Rockwell Automation Guardmaster Allen-Bradley 440R-S35001 User manual

Minotaur Safety Relay (MSR)
to Guardmaster Safety Relay
(GSR) Conversion - Phase 4
Catalog Numbers 440R-S35001, 440R-S35003, 440R-S35002,
440R-W23219, 440R-W23220, 440R-W23218, 440R-W23217,
440R-23221, 440R-W23222, 440R-W23223, 440R-W23224,
440R-W23225, 440R-W23226
Reference Manual Original Instructions

2Rockwell Automation Publication 440R-RM003A-EN-P - July 2021
Minotaur Safety Relay (MSR) to Guardmaster Safety Relay (GSR) Conversion - Phase 4 Reference Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 440R-RM003A-EN-P - July 2021 3
Table of Contents
Preface
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 1
Introduction Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GSR Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Conversion Concerns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Panel Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiring Terminal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiring Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Output Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 2
CU3 Control Unit Feature Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power Supply and Thresholds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Threshold and Delay Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Terminal Locations and Panel Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Threshold Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Output Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Feedback Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 3
MSR300 Safety Relay Terminal Locations and Panel Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Host Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Input Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Muting Lamp Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Single Input Module, Single Output Module . . . . . . . . . . . . . . . . . . . 19
Three Input Modules and Three Output Modules . . . . . . . . . . . . . . . 20
Two Zones, Global E-stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Global E-stop, Local E-stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Robot Zone (Function 8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Robot Zone with Additional Safe Area (Function 9) . . . . . . . . . . . . . 27
One N.C. and One N.O. Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Two-hand Control Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Three-channel Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connected Components Workbench Example - Muting with E-stop . 33
Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Output Load Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4Rockwell Automation Publication 440R-RM003A-EN-P - July 2021
Notes:

Rockwell Automation Publication 440R-RM003A-EN-P - July 2021 5
Preface
A number of older Allen-Bradley Guardmaster® safety relays are discontinued
and no longer available for sale. This publication suggests examples for how to
convert these existing safety relay applications to safety relays with the latest
technologies.
The products that are described in this publication can be used in various
ways. Therefore, you must verify that each application and use of this control
equipment meets all performance and safety requirements. Designers must
consider applicable laws, regulations, codes, and standards.
The wiring diagrams in this publication are intended as examples. Because
many variables and requirements are associated with any particular
installation, Rockwell Automation does not assume responsibility or liability
for actual use that is based on these examples.
The following MSR safety relays will continue to be offered for the foreseeable
future (five or more years).
MSR Family Cat. No. MSR Family Cat. No. MSR Family Cat. No. MSR Family Cat. No.
MSR125
440R-D23171
MSR127
440R-N23126
MSR132
440R-E23191
MSR138
440R-M23080
440R-D23170 440R-N23129 440R-E23192 440R-M23143
440R-D23169 440R-N23125 440R-E23193 440R-M23143S
440R-D23168 440R-N23128 440R-E23194 440R-M23141
440R-D23166 440R-N23124 440R-E23195 440R-M23140
440R-D23164 440R-N23127 440R-E23097 440R-M23147
440R-D23163 440R-N23132 440R-E23159 440R-M23147S
MSR126
440R-N23117 440R-N23135 440R-E23160 440R-M23145
440R-N23116 440R-N23132S 440R-E23098 440R-M23144
440R-N23115 440R-N23135S 440R-E23161 440R-M23151
440R-N23114 440R-N23131 440R-E23162 440R-M23149
440R-N23113 440R-N23134
MSR142
440R-G23214 440R-M23148
440R-N23112 440R-N23130 440R-G23215 440R-M23084
440R-N23123 440R-N23133 440R-G23215 440R-M23082
440R-N23122 440R-N23213
MSR131
440R-C23139 440R-M23081
440R-N23121 MSR5T 440R-B23020 440R-C23139S 440R-M23088
440R-N23120 MSR117 440R-B23211 440R-C23137 440R-M23086
440R-N23119
MSR124
440R-G23107 440R-C23136 440R-M23085
440R-N23118 440R-G23108 440R-M23092
440R-G23110 440R-M23090
440R-M23089

