Safety Relay Training

Safety Relay Training

What You Will Learn:
After completing this lesson, you will be able to:
• Review the basic safety relay principles
• Understand the operation of the MSR 131 used with the Nachi robot
• Understand the 3 operational modes of the Safely Relays, Dual Channel +1- Mode, Automatic/Manual
Reset, Manual Monitored Reset
• Understand troubleshooting the Safety relays using the LED indicators and logical troubleshooting
techniques.
• Understand the common Safety relay circuit configurations -
• Component removal and replacement
Why Safety Relays?•
Before You Begin:
Per ANSI B11.19, Section 2.12, Definitions: Control Reliability is defined as a method of ensuring the
integrity of the performance of guards, devices, or control systems
Per ANSI B11.19, Section 5.5.1, Control Reliability: When required by the performance requirements of
the safeguarding, the device, system, or interface shall be designed, constructed, and installed such that a
single component failure within the device, interface or system shall prevent a successive machine cycle.
This requirement does not apply to those components whose function does not affect safe operation of the
machine tool.
Requirements for a Control Reliable System
 The use of redundant components (e.g. redundant safety contacts, output devices, safety relays
etc.)
 Capability of monitoring failures (e.g. safety relays, safety PLC, routine maintenance. etc.) Mere
redundancy in not sufficient. Multiple failures may have unpredictable effects, therefore,
monitoring and response to a single failure is essential. (ANSI Eli 20 section E6.13)
 Monitoring Relays: require the use of positive guided relay contacts.
Control Reliability
The control system shall be constructed so that:
 A single failure within the system does not prevent the normal stopping action.
 Does prevent initiation of a successive cycle or stroke until the failure is coxTected.
 Failure shall be detectable by a simple test, or indicated by the control system.
Page 1 of 22
Safety Relay Basics

A safety relay circuit contains a pair of multipole positive-guided contacts used for switching power to the
load. If one of the contacts is welded, the other contact can safely switch off the load. Each relay contains
a N/C contact in the restart circuit which is used for self-checking. This N/C contact remains open in the
event of a weld and prevents the safety circuit from restarting.
Conventional multipole relays cannot be used for safety purposes. After a conventional N/O relay contact
welds, and the relay dc-energizes, the N/C contact is allowed to return to the closed position and the
we)ded contact stays closed.
Standard Relay
NC NO NO
Force Guided Relay

NC NO NO
Page 2 of 22
During operation of a relay the coil is energized pulling in the contacts. Contacts that were closed open
and those that were open close.
NC NO NO
The safety circuit with conventional contacts has no way of “knowing” that a contact weld has occurred
and the machine is allowed to restart.
Welded
Contact
NC NO NO
Page 3 of 22
Positive-guided contacts, also called captive or force-guided contacts, are designed so that all sets of
contacts move in unison, using a mechanical linkage. A contact weld holds all contacts in place. This
ensures that the N/C contact stays open after a N/U contact welds shut. Once one of the N/U contacts
welds, the safety relay cannot be restarted. This feature is required by ANSI
Held Welded Held
Open Contact Closed
NC NO NO
Page 4 of 22
Safety Relay operation:

The following diagrams show the concept of safety relay operation. The diagrams do not represent the
actual circuitry in the relay but does show their operational characteristics. There are other possible wiring
configurations for safety relays. An E-Stop application is used in this example.
DC IN
A1 A2
DC OUT
DC + DC - E-Stop 3 E-Stop 2 E-Stop 1

S33 To Digitial
Circuit
E-Stop 3 E-Stop 2 E-Stop 1 Below
S21
S11
S11 CH1
CH1 IN
K3
S12 K1
K1 To Digitial
Circuit Below
Reset CH2 IN K3
S52 K2 S22
S34
K2 START
CH2 (RESET)
Y1
Y1 To Digitial
Circuit Below
K1 K2
Y2 K3
K3
S37
+24VDC To Voltage
Y31 Converter
K1
To To
Fuse OK Y35 K2
Relay Reset Y32
0 VDC
Y30
13 14
K1 K2 K3
23 24
K1 K2 K3
33 34
K1 K2 K3
K1
41 42
K2
51 52
The diagram shows:

 Each B-Stop push button has two sets of contacts
 One set on the hot side of the circuit the other on the return side
 Manual reset push button to reset the relay
 Safety output contacts at the bottom
 Output monitors Y32 relay reset, Y35 Power applied
Page 5 of 22
Page 6 of 22
Input Channel Open

Estop Circuit Input Open
DC IN
A1 A2
DC OUT

S33 To Digitial
Circuit
S21
S11
S11 CH1
CH1 IN
K3
S12 K1
K1 To Digitial
Circuit Below
Reset CH2 IN K3
S52 K2 S22
S34
K2 START
CH2 (RESET)
Y1
Y1 To Digitial
Circuit Below
K1 K2
To
Y2 K3
CH
POWER
CH 1 IN
CH 2 IN
START/RUN
CHI
CH2
 E-Stop 1 open
 No continuity to K1 or K2
 Relay not ready to be reset
 Only power LED on
Page 7 of 22
Input Channels Closed

Estop Circuit all inputs closed
DC IN
A1 A2
DC OUT

S33 To Digitial
Circuit
S21
S11
S11 CH1
CH1 IN
K3
S12 K1
K1 To Digitial
Circuit Below
Reset CH2 IN K3
S52 K2 S22
S34
K2 START
CH2 (RESET)
Y1
Y1 To Digitial
Circuit Below
K1 K2
Y2 K3
CH
POWER
CH 1 IN
CH 2 IN
START/RUN
CHI
CH2
 E-Stop string closed

 Continuity across Cl-I I in and CH 2 in LED
 CH 1 lin and CH 2 in LED’s On
 Relay ready to be reset
Page 8 of 22
Reset Input Depressed

Estop Circuit Reset Closed
DC IN
A1 A2
DC OUT

S33 To Digitial
Circuit
S21
S11
S11 CH1
CH1 IN
K3
S12 K1
K1 To Digitial
Circuit Below
Reset CH2 IN K3
S52 K2 S22
S34
K2 START
CH2 (RESET)
Y1
Y1 To Digitial
Circuit Below
K1 K2
Y2 K3
CH
POWER
CH 1 IN
CH 2 IN
START/RUN
CHI
CH2
 Manual reset closed

 K3 coil on via NC contacts from K1 K2
 K3 on closes K3 contacts on K1 and K2
 K1 and K2 now have a complete current path and energize
 CH1, CH2 and start LED’s on
Page 9 of 22
Relay Reset
Estop Circuit Reset Closed
K1 and K2 On
DC IN
A1 A2
DC OUT

S33 To Digitial
Circuit
S21
S11
S11 CH1
CH1 IN
K3
S12 K1
K1 To Digitial
Circuit Below
Reset CH2 IN K3
S52 K2 S22
S34
K2 START
CH2 (RESET)
Y1 To Digitial
Circuit Below
K1 K2
Y2 K3
CH
POWER
CH 1 IN
CH 2 IN
START/RUN
CHI
CH2
 K1 and K2 on
 Seal contacts keep K1 and K2 on
 K1 and K2 contacts open in K3 circuit
 K3 turns off
 Relay is reset
 CH1, CH2 in and CH1, CH2 LED’s on start LED off
Page 10 of 22
Relay Reset
MSR 131 Circuit Diagram
DC IN
A1 A2
DC OUT

S33 To Digitial
Circuit
S21
S11
S11 CH1
CH1 IN
K3
S12 K1
K1 To Digitial
Circuit Below
Reset CH2 IN K3
S52 K2 S22
S34
K2 START
CH2 (RESET)
Y1
POWER
Y1 To Digitial
Circuit Below
K1 K2
CH 1 IN Y2 K3
K3
S37
CH 2 IN +24VDC To Voltage
Y31 Converter
START/RUN CH To
Fuse OK Y35 2 K2
CHI Relay Reset Y32
0 VDC
Y30
CH2
13 14
K1 K2 K3
23 24
K1 K2 K3
33 34
K1 K2 K3
K1
41 42
K2
51 52
 Relay Reset
 Safety Contacts at 13, 14, 23, 24, 33, 34 closed
 NC contacts 41,42, 51, 52 open
Page 11 of 22
GuardMaster MSR Safety Relays:

Safety Relay Selections
 MSR131 Cat # 440R-C23137 (Safety Relay)
 MSR138 Cat # 440R-M23080 (Time Delay Safety Relay)
 MSRI22 Cat # 440R-E23 157 (Expansion Module)
MSRI3I Features:
 Light curtain, Safety mat, Safety Contact inputs
 Positive guided safety. contacts
 Auxiliary contacts
 2 Solid State Outputs, Inputs Closed and Relay Reset
 Cross fault monitoring
 Monitored or Automatic reset
 Removable terminals
A1 S33 S34 S11 13 23

S52
X3 S11 S12 33 41 51
S22
S21 51
MSR131RT
P
13 23 33 41
PWR
51
START
CH1 CH1
IN
CH2 CH2
14 24 34 42
52
X4 Y30 Y31 Y35 42 52
Y32
A2 Y1 Y2 52
X2 14 24
X1 34
CH2
Page 12 of 22
MSRI3 Cat # 440R-C23137 Specifications

Standards IEC/EN60204-1, ISOTR 2100, 1 (EN 954-1)
Safety Category Cat. 4 per EN 954-1
Approvals CE marked for all applicable directives, cULus and
BG
Power Supply 24V AC/Dc, i IOV AC or 230V AC
0.8 to 1.1 x rated voltage, 50/60Hz
Power Consumption 4W
Fuses for Safety Output (External 6A slow blow or IOA quick blow
Recommended)
Safety Inputs I N.C., 2 N.C., Light Curtain or Safety mat
Maximum Allowable Input 70 ohms
Resistance
Reset Monitored manual or Automatic/manual
Outputs 3 N.O. safety
2 N.C. auxiliary
1 S.S. Inputs closed
1 S.S. outputs active
Safety and Aux B300, AC-15, 5A/250V AC P300, DC-13, 3A/24V
DC
Solid State 30mA short circuit protected
Power On Delay 1s
Response Time 15ms
Recovery Time 100ms
Indication LEDs Green = Power
Green = Start
Green = CH1 Input closed
Green = CH2 Input Closed
Green = CH1 Output Active
Green = CH2 Output Active
Page 13 of 22
Input Wiring Configurations:

 N.C. Safety Input Contacts
 Cascaded Relay Contacts
 MSR1 31 checks for cross fault across inputs.
 Cascaded Control Relays
MSR13I’s output monitoring can accommodate:
 Automatic, resets on power up if E-Stop and Yl, Y2 closed
 Manual reset, requires a low to high transition after the E-Stop circuit is closed
 Monitored Manual reset, requires closed contacts in the Yl, Y2 loop. Used to check externally
controlled relays
 Two solid state outputs can be monitored by a PLC to determine relay input conditions and reset
status
MSRI3 2 F Monitored Reset

L1(120 vAC)
Reset
Safety
Inputs
L1 L2L3
A1 S11 S12 S21 S22 S52 S11 Y31 S33 S34 13 23 33 41 51
CH1 IN CH2 IN
K1
MSR131
K2
A2 X1 X2 X3 X4 Y30 Y32 Y35 Y1 Y2 14 24 34 42 52
M
K1 K2
L2(Ground) Relay Inputs

Reset Closed
 Input 1 and 2 Closed
 Reset closed on S33 and S34
 Ki and K2 contacts closed in Yl and Y2 monitor loop
 Y 1, Y2 loop open prevents a successful reset
 KI orK2 with welded contacts will open Yl, Y2 loop
Page 14 of 22
MSR 2 N.C. Automatic Reset

L1(120 vAC)
Reset
Safety
Inputs
L1 L2L3
A1 S11 S12 S21 S22 S52 S11 Y31 S33 S34 13 23 33 41 51
CH1 IN CH2 IN
K1
MSR131
K2
A2 X1 X2 X3 X4 Y30 Y32 Y35 Y1 Y2 14 24 34 42 52
M
K1 K2

Reset Closed
 Jumpers at S33, S34, S52, S11, Xl, 3 X3, X4
 Relay no longer requires an external reset command
 Relay attempts auto reset on power up and continues until input I and 2 closed
 KI or K2 weld will prevent a successful reset
Page 15 of 22
Troubleshooting MSRI3
CH1 CH2
Power Start CH1 CH2 S.S. S.S.
Case IN IN Gate Output Check
LED LED LED LED Y35 Y32
LED LED
When pressing the reset button, the
Start LED turns ON, but
1 Reset On Off Closed Off outputs do not turn ON. Check the
On On On Off Off monitoring loop between Y1 and Y2;
On
it should be a closed circuit.
L1(120 vAC)
Check Here
Reset
Safety
Inputs
L1 L2L3
A1 S11 S12 S21 S22 S52 S11 Y31 S33 S34 13 23 33 41 51
CH1 IN CH2 IN
K1
MSR131
K2
A2 X1 X2 X3 X4 Y30 Y32 Y35 Y1 Y2 14 24 34 42 52
M
K1 K2

