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1. K1 440R D23171 1 18 28 49 A2 s21 s22 24 k k2 To PLC 440R S12R2 EMD A 440R EM4R2D ii Rockwell Automation Publication 440R UM011B EN P April 2015 L 2 _ a2 18 28 38 48 To PLC MSR178DP Example Schematic On Delay AC Powered A 1606 XLP15E power supply can be used in applications where the MSR178 is powered by either 115V AC or 230V AC L1 115V AC 72406 Set Range Switch to5 60r7 Sija K1 K2 37 45 su sn Taif ssafis 23 RANGE 0 TIME 1 1 2 Me Y 440R S12R2 440R EM4R2D 12 522 32 2 111 14 24 a2 18 28 38 48 MSR178 440R M23227 To PLC 24V Com To PLC Response Time MSR178DP 20 ms SI 25 ms Single wire safety output EMD 35 ms MSR125 20 ms Since the MSR178DP has a faster response time than all combinations of SI EMD and MSR125 the safety distance must be examined closely and adjusted if necessary ATTENTION A Output Load Capability The MSR178DP has a higher current capability than the CI as shown in the table See Interposing Relays on page 3 for a wiring example of using interposing relays for applications where the load exceeds the CI capability Load Type MSR178DP EMD 300 15 300 15 Inductive 6A Q 250V
2. AC Inductive 15A N300 DC 13 DC 3Aat2AV DC 2 Aat 24V DC Thermal non switching 10 A maximum in one circuit JA See current limit curve The current through the contacts in the MSR123RT must be adjusted to its current limit curve Current x number of contact paths 2 0 0 130 20 30 40 50 60 Ambient Temperature Rockwell Automation Publication 440R UM011B EN P April 2015 29 MSR178DP MSR178DP The preferred migration for the MSR178DP is to the GSR SI and EMD relay combination This migration will cover most of the applications The MSR178DP is available with 24V DC 115V AC and 230V AC all included in the same catalog number A 1606 power supply is needed in order to convert the AC supply to DC The MSR178DP function can also be initiated with a two hand control requirement An MSR125HP provides the replacement two hand MSR178DP converts to GSR SI The MSR178 timing range can be set anywhere from 0 1 seconds to 30 minutes using a combination of jumpers and an analog potentiometer The EMD can also be set between 0 1 seconds and 30 minutes by setting two multi position switches Terminal Locations and Panel Space The MSR178DP has a 35 mm 1 38 in wide body with two rows of terminals at the top and bottom The GSR CI and EMD are similar in that they also two rows of terminals at the top and bottom in a 22 5 mm 0 88 in width plus the E
3. conversion is intended to maintain or even reduce panel space Wiring Terminal Locations Moving a wire 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 the user can plan the conversion appropriately Wiring Changes Example schematics comparing the older and recommended that newer devices 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 may require the user to adjust the safety distance This adjustment may be a non issue when a safety gate must be opened manually There is more likely to be an issue when presence sensing devices like light curtains and safety mats are used Rockwell Automation Publication 440R UM011B EN P April 2015 Introduction Interposing Relays 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 this example 24V DC M 440R S13R2 24V Com CR1 and CR2 consist of 700 HPSXZ24 relay 700 HN123 base 700 AD1LR diode amp LED 700 HN119 retainer Monitored Reset Operation The reset o
4. 15 C300 AC 15 B300 AC 15 4A 250V AC 15A 1 5 A 250V AC N300 DC 13 DC 13 DC 2 Aat 30V DC 2 hat 24V DC 2 Aat 24V DC Thermal non switching 4A 2A 6 A on 1 circuit Rockwell Automation Publication 440R UM011B EN P April 2015 19 MSR16R T MSR16R T The preferred migration for the MSR16R T is to the GSR CI relay The MSR16T is only available with 24V AC DC power one dual channel input By setting an internal switch the MSR16R T can be set for monitored manual or automatic reset It has three normally open outputs The CI has one switch to configure the reset as automatic or monitored manual Dual channel operation is determined by the wiring m converts to GSR CI The MSR16R T has a 22 5 mm 0 88 in wide body with two rows of terminals at the top and bottom The GSR CI has is similar in that it also two rows of terminals at the top and bottom in a 22 5 mm 0 88 in width Terminal Locations and Panel Space 22 5 mm 22 5 mm 0 88 in 0 88 in 33 13 23 13 23 33 41 A1 S13 S23 X1 A1S11 S12 L11 MSR16T 440R N23059 GSR Cl 440R S13R2 24V AC DC 521 522 534 A2 14 24 34 42 A2 514 524 X2 34 14 24 Schematic Automatic Reset Inside the MSR16R T cover set the internal switch to T On the CI configure the rotary switch on its front face to AM 24V DC 0 RESET AM MSR16T GSR Cl 440R N23059 440R S13R2 24V Com 20 Rockwell Automat
