Safety Relay Troubleshooting Guide

Troubleshooting Safety Relay Based Systems

MSR131

MSR131 Toubleshooting Guide Rev C.doc Page 1 of 22 December 27, 2005

 Table of Contents

1) Introduction......................................................................................................................................... 3
2) Power Supply ...................................................................................................................................... 4
a) FAQ: What is the inrush current on power-up?............................................................................................................5
3) Input Circuit – 2NC ............................................................................................................................ 7
a) FAQ: How much inrush current is present at the inputs?...........................................................................................10
4) Input Circuit – Distribution Block .................................................................................................... 11
5) Input Circuit – Light Curtain ............................................................................................................ 12
a) FAQ: Once the input circuit is opened, how long must it stay open?..........................................................................13
b) FAQ: Under what conditions is the order of input circuit closing important?.............................................................13
6) Safety Mat Input ............................................................................................................................... 14
a) FAQ: What causes only one output LED to turn on? ..................................................................................................15
7) Reset Circuit...................................................................................................................................... 15
a) FAQ: How soon after the inputs are closed can the reset button be pressed? ............................................................17
8) Monitoring Circuit ............................................................................................................................ 18
9) Output Circuits.................................................................................................................................. 20
10) Timing Requirements........................................................................................................................ 21
11) Single Point Lesson........................................................................................................................... 21

MSR131 Toubleshooting Guide Rev C.doc Page 2 of 22 December 27, 2005

1) Introduction

The troubleshooting process for the MSR131 safety relay follows a straight forward process. The process starts with
the power supply and follows the normal sequence of events that take place in the relay.

The troubleshooting process is as follows:

1. Power
2. Inputs
3. Reset
4. Monitoring
5. Outputs

The MSR131 safety relay goes into a lockout state when it detects a fault condition. The fault condition can be either
external or internal to the MSR131, as the MSR131 monitors external devices as well as itself. This lockout state
prevents the safety outputs from being energized, until the fault condition is corrected and the MSR131 is satisfied.

If an external fault is corrected, the MSR131 is reset in one of two methods:

1. Cycle an input device (the preferred method), or

2. Cycle the power.

In many cases, the fault will be either an open-circuit or a short-circuit condition. In these cases, a digital multimeter
can be used to accomplish the troubleshooting. An oscilloscope is needed when timing issues are suspected of
causing lockouts.

Note: The measurements in this document were taken on sample products. Actual measurements will vary from unit
to unit, as well as with temperature.

In this guide, the reader is asked to make measurements with a multimeter. An example of the terminology used is
“S12/S22”, where one test lead is placed on terminal S12 and the other terminal is placed on terminal S22.

FAQ = Frequently Asked Question

EOT = End of Troubleshooting

!
Troubleshooting safety relay based systems sometimes requires the application of power.
Troubleshooting must be performed by trained persons familiar with safety publications ANSI
NFPA70E and ANSI Z244.1 and local applicable codes.

MSR131 Toubleshooting Guide Rev C.doc Page 3 of 22 December 27, 2005

2) Power Supply
The power supply is protected by electronic current limiting. If a short circuit or overload occurs, the resistance goes
up to prevent damage to the MSR131. When the fault is cleared, the resistance returns to normal, and the MSR131
begins to operate properly. See Safety Mat inputs for further details.
Step P1
Is power LED on?
If not, go to Step P2.
If blinking, go to Step P4
If yes, go to Input Circuits.

Step P2
Measure supply voltage at A1/A2 for 24VDC or 115VAC, depending on the model used.

DMM
24 Example for 24VDC
Volts

Example for 24VDC

DMM
440R-C23139 (24V AC/DC)
24
+V 440R-C23137 (115V AC) -V
Amps Reference Information: Power Supply Current
A1 Circuit Protection A2
AC
S11
24VDC The power supply current depends on the type of
(+) (-)
S11 inputs used. Use an ammeter to measure the
PWR
S21 Y30 current. Values shown with safety outputs
Inputs
Y35
energized.
Y31 Closed
Output
Y32
Active Light Curtain 23mA DC @ 20.4V DC
X1
Reset
S33 28mA DC @ 24.0V DC
X2 Start Start S34 31mA DC @ 26.4V DC
Logic
Check Power X3 Y2
Supply on Side Label X4 Y1
19mA AC@ 98V AC
24mA AC@115V AC
S22
CH2 CH2 26m A AC@126VAC
S52 CH2

& 2 NC Contacts 70mA DC @ 20.4V DC

CH1 CH1 85mA DC @ 24.0V DC
S12 CH1
CH1
13
CH2
14
95mA DC @ 26.4V DC
23 24
31mA AC @ 98V AC
33 34
38mA AC @ 115V AC
41 42 42mA AC @ 126V AC
51 52
Safety Mat/Crossfault 115mA DC @ 24VDC
45mA AC @ 115VAC

If OK, go to Step P3.

