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Allen-Bradley Guardmaster MSR125HP (440R-D23171) Two-Hand Control Safety Relay
This unit is a dedicated two-hand control safety relay under the Guardmaster series of Rockwell Automation. Es verfügt über einen Zweikanaleingang, 2 KEINE Sicherheitskontakte, Kategorie 4 / Leistungsniveau z (PL e) safety rating and removable terminals. Designed specifically for high-risk machinery requiring synchronized two-hand operation, it keeps operators’ hands within safe zones and prevents personal injuries.
- Erklärung des Modellcodes
MSR125HP‑440R‑D23171 is a two-hand control safety relay of the Guardmaster series manufactured by Allen‑Bradley / Rockwell Automation, USA. The model breakdown and corresponding order number are specified below:
| Codesegment | Beschreibung |
| MSR | Seriencode: Minotaur Safety Relay |
| 125 | Funktionscode: Two-hand control unit, compliant with Type III safety requirements of ISO 13851 |
| PS | Feature code: Hohe Leistung, equipped with removable terminals (differentiated from MSR125H with fixed terminals) |
| 440R-D23171 | Order number: Exclusive Rockwell identification code, for 24V DC power supply and two-hand control function |
Key Ordering Information
Main Order Number: 440R-D23171 (Standard version with removable terminals)
Alternatives Modell: 440R‑D23168 (MSR125H, fixed terminals)
Compatible Model: 440R‑D23172 (with 0.5-second time delay function)
- Grundlegende technische Spezifikationen
| Kategorie | Technische Daten | Bemerkungen |
| Allgemeine Spezifikationen | ||
| Typ | Two-hand control monitoring safety relay | Compliant with Type III requirements of ISO 13851 |
| Betriebsspannung | 24In DC (-15%/+20%) / 24V und (-15%/+10%) | Max. ripple voltage: 10% |
| Stromverbrauch | Max. 3W | Design mit geringem Stromverbrauch |
| Schutz vor Eindringen | IP40 (Gehäuse) / IP20 (Terminals) | Suitable for control cabinet installation |
| Eingabemerkmale | ||
| Monitoring Channels | Dual channel (1NC + 1NO input) | Dedicated for two-hand control, synchronized triggering required |
| Eingabetyp | Dry contact signal | Compatible with two-hand control buttons and foot switches |
| Synchronization Time Window | ≤ 0.5 zweite | Operation beyond this window is deemed unsafe |
| Ausgabeeigenschaften | ||
| Sicherheitskontakte | 2 Normalerweise geöffnet (NEIN) Kontakte | AC15: 230V/6A; DC13: 24V/6A |
| Hilfsausgang | Keiner | Optimized for safety control |
| Leistungsniveau | PL e (Highest level) | Compliant with EN ISO 13849‑1 |
| Safety Category | Kategorie 4 | Compliant with EN IEC 61508 |
| Safety Integrity Level | SIL 3 | Meets requirements for high-risk applications |
| Physikalische Eigenschaften | ||
| Abmessungen | 22.5mm × 99mm × 121mm | DIN-Schienenmontage, platzsparend |
| Montage | 35mm Standard-DIN-Schiene | Standard industrial installation |
| Betriebstemperatur | -25°C ~ 60°C | Großer Temperaturbereich für Industrieumgebungen |
| Terminals | Removable screw terminals | Cable cross-section: 0.25mm² ~ 2.5mm² |
| Zertifizierungen | UL, CSA, CE, TÜV | Konform mit internationalen Sicherheitsstandards |
- Cross-Brand Compatibility List
| Marke | Ersatzmodell | Kompatibilitätsbeschreibung |
| Allen-Bradley | MSR125H (440R‑D23168) | Identical functions, only differs in terminal type (fixed terminals) |
| Schmersal | SRB301‑24V (101190686) | General-purpose safety relay with 3 Sicherheitskontakte; two-hand control logic needs reconfiguration |
| Siemens | 3SK1122‑1AB30 | Dedicated two-hand control relay, 2 Sicherheitskontakte, 24In DC |
| Schneider Electric | XPSAC5121 | 24V AC/DC, 3 Sicherheitskontakte; two-hand control requires additional programming |
| Omron | G9SA‑501 | Two-hand control unit, 2 Sicherheitskontakte, STOPPEN 0 Stopp-Kategorie |
Auswahltipp: Choose dedicated two-hand control relays; match synchronization window and contact quantity; do not downgrade safety ratings; select terminals according to on-site demands.