5. 15W 0 54 0 63 A MSR8T 1606 XLP15E GSR CI 440R C23031 110 230V AC 440R S13R2 100 240V AC 521 522 534 2 2514 X2 14 24 34 42 52 LN 14 24 34 42 The power safety inputs and outputs are similar The reset monitoring circuit is slightly different The schematics below show comparisons of the typical ways an MSR8T can be applied and the GSR Cl equivalent 4 Rockwell Automation Publication 440R UM011B EN P April 2015 MSR8T Example Schematic DC Powered 24V DC Y GSRCI 440R S13R2 24V Com Example Schematic AC Powered A small 1606 power supply converts 100 240V AC to 24V DC to power the CI relay The outputs of the CI relay can switch up to 240V AC loads The MSR8T has an internal switch that sets the power to either 115V or 230V AC L1 110 or 230V AC MSR8T t 440R E23031 230V AC 110V AC 24V Com L2 AC Com Rockwell Automation Publication 440R UM011B EN P April 2015 5 MSR8T Example Schematic AC Powered Alternative As an alternative the AC powered MSR8 can be replaced by an equivalent MSR127 The user must select the appropriate MSR127 L1 110 or 230V AC E 440R E23031 230V AC 110V AC L2 AC Com Response Time MSR8T 90 ms 35 ms Since the CI has a faster response time the safety distance for the CI is shorter than the MSR8T No further action is required Output Load Capability The MSR8T has a hi
6. 21 S22 S34 A2 A2S14 S23 X2 42 14 24 34 14 24 34 42 The power safety inputs and outputs are similar The reset monitoring circuit is slightly different The schematics below show comparisons of the four different ways an MSR11R can be applied and the GSR CI equivalent Example Schematic 24V DC Reset Reset LL ie RESET LS 62 7 O N 7 1c i 440R J23044 j 440R S13R2 24V Com Rockwell Automation Publication 440R UM011B EN P April 2015 11 MSR11R Response Time MSR11R 50ms Cl 35 ms Since the Cl has a faster response time the safety distance for the Cl is shorter than the MR11R No further action is required Output Load Capability The MSR11R has a higher current capability than the Cl as shown in the table See Interposing Relays on page 3 for a wiring example of using interposing relays for applications where the load exceeds the Cl capability Load Type MSR11R cl AC Inductive a DC eds 2 A at 24V DC Thermal non switching 4A 2A 12 Rockwell Automation Publication 440R UM011B EN P April 2015 MSR12T MSR12T The preferred migration for the MSR12T is to the GSR Cl relay The MSR12T is only available with one dual channel and automatic reset Currently only the 24V DC and 110V AC versions are available The 230V AC version was obsoleted earlier The Cl has one switch to configure the reset as automatic or monitored manual Dual channel operation is
7. 33 34 43 44 37 38 47 48 1 511 512 L11 Al 2 A1 A2 A1 A2 GSR CI GSR EM GSR EM GSR EMD 440R S13R2 440R EM4R2 440R EM4R2 440R EM4R2D S21 S22 534 A2 L12 L11 X32 L12 L11 X32 L12 L11 X32 14 24 34 42 13 14 23 24 13 14 23 24 17 18 27 28 For applications powered by 115V AC or 230V AC the 1606 XLP15E can be used to convert the AC supply to 24V DC while still occupying less than the amount of panel space required by the MSRTORD Rockwell Automation Publication 440R UM011B EN P April 2015 7 MSR10RD 112 5 mm 4 43 in eMM 13 23 33 41 33 34 43 44 33 34 43 44 37 38 47 48 24V 15W 1 511 512 L11 1 A2 A1 A2 A1 A2 0 54 0 63 A Tono ter GSR Cl GSR EM GSREM GSR EMD 440R S13R2 440R EM4R2 440R EM4R2 440R EM4R2D 100 240v AC 521 522 534 2 112 L11 X32 L12111 X32 L12 L11 X32 LN 14 24 34 42 13 14 23 24 13 14 23 24 17 18 27 28 Example Schematic DC Powered 24V DC 2 Z 440R G23029 440R G23067 440R G23068 24V Com The GSR equivalent circuit is as follows T B2 X32 1 17 27 37 47 RANGE zi TIME 1 AAA TAO EM4R2D NUR L12 L11 A2 18 28 38 48 L12 L11 14 LL LIT MIT 1 Ke K3 To PLC To PLC 24V Com RESET AM GSRCI 440R S13R2 8 Rockwell Automation Publication 440R UM011B EN P April 2015 MSR10RD Example Schematic AC Powered The MSR10RD has an internal
8. code and links to software service packs You can also visit our Support Center at https rockwellautomation custhelp com for software updates support chats and forums technical information FAQs and to sign up for product notification updates In addition we offer multiple support programs for installation configuration and troubleshooting For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com services online phone Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outsid
9. switch that sets the power to either 115V or 230V AC L1 115 230V AC The GSR solution requires a power supply The 1606 XLP15E provides 15 W enough to power the four GSR relays Each GSR relay consumes a maximum 3 5 W 115 230V AC E pe Reset K8 K7 l 511 521 34 13 23 33 41 X32 A1 13 1 33 43 X32 A1 13 23 33 43 x32 1 17 27 37 47 RESET RANGE 9 TIME 1 Om NY GSR CI X GSR EM GSREM X X X 5 440R S13R2 440R EM4R2 440R EM4R2 AUR EM4R2D 512 522 2 111 14 24 34 42 2112 14 24 34 12 11 2 14 24 34 18 28 38 48 To PLC 5 Ke kn TOPLC 24V Com L2 Response Time MSR10RD 50 ms 35 ms EM 70 ms 35 ms from the CI 35 ms from the safety wire input EMD 70 ms 35 ms from the CI 35 ms from the safety wire input Since the CI has a faster response time the safety distance for the CI is shorter than the MSR1ORD The response time of the loads that are connected to the EM and EMD are longer and must be evaluated for adequate safety distance Rockwell Automation Publication 440R UM011B EN P April 2015 9 MSR10RD Since the MSR10RD is faster than the EM and EMD relays the safety distance must be examined close
