Minotaur Safety Relay (MSR) to Guardmaster Safety Relay (GSR) Conversion

Important User Information

Read this document and related resources before installing, configuring, operating, or maintaining this product. Users must be familiar with installation and wiring instructions, as well as applicable codes, laws, and standards. All activities must be performed by trained personnel. Rockwell Automation is not liable for indirect or consequential damages resulting from the use or application of this equipment. Examples and diagrams are for illustrative purposes only. Rockwell Automation assumes no patent liability. Reproduction of this manual without written permission is prohibited.

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IMPORTANT: Identifies critical information for successful application and understanding.

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Additional Resources

Several publications provide additional information on related Rockwell Automation products:

• Guardmaster EtherNet/IP Network Interface User Manual, publication 440R-UM009
• Guardmaster Safety Relays User Manual, publication 440R-UM013
• Minotaur Safety Relay User Manual, publication 440R-UM014
• Guardmaster Configurable Safety Relay, Publication 440C-UM001
• 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: rok.auto/certifications

Publications can be viewed or downloaded at rok.auto/literature.

Preface

Many older Allen-Bradley Guardmaster® safety relays are discontinued. This publication offers conversion examples to newer safety relays with advanced technologies. Product obsolescence is a normal part of the industrial business cycle. This manual provides cost-effective recommendations for converting MSR family safety relays to the state-of-the-art GSR family, addressing key concerns like panel space, wiring terminal location, wiring changes, response time, and output load capability.

IMPORTANT: The following MSR safety relays will continue to be offered for the foreseeable future:

• MSR Family: MSR22LM, MSR41, MSR42, MSR45, MSR5T, MSR55, MSR117, MSR124, MSR125, MSR126, MSR127, MSR131, MSR132, MSR138, MSR142

This manual is intended for machine safeguard system designers trained in safeguard system design and risk assessments. It guides the selection of appropriate GSR solutions by highlighting feature differences and requires a risk assessment of the converted design to confirm compliance with safeguarding requirements.

Chapter 1: Product Overview

GSR 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

Conversion Concerns

Replacement involves more than a one-by-one swap. New Machinery Directives and evolving standards drive design changes. This publication assists in converting legacy MSR solutions to smarter, cost-effective GSR designs, ensuring compliance with the latest requirements.

Panel Space

Conversions aim to maintain or reduce panel space, accommodating potential future expansion.

Wiring Terminal Location

Recommended conversions show terminal locations of old and new devices to aid planning.

Wiring Change

Example schematics compare older MSR devices with recommended GSR equivalents.

Response Time

Response time is critical for safety distance calculations. An increase in response time requires adjustment of safety distances, especially for presence-sensing devices like light curtains and safety mats.

Output Load Capability

Safety relays have limitations on current switching. Interposing relays can be used when loads exceed relay ratings. Figure 1 and Figure 2 illustrate the use of interposing relays (e.g., 700-HPSXZ24 relay with 700-HN123 base, 700-AD1LR diode, 700-HN119 retainer).

Monitored Reset Operation

GSR relays require the reset signal to be released within 0.25 to 3 seconds, unlike MSR relays which reset on the trailing edge of the signal. Figure 3 illustrates this reset operation signal timing.

Chapter 2: Phase 1 (April 2015)

MSR8T Safety Relay

Conversion: MSR8T to GSR CI (440R-S13R2).

Features: GSR CI offers configurable reset (automatic/monitored manual) and dual-channel operation via wiring. It has a narrower 22.5 mm (0.88 in.) width compared to the MSR8T's 45 mm (1.77 in.). AC-powered MSR8T requires a 24V DC power supply (e.g., 1606-XLP15E) for the GSR CI.

Terminal Locations & Panel Space: MSR8T has terminals top/bottom; GSR CI has two rows top/bottom.

Wiring Schematics: Figure 4 (DC Powered) and Figure 5 (AC Powered) show MSR8T wiring compared to GSR CI, including the use of a 1606-XLP15E power supply for AC to DC conversion.

Response Time: MSR8T: 90 ms; GSR CI: 35 ms. GSR CI is faster, potentially shortening safety distance.

Output Load Capability

MSR8T has higher current capability than GSR CI. Interposing relays may be needed for loads exceeding GSR CI ratings. Table 2 compares current capabilities (MSR8T: AC-15 4A, DC-13 3A; GSR CI: AC-15 1.5A, DC-13 2A).

MSR10RD Safety Relay

Conversion: MSR10RD to GSR CI (440R-S13R2) plus two EM expansion relays (440R-EM4R2) and one EMD expansion relay (440R-EM4R2D).

Features: MSR10RD has 8 immediate and 1 delayed safety outputs, plus auxiliary outputs. The GSR solution consolidates functions into a smaller panel space (90 mm / 3.54 in. total).

Terminal Locations & Panel Space: MSR10RD is 152 mm (5.98 in.) wide. The GSR solution is significantly narrower.

Wiring Schematics: Figure 9 & 10 show DC and AC powered MSR10RD compared to the GSR CI, EM, and EMD equivalents. Figure 11 shows AC powered conversion with 1606-XLP15E.

Response Time: MSR10RD: 50 ms; GSR CI + EM/EMD: 70 ms (35ms + 35ms). ATTENTION: MSR10RD is faster; safety distance must be evaluated.

