go to Input Circuits.
440R-C23139 (24V AC/DC) +V
A1 S11 S11 DMM 24 Volts X1 S21 Y31

440R-C23137 (115V AC)

Circuit Protection AC (+) PWR 24VDC (-) Y30 Inputs Y35 Closed Output Y32 Active A2

-V

Should be 17 to 33 VDC depending on Supply Voltage

X2 X3 X4 S22 S52

Start Logic

Start

Reset

S33 S34 Y2 Y1

CH2
&

CH2 CH2

S12

CH1 CH1

CH1 CH1
CH2

13

14 24 34 42 52

23 33 41 51

MSR131 Toubleshooting Guide Rev C.doc

Page 5 of 22

December 27, 2005

Step P4
Pop out the top front terminal block (with S11). Did the Power LED stop blinking? If yes, turn off power to the unit. Use your ohm meter and check for shorts between the CH1 and CH2 circuit. If a safety mat is connected to the MSR131, check for objects on the safety mat.

Pop out the top terminal block.

Check for shorts.

If a short is found, trace the input wiring and remove the short. Re-insert the top connector, and apply power. Go to Input Circuits.

MSR131 Toubleshooting Guide Rev C.doc

Page 6 of 22

December 27, 2005

3) Input Circuit 2NC

The typical 2 normally closed (NC) series circuit is wired as shown below. This arrangement employs redundancy (two circuits) and diversity (one pull up and one pull down). The internal relay to CH1 is pulled up by the external interlocks or e-stops to 24V at S11. A jumper is connected from S11 to S52 to supply power to CH2. CH2 is pulled down to ground by the external interlocks or e-stops to S21. Crossfaults, shorts from CH1 to CH2, can be detected by the diversity principle the Power LED blinks.
+V
A1 Circuit Protection AC (+) PWR 24VDC (-) Y30 Inputs Y35 Closed Output Y32 Active A2

-V

Gate Interlocks or E-Stops Channel 1 Channel 2

S11 S11 S21 Y31

X1 X2 X3 X4 S22 S52 CH2

&

Start Logic

Start

Reset

S33 S34 Y2 Y1

CH2 CH2

S12

CH1 CH1

CH1 CH1
CH2

13

14 24 34 42 52

23 33 41 51

Operation
With 2NC circuits, the safety outputs de-energize when either CH1 or CH2 opens. If one channel opens, then the other channel must also open before the safety outputs can re-energize. The timing between the inputs is flexible: 1) CH1 can open before or after CH2 - the order in which the channels open and close is not critical. 2) the first channel that opens can close before the second channel opens and closes. 3) there is no time within which the second channel must operate; it could operate seconds, minutes or even days later. After both inputs have been opened and then closed, the input is said to be satisfied. The MSR131 is ready to check the reset and monitoring circuit. If those circuits are satisfied, the safety outputs will be energized.

MSR131 Toubleshooting Guide Rev C.doc

Page 7 of 22

December 27, 2005

Step I1
Are the CH1 and CH2 LEDs on? If yes, go to Step Reset Circuit. If only CH1 LED is on, then an open circuit exists on CH2. Go to Step I2. If only CH2 LED is on, then an open circuit exists on CH1. Go to Step I2. If neither CH1 LED nor CH2 LED is on, then both CH1 and CH2 circuits must be open. Go to Step I2.

Step I2
At the MSR131, measure the cross channel voltages. This should confirm the input LED Status: Relay Terminals S52/S22 S21/S12 S52/S22 S21/S12 S52/S22 S21/S12 S52/S22 S21/S12 Voltage 24V 24V 0V 0V 24V 0V 0V 24V Look for: Both Channels are OK Input LED Both on

Both Channels are open.

Both off

Channel 1 is open.

CH2 on

Channel 2 is open.

CH1 on

When troubleshooting 2NC circuits, the easiest approach is to measure the cross channel voltage at each of the devices. Open the cover of an interlock to expose the wiring terminals. . The two contacts closest to the actuator are the safety contacts. Using a voltmeter, measure the voltage from Channel 1 to Channel 2.