6Rockwell Automation Publication 440R-RM003A-EN-P - July 2021
Who Should Use this
Manual?
This publication is intended for those machine safeguard system designers
who have been adequately trained in the design and use of safeguard systems
and risk assessments.
Use this manual to guide the conversion from the CU3 control unit to the
MSR55P safety relay. This manual provides guidance on the differences
between the control units’ key features to help you select an appropriate
solution for your application. You must perform a risk assessment of your
converted design to confirm it meets your safeguarding requirements.
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
Resource Description
Guardmaster EtherNet/IP Network Interface User
Manual, publication 440R-UM009 Provides detailed information to install, wire, configure, troubleshoot, and use the EtherNet/IP™ module.
Guardmaster Safety Relays User Manual,
publication 440R-UM013 Provides detailed information to install, wire, configure,
troubleshoot, and use Guardmaster safety relays.
Minotaur Safety Relay User Manual, publication
440R-UM014 Provides detailed information to install, wire, configure,
troubleshoot, and use the Minotaur™ MSR55P safety relay.
Guardmaster Configurable Safety Relay,
Publication 440C-UM001
Provides detailed information to install, wire, configure,
troubleshoot, and use the Guardmaster configurable safety
relay.
System Design for the Control of Electrical Noise
Reference Manual, publication GMC-RM001
Provides a thorough review of the installation and grounding
of noisy components and what can be done to minimize their
potential to inject noise into the system.
Industrial Automation Wiring and Grounding
Guidelines, publication 1770-4.1 Provides general guidelines for installing a
Rockwell Automation® industrial system.
Product Certifications website,
rok.auto/certifications Provides declarations of conformity, certificates, and other certification details.

Rockwell Automation Publication 440R-RM003A-EN-P - July 2021 7
Chapter 1
Introduction
Product Overview The next generation Guardmaster® safety relay (GSR) family is a high-quality
replacement for most of the Minotaur™ safety relay (MSR) family.
The consistent 22.5 mm (0.9 in.) wide housing design and configurable
functions for reset and logic of GSR modules let you consolidate various
functions of MSR modules with fewer relays. These features help you reduce
your stocking requirements.
The MSR family of safety relays typically offers one dedicated safety function
for each safety circuit and actuator. MSR solutions have less connectivity to
each other than GSR modules. If you add safety circuits, those circuits require
additional safety relay modules and safety contacts for cascading to the
maintain PLd or PLe safety ratings according to EN ISO 13849-1 or SIL 2 or SIL
3 according to IEC 62061.
The GSR family of safety relays offers configurable safety functions and
consolidated safety circuits, which result in fewer units, less space, and less
cost. Due to the unique capability to cascade single-wire safety (SWS), logic
combinations and zones are constructed quickly.
A replacement with GSR modules is meant to be more than just a swap out.
New Machinery Directives have changed the designs of machines over the
years. These changes have harmonized standards and demands of safety
solutions that contribute to productivity and flexibility.
This publication offers detailed information to help with your conversion from
the legacy MSR family to a smarter and cost-effective design of machine in
compliance with the latest requirements of Machinery Directive and
harmonized standards.
For further assistance in replacing those devices, contact Rockwell Automation
support, your local Allen-Bradley distributor, or Rockwell Automation sales
office.

8Rockwell Automation Publication 440R-RM003A-EN-P - July 2021
Chapter 1 Introduction
GSR Benefits The GSR family of safety relays provides the following benefits:
• One or two (dual-channel) inputs
• Single wire safety (SWS) expansion
• Narrow package (less panel space)
• Configurable operation
• Cat 4 PLe and SIL 3 rating on most models
• RoHS compliance
Conversion Concerns Product obsolescence is a part of the industrial business cycle. This publication
provides cost-effective recommendations for converting your MSR family of
safety relays to the state-of-the-art GSR family, and considers the following
major concerns.
Panel Space
Many control panel designers leave space in their panels for future expansion
and improvements. Panel space can become tight as the extra space is used.
With panel space in mind, the recommended conversion is intended to
maintain, or even reduce, panel space.
Wiring Terminal Location
The need to move 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 you
can plan the conversion appropriately.
Wiring Change
Example schematics are provided that compare the older device and the
recommended newer device for each of the applications that the older device
can provide.
Response Time
Response time is the time that is required to perform the safety function. For
each conversion, the comparable response time is provided. An increase in the
response time requires you to adjust the safety distance. This increase is not as
much of an issue when a safety gate must be opened manually. However, this
additional response time is likely to be an issue when presence-sensing devices
like light curtains and safety mats are used.