Output Load Capability

MSR10RD has higher current capability than GSR CI, EM, and EMD relays. Table 4 compares capabilities (MSR10RD: AC-15 4A, DC-13 3A; GSR CI: AC-15 1.5A, DC-13 2A; EM/EMD: AC-15 1.5A, DC-13 2A).

MSR11R Safety Relay

Conversion: MSR11R to GSR CI (440R-S13R2).

Features: MSR11R is single dual-channel, monitored manual reset. GSR CI offers configurable reset and dual-channel operation via wiring. MSR11R is 45 mm (1.77 in.) wide; GSR CI is 22.5 mm (0.88 in.).

Terminal Locations & Panel Space: MSR11R terminals top/bottom; GSR CI two rows top/bottom.

Wiring Schematics: Figure 17 shows DC powered MSR11R compared to GSR CI.

Response Time: MSR11R: 50 ms; GSR CI: 35 ms. GSR CI is faster.

Output Load Capability

MSR11R has higher current capability than GSR CI. Table 6 compares capabilities (MSR11R: AC-15 4A, DC-13 3A; GSR CI: AC-15 1.5A, DC-13 2A).

MSR12T Safety Relay

Conversion: MSR12T to GSR CI (440R-S13R2).

Features: MSR12T is dual-channel, automatic reset. GSR CI offers configurable reset and dual-channel operation via wiring. MSR12T is 45 mm (1.77 in.) wide; GSR CI is 22.5 mm (0.88 in.). AC powered MSR12T requires a 24V DC power supply (e.g., 1606-XLP15E).

Terminal Locations & Panel Space: MSR12T terminals top/bottom; GSR CI two rows top/bottom.

Wiring Schematics: Figure 18 (DC Powered), Figure 19 (AC Powered), and Figure 22 (AC Powered Alternative using MSR127) show MSR12T wiring compared to GSR CI.

Response Time: MSR12T: 50 ms; GSR CI: 35 ms. GSR CI is faster.

Output Load Capability

MSR12T has higher current capability than GSR CI. Table 8 compares capabilities (MSR12T: AC-15 4A, DC-13 3A; GSR CI: AC-15 1.5A, DC-13 2A).

MSR14T Safety Relay

Conversion: MSR14T to GSR CI (440R-S13R2).

Features: MSR14T is 24V DC powered, dual-channel, automatic reset, with 2 N.O. and 1 N.C. outputs. GSR CI offers configurable reset and dual-channel operation via wiring. Both are 22.5 mm (0.88 in.) wide.

Terminal Locations & Panel Space: Both have two rows of terminals top/bottom.

Wiring Schematics: Figure 24 shows DC powered MSR14T compared to GSR CI.

Response Time: MSR14T: 90 ms; GSR CI: 35 ms. GSR CI is faster.

Output Load Capability

MSR14T has higher current capability than GSR CI. Table 10 compares capabilities (MSR14T: AC-15 4A, DC-13 2A; GSR CI: AC-15 1.5A, DC-13 2A).

MSR15D Safety Relay

Conversion: MSR15D to GSR CI (440R-S13R2) plus EMD expansion relay (440R-EM4R2D).

Features: MSR15D has two immediate and one off-delayed safety outputs. It's 24V DC powered, dual-channel, automatic reset. GSR CI + EMD offers configurable reset and dual-channel operation. Both configurations occupy 45 mm (1.77 in.) panel space.

Terminal Locations & Panel Space: MSR15D has terminals top/bottom; GSR CI + EMD have two rows top/bottom each.

Wiring Schematics: Figure 26 shows DC powered MSR15D compared to GSR CI + EMD.

Response Time: MSR15D: 90 ms (immediate), 0.1-35 s (delayed); GSR CI: 35 ms (immediate), 0.1-35 s (delayed). GSR CI immediate outputs are faster.

Output Load Capability

MSR15D has higher current capability than GSR CI. Table 12 compares capabilities (MSR15D: AC-15 4A, DC-13 3A; GSR CI: AC-15 1.5A, DC-13 2A; EMD: AC-15 1.5A, DC-13 2A).

MSR16R/T Safety Relay

Conversion: MSR16R/T to GSR CI (440R-S13R2).

Features: MSR16R/T has 24V AC/DC power, dual-channel input, monitored manual or automatic reset (via internal switch), and three N.O. outputs. GSR CI offers configurable reset and dual-channel operation via wiring. Both are 22.5 mm (0.88 in.) wide.

Terminal Locations & Panel Space: Both have two rows of terminals top/bottom.

Wiring Schematics: Figure 28 (Automatic Reset) and Figure 29 (Monitored Reset) show DC powered MSR16R/T compared to GSR CI.

Response Time: MSR16R/T: 90 ms; GSR CI: 35 ms. GSR CI is faster.

Output Load Capability

MSR16R/T has higher current capability than GSR CI. Table 14 compares capabilities (MSR16R/T: AC-15 6A, DC-13 6A; GSR CI: AC-15 1.5A, DC-13 2A).

MSR23M Safety Relay

Conversion: MSR23M (safety mat interface) to GSR CI (440R-S13R2).

Features: MSR23M is available in narrow housing (24V DC) or wider housing (110V AC). Each has an internal switch for automatic/monitored manual reset. GSR CI replaces DC powered units; AC powered units require a 1606 power supply. MSR23M is 22.5 mm (0.88 in.) wide (DC) or 45 mm (1.77 in.) wide (AC); GSR CI is 22.5 mm (0.88 in.) wide.

