Rockwell Automation 440R-N23132, 440R-N23130, 440R-N23129, 440R-C23139 Installation Instructions

Reference Manual

Original Instructions

Minotaur Safety Relay (MSR) to Guardmaster Safety Relay
(GSR) Conversion – Phase 3

Bulletin Number 440R

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.

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.

Labels may also be on or inside the equipment to provide specific precautions.

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).

Table of Contents

Preface

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 1

Introduction GSR Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Conversion Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 2

CU2 Control Unit Terminal Location and PanelSpace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Output Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chapter 3

MSR7R and MSR7C Safety Relay Terminal Location and PanelSpace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Maximum Input Impedance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Response Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Output Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 4

MSR9T Safety Relay Terminal Location and PanelSpace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Maximum Input Impedance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Input Simultaneity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Response Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Output Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 5

MSR33 Safety Relay Terminal Location and PanelSpace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Input Simultaneity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Response Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Output Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Chapter 6

MSR35 Safety Relay Terminal Location and PanelSpace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Response Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Output Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Rockwell Automation Publication 440R-RM002B-EN-P - November 2018 3

Table of Contents

Chapter 7

MSR121RT Safety Relay Terminal Location and PanelSpace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Response Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Output Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Chapter 8

MSR124RT Safety Relay Terminal Location and PanelSpace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Response Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Output Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Rockwell Automation Publication 440R-RM002B-EN-P - November 2018

Preface

A number of older Allen-Bradley Guardmaster® safety relays will be
discontinued and no longer be available for sale. This publication suggests
examples for how to convert these existing safety relay applications to safety
relays with the latest technologies.

The products that are described in this publication can be used in various ways.
Therefore, designers must verify that all steps have been taken to verify that
each application and use of this control equipment meets all performance and
safety requirements. Designers must consider applicable laws, regulations,
codes, and standards.

The wiring diagrams in this publication are intended as examples. Because
many variables and requirements are associated with any particular installation,
Rockwell Automation does not assume responsibility or liability for actual use
that is based on these examples.

This publication is intended for machine safeguarding system designers who
have been adequately trained in the design and use of safeguarding systems and
risk assessments.

The following MSR safety relays will continue to be offered for the foreseeable
future (five, or more, years).

MSR Family Cat. No. MSR Family Cat. No. MSR Family Cat. No.

MSR117 440R-B23211

440R-D23171 440R-N23129 440R-M23143
440R-D23170 440R-N23125 440R-M23143S
440R-D23169 440R-N23128 440R-M23141

MSR125

MSR126

MSR131

440R-D23168 440R-N23124 440R-M23140
440R-D23166 440R-N23127 440R-M23147
440R-D23164 440R-N23132 440R-M23147S
440R-D23163 440R-N23135 440R-M23145
440R-N23117 440R-N23132S 440R-M23144
440R-N23116 440R-N23135S 440R-M2315
440R-N23115 440R-N23131 440R-M23149
440R-N23114 440R-N23134 440R-M23148
440R-N23113 440R-N23130 440R-M23084
440R-N23112 440R-N23133 440R-M23082
440R-N23123 440R-N23213 440R-M23081
440R-N23122
440R-N23121 440R-E23192 440R-M23086
440R-N23120 440R-E23193 440R-M23085
440R-N23119 440R-E23194 440R-M23092
440R-N23118 440R-E23195 440R-M23090
440R-C23139 440R-E23097 440R-M23089

440R-C23139S 440R-E23159

440R-C23137 440R-E23160 440R-G23215
440R-C23136 440R-E23098 440R-G23216

MSR127

MSR132

440R-N23126

MSR138

440R-E23191 440R-M23088

MSR142

440R-E23161
440R-E23162

440R-M23080

440R-G23214

Rockwell Automation Publication 440R-RM002B-EN-P - November 2018 5

Preface

Summary of Changes

Additional Resources

This publication contains new and updated information as indicated in the
following table.

Top ic Pag es

Updated series reference for CU2 Control Units 11

Updated AC voltage in Tab le 5

Updated text 40 and 41

footnote 19

These documents contain additional information concerning related products
from Rockwell Automation.