Rockwell Automation Publication 440R-RM003A-EN-P - July 2021 9
Chapter 1 Introduction
Output Load Capability
Every safety relay has limitations on the amount of current the relay can switch
or carry. When the load exceeds the rating of the safety relay, you can use
relays that interpose, as shown in Figure 1.
Figure 1 - Output Load Capability Using Interposing Relays
S11
S12
S21
S22
S34A1 13
L11A2 14
23
24
33
CR1 CR2
41
34 42Y32
GSR CI
440R-S13R2
0
MM
AM
+24V DC
24V Com
CR1 CR2 K1 K2
L1
K1
K2
L2 L3
M
Interposing Relays
CR1 and CR2 consist of:
700-HPSXZ24 (relay)
700-HN123 (base)
700-AD1LR (diode and status
indicator)
700-HN119 (retainer)
RESET

10 Rockwell Automation Publication 440R-RM003A-EN-P - July 2021
Chapter 1 Introduction
Notes:

Rockwell Automation Publication 440R-RM003A-EN-P - July 2021 11
Chapter 2
CU3 Control Unit
In late 2019, Rockwell Automation launched the MSR55P safety relay to provide
additional features for monitoring the speed of a motor as the motor spins
down to a stopped condition by sensing the back EMF of the motor. The
MSR55P safety relay has been well accepted, and the CU3 control unit is now
being obsoleted.
Feature Comparison Table 1 compares the key feature differences between the CU3 control unit and
the MSR55P safety relay. The MSR55P safety relay has several features that the
CU3 control unit does not.
Power Supply and
Thresholds
The power supplies for the CU3 control unit and the MSR55P safety relay are
similar, however, 24V AC cannot power the MSR55P safety relay. If the CU3
control unit is powered by 24V AC, you must provide an AC to DC converter to
use the MSR55P safety relay.
Table 2 on page 12 lists the CU3 control unit catalog numbers, threshold
voltage range, and typical applications. Table 3 on page 12 lists the MSR55P
safety relay catalog numbers, threshold voltage range, and typical applications.
Table 1 - Key Feature Comparison
Feature CU3 MSR55P
Panel space 45 mm (1.77 in.) 45 mm (1.77 in.)
Single-phase motor monitoring Yes Yes
Three-phase motor monitoring No Yes
Output monitoring Yes Yes
Fault output reporting No Yes
Monitors induction motors Yes Yes
Monitors servo motors Not recommended Yes
Adjustable threshold Yes Wider range
Delayed output capability No Yes
Safety rating Cat 1 Cat4 PLe, SIL 3

12 Rockwell Automation Publication 440R-RM003A-EN-P - July 2021
Chapter 2 CU3 Control Unit
Threshold and Delay
Settings
Both the CU3 control unit and the MSR55P safety relay have a potentiometer
for adjusting the back EMF threshold setting. To access the threshold setting
adjustment in the CU3 control unit, you must open the front cover. The
MSR55P safety relay has the threshold setting adjustment on the front face.
In addition, the MSR55P safety relay has a second potentiometer on the front
face. This potentiometer is for adjusting a delay time from when standstill is
detected to when the outputs are energized. This feature provides additional
assurance that the motor has achieved a steady state speed that is considered
safe.
Terminal Locations and
Panel Space
Figure 2 on page 13 shows the relay sizes and terminal locations. The CU3
control unit has one row of terminals at the top and bottom. The MSR55P
safety relay has two rows of terminals at the top and bottom to accommodate
the features that the CU3 control unit does not have.
Both control units are 45 mm (1.77 in.) wide. The MSR55P safety relay is taller.
To achieve optimal heat dissipation, 50 mm (2 in.) of spacing is recommended
above and below each control unit.
Table 2 - CU3 Catalog Options
Cat. No. Supply Voltage Standstill Monitoring
Voltage Threshold Typical Applications
440R-S35001 24V AC/DC
Up to 2.5V Induction motors
440R-S35002 110V AC
440R-S35002 230V AC
Table 3 - MSR55P Catalog Options
Cat. No. Supply Voltage Standstill Monitoring
Voltage Threshold Typical Applications
440R-S35011 24V DC
20...400 mV Induction motors
440R-S35012 115V AC
440R-S35013 230V AC
440R-S35014 24V DC
200 mV…4V Servo (permanent magnet)
motors
440R-S35015 115V AC
440R-S35016 230V AC