Terminal Locations & Panel Space: Figure 30 (DC Powered) and Figure 31 (AC Powered) show MSR23M terminals compared to GSR CI.

Response Time: MSR23M: 15 ms; GSR CI: 35 ms. ATTENTION: MSR23M is faster; safety distance must be evaluated.

Output Load Capability

GSR CI outputs may require interposing relays depending on the load switched by MSR23M. See Output Load Capability on page 11.

MSR123RT Safety Relay

Conversion: MSR123RT to GSR SI (440R-S12R2).

Features: MSR123RT has single/dual-channel inputs, mechanical/OSSD inputs, two electromechanical safety outputs, one solid-state auxiliary output, and configurable reset. GSR SI offers similar capabilities. MSR123RT is 45 mm (1.77 in.) wide; GSR SI + EMD expansion relay also occupies 45 mm (1.77 in.). AC powered MSR123RT requires a 1606 power supply.

Terminal Locations & Panel Space: MSR123RT terminals top/bottom; GSR SI + EMD have two rows top/bottom each.

Wiring Schematics: Figure 37-43 show various DC and AC powered MSR123RT configurations compared to GSR SI, including alternatives using MSR126.

Response Time: MSR123RT: 15 ms; GSR SI: 35 ms (safety outputs), 25 ms (SWS output). ATTENTION: MSR123RT is faster; safety distance must be evaluated.

Output Load Capability

MSR123RT has higher current capability than GSR SI. Table 18 compares capabilities (MSR123RT: AC-15 6A, DC-13 3A; GSR SI: AC-15 1.5A, DC-13 2A).

MSR178DP Safety Relay

Conversion: MSR178DP to GSR SI (440R-S12R2) plus EMD expansion relay (440R-EM4R2D).

Features: MSR178DP has two delayed and one immediate auxiliary output, supports dual-channel, single-channel mechanical, or safety mat inputs. Timing set by jumpers/potentiometer (0.1s to 30 min). GSR SI + EMD offers similar timing adjustment via switches. MSR178DP is 35 mm (1.38 in.) wide; GSR SI + EMD occupy 45 mm (1.77 in.). AC powered MSR178DP requires a 1606 power supply.

Terminal Locations & Panel Space: MSR178DP terminals top/bottom; GSR SI + EMD have two rows top/bottom each.

Wiring Schematics: Figure 45-53 show DC/AC powered MSR178DP configurations (including two-hand control with MSR125HP) compared to GSR SI + EMD.

Response Time: MSR178DP: 20 ms; GSR SI: 45 ms (safety mat), 35 ms (other); EMD: 35 ms + delay. ATTENTION: MSR178DP is faster; safety distance must be evaluated.

Output Load Capability

MSR178DP has higher current capability than GSR CI. Table 20 compares capabilities (MSR178DP: AC-15 6A, DC-13 3A; GSR CI: AC-15 1.5A, DC-13 2A).

CU1 Safety Relay

Conversion: CU1 to GSR SI (440R-S12R2) plus EMD expansion relay (440R-EM4R2D).

Features: CU1 has 24V DC/AC, 115V AC, 230V AC power options. On-delay adjustable 0.1s to 40 min. EMD adjustable 0.1s to 30 min. Cascading EMDs for longer delays. CU1 is 45 mm (1.77 in.) wide; GSR SI + EMD also occupy 45 mm (1.77 in.). AC powered requires 1606 power supply, increasing space to 67.5 mm (2.66 in.).

Terminal Locations & Panel Space: CU1 terminals top/bottom; GSR SI + EMD have two rows top/bottom each.

Wiring Schematics: Figure 56-58 show CU1 configurations compared to GSR SI + EMD.

Output Load Capability

CU1 has higher current capability than GSR CI. Table 22 compares capabilities (CU1: AC-15 4A, DC-13 2A; GSR CI: AC-15 1.5A, DC-13 2A).

Chapter 3: Phase 2 (June 2016)

CU2 Control Unit

Conversion: CU2 to GLP (Series A 205+) safety relay (440R-GL2S2P).

Features: Both use two proximity sensors. CU2 uses NPN/PNP; GLP requires PNP for both. GLP has configurable switch positions for CU2 functionality (5-8) and additional features (1-4). CU2 offers auto/manual reset via Y1/Y2; GLP ignores S44 reset input in auto mode (settings 5-8). CU2 is 45 mm (1.8 in.) wide; GLP is 22.5 mm (0.9 in.) wide. AC powered CU2 requires 1606 power supply for GLP.

Terminal Locations & Panel Space: CU2 terminals top/bottom; GLP two rows top/bottom.

Wiring Schematics: Figure 59-63 show DC/AC powered CU2 configurations compared to GLP and EM expansion relays.

Output Load Capability

CU2 has higher current capability than GLP. Table 23 compares capabilities (CU2: AC-15 5A, DC-13 3A; GLP: DC-13 0.5A; EM: AC-15 1.5A, DC-13 2A).

MSR6R/T Safety Relay

Conversion: MSR6R/T to GSR CI (440R-S13R2).

Features: MSR6R/T has 45 mm (1.8 in.) width, terminals top/bottom. GSR CI is 22.5 mm (0.9 in.) wide with two rows of terminals. AC powered MSR6R/T requires 1606 power supply for GSR CI.

Terminal Locations & Panel Space: MSR6R/T terminals top/bottom; GSR CI two rows top/bottom.