Resource Description

Guardmaster EtherNet/IP Network Interface User Manual,
publication 440R-UM009

Guardmaster Safety Relays User Manual, publication

440R-UM013

System Design for the Control of Electrical Noise Reference
Manual, publication GMC-RM001

Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1

Product Certifications website, http://

www.rockwellautomation.com/global/certification/
overview.page

Provides detailed information to install, wire,
configure, troubleshoot, and use the EtherNet/IP™
module.

Provides detailed information to install, wire,
configure, troubleshoot, and use Guardmaster safety
relays.

Provides a thorough review of the installation and
grounding of noisy components and what can be done
to minimize thei r potential for injecting noise into the
system.

Provides general guidelines for installing a
Rockwell Automation® industrial system.

Provides declarations of conformity, certificates, and
other certification details.

You can view or download publications at

http://www.rockwellautomation.com/global/literature-library/overview.page

To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.

.

6 Rockwell Automation Publication 440R-RM002B-EN-P - November 2018

Chapter 1

Introduction

The next generation Guardmaster safety relay (GSR) family is a high-quality
replacement for most of the Minotaur™ safety relay (MSR) family.

The consistent 22.5 mm (0.9 in.) wide housing design and configurable
functions for reset and logic of GSR modules let you consolidate various
functions of MSR modules with fewer relays. These features help you reduce
your stocking requirements.

The MSR family of safety relays typically offers one dedicated safety function,
for each safety circuit and actuator. MSR solutions have less connectivity to
each other than GSR modules. If you add additional safety circuits, those
circuits require additional safety relay modules and safety contacts for
cascading to maintain PLd or PLe safety ratings according to EN ISO 13849-1
or SIL 2 or SIL 3 according to IEC 62061.

The GSR family of safety relays offers configurable safety functions and
consolidated safety circuits, which result in fewer units, less space, and less cost.
Due to the unique capability to cascade single-wire safety (SWS), logic
combinations and zones are constructed quickly.

A replacement with GSR modules is meant to be more than just a swap out.

New Machinery Directives have changed machine designs over the years.
These changes have harmonized standards and demands of safety solutions
that contribute to productivity and flexibility.

This publication offers detailed information to help with your conversion from
the legacy MSR family to a smarter and cost-effective machine design in
compliance with the latest requirements of Machinery Directive and
harmonized standards.

For further assistance in replacing those devices contact Rockwell Automation

Support, your local Allen-Bradley distributor, or Rockwell Automation sales

office.

Rockwell Automation Publication 440R-RM002B-EN-P - November 2018 7

Chapter 1 Introduction

GSR Benefits

Conversion Concerns

The GSR family of safety relays provides the following benefits:

• One or two (dual-channel) inputs

•Single wire safety (SWS) expansion

• Narrow package (less panel space)

• Configurable operation

• Cat 4 PLe and SIL 3 rating on most models

•RoHS compliance

It is widely recognized that product obsolescence is a part of the industrial
business cycle. This publication provides cost-effective recommendations for
converting your MSR family of safety relays to the state-of-the-art GSR family,
and considers the following major concerns.

Panel Space

Many control panel designers leave space in their panels for future expansion
and improvements. If that extra panel space gets used, then panel space can
become tight. With panel space in mind, the recommended conversion is
intended to maintain, or even reduce, panel space.

Wiring Terminal Location

A wire that is moved from the top of the old device to the bottom of the new
device in a control panel cannot be taken lightly. Each of the recommended
conversions shows the terminal locations of the old and new devices, so you can
plan the conversion appropriately.

Wiring Change

Example schematics that compare the older device and the recommended
newer device are provided for each of the applications that the older device can
provide.

Response Time

Response time is the time that is required to perform the safety function. For
each conversion, the comparable response time is provided. An increase in the
response time requires you to adjust the safety distance. This increase is not as
much of an issue when a safety gate must be opened manually. However, this
additional response time is likely to be an issue when presence-sensing devices
like light curtains and safety mats are used.