CH1 Safety Contacts CH2 Safety Contacts

Cross channel measurement

Contact measurement

MSR131 Toubleshooting Guide Rev C.doc

Page 8 of 22

December 27, 2005

Check the input devices for open circuits. The following two diagrams show typical examples of wiring 2NC series circuits. With all the input devices closed and the MSR131 powered, measure the cross channel voltages at each of the input devices until a voltage difference is found. The open circuit lies between the device that showed 0V and the device the showed 24V. Check the connections, terminals, and wiring for an open circuit. The actual voltage shown is a nominal 24VDC; the actual voltage can range from 17 to 40V.
+V
A1

440R-C23139 (24V AC/DC) 440R-C23137 (115V AC)

Circuit Protection AC (+) PWR 24VDC (-) Y30 Inputs Y35 Closed Output Y32 Active A2

-V

+V
A1

440R-C23139 (24V AC/DC) 440R-C23137 (115V AC)

Circuit Protection AC (+) PWR 24VDC (-) Y30 Inputs Y35 Closed Output Y32 Active A2

-V

Gate Interlocks or E-Stops

S11 S11

Gate Interlocks or E-Stops

S11 S11

0V

0V

24V

S21 Y31

0V

0V

24V

S21 Y31

X1 X2 X3 X4 S22 S52 CH2

&

Start Logic

Start

Reset

S33 S34 Y2 Y1

X1 X2 X3 X4 S22

Start Logic

Start

Reset

S33 S34 Y2 Y1

CH2 CH2

S52

CH2 &

CH2 CH2

S12

CH1 CH1

CH1 CH1
CH2

S12

CH1 CH1

CH1 CH1 CH2

13

14 24 34 42 52

13 23 33 41 51

14 24 34 42 52

23 33 41 51

Open Circuit on CH1

Open Circuit on CH2

Reference Information: Input Currents The currents going into S12 (CH1) and S22 (CH2) depend on the supply voltage. Use a DC ammeter to measure these currents. VSupply 20.4V DC 24.0V DC 26.4V DC 97.8V AC 115V AC 126.5V AC CH1 25mA DC 30mA DC 34mA DC 28mA DC 33mA DC 37mA DC CH2 31mA DC 37mA DC 41mA DC 34mA DC 40mA DC 44mA DC

MSR131 Toubleshooting Guide Rev C.doc

Page 9 of 22

December 27, 2005

a) FAQ: How much inrush current is present at the inputs? When the actuator is inserted into an interlock, for example when a safety gate is closed, the inrush current to at the inputs of the MSR131 is 90mA. This inrush lasts for about 100ms. The measurements below were taken on a unit powered by 24VDC. The figures below show the current waveform when the MSR131 is set for automatic and monitored reset. The difference in the waveform is due to the safety outputs becoming energized when the MSR131 is set up for automatic reset. 80ms 100ms

CH1 90mA

CH2 90mA

Inrush Current with Auto Reset

Inrush Current with Manual Reset

MSR131 Toubleshooting Guide Rev C.doc

Page 10 of 22

December 27, 2005

4) Input Circuit Distribution Block

When troubleshooting devices connected to the distribution blocks, the order in which the devices are connected becomes important. The picture and wiring diagrams show that the connection flow. Not that the 6-pin 8-port flows through the even side and then through the odd side. The 4-pin 8-port flows in numerical order. This can be used to help identify the location of an open circuit, as described in the 2NC section above.
898R-P68MT
Brown/Green 1 J2 5 J8 1 5 J7 1 5 J3 1 5 J1 1 5 Brown/Yellow

6-Pin QD
White/Yellow 2 6 2 6 2 6 2 6 2 6 White/Green

J8 Blue 3 1

J7 3 1

898D-48LT
3

J2 1 3

J1

1 Brown

4-Pin QD
Black 4 2 4 2 4 2 4 2 White

MSR131 Toubleshooting Guide Rev C.doc

Page 11 of 22

December 27, 2005

5) Input Circuit Light Curtain

The MSR131 is designed to interface with light curtains. Light curtains with solid state outputs can be wired as shown below. These light curtains are typically powered by 24VDC. When an AC powered MSR131 is used (shown on right), the light curtain ground must be referenced to the MSR131 internal ground (S21). Solid state light curtains have two PNP type outputs called output signal switching devices (OSSD). The light curtain detects a crossfault, which is a short between the two OSSD outputs; the MSR131 does not detect this fault.

DC Powered MSR131

AC Powered MSR131

Reference Information: Light Curtain Output Currents Use a DC ammeter to measure these currents. VSupply 19.2VDC 24.0VDC 26.4VDC Ch1 28mA 36mA 40mA Ch2 24mA 31mA 35mA

The MSR131 power supply does not play a role in determining these currents.