If not, verify that the equipment power switch is set to ON.
Is the equipment connected to the power source? Are the power supply fuses blown?
Is the unit rated for the appropriate voltage – see label on side of unit? Go to Step P1.

As a reference, the current used by the MSR131, with its safety outputs energized, is shown in the side
table. This table show the typical current when the MSR131 is functional and its safety outputs are
energized.

MSR131 Toubleshooting Guide Rev C.doc Page 4 of 22 December 27, 2005

 a) FAQ: What is the inrush current on power-up?
The worst case inrush occurs at the highest supply voltage with the MSR131. The inrush current is essentially
the same regardless of whether or not the safety outputs energized on power up. At 26.4V DC, the inrush
current of the power supply is 120mA. This pulse lasts for about 10ms. At 126VAC, the peak inrush is 150mA,
and it decays exponentially to a steady state value within 3 cycles.
10ms

120mA

150mA

DC Power Inrush AC Power Inrush

Step P3
Measure the internal supply voltage of the MSR131 - S11/S21 should be 17 to 40 VDC. The internal voltage is
not tightly regulated and depends on the external power supply. If OK, go to Input Circuits.

440R-C23139 (24V AC/DC)

+V 440R-C23137 (115V AC) -V
A1 Circuit Protection A2

S11 AC
24VDC
(+) (-)
S11
PWR
S21 Y30
DMM
Inputs
24 Y31 Y35
Closed
Volts Output
Y32
Active
X1 S33
Reset
Should be X2 Start Start S34
Logic
17 to 33 VDC X3 Y2
depending X4 Y1
on Supply Voltage
S22
CH2 CH2
S52 CH2

&
CH1 CH1
S12 CH1
CH1 CH2
13 14

23 24

33 34

41 42

51 52

MSR131 Toubleshooting Guide Rev C.doc Page 5 of 22 December 27, 2005

 Step P4
Pop out the top front terminal block (with S11). Did the Power LED stop blinking?
If yes, turn off power to the unit. Use your ohm meter and check for shorts between the CH1 and CH2
circuit. If a safety mat is connected to the MSR131, check for objects on the safety mat.

Pop out the top terminal block. Check for shorts.

If a short is found, trace the input wiring and remove the short. Re-insert the top connector, and apply
power. Go to Input Circuits.

MSR131 Toubleshooting Guide Rev C.doc Page 6 of 22 December 27, 2005

3) Input Circuit – 2NC
The typical 2 normally closed (NC) series circuit is wired as shown below. This arrangement employs
redundancy (two circuits) and diversity (one pull up and one pull down). The internal relay to CH1 is pulled up
by the external interlocks or e-stops to 24V at S11. A jumper is connected from S11 to S52 to supply power to
CH2. CH2 is pulled down to ground by the external interlocks or e-stops to S21. Crossfaults, shorts from CH1
to CH2, can be detected by the diversity principle – the Power LED blinks.

+V -V

A1 Circuit Protection A2
Gate Interlocks or E-Stops S11 AC
24VDC
Channel 1 S11
(+) (-)
PWR
S21 Y30
Channel 2 Inputs
Y31 Y35
Closed
Output
Y32
Active
X1 S33
Reset
X2 Start Start S34
Logic
X3 Y2

X4 Y1

S22
CH2 CH2
S52 CH2

&
CH1 CH1
S12 CH1
CH1 CH2
13 14

23 24

33 34

41 42

51 52

Operation
With 2NC circuits, the safety outputs de-energize when either CH1 or CH2 opens. If one channel opens, then
the other channel must also open before the safety outputs can re-energize. The timing between the inputs is
flexible:
1) CH1 can open before or after CH2 - the order in which the channels open and close is not critical.
2) the first channel that opens can close before the second channel opens and closes.
3) there is no time within which the second channel must operate; it could operate seconds, minutes or even
days later.