10. the logic in the PLC Monitoring of the normally closed contacts of K1and K2 will be performed by the PLC to achieve the same retriggerable performance as the MSR178 Set Range Switch to1 2 3 0r4 sun ERI 2 RESET S1 Pot si ze Y NA 440R S12R2 112 111 2 18 48 Ly To PLC To PLC ka Rockwell Automation Publication 440R UM011B EN P April 2015 MSR178DP Example Schematic Off Delay Non Retriggerable Although the MSR178 does not have a specific setting for non retriggerable off delay the control system may be prevent a retriggerable input In this case the contactors K1 and K2 can be monitored by the SI relay When you press the S1 switch the KT and K2 contactors turn ON immediately When you release S1 the timing cycle starts The EMD timing cycle will run to its conclusion and turn off K1 and K2 If 591 is repressed and held during the timing cycle K1 and K2 will turn back ON immediately after the completion of the timing cycle they turn OFF momentarily and then turn back ON 24V DC 24V Com eae varia an 602 17 27 7 se 45 Set Range Switch to1 2 3 0r4 MSR178 440 23227 l ld 7 K2 na Jevopvsz pz vo Pie s Ly toric 1 To PLC To PLC ka Example Schematic Single Shot Jog When the jog sw
11. 34 A2 32 14 24 14 24 34 42 Schematic 24V DC E 4 MSR14T 440R L23047 RESET AM wees GSRCI 440R S13R2 24V Com 16 Rockwell Automation Publication 440R UM011B EN P April 2015 MSR14T Response Time MSR14T 90 ms Cl 35 ms Since the Cl has a faster response time the safety distance for the Cl is shorter than the MR12T No further action is required Output Load Capability The MSR14T has a higher current capability than the Cl as shown in the table See Interposing Relays on page for a wiring example of using interposing relays for applications where the load exceeds the CI capability Load Type MSR14T cl B300 AC 15 C300 AC 15 AC Inductive 4A 250V AC 15A N300 DC 13 DC 2 Aat 30V DC 2 A at 24V DC Thermal m 2A non switching Rockwell Automation Publication 440R UM011B EN P April 2015 17 MSR15D MSR15D The MSR15D is a safety relay with two immediate safety outputs and one off delayed safety output There are two models which have different delay time ranges The preferred migration for the MSR15D is to the GSR Cl with the EMD expansion relay The MSR15D is only available with 24V DC power one dual channel input and automatic reset The Cl has one switch to configure the reset as automatic or monitored manual The EMD has two rotary switches that can accommodate the MSR15D delay ranges of both MSR15D models converts to GSR C
12. 3M See Interposing Relays on page 3 for a wiring example of using interposing relays for applications where the load exceeds the CI capability Load Type MSR23M cl 300 15 C300 AC 15 AC Inductive 3A 15A P300 DC 13 DC 2 5 A at 24V DC 2 A at 24V DC 1 circuit at 8A Thermal non switching 2 circuits at 7 A 2 See current limit curve The current through the contacts in the MSR23M must be adjusted to its current limit curves 250 IPA 160 147 max 200 140 gt gt 120 E c amp 1507 100 gt e 80 100 60 a 40 507 20 met iM elk eae NN 0 0 10 20 30 40 50 23 456 7 8 Quadratic total current Switching current A safe braking continuous arcing 1 l current in contact paths max 1 switching cycle s Arc Limit Curve Under Resistive Load Quadratic Total Current Limit Curve Rockwell Automation Publication 440R UM011B EN P April 2015 MSR123RT MSR123RT The MSR123RT has the following key design characteristics Single or dual channel inputs accommodate mechanical and OSSD light curtain inputs Two electromechanical safety outputs One solid state auxiliary output MSR123RT e Reset can operate automatically or monitored manual converts to The recommended conversion is to a GSR SI GSR SI Terminal Locations and
13. 8 Terminal Locations and Panel Space 18 Example SchematiC weewwna 19 Response TMG 19 Output Load Capability 19 Rockwell Automation Publication 440R UM011B EN P April 2015 iii Table of Contents MSRIGR T mii Ia 20 Terminal Locations and Panel Space 20 Example Schematic AutomaticReset 20 Example Schematic Monitored Reset 21 Response TIG eoe oo Oe de gual 21 Output Load Capability 21 MSR23M ennei AA OCURRE anes 22 Terminal Locations and Panel Space 22 Example Schematic 24V DC with Automatic Reset 23 Example Schematic 110V AC with Monitored Reset 23 Response TING MT 23 Output Load Capability 24 MSRIU DI Ri aa 25 Terminal Locations and Panel Space 25 Example Schematic 24V DC Mechanical Contacts Monitored Reset 26 Example Schematic DC Powered Dual Channel Automatic Reset 26 Example Schematic Single Channel Monitored Reset 26 Example Sch
14. AC ISA DC DC 13 DC 13 3 Aat 30V DC 2 Aat 24V DC Thermal non switching 4A 6 Aon 1 circuit Rockwell Automation Publication 440R UM011B EN P April 2015 35 CUT CUT The preferred migration for the CUT is to the GSR SI and EMD relay combination The CUT is available with 24V DC 115V AC and 230V AC all included in the same catalog number A 1606 power supply is required to convert the AC supply to DC The CUT on delay may be adjusted from 0 1 seconds to 40 minutes The EMD can be adjusted from 0 1 seconds to 30 minutes For applications that require longer than 30 minutes two EMD relays can be cascaded using the Single Wire Safety signal CUT converts to GSR SI The CU1 has a Remote Indication accessory This device contains two LEDs red to indicate the timing cycle is in process and green to indicate that the output is ON the timing cycle is completed Terminal Locations and Panel Space The CU1 has a 45 mm 1 77 in wide body with one row of terminals at the top and bottom The combination of the GSR SI and EMD also occupy 45 mm 1 77 in of panel space 45 mm 1 77 in 45 mm 1 77 in plus the EMD expansion relay 37 38 47 48 A1 A2 S11 S21 A1 A2 CUT GSR SI GSR EMD 440R TO7114 440R S12R2 440R EM4R2D L11 Y32 S34 L12 L11 X32 13 14 23 24 17 18 27 28 For those applications powered by AC a 1606 XPL15E can be used to provide the 24V DC for the CI and EMD This increases the panel space b