Step LC1
With the light curtain made (nothing between the sender and receiver), does the voltage at terminals S12 and S52 measure 24VDC. [With the light curtain broken (object between the sender and receiver), the voltage at terminals S12 and S52 should measure 0VDC.] If yes, Go to Step LC2. If not, check to make sure the ground reference of the light curtain is the same as the MSR131. For DC powered MSR131s, this can be A2 or S21. For AC power MSR131s, the reference must be to S21. If either S12 or S52 measures zero volts, check the wiring going back to the light curtain.

Step LC2
Press the reset button. Do CH1 and CH2 LEDs turn on? If yes, go to Step Outputs. If not, go to Step Reset Circuit. MSR131 Toubleshooting Guide Rev C.doc Page 12 of 22 December 27, 2005

Note: Light curtains perform their own diagnostics. For example, a crossfault from CH1 to CH2 will be detected by the light curtain, not by the MSR131. Faults detected by the light curtain are usually indicated by red blinking LEDs on the light curtain. This troubleshooting guide is not intended to cover light curtain troubleshooting. a) FAQ: Once the input circuit is opened, how long must it stay open? This is known as the recovery time. Once an input is opened, it must stay open for at least 100ms. This gives the internal circuitry enough time to get itself ready for the next demand on the safety system. It is possible to turn light curtains off and then back on within 100ms. If this happens, the MSR131 safety outputs will remain in the de-energized mode, with one output on (typically CH2) and the other output off (typically CH1). To correct this condition, simply break and make the light curtain again. b) FAQ: Under what conditions is the order of input circuit closing important? In rare applications, two independent devices are connected like a light curtain: S12 and S52 are switched to 24V, and S21 is jumpered to S22. In addition, automatic reset is used. Under these conditions, CH2 must close before or at the same time as CH1. If this sequence is not performed properly, then the CH1 output will be on, but the CH2 output will not turn on. To correct this situation, modify the sequence of operation or used monitored reset

MSR131 Toubleshooting Guide Rev C.doc

Page 13 of 22

December 27, 2005

6) Safety Mat Input

Safety mats can also be connected to the MSR131. The wiring example below shows two parallel plate type safety mats connected in series. A current flows through the safety mats at all times to detect an open circuit. The MSR131 uses crossfault detection to detect someone stepping on the mat. When someone steps on the mat, CH1 is shorted to CH2, and the safety outputs are de-energized. The Power LED blinks to indicate the presence on the mat; all the other LEDs are off.
A1 S11 S11 S21 Y31 Circuit Protection AC (+) PWR 24VDC (-) Y30 Inputs Y35 Closed Output Y32 Active A2

X1 X2 X3

Start Logic

Start

Reset

S33 S34 Y2 Y1

Safety Mat 1

Safety Mat 2

X4 S22 S52 CH2

&

CH2 CH2

S12

CH1 CH1

CH1 CH1
CH2

13

14 24 34 42 52

23 33 41 51

Power Supply Current (24VDC Power to A1/A2): The figure below shows how the current behaves when the safety outputs are off, on and when some steps on the safety mat. Safety Mat Activated Safety Outputs ON 78mA Safety Outputs OFF 30mA 113mA

MSR131 Toubleshooting Guide Rev C.doc

Page 14 of 22

December 27, 2005

a) FAQ: What causes only one output LED to turn on? This occurs when a safety mat is connected to the MSR131 configured for automatic reset. The recovery time of the MSR131 is rated at 100ms. It is possible to drop a tool, or bounce something on the safety mat, such that the output turns off. The mat is not actuated long enough for the MSR131 to complete its internal cycle. Typically, the CH2 LED will be off; occasionally CH1 will be off. To clear this condition, step on and off the mat. If this problem persists, consider changing to monitored reset or seek an alternative relay (like the MSR23M or 440FC4000D).