After both inputs have been opened and then closed, the input is said to be satisfied. The MSR131 is ready to
check the reset and monitoring circuit. If those circuits are satisfied, the safety outputs will be energized.

MSR131 Toubleshooting Guide Rev C.doc Page 7 of 22 December 27, 2005

 Step I1
Are the CH1 and CH2 LEDs on?
If yes, go to Step Reset Circuit.
If only CH1 LED is on, then an open circuit exists on CH2. Go to Step I2.
If only CH2 LED is on, then an open circuit exists on CH1. Go to Step I2.
If neither CH1 LED nor CH2 LED is on, then both CH1 and CH2 circuits must be open. Go to Step I2.
Step I2
At the MSR131, measure the cross channel voltages. This should confirm the input LED Status:

Relay Terminals Voltage Look for: Input LED

S52/S22 24V Both Channels are OK Both on
S21/S12 24V

S52/S22 0V Both Channels are open. Both off

S21/S12 0V

S52/S22 24V Channel 1 is open. CH2 on

S21/S12 0V

S52/S22 0V Channel 2 is open. CH1 on

S21/S12 24V

When troubleshooting 2NC circuits, the easiest approach is to measure the cross channel voltage at each of the
devices. Open the cover of an interlock to expose the wiring terminals. . The two contacts closest to the
actuator are the safety contacts. Using a voltmeter, measure the voltage from Channel 1 to Channel 2.

9 ²

CH1 Safety Contacts

CH2 Safety Contacts

Cross channel measurement Contact measurement

MSR131 Toubleshooting Guide Rev C.doc Page 8 of 22 December 27, 2005

 Check the input devices for open circuits.
The following two diagrams show typical examples of wiring 2NC series circuits. With all the input
devices closed and the MSR131 powered, measure the cross channel voltages at each of the input devices
until a voltage difference is found. The open circuit lies between the device that showed 0V and the device
the showed 24V. Check the connections, terminals, and wiring for an open circuit. The actual voltage
shown is a nominal 24VDC; the actual voltage can range from 17 to 40V.

+V 440R-C23139 (24V AC/DC) -V +V 440R-C23139 (24V AC/DC) -V

440R-C23137 (115V AC) 440R-C23137 (115V AC)
A1 Circuit Protection A2 A1 Circuit Protection A2
Gate Interlocks or E-Stops S11 AC Gate Interlocks or E-Stops S11 AC
24VDC 24VDC
(+) (-) (+) (-)
S11 S11
PWR PWR
0V 0V 24V S21 Y30 0V 0V 24V S21 Y30
Inputs Inputs
Y31 Y35 Y31 Y35
Closed Closed
Output Output
Y32 Y32
Active Active
X1 S33 X1 S33
Reset Reset
X2 Start Start S34 X2 Start Start S34
Logic Logic
X3 Y2 X3 Y2

X4 Y1 X4 Y1

S22 S22
CH2 CH2 CH2 CH2
S52 CH2 S52 CH2

& &
CH1 CH1 CH1 CH1
S12 CH1 S12 CH1
CH1 CH2 CH1 CH2
13 14 13 14

23 24 23 24

33 34 33 34

41 42 41 42

51 52 51 52

Open Circuit on CH1 Open Circuit on CH2

Reference Information: Input Currents

The currents going into S12 (CH1) and S22 (CH2)
depend on the supply voltage. Use a DC ammeter to
measure these currents.

VSupply CH1 CH2

20.4V DC 25mA DC 31mA DC
24.0V DC 30mA DC 37mA DC
26.4V DC 34mA DC 41mA DC
97.8V AC 28mA DC 34mA DC
115V AC 33mA DC 40mA DC
126.5V AC 37mA DC 44mA DC

MSR131 Toubleshooting Guide Rev C.doc Page 9 of 22 December 27, 2005

 a) FAQ: How much inrush current is present at the inputs?
When the actuator is inserted into an interlock, for example when a safety gate is closed, the inrush current
to at the inputs of the MSR131 is 90mA. This inrush lasts for about 100ms. The measurements below were
taken on a unit powered by 24VDC. The figures below show the current waveform when the MSR131 is
set for automatic and monitored reset. The difference in the waveform is due to the safety outputs
becoming energized when the MSR131 is set up for automatic reset.
80ms 100ms

CH1

90mA

CH2

90mA

Inrush Current with Auto Reset Inrush Current with Manual Reset

MSR131 Toubleshooting Guide Rev C.doc Page 10 of 22 December 27, 2005

4) Input Circuit – Distribution Block
When troubleshooting devices connected to the distribution blocks, the order in which the devices are connected
becomes important. The picture and wiring diagrams show that the connection flow. Not that the 6-pin 8-port flows
through the even side and then through the odd side. The 4-pin 8-port flows in numerical order. This can be used to
help identify the location of an open circuit, as described in the 2NC section above.