Rockwell Automation Publication 440R-RM003A-EN-P - July 2021 13
Chapter 2 CU3 Control Unit
Figure 2 - Terminals and Panel Space [mm (in.)]
]
Threshold Settings Figure 3 shows the adjustment locations.
To access the voltage threshold adjustment on the CU3 control unit, use a
screwdriver to pop open the cover. Use a screwdriver to rotate the
potentiometer to the desired setting.
The MSR55P safety relay potentiometers are on the front face. Use a
screwdriver to adjust both the voltage threshold and the desired time delay so
the motor can achieve a safe standstill motion.
Figure 3 - Threshold and Delay Settings
A2 • Z2 • X2 14 24 32
A1 • Z1 • X1 13 23 31
45 (1.89)
45 (1.89)
104 (4.09)
73 (2.87)
53 54 L1 L2 L3
X1 X2 X3 11 23 33 43
12 24 34 44
A3 A4 ON ERR A1 A2
OUT
ERR
PWR
.2 .4
.7
MSR55P
1
1.5
2
3
4
.5
.3
.2
.7
ts
Vm
1
1.5
2
3
4
6
.5
.3
332311 43 53
342412 44 54
Power
Stop
Fault
Run
CU3
Zero Speed
Control Unit
53 54 L1 L2 L3
X1 X2 X3 11 23 33 43
12 24 34 44
A3 A4 ON ERR A1 A2
OUT
ERR
PWR
.2 .4
.7
MSR55P
1
1.5
2
3
4
.5
.3
.2
.7
ts
Vm
1
1.5
2
3
4
6
.5
.3
332311 43 53
342412 44 54
Voltage
Threshold
Adjustment
Voltage
Threshold
Adjustment
Time Delay
Adjustment
CU3
MSR55P

14 Rockwell Automation Publication 440R-RM003A-EN-P - July 2021
Chapter 2 CU3 Control Unit
Wiring Schematics Figure 4 and Figure 5 show a direct comparison of schematics between the CU3
control unit and the MSR55P safety relay with Power to Release guard locking
interlocks.
Figure 4 - TLS1-GD2 Guard Locking Example
Figure 5 - TLSZ-R Guard Locking Example
A2
A1
14
2313 31
24 32
CU3
L1 L2 L3
Aux
M
K2
24VDC
12 22 34
11 21 33
TLS1-GD2
41
42
53
54
A1
A2
K2
X1
X2
K1(aux)
K2 (aux)
Z1
Z2
500mA
500mA
MSR55P
440R-S35011
L1 L2 L3
M
K1
K2
3~
3~ F3
F1 F2
A2
X1 X2
L3L2L1
X3
34 44
A1 A3332311
24
12 ON ERR A454
43 53
.2 .3 .5.7
1
1.5
63
42
ts
234
5
7
10
20
30
40 15
Vm
x10mV
12 22 34
11 21 33
TLS1-GD2
41
42
53
54
A1
A2
K1 (aux)
K2 (aux)
K1
K2
K1
K2
24V Common
Guard
Closed and
Locked
Guard
Closedand
Locked
ON Status
ON Status
Error Status
Start
Stop
Start
Stop Fuse
Fuse To Other
Safety
Devices
A2
A1
14
2313 31
24 32
CU3
L1 L2 L3
Aux
M
K2
24VDC
K2
TLSZ-R
X1
X2
K1 (aux)
K2 (aux)
Z1
Z2
500mA
500mA
MSR55P
440R-S35011
L1 L2 L3
M
K1
K2
3~
3~ F3
F1 F2
A2
X1 X2
L3L2
L1
X3
34 44
A1 A3332311
24
12 ON ERR A454
43 53
.2 .3 .5.7
1
1.5
63
42
ts
234
5
7
10
20
30
40 15
Vm
x10mV
K1 K2
TLSZ-R
K1 (aux)
K2 (aux)
K1 K2
To Other
Safety
Devices
ON Status
ON Status
Error Status
24V Common
Start
Stop
Start
Stop Fuse
Fuse
Brown
Red
Yellow
Green
Pink
Gray
Blue
Brown
Red
Yellow
Green
Pink
Gray
Blue