7) Reset Circuit Operation

The MSR131 provides two terminals for reset: S33/S34. There are two types of reset functions: automatic and monitored. Automatic To configure the MSR131 for automatic reset, jumpers must be added between X1/X2, X3/X4 and S33/S34. The MSR131 safety outputs are energized immediately after the inputs and monitoring circuits are satisfied. Monitored To configure the MSR131 for monitored reset, remove jumpers from X1/X2 and X3/X4. Connect a normally open contact, typically a manually operated pushbutton, between S33/S34. This normally open contact must be closed after the inputs are satisfied. If the monitoring circuit is also satisfied, the safety outputs will be energized.
A1 S11 S11 S21 Y31 Circuit Protection AC (+) PWR 24VDC (-) Y30 Inputs Y35 Closed Output Y32 Active A2
A1 S11 S11 S21 Y31 Circuit Protection AC (+) PWR 24VDC (-) Y30 Inputs Y35 Closed Output Y32 Active A2

X1 X2 X3 X4 S22 S52 CH2

&

Start Logic

Start

Reset

S33 S34 Y2 Y1

X1 X2 X3 X4 S22

Start Logic

Start

Reset

S33 S34 Y2 Y1

CH2 CH2

S52

CH2 &

CH2 CH2

S12

CH1 CH1

CH1 CH1
CH2

S12

13

14 24 34 42 52

CH1 CH1

CH1 CH1 CH2

13 23 33 41 51

14 24 34 42 52

23 33 41 51

Automatic Reset

Monitored Reset

When CH1 closes, voltage is applied to S33. This voltage is then applied to S34 and Y2 through the jumper or the reset contact. The Start LED turns on when S34 is powered by the circuit from S33.

MSR131 Toubleshooting Guide Rev C.doc

Page 15 of 22

December 27, 2005

Step R1
Measure the voltages at the terminals under the conditions of the inputs and outputs, shown below. Automatic Reset Inputs Both Open Both Closed

Outputs De-energized De-energized

S33/S21 0VDC 24VDC

S34/S21 0VDC 0VDC

Both Closed

De-energized

24VDC

24VDC

Status & Action MSR131 working OK When CH1 closes, voltage is applied to S33. The Start LED turns on when S34 is powered by the jumper from S33. If the Start LED does not turn on and S34/S21 is 0VDC, then look for an open circuit from S33 to S34. Look for an open monitoring circuit Y1/Y2. Go to the Monitoring Circuit.

Monitored Reset Inputs Both Open Both Closed

Outputs De-energized De-energized

S33/S21 0VDC 24VDC

S34/S21 0VDC 0VDC

Both Closed

De-energized

24VDC

24VDC

Status & Action MSR131 working OK When CH1 closes, voltage is applied to S33. The Start LED turns on when S34 is powered by the closing of the reset contact. If the Start LED does not turn on and S34/S21 is 0VDC, then look for an open circuit from S33 to S34. Look for 1 of 2 conditions: 1) If the Start LED is on, then the reset contact is stuck in the closed position and was closed prior to the inputs being satisfied; or 2) If the Start LED turns on and off when the reset button is pressed and released, then look for an open monitoring circuit Y1/Y2. Go to the Monitoring Circuit.

MSR131 Toubleshooting Guide Rev C.doc

Page 16 of 22

December 27, 2005

Step R2
Use an oscilloscope to measure the reset signal. Place a small resistor; 10 ohms will work, in series with S33/S34. Connect the oscilloscope leads across the resistor. Trigger the scope to capture the single shot. The reset signal of an 115VAC powered MSR131 is 70mA and lasts for 34mS. For a 24V DC powered MSR131, the reset current is 55mA and lasts for 44ms. 34mS 44mS

55mA

70mA

115V AC Powered MSR131

24VDC Powered MSR131

a) FAQ: How soon after the inputs are closed can the reset button be pressed? 100ms. When monitored manual reset is used, the reset contacts cannot be closed until at least 100ms after the inputs are satisfied.

MSR131 Toubleshooting Guide Rev C.doc

Page 17 of 22

December 27, 2005

8) Monitoring Circuit Operation

The MSR131 provides two terminals for monitoring of external devices. The typical purpose of the monitoring circuit is to assure the status of external devices, prior to energizing the safety outputs. In the examples below, the output contactors (on left) and the interlock solenoid (on right) must be in the non-actuated position before the MSR131 safety outputs can be energized. The MSR131 requires this circuit to be closed before energizing its safety outputs. After the safety outputs are energized, the monitoring circuit is not used.
+V
A1 S11 S11 S21 Y31 Circuit Protection AC (+) PWR 24VDC (-) Y30 Inputs Y35 Closed Output Y32 Active A2

-V
A1 S11 S11 S21 Y31 Circuit Protection AC (+) PWR 24VDC (-) Y30 Inputs Y35 Closed Output Y32 Active A2

