Rockwell Automation Allen-Bradley Minotaur MSR138DP User manual

Installation Instructions
Original Instructions
Minotaur MSR138DP, MSR138.1DP Monitoring Safety Relay
Catalog Numbers 440R, MSR138DP, MSR138.1DP
Summary of Changes
This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.
Introduction
This device is intended to be part of the safety-related control system of a
machine.
Rockwell Automation does not accept responsibility for failure of this device if you
do not impalement the procedures that are given in this publication, or if you use
the unit outside the recommended specifications that are listed in this publication.
Description
A valid reset operation concurrently activates instantaneous and delayed safety
outputs. The status indicators of instantaneous outputs CH1 and CH2 and delayed
outputs CHT1 and CHT2 are lighted. At the demand of the safety function and if any
fault occurs, the instantaneous safety outputs de-energize within the specified
response time. The delayed safety outputs open once the delay time has lapsed. If
the time-reset circuit opens during delay timing stops, the time lapse and the
delayed contacts open instantaneously.
Specifications
Topic Page
Updated Response time 1
Updated Declaration of Conformity 4
IMPORTANT Before installation, perform a risk assessment to determine
whether the specifications of this device are suitable for all
foreseeable operational and environmental characteristics
of the machine to which it is to be fitted. At regular
intervals during the life of the machine, check whether the
characteristics foreseen remain valid.
WARNING: Danger of serious injuries. Misuse can result in
malfunction.
• Only authorized and trained personnel can start up, assemble,
or retrofit the device.
• Installation must be in accordance with the following steps.
WARNING: Danger of serious injuries.
Incorrect installation or manipulation can result in serious
injuries. Do not defeat, tamper, remove, or bypass this unit.
ATTENTION: If any malfunction or damage is present, do not
attempt to repair. Replaced the unit before machine operation
is allowed. Do not dismantle the unit.
IMPORTANT The safety inputs of these products are described as
normally closed (N.C.), that is, with the guard closed, the
actuator in place (where relevant), and the machine able to
start. You must prevent exposure to shock and/or vibration
in excess of those specifications in IEC 60068 part: 2-6/7.
Adherence to the recommended inspection and
maintenance instructions forms part of the warranty.
IMPORTANT All information complies with the state of this publication
and is subject to change without notice.
Table 1 - Technical Specifications
Attribute Value
Functional safety data
According to ISO 13849-1:
•PLd,Cat.3
•MTTF
d[a]: 372
• DC average: 60%
Delayed -
•PLe,Cat.4
•MTTF
d[a]: 295
• DC average: 90%
According to IEC 62061 and IEC 61508:
• SIL CL 2
• PFH [1/h]: 238E-09
•HFT:1
•DC:60%
Delayed -
• SIL CL 3
• PFH [1/h]: 238E-09
•HFT:1
•DC:90%
•TM(PTI)[a]:20
• dop [d]/hop [h] (1): 365/24
• tcycle [h]/[s] (2): 8/28,800
Power supply 24V AC/DC, 115V AC, 230V AC
0.85...1.1 x rated voltage 50/60 Hz
Power consumption 4 W
Safety inputs 1 N.C., 2 N.C., light curtain
Input simultaneity Infinite
Allowable input resistance,
max 135 Ω
Reset Manual monitored or automatic/manual
Outputs MSR138DP: 2 N.O. safety instant, 3 N.O. safety delayed
MSR138.1DP: 2 N.O. safety delayed, 1 N.C aux. delayed, 2 N.O. safety instant.