Reset Closed
A1 S33 S34 S11 13 23

S52
X3 S11 S12 33 41 51
S22
S21 51
MSR131RT
P
13 23 33 41
PWR
51
START
CH1 CH1
IN
CH2 CH2
14 24 34 42
52
X4 Y30 Y31 Y35 42 52
Y32
A2 Y1 Y2 52
X2 14 24
X1 34
Page 16 of 22
Troubleshooting MSRI 31
CH1 CH2
LED LED
1) Check the gate switch going to S21
and S22; it should he a closed circuit.
2) Check the circuit between S11 and
2 Off Off Closed Off S52 it should be a jumper. If the gate
On Off On Off On Off is opened, the CH1 IN LED and CH1
LED will turn off, If gate is re-closed
again, CH1 IN LED will turn on.
L1(120 vAC)
Check Here
Reset
Safety
Inputs
L1 L2L3
A1 S11 S12 S21 S22 S52 S11 Y31 S33 S34 13 23 33 41 51
CH1 IN CH2 IN
K1
MSR131
K2
A2 X1 X2 X3 X4 Y30 Y32 Y35 Y1 Y2 14 24 34 42 52
M
K1 K2

Reset Closed
A1 S33 S34 S11 13 23
S52
X3 S11 S12 33 41 51
S22
S21 51
MSR131RT
P
13 23 33 41
PWR
51
START
CH1 CH1
IN
CH2 CH2
14 24 34 42
52
X4 Y30 Y31 Y35 42 52
Y32
A2 Y1 Y2 52
X2 14 24
X1 34
Page 17 of 22
Troubleshooting MSRI3
CH1 CH2
LED LED
1) Check the gate switch circuit going
to S11, S12 and S52. The circuit may
have opened while the gate was
3 Off Off Closed Off closed. If the gate is opened, the CH2
On Off Off On Off On IN LED and CH2 LED will turn off.
If the gate is re-closed again, CH2 IN
LED will turn on.
L1(120 vAC)
Check Here
Reset
Safety
Inputs
L1 L2L3
A1 S11 S12 S21 S22 S52 S11 Y31 S33 S34 13 23 33 41 51
CH1 IN CH2 IN
K1
MSR131
K2
A2 X1 X2 X3 X4 Y30 Y32 Y35 Y1 Y2 14 24 34 42 52
M
K1 K2

Reset Closed
A1 S33 S34 S11 13 23
S52
X3 S11 S12 33 41 51
S22
S21 51
MSR131RT
P
13 23 33 41
PWR
51
START
CH1 CH1
IN
CH2 CH2
14 24 34 42
52
X4 Y30 Y31 Y35 42 52
Y32
A2 Y1 Y2 52
X2 14 24
X1 34
Page 18 of 22
Troubleshooting MSR
CH1 CH2
LED LED
Check for short circuit across the
4 Off Off Closed Off inputs: S11 to S2I, S11 to S22, S12 to
Blinking Off Off Off Off Off S22
L1(120 vAC)
Check Here
Reset
Safety
Inputs
L1 L2L3
A1 S11 S12 S21 S22 S52 S11 Y31 S33 S34 13 23 33 41 51
CH1 IN CH2 IN
K1
MSR131
K2
A2 X1 X2 X3 X4 Y30 Y32 Y35 Y1 Y2 14 24 34 42 52
M
K1 K2

Reset Closed
A1 S33 S34 S11 13 23
S52
X3 S11 S12 33 41 51
S22
S21 51
MSR131RT
P
13 23 33 41
PWR
51
START
CH1 CH1
IN
CH2 CH2
14 24 34 42
52
X4 Y30 Y31 Y35 42 52
Y32
A2 Y1 Y2 52
X2 14 24
X1 34
Page 19 of 22
Troubleshooting MSR131
CH1 CH2
LED LED
Check the Reset button; it may be
5 On Off Closed Off
On On On On Off Off shorted or held in the closed position.
L1(120 vAC)
Reset Check Here
Safety
Inputs
L1 L2L3
A1 S11 S12 S21 S22 S52 S11 Y31 S33 S34 13 23 33 41 51
CH1 IN CH2 IN
K1
MSR131
K2
A2 X1 X2 X3 X4 Y30 Y32 Y35 Y1 Y2 14 24 34 42 52
M
K1 K2