X1 X2 X3 X4 S22 S52 CH2

&

Start Logic

Start

Reset

S33 S34 Y2 Y1

X1 X2 X3 X4 S22 S52 CH2 & S12 CH1 CH1

Start Logic

Start

Reset

S33 S34 Y2 Y1
Guardlocking Interlock

CH2 CH2

CH2 CH2

S12

CH1 CH1

CH1 CH1
CH2

CH1 CH1 CH2

13

14 24 34 42 52

K1 K2

13 23 33 41 51

14 24 34 42 52

23 33 41 51

L1 L2 L3

M
K1 K2

Monitoring Output Devices (Contactors)

Monitoring Input Devices (Guardlocking Interlock)

When CH1 closes, voltage is applied to S33. When the reset circuit, S33/S34 is closed, voltage is then applied to Y2. If the monitoring circuit is closed, the voltage is then applied to Y1 to allow completion of the monitoring function. The monitoring signal is short in duration (see Step M2). The Y1/Y2 circuit is opened as soon as the external devices (ie. contactors) are energized.

MSR131 Toubleshooting Guide Rev C.doc

Page 18 of 22

December 27, 2005

Step M1
Measure the voltages at the terminals under the conditions of the inputs and outputs, shown below. Automatic Reset Inputs Both Open Both Closed

Outputs De-energized De-energized

Y2/S21 0VDC 24VDC

Y1/S21 0VDC 0VDC

Both Closed Monitored Reset Inputs Both Open Both Closed

Energized

24VDC

24VDC

Status & Action MSR131 working OK When CH1 closes, voltage is applied to Y2 through the reset circuit (S34) and the Start LED is on. Since voltage is at Y2, look for an open circuit from Y2 to Y1. MSR131 working OK

Outputs De-energized De-energized

Y2/S21 0VDC 0VDC

Y1/S21 0VDC 0VDC

Both Closed

De-energized

24VDC

0VDC

Status & Action MSR131 working OK Voltage is applied to Y2 by the closing of the reset contact. Look for an open circuit in the reset circuit. . Go to the Reset Circuit. Voltage is applied to Y2 by the closing of the reset contact. Look for an open circuit in the Y2/Y1 circuit.

Step M2
Use an oscilloscope to measure the monitoring signal current. Place a small resistor; 10 ohms will work, in series with Y2/Y1. Connect the oscilloscope leads across the resistor. Trigger the scope to capture the single shot. The monitoring current of an 115VAC powered MSR131 is 65mA and lasts for 34mS. The source of the monitoring current is S33. The current enters S34 and is split. Approximately 5mA is used by the MSR131, and the remaining 65mA is diverted to the monitoring circuit. 34mS

650mv/10 ohms = 65mA

MSR131 Toubleshooting Guide Rev C.doc

Page 19 of 22

December 27, 2005

9) Output Circuits
The output circuits are redundant voltage-free, electromechanical contacts. Initial contact resistance should be less than 1 ohm. Over the life of the contacts, resistance may go up, but should remain less than a couple ohms. Follow the steps below using the figure below as a guide.
DMM 0.235 Amps 120VAC Power DMM 120 Volts

Step O3
Gnd

CH1

13

CH2

14 24 34 42
A1
K2

A1 A2 A1

K1

A2

23 33 41 51
MSR138.1DP

K3

A2

52
A1
K4

A2

DMM

Step O1

120 Volts

DMM 120 Volts

Step O2

Step O1
Check the supply side of the output contacts. Does the voltage at terminals 13, 23, 33 and 41 with respect to the appropriate power supply reference (this may not be the same as A2 or S21) meet expectations? If yes, go to Step O2. If not, check the upstream fuses and wiring.

Step O2
With the CH1 and CH2 LEDs on, do the voltages on the load side of the safety relay meet expectations? If yes, go to Step O3. If not, then the output contact in the MSR131 may be worn or contaminated. To confirm this, remove the power wires from the terminals (both the supply and load side) and use an ohm meter to measure the contact resistance. [This is not shown in the figure above.] Cycle the inputs and measure the resistance a few times, as the circuit may be intermittent.

Step O3
The output voltage is ok. Does the load energize? If yes, then MSR131 works OK. EOT. If not, the trouble resides with the wiring to the load or the load itself. The load may be disconnected or not functioning properly. Measure the voltage at the load. Measure the current going to the load. Replace the load, if necessary.

