Allen-Bradley MSR230P-440R-H23180 Safety Relay

For industrial equipment involving personal safety protection, machine interlock stop, safety door / light curtain / emergency stop / two-hand control, the Allen‑Bradley 440R series safety relays are the standard default components for Rockwell Automation safety circuits. They cover almost all safety applications for machinery in discrete manufacturing and process industries.

1. Model Segment Definition

2. Core Specifications

3. Standard Accessories List
4. Safety Relay Main Unit (440R-H23180 / MSR230P)
5. Installation Manual (Hard copy + Electronic version)
6. Certificate of Conformity & Warranty Card
7. DIN rail mounting clips
8. Terminal identification labels
9. Reset button protective cover (Optional)
10. Cross-Brand Equivalent & Replacement Table

5. Selection Guidelines & Replacement Solutions

Selection Guidelines

1. Safety Function Matching

Suitable for single/dual-channel safety input monitoring: emergency stop buttons, safety door switches, safety mats, etc.

Meets high safety rating Cat.4 / PL e / SIL 3 for hazardous machinery protection.

Not suitable for complex functions such as safety door interlock or two-hand control.

2. Electrical Parameter Verification

Control voltage must match 24VDC (19.2~31.2VDC).

Safety output load current ≤3A@24VDC or ≤6A@240VAC.

Auxiliary output load current ≤3A@24VDC/240VAC.

3. Installation & Environmental Requirements

Operating temperature: -25℃~+60℃ (derate above 40℃).

Relative humidity: 5%~95% (non-condensing).

Install inside control cabinet; avoid dust, corrosive gas and heavy vibration.

Replacement Solutions

1. Same-Brand Upgrade Replacement

440R-EM4R2: Modular, expandable functions, compatible with original mounting dimensions.

440R-M23088 (MSR138.1DP): Single-channel monitoring, 2NO+1NC, equivalent performance.

2. Function Expansion Options

Add 440R-EM series expansion modules for multi-channel safety monitoring.

Adopt 440R-GSR intelligent safety relays with Profinet / EtherNet/IP communication.

Upgrade to Guardmaster MSR200 expandable system, supports up to 22 input points.

3. Cross-Brand Recommendation

Cost performance: Schneider XPSAC5121 (compact & low cost)

Premium safety performance: Pilz PNOZ X1 (fast response, full certifications)

Siemens system integration: 3SK1111-1AB30 (seamless TIA Portal integration)

6. Application Scenarios

Machine tool safety door monitoring & emergency stop control

Packaging machinery safety protection systems

Production line safety interlock control

Robot workstation safety perimeter protection

Printing machinery safety protection circuits

7. MSR Series Main Model List

8. Cross-Brand Compatibility Chart (24VDC, 2NO+1NC)

9. Key Features Summary
10. High Safety Rating

Complies with EN ISO 13849-1 Cat.4, PL e and SIL 3, suitable for high-risk machinery applications.

2. Flexible Reset

Supports both manual and automatic reset modes to fit different site requirements.

3. Reliable Performance

Dual-channel input monitoring with fail-safe design, ensuring safety outputs open under hazardous conditions.

4. Compact Structure

45mm DIN rail mounting saves control cabinet space.

5. Global Certifications

CE, UL, CSA, TÜV approved, suitable for international projects.

Allen-Bradley Guardmaster Minotaur MSR Series Full Model List

1. Model Naming Rule

2. Full Main Model List by Category

2.1 Monitoring Safety Relays (Emergency Stop / Safety Door)

2.2 Two-Hand Control Safety Relays

2.3 Time-Delay Safety Relays

2.4 Special Function Safety Relays

3. Obsolete Model Replacement Guide

4. Quick Selection Table by Control Voltage

4.1 24VDC Models

4.2 230VAC Models

4.3 24VAC/DC Universal Models

5. General Parameter Summary

Rockwell Allen‑Bradley 440R Series Safety Relay Full Application Overview

1. Product Positioning

The 440R series is the core safety relay lineup of AB Guardmaster, including traditional MSR basic type, EM expansion type, GSR intelligent communication type, time-delay and two-hand dedicated types. All meet PL e / Cat.4 / SIL 3 high safety levels.