Output rating
•UL:B300
• 5 A/250 V AC, 24V DC
•AC-15:6A/250VAC
•DC-13:3A/24VDC
Output rating (solid-state) •30VDC
• 20 mA short circuit protected
Fuses output (external) 6 A slow blow or 10 A quick blow
Switched current/voltage,
min 10 mA/10V
Contact material AgSnO2+ 0.5µAu
Electrical life (operations)
• 100,000 (220V AC/4 A/880VA cosφ= 0.35)
• 500,000 (220V AC/1.7 A/375VA cosφ= 0.6)
• 1,000,000 (30V DC/2 A/60 W)
• 2,000,000 (10V DC/0.01 A/0.1 W)
Mechanical life 10,000,000 cycles
Power on delay 1 s
Response time 18 ms
Recovery time 100 ms
Time delays Off delay (for delayed output contacts only)
Impulse withstand voltage 2500V
Pollution degree 2

2Rockwell Automation Publication 440R-IN088A-EN-P - July 2022
Minotaur MSR138DP, MSR138.1DP Monitoring Safety Relay Installation Instructions
Diagnostics
The solid-state status signal Y35 indicates the safety input state. The solid-state
status output Y32 and the auxiliary (N.C.) output 41-42 signals the safety output
state.
Safety Input
One safety device can be monitored per unit. According to the wiring inputs,
cross-loop monitoring of the inputs is enabled or disabled. You can enable
cross-loop monitoring for 2-channel safety inputs in 4-wire connection (S11-S12,
S21-S22). Cross-loop monitoring is disabled for single-channel inputs, dual-channel
inputs in 3-wire connection, and 24V DC signals. For external 24V DC signals, the
negative pole must connect to S21.
Reset
• Reset modes - The reset mode is configurable for automatic/manual start
and manual monitored reset (MSRxxxRT).
A valid start/reset can only operate if the feedback circuit (Y1-Y2) and the
time-reset circuit (Y39-Y40) are closed. Feedback contacts (N.C.) of
controlled actuators connect to Y1-Y2. Start/reset during the time lapse
causes a fault state. To avoid a lockout condition by start/reset, the N.C.
contacts (55-56) of the MSR138.1 safety relay connect in series with the
feedback circuit Y1-Y2.
• T - Automatic/manual start (a)
In Automatic/Manual Start mode, the reset circuit S33-S34 is not
monitored against signal changes (no edge detection). The safety relay is
active once the safety inputs and the reset circuit close. If the safety
inputs and reset circuit concurrently close during power-up, the safety
relay activates immediately.
• R - Manual monitored reset (b)
In Manual Monitored Reset mode, a signal change of the reset circuit
(S33-S34) is required and monitored. A reset fault occurs if the safety
inputs remain open while the reset circuit is closed.
- Positive edge:
The safety relay is active once the safety inputs close and then the
reset circuit is closed.
- Negative edge (440R-xxxxxM):
The safety relay is active once the safety inputs close and then the
reset circuit closes and releases again. The circuit resets upon release
of the Reset button.
For both methods, the MSR138/.1DP safety relay is suitable for the safety
requirements according to EN/ISO 13849-1.
Installation group Overvoltage category III, VDE 0110-1
Operating temperature -5…+55 °C (23…131 °F)
Relative Humidity 90%
Enclosure protection IP40 (NEMA 1)
Terminal protection IP20
Wiring Use copper that withstands 60/75 °C (140/167 °F)
Conductor size 0.2...2.5 mm2(24…12 AWG)
Torque settings Terminal screws: 0.6…0.8 N•m (5…7 lb•in)
Case material Polyamide PA 6.6
Mounting 35 mm (1.38 in.) DIN rail in enclosure to a minimum of IP54
Weight 24V AC/DC: 350 g (0.77 lb)
115V AC or 230V AC: 490 g (1.08 lb)
Vibration 10…55 Hz, 0.35 mm (0.01 in.)
(1) Operation time (day, hour)
(2) Cycle time (hour, sec)
Max PLc: 1-CH (1); N.C.
(1) 1-CH = Single-channel
Max PLd: 2-CH (2); 3-wire connection
(2) 2-CH = Dual-channel
Max PLe: 2-CH (2); 24V DC signal
Max PLe: 2-CH (2); 4-wire connection, cross
faults require fault reset
Table 1 - Technical Specifications (Continued)
Attribute Value
(a) T = Jumper X1-X2, X3-X4
(b) R = No jumper
MSRxxxT
MSRxxxT
440R-xxxxxM
MSRxxxR
MSRxxxR
440R-xxxxxM
MSRxxxR
440R-xxxxxM

Rockwell Automation Publication 440R-IN088A-EN-P - July 2022 3
Minotaur MSR138DP, MSR138.1DP Monitoring Safety Relay Installation Instructions
Installation
Do not install this product until the installer obtains a copy of the instructions of
the manufacturer, in a language that they can understand. This instruction
publication is available in multiple languages at rok.auto/literature.