MSR131 Toubleshooting Guide Rev C.doc

Page 20 of 22

December 27, 2005

10) Timing Requirements

Time requirements in the table below should be followed to make sure that safety circuits are monitored in a correct manner. Incomplete de-energizing of either internal safety channels or too short time before reset will be detected as circuit failure and requires one correct cycling of inputs before reset. Definitions: Response time via E-Stop: Time from opening input contacts until opening the safety outputs. Response time via loss of supply: Time until opening the safety outputs when supply is switched off. Recovery time: Required time after relay has de-energized before it shall be energized again. Auto-Reset: Unit resets as soon as inputs are closed provided all internal relays have been de-energized before. Monitored reset: Reset is only possible if reset loop S33-S34 is open before inputs are closed and will be closed after inputs are closed for at least 200ms. This prevents automatic reset when the reset button is bridged. All times are maximum or minimum times. Computer (PLC) controlled actuation of the reset signal must not occur before the recovery time has elapsed and should be maintained for at least 100ms.

Time Description Via E-Stop Via loss of supply Via E-Stop Recovery time With monitored reset Via loss of supply Via Reset button Switch-on delay Via Auto-Reset Via supply Reset Signal duration

Time <15ms <100ms <100ms <100ms <250ms <60ms <100ms <200ms >100ms

Response time

11) Single Point Lesson

The following page contains a simplified single page troubleshooting guideline.

MSR131 Toubleshooting Guide Rev C.doc

Page 21 of 22

December 27, 2005

MSR131 Troubleshooting Guide

A1 S33 S34 S52 S11 13 X3 S11 S12 S21 S22 41 23 51 33 51

This troubleshooting guide assumes that the MSR131 has been wired per the schematic shown. This schematic shows connections that demonstrate the functionality of the MSR131. Additional components are necessary to complete the safety system. Configuration: Dual Channel Safety Gate, Manual Reset, Output Monitoring Maximum Allowable Input Resistance: 45 ohms
X4 A2

L1 (120 VAC) open

MSR131RTP
PWR START CH1 IN CH2 IN 14 24 34 42 52 Y30 S31 Y32 Y1 Y2 X1 Y35 42 52 X2 14 24 52 34
24V Ground

24V DC

Reset

13 23 33 41 51

A1 S11 S12 S21 S22 S52 S11Y31 S33 S34 13 23 33 41 51 closed

CH1 CH2

L1 L2 L3

MSR131RTP
Output Active Inputs Closed

K1 K2

A2 X1 X2 X3 X4 Y30 Y32 Y35 Y2 Y1 14 24 34 42 52

K1 K2

L2

Dual Channel Gate Interlock, Monitored Manual Reset, Dual Channel Output, Monitored Output
CH1 IN LED CH2 IN LED S. S. Y35 Inputs S. S. Y32 Outputs

Power LED

Start LED

CH1 LED

CH2 LED

Gate Closed

Output Devices Off

Check When pressing the reset button, the Start LED turns ON, but outputs do not turn ON. Check the monitoring loop between Y1 and Y2; it should be a closed circuit. 1) Check the gate switch circuit going to S21 and S22; it should be a closed circuit. 2) Check the circuit between S11 and S52; it should be a closed circuit. If the gate is opened, the CH1 IN LED and CH1 LED will turn off. If gate is re-closed again, CH1 IN LED will turn on. 1) Check the gate switch circuit going to S12 and S52. The circuit may have opened while the gate was closed. If the gate is opened, the CH2 IN LED and CH2 LED will turn off. If the gate is re-closed again, CH2 IN LED with turn on. Check for short circuit across the inputs: S11 to S21, S11 to S22, S12 to S21, or S12 to S22.

On

Reset On

On

On

Off

Off

On

Off Closed Off

On

Off

On

Off

On

Off

Off

Off Closed Off

On

Off

Off

On

Off

On

Off

Off Closed Off

Blinking

Off

Off

Off

Off

Off

Off

Off Closed Off Check the Reset button; it may be shorted or held in the closed position.

On

On

On

On

Off

Off

On

Off Closed Off Check power applied to A1 and A2.

Off

Off

Off

Off

Off

Off

Off

Off Closed Off 1) Check for power at terminals 13, 14, 23 and 24. 2) An internal component failure may have occurred in the MSR131.

On

On

On

On

On

On

On

On

MSR131 Toubleshooting Guide Rev C.doc

Page 22 of 22