Rockwell Automation Publication 440R-RM003A-EN-P - July 2021 15
Chapter 2 CU3 Control Unit
Output Load Capability The following table compares the output load capabilities of the CU3 control
unit and MSR55P safety relay. The output switching capability of the two relays
is similar. For AC loads, the MSR55P safety relay is derated when operating at
higher ambient temperatures.
The MSR55P safety relay has a higher DC current rating than the CU3 control
unit.
Feedback Monitoring As shown in Figure 6, both the CU3 control unit and the MSR55P safety relay
are able to monitor their respective output devices with automatic/manual
monitoring on terminals X1 and X2.
Automatic monitoring is accomplished by connecting the monitored contacts
in series to X1 and X2. Manual reset is accomplished by adding a momentary
normally open push button in series with the monitored contacts.
Figure 6 - Automatic and Manual Reset
Load Description CU3 MSR55P
AC-15 B300 5 A @ 250V AC
5 A @ 120V AC 5 A @ 250V AC @ 40 °C (104 °F) 2 A @ 250V AC @ 60 °C (140 °F)
DC 3 A @ 24V DC 4 A @ 24V DC
Upon manual reset, the MSR55P displays a fault code 4.
L1 L2 L3
M
K2
K2
X1
X2
3~
L1 L2 L3
M
K2
K2
X1
X2
3~
Automatic Manual
Reset

16 Rockwell Automation Publication 440R-RM003A-EN-P - July 2021
Chapter 2 CU3 Control Unit
Notes:

Rockwell Automation Publication 440R-RM003A-EN-P - July 2021 17
Chapter 3
MSR300 Safety Relay
The best migration for the MSR300 safety relay is to the GSR relays. This
migration can use many of the GSR relays due to the various relay
configurations of the MSR300 safety relay.
Alternatively, you can migrate the MSR300 safety relay to the CR30 safety
relay. The CR30 safety relay requires a computer that runs Connected
Components Workbench™ software to accomplish the configuration. The
Connected Components Workbench software is a free download from
Rockwell Automation.
Terminal Locations and
Panel Space
Host Module
The host module for the MSR300 safety relay is either an MSR310P or an
MSR312P. You can replace both of these modules with either a DI or DIS safety
relay. The MSR3xx has a 35 mm (1.38 in.) wide body as compared to the
22.5 mm (0.89 in.) for the GSR relays.
If communications are used in the application, you must convert from RS-232
or DeviceNet® to EtherNet/IP™ and add the GSR ENTER module.
Figure 7 - Host Module Terminals and Panel Space [mm (in.)]
35 (1.38)
S11 S21 S31 GND RxD1 A1
Y10 S34 Y40 Y41 Y42 A2
Y11 Y12 Y13 Y31 Y32 Y33
S41 S51 TxD1 TxD2
MSR310P
440R-W23219
(RS232)
35 (1.38)
S11 S21 S31 V+ V- A1
Y10 S34 Y40 Y41 Y42 A2
Y11 Y12 Y13 Y31 Y32 Y33
S41 S51 SHD CANH CANL Y34
MSR312P
440R-W23220
(DeviceNet)
22.5 (0.89)
A1 A2 S11 S21
L12 L11 Y32 S34
13 14 23 24
S12 S22 S32 S42
GSR DI
440R-D22R2
22.5 (0.89)
A1 A2 S11 S21
L12 L11 Y32 S34
34 44 14 24
S12 S22 S32 S42
GSR DIS
440R-D22S2
A1 A2
LNK1
LNK2
GSR
Ethernet/IP
440R-ENETR
22.5 (0.89)

18 Rockwell Automation Publication 440R-RM003A-EN-P - July 2021
Chapter 3 MSR300 Safety Relay
Input Module
Each MSR300 safety relay system must have at least one MSR320P safety relay
input module and can have up to 10 input modules. An equivalent GSR module
is the DI or DIS safety relay. The MSR320P safety relay occupies slightly less
panel space at 17.5 mm (0.69 in.) compared to 22.5 mm (0.89 in.) for the GSR
relays.
Figure 8 - Input Module Terminals and Panel Space [mm (in.)]
Output Module
Each MSR300 safety relay system must have at least one output module and
can have up to six output modules. Equivalent modules in the GSR family are
the EM safety relay for Immediate Outputs and the EDM safety relay for
delayed outputs.
The significant difference is that the EM and EMD safety relays require power,
ground and SWS connections, whereas the MSR330P and MSR338P safety
relays get their power through the ribbon cable.
Figure 9 - Output Module Terminals and Panel Space [mm (in.)]
22.5 (0.89)
A1 A2 S11 S21
L12 L11 Y32 S34
34 44 14 24
S12 S22 S32 S42
GSR DIS
440R-D22S2
22.5 (0.89)
A1 A2 S11 S21
L12 L11 Y32 S34
13 14 23 24
S12 S22 S32 S42
GSR DI
440R-D22R2
S12 S22 S32
S42 S52 S62
MSR320P
440R-W23218
17.5 (0.69)
A1 A2
L12 L11 X32
13 14 23 24
33 34 43 44
GSR EM
440R-EM4R2
22.5 (0.89)
14 24 34 42
13 23 33 41
MSR330P
440R-W23221
440R-W23222
440R-W23223
22.5 (0.89)
MSR338P
440R-W23224
440R-W23225
440R-W23226
A1 A2 B1 B2
L12 L11 X32
17 18 27 28
37 38 47 48
GSR EMD
440R-EM4R2D
22.5 (0.89)
18 28 38 46
17 27 37 45
Y3 Y5 Y6 Y4
Y3 Y7 Y8 Y4
22.5 (0.89)
Immediate Outputs Delayed Outputs