- Full Model List of MSR Two-Hand Control Series
Modell Bestellnummer Stromspannung Kontaktkonfiguration Terminaltyp Sonderfunktion MSR125HP 440R-D23171 24V AC/DC 2 KEINE Sicherheitskontakte Removable Two-hand control, instantaneous output MSR125H 440R‑D23168 24V AC/DC 2 KEINE Sicherheitskontakte Behoben Two-hand control, instantaneous output MSR125HP‑0.5s 440R‑D23172 24V AC/DC 2 KEINE Sicherheitskontakte Removable Two-hand control, 0.5s delayed output MSR125H‑0.5s 440R‑D23169 24V AC/DC 2 KEINE Sicherheitskontakte Behoben Two-hand control, 0.5s delayed output MSR125HP‑240V 440R‑D23173 240V und 2 KEINE Sicherheitskontakte Removable Two-hand control, high voltage version Häufige Fehler & Fehlerbehebung
| Fehlerphänomen | Mögliche Ursachen | Lösungen |
| Betriebsanzeige aus | 1. Power disconnected or abnormal voltage | 1. Check power connection and voltage (20.4V~28.8V DC) |
| 2. Internal fuse blown | 2. Replace 2A internal fuse | |
| Safety contacts fail to activate | 1. Two buttons not synchronized (interval over 0.5s) | 1. Standardize operation to ensure synchronized actuation |
| 2. Fault in input channels | 2. Inspect buttons and wiring, replace defective parts | |
| 3. Falsche Einstellung des Reset-Modus | 3. Verify reset mode (automatic / Handbuch) | |
| Häufige Fehlauslösungen | 1. Elektromagnetische Störungen | 1. Apply shielding and keep away from interference sources |
| 2. Loose cable connections | 2. Retighten cables and ensure reliable connection | |
| 3. Improper synchronization window | 3. Confirm fixed 0.5s synchronization window (non-adjustable) | |
| Zurücksetzen fehlgeschlagen | 1. Safety circuit not fully closed | 1. Inspect all safety input devices |
| 2. Manual reset button not pressed | 2. Press reset button (under manual reset mode) | |
| 3. Internal component failure | 3. Replace the safety relay module |
Quick Troubleshooting Guide: Check power supply first, then synchronization. For inactive contacts, inspect inputs; for false tripping, eliminate interference; for reset failure, verify the whole safety circuit.
- Anwendungsumgebungen & Branchenfälle
6.1 Anwendbare Szenarien
Stamping & Bending Machinery: Presses, press brakes, shears and other metalworking equipment requiring two-hand operation
Injection & Molding Machinery: Mold area protection for injection molding machines and die-casting machines to prevent hand injuries
Assembly & Testing Tooling: Custom automated equipment with mandatory two-hand operation for operational safety
Schweißen & Cutting Equipment: Start-up control for welding robots and plasma cutters to avoid accidental activation
Verpackungsmaschinen: Sealing and cutting stations with synchronized two-hand operation to protect operators
6.2 Nicht empfohlene Szenarien
Single-button controlled equipment: Two-hand control function cannot be utilized, resulting in unnecessary cost
Outdoor harsh environments: IP40 rating is not suitable for outdoor installation
Highly corrosive environments: No anti-corrosion coating, incompatible with acid, alkali and corrosive substances
High vibration environments: Vibration exceeding 5g will shorten relay service life
6.3 Typische Anwendungsfälle
Fall 1: Two-Hand Start Safety System for CNC Press
Anwendung: Start control for 160-ton CNC press, preventing operators from reaching into the stamping zone
Konfiguration: MSR125HP (440R-D23171) + 2 mushroom-head two-hand buttons (mounted on both sides of machine, spacing ≥ 60cm)
Funktionsprinzip: Both buttons must be pressed synchronously within 0.5 second to close safety contacts and start the press. The machine stops immediately once either button is released.
Wirkung: Complies with Category 4 / PL e standards, eliminating risks of hands entering hazardous areas during operation.
Fall 2: Mold Closing Safety Protection for Injection Molding Machine
Anwendung: Mold closing control for 200-ton injection molding machine, preventing pinching injuries during part removal
Konfiguration: MSR125HP + two-hand buttons (mounted on both sides of control panel) + magnetic safety switch for safety gate
Funktionsprinzip: Mold closing can only be initiated when the safety gate is fully closed and both buttons are pressed synchronously. Mold movement stops instantly if the gate is opened or any button is released.
Wirkung: Dual safety protection implemented, fully compliant with safety standards for rubber and plastics industry.
Fall 3: Two-Hand Coordinated Workstation for Automated Assembly Line
Anwendung: Press-fitting station for automotive component assembly line, two-hand operation required to activate the press head
Konfiguration: MSR125HP + foot switch (auxiliary control) + two-hand buttons (main control)
Funktionsprinzip: Activate foot switch to clamp workpieces, then press both buttons synchronously to start the press head, ensuring operators’ hands stay in safe positions.
Wirkung: Improves production efficiency while guaranteeing operator safety, ideal for mass production lines.
- Betriebsrichtlinien & Installationsspezifikationen
- Two-hand button installation: Maintain a minimum spacing of 60cm between two buttons to prevent actuation with one single hand.
- Verkabelungsregeln: Adopt cross wiring for dual input channels to enhance fault detection capability.
- Reset mode selection
Automatischer Reset: System recovers automatically after fault removal, suitable for continuous production lines.
Manueller Reset: Reset button must be pressed manually, recommended for high-risk applications.
- Maintenance schedule: Inspect contact status and wiring every 6 months to ensure stable and safe operation.
- Ersatzteilmanagement: Prepare one identical relay as spare part to minimize downtime caused by equipment failure.