15. Conversion Manual Allen Bradley Minotaur Safety Relay MSR to Guardmaster Safety Relay GSR Conversion Catalog Numbers 440R Family of Safety Relays 1 z M i T 2 Allen Bradley Rockwell Software Automation 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
16. ED flashes After the time expires the outputs turn ON When you release switch S1 the outputs turn OFF immediately If you release S1 in the middle of the timing cycle and then reapply S1 the timer starts from zero Rockwell Automation Publication 440R UM011B EN P April 2015 31 MSR178DP 24V DC as ar vz2 ni 812 22 17 27 37 46 45 511521 a ssa 13 23 LI L Teervsrpsr paene 24V Com 24V DC MSR178 440R M23227 24V Com 32 eaa e emi na v 27 37 Jas Set Range Switch to5 60r7 pea amp 77 27 87 47 RANGE 0 TIME 1 1 2 4 RESET sd To PLC ToPLC Example Schematic Off Delay Retriggerable The MSR178 off delay is retriggerable To achieve similar result the EMD requires a jumper from B1 to B2 When you press S1 K1 and K2 turn ON immediately You can release S1 immediately it does not have to be held closed Both systems have an LED that flashes to indicate the timing cycle is in process On the MSR178 it s the CH1 IN and CH2 IN LEDs On the EMD it s the Logic IN LED After the time expires the outputs turn OFF and all four LEDs turn OFF If you repress S1 during the timing cycle K1 and K2 remain ON the timing cycle is retriggered and starts again from zero If you have use the auxiliary signal to the PLC you can use one of the normally open contacts of the EMD and reverse
17. MD expansion relay 35 mm 1 38 in 45 mm 1 77 in M Y10 Y21 Y22 17 27 37 37 38 47 48 24V B11 B12 A3 A2 Al 1 A2 511 521 A1 A2 MSR178 GSR SI GSR EMD 440R M23227 440R S12R2 440R EM4R2D GND B21B22 49 45 46 L11 Y32 534 112 11 X32 Y11 Y31 Y32 18 28 38 13 14 23 24 17 18 27 28 For AC operation the 1606 XLP15E can be used to supply 24V to the SI and EMD and MSR125 The MSR125HP is also available in 115V AC or 230V AC In the worst case scenario the panel space that is required to replace the MSR178DP is 90 mm 3 54 in 30 Rockwell Automation Publication 440R UM011B EN P April 2015 24V 15W 0 54 0 63 A 1606 XLP15E 100 240V AC 24V 15W 0 54 0 63 A 1606 XLP15E 100 240V AC MSR178DP 90 mm 3 54 in Y1 Y2 13 23 512 522 37 38 47 48 511 512 S13 A1 A2 S11 521 A1 A2 MSR125HP GSR SI GSR EMD 440R D23171 440R S12R2 440R EM4R2D S21 S22 S23 A2 L11 Y32 S34 L12 L11 X32 14 24 13 14 23 24 17 18 27 28 90 mm 3 54 in Y1 Y2 13 23 13 23 33 41 37 38 47 48 S11 512 S13 A1 511 512 L11 A1 A2 MSR125HP GSRCI GSR EMD 440R D23171 440R S13R2 440R EM4R2D 521 S22 523 2 1521 S22 S34 2 112 L11 X32 14 24 34 42 17 18 27 28 Example Schematic On Delay When you press and hold S1 the LEDs on both examples start flashing to indicate that the timing has started On the MSR178 the CH1 IN and CH2 IN LEDs flash On the EMD the Logic IN L
18. Panel Space 45 mm 1 77 in 22 5 mm 0 88 in 1 511 552 512 Y31 Y32 13 23 12 S22 A1 A2 S11 S21 MSR123RT GSR SI 440R J23106 440R S12R2 L11 Y32 S34 S21 22 X5 S33 534 14 24 A2 13 14 23 24 For those applications where the MSR123RT is powered by 115V AC or 230V AC a 1606 XLP15E power supply can be used With the additional power supply the panel space by the replacement design occupies a smaller space than the MSR123RT by itself 45 mm 1 77 in 45 mm 1 77 in Al 511552512 Y32 13 23 Fo S12 522 2415W A1 A2 511 S21 0 54 0 63 A MSR123RT 1606 XLP15E GSR SI 440R J23104 110V AC 440R S12R2 440R J23103 230V AC 100 240V AC E1399 534 521 522 X5 533 534 14 24 A2 LN 13 14 23 24 Rockwell Automation Publication 440R UM011B EN P April 2015 25 MSRT23RT Example Schematic 24V DC Mechanical Contacts Monitored Reset 24V DC Z MsRi23RT i RESET 440R CJ23106 f ess M 440R S12R2 24V Com 24V DC 6 7 7 MSR123RT 440R CJ23106 5 M 440R S12R2 24V Com Example Schematic Single Channel Monitored Reset 24V DC Reset Reset K 4 7 MSR123RT 7 440R CJ23106 K2 Ave 24V Com 26 Rockwell Automation Publication 440R UM011B EN P April 2015 MSR123RT Example Schematic Single Channel Automatic Reset 24V DC E MSR123RT TE 440R CJ23106 GSRSI 440R S12R2 24V Com 24V DC Light Cur