Wiring Schematics: Figure 66-70 show DC/AC powered MSR6R/T configurations compared to GSR CI.

Response Time: MSR6R/T: 50 ms; GSR CI: 35 ms. GSR CI is faster.

Output Load Capability

MSR6R/T has higher current capability than GSR CI. Table 25 compares capabilities (MSR6R/T: AC-15 4A, DC-13 3A; GSR CI: AC-15 1.5A, DC-13 2A).

MSR17T Safety Relay

Conversion: MSR17T to GSR CI (440R-S13R2).

Features: MSR17T is 24V DC powered, 45 mm (1.8 in.) wide, terminals top/bottom. GSR CI is 22.5 mm (0.9 in.) wide with two rows of terminals.

Terminal Locations & Panel Space: MSR17T terminals top/bottom; GSR CI two rows top/bottom.

Wiring Schematics: Figure 72-75 show DC powered MSR17T configurations compared to GSR CI.

Response Time: MSR17T: 13 ms; GSR CI: 35 ms. ATTENTION: MSR17T is faster; safety distance must be evaluated.

Output Load Capability

GSR CI has higher AC current capability and similar DC rating to MSR17T. Table 27 compares capabilities (MSR17T: AC-15 0.75A, DC-13 2A; GSR CI: AC-15 1.5A, DC-13 2A).

MSR18T Safety Relay

Conversion: MSR18T depends on function. 1 N.C./1 N.O. or 2 N.C. inputs convert to GSR CI + EM. Two-hand control converts to MSR125 + MSR132E. 1 N.C./1 N.O. with auto reset converts to MSR9T + MSR132E.

Features: MSR18T is 90 mm (3.5 in.) wide. GSR CI + EM are 22.5 mm each. AC powered MSR18T requires 1606 power supply for GSR relays.

Terminal Locations & Panel Space: MSR18T terminals top/bottom; GSR CI/EM have two rows top/bottom each.

Wiring Schematics: Figure 76-84 show DC/AC powered MSR18T configurations for various functions compared to replacements.

Response Time: MSR18T (20ms) is faster than GSR CI (35ms), MSR9T (60ms), MSR132E (50ms), MSR125H (20ms). ATTENTION: Safety distance must be evaluated.

Output Load Capability

Table 30 compares current capabilities across MSR18T, GSR CI, EM, MSR9T, MSR132E, MSR125.

MSR19E Safety Relay

Conversion: MSR19E to two EM safety relays (440R-EM4R2).

Features: MSR19E has two input channels, 90 mm (3.5 in.) wide. Two EM relays use 45 mm (1.8 in.) panel space. AC powered MSR19E requires 1606 power supply for EM relays.

Terminal Locations & Panel Space: MSR19E terminals top/bottom; EM relays have two rows top/bottom each.

Wiring Schematics: Figure 87-88 show DC/AC powered MSR19E compared to two EM relays.

Response Time: MSR19E: 20 ms; EM: 35 ms. ATTENTION: MSR19E is faster; safety distance must be evaluated.

Output Load Capability

MSR19E has higher current capability than EM relays. Table 32 compares capabilities (MSR19E: AC-15 0.75A, DC-13 2A; EM: AC-15 1.5A, DC-13 2A).

MSR30RT/RTP Safety Relay

Conversion: MSR30RT/RTP to DIS safety relay (440R-D22S2).

Features: MSR30 is 24V DC, single/dual-channel, auto/monitored reset, with 2 N.O. and 1 N.C. solid-state outputs. DIS relay has configurable reset and logic via rotary switch, supports single/dual-channel inputs. MSR30 has Startup Test feature; DIS does not.

Terminal Locations & Panel Space: Both are 22.5 mm (0.9 in.) wide with two rows of terminals top/bottom.

Wiring Schematics: Figure 90-95 show MSR30 configurations compared to DIS relay.

Response Time: MSR30RT/RTP: 15 ms (immediate), 25 ms (safety mats); DIS: 25 ms (mechanical), 30 ms (safety mats). ATTENTION: MSR30RT/RTP is faster; safety distance must be evaluated.

Output Load Capability

MSR30RT/RTP has higher DC current capability than DIS. Table 34 compares capabilities (MSR30: DC 2A; DIS: DC 1.5A).

MSR38DP Safety Relay

Conversion: MSR38DP to GLT safety relay (440R-GL2S2T) for most applications. For safety mat applications, use GSR SI (440R-S12R2) + EMD (440R-EM4R2D).

Features: MSR38D has two delayed and one immediate auxiliary output, supports dual-channel, single-channel mechanical, or safety mat inputs. GLT is recommended. MSR38D is 22.5 mm (0.9 in.) wide; GLT is also 22.5 mm (0.9 in.) wide. GSR SI + EMD occupy 45 mm (1.8 in.).

Terminal Locations & Panel Space: MSR38D terminals top/bottom; GLT and GSR SI + EMD have two rows top/bottom each.

Wiring Schematics: Figure 96-103 show MSR38D configurations compared to GLT or GSR SI + EMD.

Response Time: MSR38D: 15 ms + delay; GLT: 55 ms + delay; GSR SI: 45 ms; EMD: 35 ms + delay. ATTENTION: MSR38D is faster; safety distance must be evaluated.

Output Load Capability

MSR38D has higher DC current capability than GLT. Table 36 compares capabilities (MSR38D: DC 2A; GLT: DC 0.3A; EMD: DC 2A).