898R-P68MT
J2 J8 J7 J3 J1
Brown/Green 1 5 1 5 1 5 1 5 1 5 Brown/Yellow

6-Pin QD
White/Yellow 2 6 2 6 2 6 2 6 2 6 White/Green

898D-48LT
J8 J7 J2 J1
Blue 3 1 3 1 3 1 3 1 Brown

4-Pin QD
Black 4 2 4 2 4 2 4 2 White

MSR131 Toubleshooting Guide Rev C.doc Page 11 of 22 December 27, 2005

5) Input Circuit – Light Curtain
The MSR131 is designed to interface with light curtains. Light curtains with solid state outputs can be wired as
shown below. These light curtains are typically powered by 24VDC. When an AC powered MSR131 is used (shown
on right), the light curtain ground must be referenced to the MSR131 internal ground (S21). Solid state light curtains
have two PNP type outputs called output signal switching devices (OSSD). The light curtain detects a crossfault,
which is a short between the two OSSD outputs; the MSR131 does not detect this fault.

DC Powered MSR131 AC Powered MSR131

Reference Information: Light Curtain Output Currents

Use a DC ammeter to measure these currents.

VSupply Ch1 Ch2

19.2VDC 28mA 24mA
24.0VDC 36mA 31mA
26.4VDC 40mA 35mA

The MSR131 power supply does not play a role in

determining these currents.

Step LC1
With the light curtain made (nothing between the sender and receiver), does the voltage at terminals S12 and S52
measure 24VDC. [With the light curtain broken (object between the sender and receiver), the voltage at
terminals S12 and S52 should measure 0VDC.]
If yes, Go to Step LC2.
If not, check to make sure the ground reference of the light curtain is the same as the MSR131. For DC
powered MSR131’s, this can be A2 or S21. For AC power MSR131’s, the reference must be to S21.
If either S12 or S52 measures zero volts, check the wiring going back to the light curtain.
Step LC2
Press the reset button. Do CH1 and CH2 LEDs turn on?
If yes, go to Step Outputs.
If not, go to Step Reset Circuit.
MSR131 Toubleshooting Guide Rev C.doc Page 12 of 22 December 27, 2005
 Note: Light curtains perform their own diagnostics. For example, a crossfault from CH1 to CH2 will be
detected by the light curtain, not by the MSR131. Faults detected by the light curtain are usually indicated by
red blinking LEDs on the light curtain. This troubleshooting guide is not intended to cover light curtain
troubleshooting.

a) FAQ: Once the input circuit is opened, how long must it stay open?
This is known as the recovery time. Once an input is opened, it must stay open for at least 100ms. This gives the
internal circuitry enough time to get itself ready for the next demand on the safety system. It is possible to turn
light curtains off and then back on within 100ms. If this happens, the MSR131 safety outputs will remain in the
de-energized mode, with one output on (typically CH2) and the other output off (typically CH1). To correct this
condition, simply break and make the light curtain again.

b) FAQ: Under what conditions is the order of input circuit closing important?
In rare applications, two independent devices are connected like a light curtain: S12 and S52 are switched to
24V, and S21 is jumpered to S22. In addition, automatic reset is used. Under these conditions, CH2 must close
before or at the same time as CH1. If this sequence is not performed properly, then the CH1 output will be on,
but the CH2 output will not turn on.

To correct this situation, modify the sequence of operation or used monitored reset

MSR131 Toubleshooting Guide Rev C.doc Page 13 of 22 December 27, 2005

6) Safety Mat Input
Safety mats can also be connected to the MSR131. The wiring example below shows two parallel plate type
safety mats connected in series. A current flows through the safety mats at all times to detect an open circuit.
The MSR131 uses crossfault detection to detect someone stepping on the mat. When someone steps on the mat,
CH1 is shorted to CH2, and the safety outputs are de-energized. The Power LED blinks to indicate the presence
on the mat; all the other LEDs are off.