19. ations and Panel Space For those applications where the MSR23M is powered by 110V AC a 1606 XLP15E power supply can be used With the additional power supply the panel space by the replacement design occupies a smaller space than the MSR18RT by itself 22 5 mm 22 5 mm 0 88 in 0 88 in A1 S33 S34 13 23 33 41 13 23 24 31 A1S11 S12 L11 MSR23M 440R P23073 GSR CI 24V DO 440R S13R2 14 S11 S12 32 S21 S22 34 A2 521 522 A2 14 24 34 42 45 mm 1 77 in 45 mm 1 77 in S33 534 E 13 23 24 31 24V 15W 0 54 0 63 A 13 23 33 41 A1S11 S12 L11 MSR23M 1606 XLP15E GSR CI 440R P23074 110V AC 440R S13R2 14 S11 S12 32 100 240v 1521 522 534 A2 S21 S22 LN 14 24 34 42 Rockwell Automation Publication 440R UM011B EN P April 2015 MSR23M Example Schematic 24V DC with Automatic Reset 24V DC MSR23M 440R P 23073 24V Com Example Schematic 110V AC with Monitored Reset L1 110V AC 1 Reset Reset 111213 R 0 T ud ud 440R P23074 O L2 AC Com Response Time 24V Com MSR23M 15 ms 2 35 ms Since the MSR23M is faster than the CI the safety distance must be examined closely and adjusted if A necessary Rockwell Automation Publication 440R UM011B EN P April 2015 23 24 MSR23M Output Load Capability The outputs of the CI may require interposing relays depending on the load being switched by the MSR2
20. d 38 Response 38 Output Load Capability 39 iv Rockwell Automation Publication 440R UM011B EN P April 2015 GSR Benefits Introduction The Guardmaster Safety Relay GSR next generation family of safety relay series are high quality replacements for most of the Minotaur Safety Relay MSR family of safety relays In their consistent narrow design of 22 5 mm 0 88 in housing and equipped with configurable functions for reset and logic the GSR relays can consolidate various functions of MSR with fewer models Therefore reducing stock requirements The MSR product line of safety relay modules typically offers one dedicated safety function for one safety circuit and actuator The MSR solutions have less connectivity to each other than the superior GSR relays Adding a second or third safety circuit requires more safety relay modules and safety contacts for cascading to maintain PLd or PLe safety ratings according to EN ISO 13849 1 respectively SIL 2 or SIL 3 according to IEC 62061 GSR instead offers configurable safety functions and consolidates safety circuits which result in fewer units less space and fewer costs Due to the unique SWS cascading capability logic combinations and zones can be constructed quickly A replacement with GSR is meant to be more than a one b
21. determined by the wiring MSR12T converts to Terminal Locations and Panel Space GSR CI The MSR12T has a row of terminals at the top and bottom Its width is 45 mm 1 77 in The GSR CI has two rows of terminals at the top and bottom allowing a smaller 22 5 mm 0 88 in width 45 mm 1 77 in 22 5 mm 0 88 in A1513 S24 X1 41 13 23 33 13 23 33 41 1 511 512 L11 MSR12T GSR CI 440R K23041 24V DC 440R S13R2 21 S22 S34 A2 A2 S14 S23 X2 42 14 24 34 14 24 34 42 The MSR12T also has option for 110V AC Since the GSR Cl is powered by 24V DC the 1606 XLP15E can be used to convert the AC supply to 24V DC while still occupying the same amount of space 45 mm 1 77 in gt 45 mm 1 77 in 1 513 S24 X1 41 13 23 33 13 23 33 41 PA Tow A1S11 S12 L11 0 54 0 63 A MSR12T 1606 XLP15E GSR Cl 440R K23042 110V AC 440R S13R2 100 240V S21 522 534 A2 A2S14 S23 X2 42 14 24 34 1 24 34 42 Rockwell Automation Publication 440R UM011B EN P April 2015 13 MSRT2T Example Schematic DC Powered 24V DC RESET AM GSRCI 440R S13R2 MSR12T 440R K23041 24V Com L1 110V AC 24V Com L2 AC Com Example Schematic AC Powered Alternative As an alternative the AC powered MSR12 can be replaced by an equivalent MSR127 The user must select the appropriate MSR127 L1 110V AC L2 AC Com 14 Rockwell Automation Publicat
22. 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 P 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 ARCFLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to poten
23. e United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page Rockwell Otomasyon Ticaret 5 Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headguarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 440R UM011B EN P April 2015 Copyright O 2015 Rockwell Automation Inc All rights reserved Printed in the U S A
24. ematic Single Channel AutomaticReset 27 Example Schematic Light Curtain Monitored Reset 27 Example Schematic AC Powered Monitored Reset 27 Example Schematic AC Powered Alternative 28 Response MENG ns dax 28 Output Load Capability 29 MSR ESDP mii ia 30 Terminal Locations and Panel Space 30 Example Schematic On Delay 31 Example Schematic Off Delay Retriggerable 32 Example Schematic Off Delay Non Retriggerable 33 Example Schematic Single Shot Jog 33 Example Schematic Single Shot Two hand Control 34 Example Schematic On Delay AC Powered 35 Response Hle 35 Output Load Capability 35 CUT ka ese II e cvsu ssececesevs t eos ek s 36 Terminal Locations and Panel Space 36 Example Schematic ON Delay up to 30 minutes 37 Example Schematic ON Delay up to 60 minutes 37 Example Schematic AC Powere