MSR121RT Safety Relay

Conversion: MSR121RT to GSR CI (440R-S13R2).

Features: MSR121RT has 24V AC/DC power, auto/monitored reset. GSR CI offers configurable reset and dual-channel operation via wiring. MSR121RT is 55 mm (2.17 in.) wide; GSR CI is 22.5 mm (0.9 in.) wide. AC powered MSR121RT requires 1606 power supply for GSR CI, reducing panel space to 45 mm (1.8 in.).

Terminal Locations & Panel Space: MSR121RT terminals top/bottom; GSR CI two rows top/bottom.

Wiring Schematics: Figure 104-114 show DC/AC powered MSR121RT configurations compared to GSR CI.

Response Time: MSR121RT: 15 ms (24V AC/DC), 20 ms (AC); GSR CI: 35 ms (mechanical/OSSD), 45 ms (safety mat). ATTENTION: MSR121RT is faster; safety distance must be evaluated.

Output Load Capability

MSR121RT has higher current capability than GSR CI. Table 65 compares capabilities (MSR121RT: AC-15 6A, DC-13 6A; GSR CI: AC-15 1.5A, DC-13 2A).

MSR124RT Safety Relay

Conversion: MSR124RT to GSR CI (440R-S13R2) + EM (440R-EM4R2).

Features: MSR124RT has single/dual-channel inputs, mechanical/OSSD inputs, 5 N.O. safety outputs, 1 auxiliary output, configurable reset. It's 100 mm (3.93 in.) wide. GSR CI + EM occupy 67.5 mm (2.66 in.) with 1606 power supply for AC. MSR230P (immediate) replaced by EM; MSR238P (delayed) replaced by EMD.

Terminal Locations & Panel Space: MSR124RT terminals top/bottom; GSR CI/EM have two rows top/bottom each.

Wiring Schematics: Figure 172-178 show DC/AC powered MSR124RT configurations compared to GSR CI + EM.

Response Time: MSR124RT: 20 ms; GSR CI: 35 ms; EM: 25 ms (SWS) + 35 ms = 60 ms. ATTENTION: MSR124RT is faster; safety distance must be evaluated.

Output Load Capability

Table 68 compares current capabilities (MSR124RT: AC-15 5A, DC-13 4A; GSR CI: AC-15 1.5A, DC-13 2A; EM: AC-15 4A, DC-13 2A).

Chapter 4: Phase 3 (July 2018)

CU2 Control Unit

Conversion: CU2 to GLP (Series A 205+) safety relay (440R-GL2S2P).

Features: Both use two proximity sensors. CU2 uses NPN/PNP; GLP requires PNP for both. GLP has configurable switch positions for CU2 functionality (5-8) and additional features (1-4). CU2 offers auto/manual reset via Y1/Y2; GLP ignores S44 reset input in auto mode (settings 5-8). CU2 is 45 mm (1.8 in.) wide; GLP is 22.5 mm (0.9 in.) wide. AC powered CU2 requires 1606 power supply for GLP.

Terminal Locations & Panel Space: CU2 terminals top/bottom; GLP two rows top/bottom.

Wiring Schematics: Figure 144-148 show DC/AC powered CU2 configurations compared to GLP and EM expansion relays.

Output Load Capability

CU2 has voltage-free contacts; GLP has solid-state outputs. EM expansion relay provides voltage-free contacts. Table 50 compares current capabilities (CU2: AC-15 5A, DC-13 3A; GLP: DC-13 0.5A; EM: AC-15 1.5A, DC-13 2A).

MSR7R and MSR7C Safety Relays

Conversion: MSR7R/MSR7C to MSR125H/HP safety relay (440R-D23171 for fixed terminals, 440R-D23166 for removable terminals).

Features: MSR7R/C are logic units for two-hand controls. MSR7R for mechanical switches; MSR7C for electronic-sensing palm buttons. MSR125H/HP is a recommended replacement. MSR7 is 45 mm (1.8 in.) wide; MSR125 is 22.5 mm (0.9 in.) wide.

Terminal Locations & Panel Space: MSR7 terminals top/bottom; MSR125 has two rows top/bottom.

Wiring Schematics: Figure 150 (MSR7R) and Figure 151 (MSR7C) show wiring compared to MSR125. Figure 152 shows MSR125 with expansion relay.

ATTENTION: Risk assessment required for MSR7C to MSR125 conversion, evaluating hands-on-buttons during power interruption.

Maximum Input Impedance

MSR7 tolerates up to 500 Ω; MSR125 tolerates 40 Ω. This difference is usually not an issue due to typical cable resistance.

Response Time

MSR125 (20 ms) is faster than MSR7 (50 ms) without expansion. With MSR132 expansion (50 ms), MSR125 + MSR132 total response time is 70 ms. Safety distance may need recalculation if MSR132 is used.

Output Load Capability

MSR125 has higher current capability than MSR7. Table 53 compares capabilities (MSR7: AC-15 4A, DC-13 2A; MSR125: AC-15 6A, DC-13 3A).

MSR9T Safety Relay

Conversion: MSR9T to SiphaTM 2 controller (440N-S32021).

Features: MSR9T used older diversity concept (1 N.C. + 1 N.O. contact). Sipha 2 uses same diversity, supports contact and non-contact switches. MSR9T and Sipha 2 are 45 mm (1.8 in.) wide with terminals top/bottom. Sipha 2 has different terminal locations.