Rockwell Automation Publication 440R-RM003A-EN-P - July 2021 19
Chapter 3 MSR300 Safety Relay
Muting Lamp Module
The MSR300 safety relay family has a separate muting lamp module: the
MSR329. The GSR family has no equivalent; the machine control system can
provide a muting lamp function.
Figure 10 - Muting Lamp Module Terminals and Panel Space [mm (in.)]
Wiring Schematics Single Input Module, Single Output Module
At the basic level, the MSR300 safety relay system has one input module and
one output module. You can replace the MSR300 safety relay system with one
DI safety relay.
Automatic and Manual Reset
A1 A2
H11 G1 H12
H21 G2 H22
MSR329P
440R-W23217
17.5 (0.69)
No Direct Replacement in GSR Family
A1 S11 S21S12 S22
S32 L11 Y32L12
13
14S42
23
24
S34
A2
DI
440R-D22R2
01
2
3
4
56
7
8
41
42
13
14 24 34
23 33
K1
K2
S31S11 S41 S51
S34 Y10 Y11 Y12 Y13
A1S21
+24V DC
24V Com
A2
K1
K2
MSR310P
440R-W23219
K1
K2
K1
K2
Y41Y40 Y42
Y32Y31 Y33
MSR330P
440R-W23221
MSR320P
440R-W23218
S12
S42 S52 S62
S22 S32
LOGIC
Reset
Group 1
To PLC
Function 2
Group 1
Reset 1

20 Rockwell Automation Publication 440R-RM003A-EN-P - July 2021
Chapter 3 MSR300 Safety Relay
Three Input Modules and Three Output Modules
In the following example, the MSR300 safety relay has three input modules
and three output modules. Each input module is set to another type of device
(OSSD, single channel, and dual channel) and different output group (groups
1, 2, and 3). The equivalent GSR system is three DI safety relays. Both systems
monitor the output contactors and one reset button resets the safety system.
41
42
13
14 24 34
23 33 41
42
13
14 24 34
23 33 41
42
13
14 24 34
23 33
S31S11 S41 S51
S34 Y10 Y11 Y12 Y13
A1S21
+24V DC
24V Com
A2
K1
K2
K3
K4
K5
K6
MSR310P
440R-W23219
K1 K2
Y41Y40 Y42
Y32Y31 Y33
MSR330P
440R-W23221
MSR330P
440R-W23223
MSR330P
440R-W23222
MSR320P
440R-W23218
S12
S42 S52 S62
S22 S32S12
S42 S52 S62
S22 S32S12
S42 S52 S62
S22 S32
OSSD1
+24V
0V
OSSD2
OSSD1
+24V
0V
OSSD2
K3 K4 K5 K6
Group 1 Group 3
Group 2
Reset
Group 1 Group 3Group 2
Function 6 Function 1 Function 2
Group 1 Group 3
Group 2
A1 S11 S21S12S22
S32 L11 Y32L12
13
14S42
23
24
S34
A2
DI
440R-D22R2
01
2
3
4
56
7
8
A1 S11 S21S12 S22
S32 L11 Y32L12
13
14S42
23
24
S34
A2
DI
440R-D22R2
01
2
3
4
56
7
8
A1 S11 S21S12S22
S32 L11 Y32L12
13
14S42
23
24
S34
A2
DI
440R-D22R2
01
2
3
4
56
7
8
+24V DC
24V Com
K5
K6
K3
K4
OSSD1
+24V
0V
OSSD2
OSSD1
+24V
0V
OSSD2 K1 K2
K1
K2
K3 K4 K5 K6
Reset
LOGIC LOGIC LOGIC
To PLC To PLC To PLC