25. gher current capability than the CI as shown in the table See Interposing Relays on page 3 for a wiring example of using interposing relays for applications where the load exceeds the CI capability Load Type MSR8T cI AC Inductive m merid i saat 20 Thermal non switching 2A Rockwell Automation Publication 440R UM011B EN P April 2015 MSR10RD converts to GSR CI plus 2 EM and 1 EMD expansion relays MSR10RD MSR10RD The MSR10RD has eight immediate safety outputs and one delayed safety output plus an immediate auxiliary output and a delayed auxiliary output The preferred migration for the MSR10RDT is to the GSR Cl relay with two EM expansion relays and one EMD expansion relay The MSR10RD comes complete with an option for 24V DC 115V AC and 230V AC For AC powered applications a 1606 power supply can be used to provide 14V to the GSR relays Terminal Locations and Panel Space The MSR10RD has a row of terminals at the top and bottom Its width is 152 mm 5 98 in 152 mm 5 98 in lt gt Al 513 523 x1 13 23 33 43 53 63 73 83 91 D13 D21 MSR10RD 440R G23029 0 1 to 10s Delay 440R G23067 1 0s Delay 440R G23068 0 5s Delay A2 S14 524 2 14 14 34 44 54 64 74 84 92 D14 D22 For 24V DC powered applications a GSR CI two EM and one EMD relay are needed these occupy only 90 mm 3 54 in of panel space 90 mm 3 54 in 13 23 33 41 33 34 43 44
26. ime to 10 to 1 2 30r4 RANGEO TIME 1 2 1 2 RESET 17 2 3 t 4 H a s Sum 0 MMN 7 EMD EMD X 440R 107114 LA 440R EM4R2D To PLC 24V Com Example Schematic AC Powered For AC powered applications a 1606 XLP15E power supply is recommended to provide the 24V DC supply to the CI and EMD relays L1 115V AC 230V AC Set Range Switch to 1 2 3 0r 4 4 aS 1 151 e 440R TO7114 440R S12R2 Response Time CUT set by the timer selection EMD set by the timer selection For most applications there should be no further action is required by the user as the timings can be made equivalent 38 Rockwell Automation Publication 440R UM011B EN P April 2015 CUT Output Load Capability The CU1 has a higher current capability than the Cl as shown in the table See Interposing Relays on page 3 or a wiring example of using interposing relays for applications where the load exceeds the CI capability Load Type CU1 cl B300 AC 15 C300 AC 15 AC Inductive 4A Q 250V AC 15 N300 DC 13 DC 2 Aat 30V DC 2 A at 24V DC Thermal non switching 2 Rockwell Automation Publication 440R UM011B EN P April 2015 39 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical and application notes sample
27. ion 440R UM011B EN P April 2015 Response Time MSR12T 50 ms 2 35 ms MSRT2T Since the CI has a faster response time the safety distance for the CI is shorter than the MR12T No further action required by the user Output Load Capability The MSR12T has a higher current capability than the Cl as shown in the table See Interposing Relays on page 3 for a wiring example of using interposing relays for applications where the load exceeds the CI capability Load Type MSR12T cl UR DC D 2Aat24V DC Thermal non switching 4A 2A Rockwell Automation Publication 440R UM011B EN P April 2015 15 MSR14T MSR14T The preferred migration for the MSR14T is to the GSR Cl relay The MSR14T is only available with 24V DC power one dual channel input and automatic reset It has two normally open outputs and one normally closed output The Cl has one switch to configure the reset as automatic or monitored manual Dual channel operation is determined by the wiring MSR14T Terminal Locations and Panel Space converts to GSR CI The MSR14T has a 22 5 mm 0 88 in wide body with two rows of terminals at the top and bottom The GSR CI has is similar in that it also two rows of terminals at the top and bottom in a 22 5 mm 0 88 in width 22 5 mm 22 5 mm 0 88 in 0 88 in 31 13 23 13 23 33 41 A1 513 S23 X1 A1S11 S12 L11 MSR14T 440R L23047 GSR Cl 24V DC 440R S13R2 A2 S14 S24 X2 521 522 5
28. ion Publication 440R UM011B EN P April 2015 MSR16R T Example Schematic Monitored Reset Inside the MSR16R T cover set the internal switch to R On the Cl configure the rotary switch on its front face to MM 24V DC V ud eh atl e f MSR16T Reset L1L2 HAA s 0 RESET O AP 440R N23059 3R2 24V Com Response Time MSR16R T 90 ms 35 ms Since the has a faster response time the safety distance for the CI is shorter than the MR16T No further action is required Output Load Capability The MSR16R T has a higher current capability than the CI as shown in the table See Interposing Relays on page 3 for a wiring example of using interposing relays for applications where the load exceeds the CI capability I en DC WA 2 Aat 24V DC Thermal non switching 6A 2A Rockwell Automation Publication 440R UM011B EN P April 2015 21 MSR23M MSR23M converts to GSR CI 22 MSR23M The MSR23M is a safety relay that is designed to interface with safety mats The MSR23M is available in narrow housing for 24V DC applications and wider housing for applications requiring 110V AC Each unit has an internal switch that sets the relay for automatic reset or monitored manual reset The recommended conversion is to a GSR CI for the DC powered unit and a GSRCI with a 1606 power supply for the MSR23M powered at 110V AC Terminal Loc