Wiring Schematics: Figure 154 (24V AC/DC) and Figure 155 (110/115/230V AC) show MSR9T wiring compared to Sipha 2.

Maximum Input Impedance

MSR9T tolerates 500 Ω; Sipha 2 tolerates 200 Ω (terminals 1-4) and 150 Ω (terminals 2-3). This difference is usually not an issue.

Input Simultaneity

MSR9T: 500 ms. Sipha 2: minimum approach speed 17 mm/s (0.67 in./s). If N.O. opens first, N.C. can close anytime. If N.C. closes first, N.O. must open within 1.4 seconds.

Response Time

MSR9T: 50 ms; Sipha 2: 40 ms. Sipha 2 is faster; safety distance does not require recalculation.

Output Load Capability

Table 56 compares current capabilities (MSR9T: AC-15 4A, DC-13 3A; Sipha 2: AC-15 4A, DC-13 2A).

MSR33 Safety Relay

Conversion: MSR33 to Sipha 2 controller (440N-S32021).

Features: MSR33 offered fixed or removable terminals, solid-state outputs. Sipha 2 has fixed terminals, electromechanical outputs. MSR33 has Startup Test feature; Sipha 2 does not. MSR33 is 22.5 mm (0.9 in.) wide; Sipha 2 is 45 mm (1.8 in.) wide.

Terminal Locations & Panel Space: MSR33 terminals top/bottom; Sipha 2 terminals top/bottom, requiring more space.

Wiring Schematics: Figure 157 (Manual Reset) and Figure 158 (Automatic Reset) show MSR33 wiring compared to Sipha 2. Note differences in reset action and auxiliary output logic.

Input Simultaneity

MSR33 allows infinite time between input state changes. Sipha 2 has minimum approach speed of 17 mm/s (0.67 in./s).

Response Time

MSR33: 15 ms; Sipha 2: 40 ms. ATTENTION: MSR33 is faster; safety distance must be evaluated.

Output Load Capability

Table 59 compares DC load capabilities (MSR33: DC 2A; Sipha 2: DC 2A).

MSR35 Safety Relay

Conversion: MSR35 to MSR125H/HP safety relay (440R-D23171 for fixed, 440R-D23166 for removable terminals).

Features: MSR35 is an electronic two-hand control relay, 24V DC powered, with fixed or removable terminals. MSR125H/HP is a recommended replacement. Both are 22.5 mm (0.9 in.) wide with two rows of terminals top/bottom.

Terminal Locations & Panel Space: Both have two rows of terminals top/bottom.

Wiring Schematics: Figure 160 (Category IIIC) and Figure 161 (Category IIIA) show MSR35 wiring compared to MSR125.

Response Time

MSR35: 15 ms; MSR125: 20 ms. ATTENTION: MSR35 is faster; safety distance must be evaluated.

Output Load Capability

MSR125 has higher DC current rating than MSR35. Table 62 compares capabilities (MSR35: DC 2A; MSR125: DC 3A).

MSR121RT Safety Relay

Conversion: MSR121RT to GSR CI (440R-S13R2).

Features: MSR121RT has 24V AC/DC power, auto/monitored reset. GSR CI offers configurable reset and dual-channel operation via wiring. MSR121RT is 55 mm (2.17 in.) wide; GSR CI is 22.5 mm (0.9 in.) wide.

Terminal Locations & Panel Space: MSR121RT terminals top/bottom; GSR CI two rows top/bottom.

Wiring Schematics: Figure 163-170 show DC powered MSR121RT configurations (dual-channel, single-channel, OSSD, safety mat) compared to GSR CI.

Response Time: MSR121RT: 15 ms (24V AC/DC); GSR CI: 35 ms (mechanical/OSSD), 45 ms (safety mat). ATTENTION: MSR121RT is faster; safety distance must be evaluated.

Output Load Capability

MSR121RT has higher current capability than GSR CI. Table 65 compares capabilities (MSR121RT: AC-15 6A, DC-13 6A; GSR CI: AC-15 1.5A, DC-13 2A).

MSR124RT Safety Relay

Conversion: MSR124RT to GSR CI (440R-S13R2) + EM (440R-EM4R2).

Features: MSR124RT has single/dual-channel inputs, mechanical/OSSD inputs, 5 N.O. safety outputs, 1 auxiliary output, configurable reset. It's 100 mm (3.93 in.) wide. GSR CI + EM occupy 67.5 mm (2.66 in.) with 1606 power supply for AC. MSR230P (immediate) replaced by EM; MSR238P (delayed) replaced by EMD.

Terminal Locations & Panel Space: MSR124RT terminals top/bottom; GSR CI/EM have two rows top/bottom each.

Wiring Schematics: Figure 172-178 show DC/AC powered MSR124RT configurations compared to GSR CI + EM.

Response Time: MSR124RT: 20 ms; GSR CI: 35 ms; EM: 25 ms (SWS) + 35 ms = 60 ms. ATTENTION: MSR124RT is faster; safety distance must be evaluated.

Output Load Capability

Table 68 compares current capabilities (MSR124RT: AC-15 5A, DC-13 4A; GSR CI: AC-15 1.5A, DC-13 2A; EM: AC-15 4A, DC-13 2A).

Chapter 5: Phase 4 (July 2021)

CU3 Control Unit

Conversion: CU3 to MSR55P safety relay (various catalog numbers depending on supply voltage and motor type).