Reset Closed
A1 S33 S34 S11 13 23
S52
X3 S11 S12 33 41 51
S22
S21 51
MSR131RT
P
13 23 33 41
PWR
51
START
CH1 CH1
IN
CH2 CH2
14 24 34 42
52
X4 Y30 Y31 Y35 42 52
Y32
A2 Y1 Y2 52
X2 14 24
X1 34
Page 20 of 22
CH1 CH2
LED LED
6 Off Off Closed Off Check power applied to A1 and A2.

Off Off Off Off Off Off
L1(120 vAC)
Reset Check Here
Safety
Inputs
L1 L2L3
A1 S11 S12 S21 S22 S52 S11 Y31 S33 S34 13 23 33 41 51
CH1 IN CH2 IN
K1
MSR131
K2
A2 X1 X2 X3 X4 Y30 Y35 Y1 Y2 14 24 34 42 52
M
K1 K2

Reset Closed
A1 S33 S34 S11 13 23
S52
X3 S11 S12 33 41 51
S22
S21 51
MSR131RT
P
13 23 33 41
PWR
51
START
CH1 CH1
IN
CH2 CH2
14 24 34 42
52
X4 Y30 Y31 Y35 42 52
Y32
A2 Y1 Y2 52
X2 14 24
X1 34
Page 21 of 22
CH1 CH2
LED LED
1) Check for power at terminals 13, 14,
23 and 24.
7 On On Closed Off 2) An internal component failure may
On On On On On On have occurred in the MSR131 if power
is present at 13 and 23.
L1(120 vAC)
Reset Check Here
Safety
Inputs
L1 L2L3
A1 S11 S12 S21 S22 S52 S11 Y31 S33 S34 13 23 33 41 51
CH1 IN CH2 IN
K1
MSR131
K2
A2 X1 X2 X3 X4 Y30 Y35 Y1 Y2 14 24 34 42 52
M
K1 K2

Reset Closed
A1 S33 S34 S11 13 23
S52
X3 S11 S12 33 41 51
S22
S21 51
MSR131RT
P
13 23 33 41
PWR
51
START
CH1 CH1
IN
CH2 CH2
14 24 34 42
52
X4 Y30 Y31 Y35 42 52
Y32
A2 Y1 Y2 52
X2 14 24
X1 34
Page 22 of 22

Safety Relay Training

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Safety Relay Training

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Safety Relay Training

Safety Relay Training

Safety Relay Basics

Force Guided Relay

Safety Relay operation:

DC + DC - E-Stop 3 E-Stop 2 E-Stop 1

Relay Reset Y32

The diagram shows:

Input Channel Open

DC + DC - E-Stop 3 E-Stop 2 E-Stop 1

Input Channels Closed

DC + DC - E-Stop 3 E-Stop 2 E-Stop 1

 E-Stop string closed

Reset Input Depressed

DC + DC - E-Stop 3 E-Stop 2 E-Stop 1

 Manual reset closed

DC + DC - E-Stop 3 E-Stop 2 E-Stop 1

DC + DC - E-Stop 3 E-Stop 2 E-Stop 1

CHI Relay Reset Y32

GuardMaster MSR Safety Relays:

A1 S33 S34 S11 13 23

MSRI3 Cat # 440R-C23137 Specifications

Input Wiring Configurations:

MSRI3 2 F Monitored Reset

L2(Ground) Relay Inputs

MSR 2 N.C. Automatic Reset

L2(Ground) Relay Inputs

L2(Ground) Relay Inputs

A1 S33 S34 S11 13 23

L2(Ground) Relay Inputs

L2(Ground) Relay Inputs

L2(Ground) Relay Inputs

L2(Ground) Relay Inputs

6 Off Off Closed Off Check power applied to A1 and A2.

L2(Ground) Relay Inputs

L2(Ground) Relay Inputs

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