29. itch is pressed and held the 1 K2 contactors turn ON during the timing cycle If the jog switch is released before the end to the timing cycle the K1 and K2 contactors turn OFF immediately The jog function cannot be restarted until after completion of the timing cycle If you have use of the MSR178 auxiliary signal to the PLC you can use one of the normally open contacts of the EMD and reverse the logic in the PLC Rockwell Automation Publication 440R UM011B EN P April 2015 33 MSR178DP 24V DC MSR178 440R M23227 24V Com 24V DC Al 24 MSR178 440R M23227 A2 Set Range Switch To PLC Example Schematic Single Shot Two hand Control The MSR178 can generate a shot output with a two hand control operation Switches 51 and S2 must be actuated within 0 5s of each other and the K1 and K2 outputs will turn ON for the specified duration To accomplish the combination of features a two hand control must be used and the SI and EMD The MSR125 is recommended for this but it requires that 51 and S2 to be converted to normally open normally closed switches Set Range Switch S1 524 to8or9 t 9 E 811 812 821 822 Y T 37 46 A1 11 512 51 13 23 Y1 B1 82 X32 17 27 37 47 RANGE 0 TIME 1 TIME YA RESET 2 S8 A 70 ei 5 riko MSR125 2 si MM gt GND Y32 Y31 Y21 Y10 24V Com 34
30. l Terminal Locations and Panel Space The MSR15D has a 45 mm 1 77 in wide body with a row of terminals at the top and bottom The combination the GSR Cl and EMD also occupy 45 mm 1 77 in of panel space They each have two rows of terminals at the top and bottom 45 mm 1 77 in 45 mm 1 77 in 1 S13 S23 X1 31 13 23 47 13 23 33 41 37 38 47 48 A1S11 S12 L11 A1 A2 plus the EMD expansion relay MSR15DT GSR Cl GSR EMD 440R M23048 0 1 to 10s 440R S13R2 440R EM4R2D 440R M23057 1 to 35s 521 S22 S34 2 112 L11 X32 A2 S1 S24 X2 32 14 24 48 14 24 34 42 17 18 27 28 18 Rockwell Automation Publication 440R UM011B EN P April 2015 MSR15D Example Schematic For off delay operation the Range switch on the EMD should be set to values 1 2 or 4 A jumper between B1 and B2 is used if retriggerable operation is desired 24V DC 24V Com Response Time MSR15D 90 ms immediate outputs 0 1 to 35 s delayed output Cl 35 ms immediate outputs 0 1 to 35 s delayed output Since the CI has a faster response time the safety distance for the CI is shorter than the MR15D No further action is required Output Load Capability The MSR15D has a higher current capability than the CI as shown in the table See Interposing Relays on page 3 for a wiring example of using interposing relays for applications where the load exceeds the CI capability Load Type MSR15D EMD AC Inductive B300 AC
31. ly and adjusted if necessary ATTENTION A Output Load Capability The MSR10RD has a higher current capability than the Cl EM and EMD as shown in the table See Interposing Relays on page 3 for a wiring example of using interposing relays for applications where the load exceeds the GSR capability Load Type MSR10RD EMD B300 AC 15 B300 AC 15 AC Inductive 8300 AC 15 300 C 15 1 5 A 250V 1 5 A 250V 4 15A AC AC DC P300 DC 13 DC 13 DC 13 DC 13 3 A at 24V DC 2 Aat 24V DC 2 A at 24V DC 2 A at 24V DC n Rr 9 4A 2A 6 Aon 1 circuit 6A on 1 circuit Rockwell Automation Publication 440R UM011B EN P April 2015 MSR11R MSR11R The preferred migration for the MSR11R is to the GSR Cl relay The MSR11R is only available with one dual channel and monitored manual reset Currently only the 24V version is available The 110V AC and 230V AC versions were obsoleted earlier The Cl has one switch to configure the reset as automatic or monitored manual Dual channel operation is determined by the wiring MSR11R converts to GSR CI Terminal Locations and Panel Space The MSR11R has a row of terminals at the top and bottom Its width is 45 mm 1 77 in The GSR CI has two rows of terminals at the top and bottom allowing a smaller 22 5 mm 0 88 in width 45 mm 1 77 in 22 5 mm 0 88 in 1 513 S24 X1 41 13 23 33 13 23 33 41 A1S11 S12 L11 MSR11R GSR Cl 440R J23044 440R S13R2
32. ns and Panel Space 7 Example Schematic DC Powered 8 Example Schematic AC Powered 9 Response 9 Output Load Capability 10 MSI URA 11 Terminal Locations and Panel Space 11 Example Schematic Ce tto e Orb AT REO Ron UE ER a teens wee 11 Response 12 Output Load Capability 12 MRI 13 Terminal Locations and Panel Space 13 Example Schematic DC Powered 14 Example Schematic AC Powered 14 Example Schematic AC Powered Alternative 14 Response 14 Output Load Capability 15 5 4 ii aa 16 Terminal Locations and Panel Space 16 Example SchematiC wemwwna 16 Response 225 osse aa 17 Output Load Capability 17 MSRISD ii disaini ns 1
33. peration of the GSR relays is slightly different from the operation of the MSR relays The reset operation of the MSR relays occurs on the trailing edge of the signal for example when the reset button is released The reset on the GSR relays must see the reset signal released within the range of 0 25 3 s MSR GSR Reset Button Reset Button Released Released within Time Range Y Y 24V 0 255 35 Rockwell Automation Publication 440R UM011B EN P April 2015 3 MSR8T MSR8T The preferred migration for the MSR8T is to the GSR CI relay The CI has one switch to configure the reset as automatic or monitored manual Single or dual channel operation is determined by the wiring Terminal Locations and Panel Space The MSR8T has a row of terminals at the top and bottom Its width is 45 mm 1 77 in The GSR CI has two rows of terminals at the top and bottom allowing a smaller 22 5 mm 0 88 in width MSR8 converts to 45 mm 1 77 in 2 mm 0 88 in LUE 1 GSR CI 1 513 X1 13 23 33 41 51 13 23 33 41 A1S11 S12 L11 MSR8T GSR Cl 440R E23030 440R S13R2 521 S22 534 A2 A2S14 X2 14 24 34 42 52 14 24 34 42 The MSR8T also has option for 115V AC and 230V AC Since the GSR Cl is powered by 24V DC the 1606 XLP15E can be used to convert the AC supply to 24V DC while still occupying the same amount of space 45 mm 1 77 in 45 mm 1 77 in A1 S13 X1 13 23 33 41 51 13 23 33 41 A1S11 S12 L11 24V