DIN rail mount, compatible with emergency stop, safety door, light curtain, safety mat, two-hand button and all standard safety sensors.

2. General Safety Application Scenarios

2.1 Emergency Stop Circuit Monitoring

Dual-channel contact detection for mushroom emergency stop buttons

Immediate power cut on E-stop; restart allowed only after reset

Standard safety circuit for all industrial machines

Typical model: 440R‑H23180(MSR230P), 440R‑M23088

2.2 Safety Guarding Door / Access Door Interlock

Machine guard doors, cabinet doors, perimeter fence doors stop machine when opened

Machine prohibited from starting if door not fully closed and locked

Compatible with hinge safety switches, bolt safety switches, electromagnetic door interlocks

2.3 Safety Light Curtain / Safety Scanner Interlock

Interface with photoelectric light curtains and laser safety scanners

Automatically cuts power when personnel enter hazardous area; reset permitted after evacuation

Ideal for robotic stations, stamping and pick-and-place stations

2.4 Two-Hand Synchronous Start Control

Safe two-hand start for presses, punch presses and riveting machines

Machine action only activates when both buttons pressed simultaneously to prevent hand injury

Dedicated models: 440R‑D23166, MSR125H

2.5 Time-Delay Safe Stop

Delayed power-off for fans, inertial loads and high-speed spindles

Safety signal triggers delayed output disconnection; unlock maintenance only after full mechanical stop

Time-delay models: 440R‑M23048, MSR15D adjustable delay

2.6 Safety Mat / Safety Edge Detection

Safety mats and safety edges installed around robots and hazardous zones

Immediate machine stop when stepped on or touched

2.7 Multi-Unit Group Safety Interlock

Multi-station production line interlock: any station safety trigger stops the whole line

Use 440R‑EM expansion modules for multi-channel safety cascading

2.8 VFD / Servo Drive Safe Torque Off

Connect to STO / emergency stop terminals of VFD and servo drives

Safety relay dry contact cuts drive enable to realize safe torque off

3. Industry-Specific Applications
4. General Machine Tools

Lathe, milling, machining center, grinder, drill press: E-stop, guard door interlock, spindle safe stop.

2. Automation Production & Conveyor Lines

Assembly lines, chain conveyors, roller lines: line E-stop, sectional safety isolation, fence interlock.

3. Robot Workstations & Manipulators

6-axis robot, gantry manipulator: fence safety door, light curtain protection, external safety interlock.

4. Packaging, Printing & Paper Machinery

Labeling, carton sealing, winding, printing machine: roller guard interlock, operator area light curtain protection.

5. Injection Molding & Plastic Extrusion

Injection blower, extruder: mold safety door, two-hand start, light curtain anti-entry protection.

6. Stamping, Forging & Hydraulic Press Equipment

Press, hydraulic press, bending machine: two-hand anti-pinch start, mold area light curtain & safety mat protection.

7. Logistics & Warehousing Equipment

AS/RS stacker, sorter, elevator: maintenance door interlock, crossing area personnel safety stop.

8. Automotive OEM & Component Manufacturing

Welding, painting, assembly workshop: robot cell interlock, fixture safety door group interlock.

9. Food & Pharmaceutical Machinery

Filling, sealing, pharmaceutical lines: hygienic safety switch interface, maintenance mode safety lock.

10. Lifting & Hoisting Equipment

Crane, lifting platform: limit switch & E-stop monitoring, fence door interlock, overload safety interlock.

11. HVAC & Industrial Fans/Pumps

Large fan, air compressor, chiller: cabinet door power interlock, inertial load delayed safe stop.

12. Custom Non-Standard Automation

Assembly, testing, marking, riveting machines: global E-stop, local light curtain protection, multi-cylinder/servo interlock.

4. 440R Subseries Application Matching