Features: MSR55P offers enhanced features over CU3, including single-phase and three-phase motor monitoring, output monitoring, fault reporting, servo motor monitoring, adjustable thresholds, delayed output capability, and higher safety ratings (Cat 4 PLe, SIL 3). CU3 is 45 mm (1.77 in.) wide; MSR55P is also 45 mm wide but taller for heat dissipation.

Power Supply and Thresholds: CU3 supports 24V AC/DC, 110V AC, 230V AC. MSR55P supports 24V DC, 115V AC, 230V AC. MSR55P does not support 24V AC; an AC-to-DC converter is needed. Threshold ranges differ.

Threshold and Delay Settings: CU3 has a potentiometer behind a cover; MSR55P has front-accessible potentiometers for threshold and delay time.

Terminal Locations & Panel Space: CU3 terminals top/bottom; MSR55P has two rows top/bottom.

Wiring Schematics: Figure 182 (TLS1-GD2 Guard Locking) and Figure 183 (TLSZ-R Guard Locking) show CU3 compared to MSR55P wiring.

Output Load Capability

Similar switching capability. MSR55P has higher DC current rating. Table compares AC-15 and DC loads.

Feedback Monitoring

Both CU3 and MSR55P support automatic/manual monitoring on X1/X2. Manual reset on MSR55P displays fault code 4.

MSR300 Safety Relay

Conversion: MSR300 to GSR relays (DI, DIS, EM, EMD) or CR30 safety relay (requires Connected Components Workbench software).

Features: MSR300 family includes host modules (MSR310P, MSR312P), input modules (MSR320P), output modules (MSR330P, MSR338P), and muting lamp module (MSR329P). GSR equivalents are DI/DIS (inputs), EM (immediate outputs), EMD (delayed outputs), and no direct GSR equivalent for muting lamp.

Terminal Locations & Panel Space: MSR3xx host modules are 35 mm wide; GSR DI/DIS are 22.5 mm. MSR320P is 17.5 mm; EM/EMD are 22.5 mm. MSR330P/MSR338P are 22.5 mm. GSR modules require separate power connections; MSR300 modules get power via ribbon cable.

Wiring Schematics: Figure 185 (Host Modules), Figure 186 (Input Modules), Figure 187 (Output Modules), Figure 189 (Single Input/Output), Figure 190 (3 Inputs/3 Outputs), Figure 191 (2 Zones, Global E-stop), Figure 192 (Global/Local E-stop) show MSR300 configurations compared to GSR equivalents.

Muting Lamp Module

MSR329P muting lamp module has no direct GSR equivalent; machine control system can provide this function.

Immediate Outputs

MSR230P immediate outputs replaced by GSR EM safety relay.

Delayed Outputs

MSR238P delayed outputs replaced by GSR EMD safety relay.

Communications

For applications using RS-232 or DeviceNet, convert to EtherNet/IPTM and add GSR ENTER module.

MSR33 Safety Relay

Conversion: MSR33 to Sipha 2 controller (440N-S32021).

Features: MSR33 offered fixed/removable terminals, solid-state outputs. Sipha 2 has fixed terminals, electromechanical outputs. MSR33 has Startup Test; Sipha 2 does not. MSR33 is 22.5 mm wide; Sipha 2 is 45 mm wide.

Terminal Locations & Panel Space: MSR33 terminals top/bottom; Sipha 2 terminals top/bottom, requiring more space.

Wiring Schematics: Figure 157 (Manual Reset) and Figure 158 (Automatic Reset) show MSR33 wiring compared to Sipha 2, noting differences in reset action and auxiliary output logic.

Input Simultaneity

MSR33 allows infinite time between input state changes. Sipha 2 has minimum approach speed of 17 mm/s (0.67 in./s).

Response Time

MSR33: 15 ms; Sipha 2: 40 ms. ATTENTION: MSR33 is faster; safety distance must be evaluated.

Output Load Capability

Table 59 compares DC load capabilities (MSR33: DC 2A; Sipha 2: DC 2A).

MSR35 Safety Relay

Conversion: MSR35 to MSR125H/HP safety relay (440R-D23171 fixed, 440R-D23166 removable terminals).

Features: MSR35 is electronic two-hand control, 24V DC, fixed/removable terminals. MSR125H/HP is recommended. Both are 22.5 mm wide with two rows of terminals.

Terminal Locations & Panel Space: Both have two rows of terminals top/bottom.

Wiring Schematics: Figure 160 (Category IIIC) and Figure 161 (Category IIIA) show MSR35 wiring compared to MSR125.

Response Time

MSR35: 15 ms; MSR125: 20 ms. ATTENTION: MSR35 is faster; safety distance must be evaluated.

Output Load Capability

MSR125 has higher DC current rating than MSR35. Table 62 compares capabilities (MSR35: DC 2A; MSR125: DC 3A).

MSR121RT Safety Relay

Conversion: MSR121RT to GSR CI (440R-S13R2).

Features: MSR121RT has 24V AC/DC power, auto/monitored reset. GSR CI offers configurable reset and dual-channel operation via wiring. MSR121RT is 55 mm (2.17 in.) wide; GSR CI is 22.5 mm (0.9 in.) wide.

Terminal Locations & Panel Space: MSR121RT terminals top/bottom; GSR CI two rows top/bottom.

Wiring Schematics: Figure 163-170 show DC powered MSR121RT configurations (dual-channel, single-channel, OSSD, safety mat) compared to GSR CI.