Figure 1 - Mounting
Mount the enclosure to a minimum of IP54.
Figure 2 - Removable Terminals (P versions only)
To remove the terminals, insert a screwdriver and slowly move as shown in
Figure 2.
Wiring Examples
Figure 3 - Example 1
Figure 3 shows dual-channel E-stop, cross fault monitored, and monitored reset.
Circuit Diagram
Figure 4 - Diagram
Approximate Dimensions
Figure 5 - Dimensions [mm (in.)]
L1
N
E-stop
E-stop Reset Timer Override Feedback Loop
Table 2 - Circuit Diagram Explanation
Abbreviation Description
A1, A2 Power
S11, S12, S21, S22 Safety input (N.C.)
X1, X2, X3, X4, S33, S34 Link for auto reset
Y1, Y2 Monitoring loop feedback
Y39, Y40 Timer override
13, 14 Safety output 1 (N.O.)
23, 24 Safety output 2 (N.O.)
37, 38 Timer output 1 (N.O.)
47, 48 Timer output 2 (N.O.)
57, 58 (1)
(1) MSR 138DP
Timer output 3 (N.O.)
55, 56 (2)
(2) MSR 138.1DP
Timer output 3 (N.C.)
PWR Status indicator illuminates green when the unit is powered,
flashing green if cross-loop faults occur
CH1 Status indicator illuminates green when the safety output
channel 1 activates
CH2 Status indicator illuminates green when the safety output
channel 2 activates
CH1 IN Status indicator illuminates green when the safety input channel
1 closes
CH2 IN Status indicator illuminates green when the safety input channel
2 closes
CHT1 Status indicator illuminates green when Delayed Safety Output
channel 1 activates
CHT2 Status indicator illuminates green when Delayed Safety Output
channel 2 activates
Start Status indicator illuminates green when the reset circuit closes
Overvoltage
Protection
24V DC
AC
Start Logic
MSR 138DP MSR 138.1DP
Logic
Channel 1 Logic
Channel 2
Timer
Override
START
PWR

Publication 440R-IN088A-EN-P - July 2022 | Supersedes Publication 440R-IN063A-MU-P - April 2011
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10000176981 Ver 01
Waste Electrical and Electronic Equipment (WEEE)
Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec.
At the end of life, this equipment should be collected separately from any unsorted municipal waste.
Safety Specifications
You can use the MSR138/.1DP safety relay in safety circuits according to
DIN EN 60204-1/VDE 0113 part 1. Safety requirements that are specified in
Specifications on page 1 are maximum, based on the operation mode and wiring.
Specifications are applicable only if the safety function is demanded at least once
within 6 months. All diagnostic tests are conducted at least before next demand.
The mission time (TM) for the proof test interval (PTI) is adopted. Components
failure rates according to SN29500.
Figure 6 - Safety Circuit
Declaration of Conformity
CE Conformity
Rockwell Automation declares that the products that are shown in this document
conform with the Essential Health and Safety Requirements (EHSRs) of the
European Machinery Directive (2006/42/EC) and EMC Directive 2014/30/EU.
For a comprehensive CE certificate visit: rok.auto/certifications.
UKCA Conformity
Rockwell Automation declares that the products that are shown in this document
are in compliance with the Supply of Machinery (Safety) Regulations (2008 No. 1597)
and Electromagnetic Compatibility Regulations (2016 No. 1091).
For a comprehensive UKCA certificate visit: rok.auto/certifications.
(a)
(a) Example
Channel 1
Channel 2
Sensor
Contact
Sensor
Contact
E-stop 800F (a)
Actuator 1
Actuator 2
Safety Relay 440R Contactor 100S (a)