8 Rockwell Automation Publication 440R-RM002B-EN-P - November 2018

Introduction Chapter 1

S11

S12

S21

S22

S34A1 13

L11A2 142324

33

CR1 CR2

41

34 42Y32

GSR CI
440R-S13R2

RESET

0

MM

AM

+24V DC

24V Com

CR1 CR2

K1 K2

L1

K1

K2

L2 L3

M

CR1 and CR2 consist of: 700-HPSXZ24 (relay)

700-HN123 (base)
700-AD1LR (diode and status indicator)
700-HN119 (retainer)

Output Load Capability

Every safety relay has limitations on the amount of current the relay can switch
or carry. When the load exceeds the rating of the safety relay, interposing relays
can be used as shown in Figure 1

Figure 1 - Output Load Capability Using Interposing Relays

.

Rockwell Automation Publication 440R-RM002B-EN-P - November 2018 9

Chapter 1 Introduction

Notes:

10 Rockwell Automation Publication 440R-RM002B-EN-P - November 2018

CU2 Control Unit

Chapter 2

Figure 2 - CU2 Control Unit

We recommend replacing the CU2 control unit with a GLP (Series A 205 or
later) safety relay.

Both the CU2 control unit and GLP safety relay use two proximity sensors to
sense the motion of the hazard. The CU2 control unit uses one proximity
sensor with an NPN output and the second proximity sensor with a PNP
output. The GLP safety relay requires PNP outputs for both proximity sensors.

The GLP safety relay has a multi-position switch that lets you configure the
GLP safety relay functionality. Switch positions 5, 6, 7, and 8 reflect the
functionality of the CU2 control unit. Additional functionalities (Cat 1 stop,
safely-limited speed, single wire safety expansion, unlock request, reset, and
lock request) are achieved with logic settings 1, 2, 3, and 4.

The CU2 control unit offers automatic/manual reset with the Y1/Y2
terminals. When the GLP safety relay is configured for logic settings 5, 6, 7, or
8, the GLP safety relay ignores the S44 reset input and operates in automatic
mode.

Ta b l e 1

shows the recommended conversions. With 110/230V AC supply
voltages, many other Bulletin 1606 power supplies can be used. If voltage-free
contacts are needed, the single wire safety signal from the GLP safety relay can
drive the EM safety relay.

Table 1 - Conversion Table

Supply Voltage CU2 Cat. No. GLP Cat. No. EM Cat. No.

24V AC/DC 440R-S07139 440R-GL2S2P

110/230V AC 440R-S07140

Rockwell Automation Publication 440R-RM002B-EN-P - November 2018 11

440R-GL2S2P with

1606-XLP15E

440R-EM4R2

Chapter 2 CU2 Control Unit

Terminal Location and

PanelSpace

The CU2 control unit is 45 mm (1.8 in.) wide and has one row of terminals at
the top and bottom. The GLP safety relay is only 22.5 mm (0.9 in.) wide and
has two rows of terminals at the top and bottom.

Figure 3 - DC Powered Terminals and Panel Space [mm (in.)]

22.5 (0.88)

45 (1.89)

S12 S22 AP S54
A1 A2 P12 P22

A1 N P N Y1 13 23 31

CU 2

A2 P N P Y2 14 24 32

73

(2.87)

GLP

L12 L11 Y32 S44
X14 X24 51 L61

119

(4.79)

The CU2 control unit can also be ordered with a 110/230V AC power supply.
Because the GLP safety relay is DC powered, a power supply (catalog number
1606-XLP15E) must be used to convert the AC supply to 24V DC. This
configuration occupies the same amount of space as one CU2 control unit.

Figure 4 - AC Powered Terminals and Panel Space [mm (in.)]

67.5 (2.66)

45 (1.89)

45 (1.89)

GLP

33 34 43 44
A1 A2

EM

L12 L11 X32
13 14 23 24

A1 N P N Y1 13 23 31

CU 2

A2 P N P Y2 14 24 32

73

(2.87)

+

DC 24-28V 15W

1606-

XLP15E

AC 100-240V

N L

S12 S22 AP S54
A1 A2 P12 P22

L12 L11 Y32 S44
X14 X24 51 L61

119

(4.79)

12 Rockwell Automation Publication 440R-RM002B-EN-P - November 2018

CU2 Control Unit Chapter 2

12

22

21 33

34

11

TLS1-GD2

41

42

53

54A1

A2

K1 (aux)

K2 (aux)