34. tain OSSD1 OSSD2 MSR123RT 440R CJ23106 GsRs 440R S12R2 24V Com Example Schematic AC Powered Monitored Reset A Bulletin 1606 XLP15E can be used to provide the 24V DC to power the GSR SI relay L1 110 or 230VAC enZ 7 MsRi23RT RESET 440R J23104 115V AC csns M 440R J23103 230V AC 440R S12R2 L2 AC Com Rockwell Automation Publication 440R UM011B EN P April 2015 27 MSRT23RT Example Schematic AC Powered Alternative As an alternative the AC powered MSR123 can be replaced by an equivalent MSR126 The user must select the appropriate MSR126 Note that the MSR126 does not have an auxiliary output L1 110 or 230V AC 440R J23104 115V AC 440R J23103 230V AC L2 AC Com Response Time MSR123RT 15 ms 51 2 35 ms The safety outputs of the CI has a 35 ms response time whereas the single wire safety output of the CI is 25 ms Since the MSR123RT is faster than the SI the safety distance must be examined closely and adjusted if necessary ATTENTION A 28 Rockwell Automation Publication 440R UM011B EN P April 2015 MSR123RT Output Load Capability The outputs of the SI may require interposing relays depending on the load being switched by the MSR123RT See Interposing Relays on page 3 for a wiring example of using interposing relays for applications where the load exceeds the SI capability Load Type MSR123RT SI 1 A300 15 C300 15
35. tial 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 Allen Bradley Guardmaster Minotaur Rockwell Automation and Rockwell Software are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Table of Contents UA AA ia 1 GSR Benefits 1 Conversion Concerns 1 Panel SACO iua ad vadens eorr ee poe eva the ere 2 Wiring Terminal Locations 2 2 nandi te 2 Interposing 3 Monitored Reset Operation 3 MSRST wi ia 4 Terminal Locations and Panel Space 4 Example Schematic DC Powered 5 Example Schematic AC Powered 5 Example Schematic AC Powered Alternative 5 Response NMG o tees 5 Output Load Capability 6 MSRIOBD iii aa 7 Terminal Locatio
36. y 22 5 mm 0 88 in to a total of 67 5 mm 2 66 in 36 Rockwell Automation Publication 440R UM011B EN P April 2015 CUT 67 5 mm 2 66 in 12 S22 37 38 47 48 054 063A 1 A2 511 521 A1 A2 GSR SI GSR EMD 1606 XLP15E 440R S12R2 440R EM4R2D 100 240V AC L11 Y32 534 L12 L11 X32 LN 13 14 23 24 17 18 27 28 Example Schematic ON Delay up to 30 minutes Timing begins when switch S1 is pressed provided the reset loop X1 X2 on the CU1 is made Switch S1 must be maintained closed for the full duration of the timing cycle The Remote Indication unit can be replaced with two LED indicators 24V DC Remote Indication Set Range Switch SIA to1 2 30r4 To PLC Timing Started or Complete Timing Complete 24V Com Example Schematic ON Delay up to 60 minutes For applications where the timing cycle is greater than 30 minutes and less than 60 minutes two EMD relays must be used The Single Wire Safety signal is cascaded L11 to L12 and then again from L11 to L12 Set the Range switch to 4 and Time switch to 10 on the first EMD to achieve a 30 minute delay At the end of its cycle it will signal the second EMD to start its timing cycle Set the Range and Time of the second EMD to achieve the desired extra time up to a total of 60 minutes Rockwell Automation Publication 440R UM011B EN P April 2015 37 CUT 24V DC Set Range Switch Set Range Switch to 4 and T
37. y one swap out Machine designs have changed over the past years that are driven by new Machinery directives changes of harmonized standards and demands of safety solutions contribute to productivity and flexibility The following sections offer detailed assistance in converting a legacy MSR solution to a smarter cost effective machine design Compliance with the latest requirements of Machinery directive and harmonized standards have also been addressed For further assistance in replacing those devices please contact Technical Support The GSR family of relays provides the following more benefits One or two dual channel inputs Single wire safety expansion Narrow package smaller panel space Configurable operation Cat 4 PLe and 5113 rating on most models RoHS compliance Rockwell Automation Publication 440R UM011B EN P April 2015 Introduction Conversion Concerns Manufacturers distributors integrators and users recognize that product obsolescence is a fact of the industrial business cycle This document attempts to provide a most cost effective recommendation for converting the MSR relay family to the state of the art GSR relay family considering the following major concerns Panel Space Many control panel designers provide space in their panels for future expansion and improvements If that extra panel space gets used then panel space can become tight Recognizing this fact the recommended

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