Response Time: MSR121RT: 15 ms (24V AC/DC); GSR CI: 35 ms (mechanical/OSSD), 45 ms (safety mat). ATTENTION: MSR121RT is faster; safety distance must be evaluated.

Output Load Capability

MSR121RT has higher current capability than GSR CI. Table 65 compares capabilities (MSR121RT: AC-15 6A, DC-13 6A; GSR CI: AC-15 1.5A, DC-13 2A).

MSR124RT Safety Relay

Conversion: MSR124RT to GSR CI (440R-S13R2) + EM (440R-EM4R2).

Features: MSR124RT has single/dual-channel inputs, mechanical/OSSD inputs, 5 N.O. safety outputs, 1 auxiliary output, configurable reset. It's 100 mm (3.93 in.) wide. GSR CI + EM occupy 67.5 mm (2.66 in.) with 1606 power supply for AC. MSR230P (immediate) replaced by EM; MSR238P (delayed) replaced by EMD.

Terminal Locations & Panel Space: MSR124RT terminals top/bottom; GSR CI/EM have two rows top/bottom each.

Wiring Schematics: Figure 172-178 show DC/AC powered MSR124RT configurations compared to GSR CI + EM.

Response Time: MSR124RT: 20 ms; GSR CI: 35 ms; EM: 25 ms (SWS) + 35 ms = 60 ms. ATTENTION: MSR124RT is faster; safety distance must be evaluated.

Output Load Capability

Table 68 compares current capabilities (MSR124RT: AC-15 5A, DC-13 4A; GSR CI: AC-15 1.5A, DC-13 2A; EM: AC-15 4A, DC-13 2A).

Chapter 5: Phase 4 (July 2021)

CU3 Control Unit

Conversion: CU3 to MSR55P safety relay (various catalog numbers depending on supply voltage and motor type).

Features: MSR55P offers enhanced features over CU3, including single-phase and three-phase motor monitoring, output monitoring, fault reporting, servo motor monitoring, adjustable thresholds, delayed output capability, and higher safety ratings (Cat 4 PLe, SIL 3). CU3 is 45 mm (1.77 in.) wide; MSR55P is also 45 mm wide but taller for heat dissipation.

Power Supply and Thresholds: CU3 supports 24V AC/DC, 110V AC, 230V AC. MSR55P supports 24V DC, 115V AC, 230V AC. MSR55P does not support 24V AC; an AC-to-DC converter is needed. Threshold ranges differ.

Threshold and Delay Settings: CU3 has a potentiometer behind a cover; MSR55P has front-accessible potentiometers for threshold and delay time.

Terminal Locations & Panel Space: CU3 terminals top/bottom; MSR55P has two rows top/bottom.

Wiring Schematics: Figure 182 (TLS1-GD2 Guard Locking) and Figure 183 (TLSZ-R Guard Locking) show CU3 compared to MSR55P wiring.

Output Load Capability

Similar switching capability. MSR55P has higher DC current rating. Table compares AC-15 and DC loads.

Feedback Monitoring

Both CU3 and MSR55P support automatic/manual monitoring on X1/X2. Manual reset on MSR55P displays fault code 4.

MSR300 Safety Relay

Conversion: MSR300 to GSR relays (DI, DIS, EM, EMD) or CR30 safety relay (requires Connected Components Workbench software).

Features: MSR300 family includes host modules (MSR310P, MSR312P), input modules (MSR320P), output modules (MSR330P, MSR338P), and muting lamp module (MSR329P). GSR equivalents are DI/DIS (inputs), EM (immediate outputs), EMD (delayed outputs), and no direct GSR equivalent for muting lamp.

Terminal Locations & Panel Space: MSR3xx host modules are 35 mm wide; GSR DI/DIS are 22.5 mm. MSR320P is 17.5 mm; EM/EMD are 22.5 mm. MSR330P/MSR338P are 22.5 mm. GSR modules require separate power connections; MSR300 modules get power via ribbon cable.

Wiring Schematics: Figure 185 (Host Modules), Figure 186 (Input Modules), Figure 187 (Output Modules), Figure 189 (Single Input/Output), Figure 190 (3 Inputs/3 Outputs), Figure 191 (2 Zones, Global E-stop), Figure 192 (Global/Local E-stop) show MSR300 configurations compared to GSR equivalents.

Muting Lamp Module

MSR329P muting lamp module has no direct GSR equivalent; machine control system can provide this function.

Immediate Outputs

MSR230P immediate outputs replaced by GSR EM safety relay.

Delayed Outputs

MSR238P delayed outputs replaced by GSR EMD safety relay.

Communications

For applications using RS-232 or DeviceNet, convert to EtherNet/IPTM and add GSR ENTER module.

Input Modules

MSR320P input module (17.5 mm) replaced by DI or DIS safety relay (22.5 mm).

Output Modules

MSR330P (immediate) replaced by EM relay; MSR338P (delayed) replaced by EMD relay.

Wiring Differences

EM and EMD relays require separate power/ground/SWS connections, unlike MSR330P/MSR338P which draw power via ribbon cable.

Wiring Examples

Figure 189 shows Single Input Module, Single Output Module conversion to DI relay. Figure 190 shows Three Input Modules/Three Output Modules conversion to three DI relays. Figure 191 and 192 illustrate Global E-stop and Local E-stop configurations.