Guard Closed

& Locked

Start

Stop

P

PP

N

Y1

Y2

A1

NPN

Proximity

Sensor

N

N

13

A2

1423243132

CU2
440R-S07139

+24V DC

24V Com

To PLC

To PLC

PNP

Proximity

Sensor

K2

K1

LOGIC SLS1

0

1

2
3

4

5

6

7

8

9

0

1

2
3

4

5

6

7

8

9

SLS2/TIME

0

1

2
3

4

5

6

7

8

9

GLP
440R-GL2S2P

A2S12 S22 L11

L12

L61

51

P12 P22

A1X14 X24 S44S54APY32

12

22

21 33

34

11

TLS1-GD2

41

42

53

54A1

A2

K1 (aux)

K2 (aux)

K1
K2

Guard Closed

& Locked

Start

Stop

K2

K1

Brown

Black

Black

Blue

Blue

Two PNP

Proximity

Sensors

L1

K1

K2

L2 L3

M

L1 L2 L3

M

12

22

21 33

34

11

TLS1-GD2

41

42

53

54A1

A2

K1 (aux)

K2 (aux)

Guard Closed

& Locked

Start

Stop

L1
115V AC
230V AC

+24V DC

L+

N-

24V Com

1606­XLP15E

NPN

Proximity

Sensor

PNP

Proximity

Sensor

Two PNP

Proximity

Sensors

P

PP

N

Y1

Y2

A1 N

N

13

A2

1423243132

CU2
440R-S07139

N

To PLC

To PLC

K2

K1

LOGIC SLS1

0

1
2
3

4

5

6

7

8

9

0

1

2
3

4

5

6

7

8

9

SLS2/TIME

0

1

2
3

4

5

6

7

8

9

GLP
440R-GL2S2P

A2S12 S22 L11

L12

L61

51

P12 P22

A1X14 X24 S44S54APY32

12

22

21 33

34

11

TLS1-GD2

41

42

53

54A1

A2

K1 (aux)

K2 (aux)

K1
K2

Guard Closed

& Locked

Start

Stop

K2

K1

Brown

Black

Black

Blue

Blue

L1

K1

K2

L2 L3

M

L1 L2 L3

M

Wiring Schematics

The following schematics compare the wiring of your existing MSR module to
the recommended newer devices for each application that the existing device
provides.

DC Powered

Figure 5 - DC Powered Schematic

AC Powered

Figure 6 - AC Powered Schematic

Rockwell Automation Publication 440R-RM002B-EN-P - November 2018 13

Chapter 2 CU2 Control Unit

NPN

Proximity

Sensor

PNP

Proximity

Sensor

Two PNP

Proximity

Sensors

L1
115V AC
230V AC

+24V DC

L+

N-

24V Com

1606­XLP15E

P

PP

N

Y1

Y2

A1 N

N

13

A2

1423243132

CU2
440R-S07139

N

K1

K2

To PLC

To PLC

K2

K1

LOGIC SLS1

0

1

2
3

4

5

6

7

8

9

0

1

2
3

4

5

6

7

8

9

SLS2/TIME

0

1

2

3

4

5

6

7

8

9

GLP
440R-GL2S2P

A2S12 S22 L11

L12

L61

51

P12 P22

A1X14 X24 S44S54APY32

K2

K1

Brown

Black

Black

Blue

Blue

A1

L11

X32

L12 14 344424

13 33 4323

A2

EM
440R-EM4R2

Figure 7 - AC Powered Loads Schematic

Output Load Capability

The CU2 control unit has voltage-free output contacts, while the GLP safety
relay has solid-state outputs. The GLP safety relay can easily expand its output
capability with the single wire safety connection to an EM expansion relay,
which has voltage-free contacts. Use an interposing relay if additional current
capability is needed. Ta b l e 2

Table 2 - Current Capability

Load Type CU2 GLP EM

AC Inductive

DC

Thermal (non-switching) 4 A 0.5 A 1 x 6 A

shows the current capability of the three relays.

B300, AC-15

5 A/120,250V

DC-13

3 A/24V DC

—

0.5 A/24V DC

B300 AC-15

1.5 A / 250V AC

DC13

2 A/24V DC (0.1 Hz)

14 Rockwell Automation Publication 440R-RM002B-EN-P - November 2018