A1 Circuit Protection A2

S11 AC
24VDC
(+) (-)
S11
PWR
S21 Y30
Inputs
Y31 Y35
Closed
Output
Y32
Active
X1 S33
Reset
X2 Start Start S34
Logic
X3 Y2

Safety Mat 1 Safety Mat 2 X4 Y1

S22
CH2 CH2
S52 CH2

&
CH1 CH1
S12 CH1
CH1 CH2
13 14

23 24

33 34

41 42

51 52

Power Supply Current (24VDC Power to A1/A2):

The figure below shows how the current behaves when the safety outputs are off, on and when some steps
on the safety mat.

Safety Mat Activated

Safety Outputs ON 113mA

78mA
Safety Outputs OFF
30mA

MSR131 Toubleshooting Guide Rev C.doc Page 14 of 22 December 27, 2005

 a) FAQ: What causes only one output LED to turn on?
This occurs when a safety mat is connected to the MSR131 configured for automatic reset. The recovery time of
the MSR131 is rated at 100ms. It is possible to drop a tool, or bounce something on the safety mat, such that the
output turns off. The mat is not actuated long enough for the MSR131 to complete its internal cycle. Typically,
the CH2 LED will be off; occasionally CH1 will be off. To clear this condition, step on and off the mat. If this
problem persists, consider changing to monitored reset or seek an alternative relay (like the MSR23M or 440F-
C4000D).

7) Reset Circuit
Operation
The MSR131 provides two terminals for reset: S33/S34. There are two types of reset functions: automatic and
monitored.

Automatic –To configure the MSR131 for automatic reset, jumpers must be added between X1/X2, X3/X4 and
S33/S34. The MSR131 safety outputs are energized immediately after the inputs and monitoring circuits are satisfied.

Monitored – To configure the MSR131 for monitored reset, remove jumpers from X1/X2 and X3/X4. Connect a
normally open contact, typically a manually operated pushbutton, between S33/S34. This normally open contact must
be closed after the inputs are satisfied. If the monitoring circuit is also satisfied, the safety outputs will be energized.

A1 Circuit Protection A2 A1 Circuit Protection A2

S11 AC S11 AC
24VDC 24VDC
(+) (-) (+) (-)
S11 S11
PWR PWR
S21 Y30 S21 Y30
Inputs Inputs
Y31 Y35 Y31 Y35
Closed Closed
Output Output
Y32 Y32
Active Active
X1 S33 X1 S33
Reset Reset
X2 Start Start S34 X2 Start Start S34
Logic Logic
X3 Y2 X3 Y2

X4 Y1 X4 Y1

S22 S22
CH2 CH2 CH2 CH2
S52 CH2 S52 CH2

& &
CH1 CH1 CH1 CH1
S12 CH1 S12 CH1
CH1 CH2 CH1 CH2
13 14 13 14

23 24 23 24

33 34 33 34

41 42 41 42

51 52 51 52

Automatic Reset Monitored Reset

When CH1 closes, voltage is applied to S33. This voltage is then applied to S34 and Y2 through the jumper or
the reset contact. The Start LED turns on when S34 is powered by the circuit from S33.

MSR131 Toubleshooting Guide Rev C.doc Page 15 of 22 December 27, 2005

 Step R1
Measure the voltages at the terminals under the conditions of the inputs and outputs, shown below.

Automatic Reset
Inputs Outputs S33/S21 S34/S21 Status & Action
Both Open De-energized 0VDC 0VDC MSR131 working OK
Both Closed De-energized 24VDC 0VDC When CH1 closes, voltage is applied to S33.
The Start LED turns on when S34 is
powered by the jumper from S33. If the
Start LED does not turn on and S34/S21 is
0VDC, then look for an open circuit from
S33 to S34.
Both Closed De-energized 24VDC 24VDC Look for an open monitoring circuit Y1/Y2.
Go to the Monitoring Circuit.

Monitored Reset
Inputs Outputs S33/S21 S34/S21 Status & Action
Both Open De-energized 0VDC 0VDC MSR131 working OK
Both Closed De-energized 24VDC 0VDC When CH1 closes, voltage is applied to S33.
The Start LED turns on when S34 is
powered by the closing of the reset contact.
If the Start LED does not turn on and
S34/S21 is 0VDC, then look for an open
circuit from S33 to S34.
Both Closed De-energized 24VDC 24VDC Look for 1 of 2 conditions: 1) If the Start
LED is on, then the reset contact is stuck in
the closed position and was closed prior to
the inputs being satisfied; or 2) If the Start
LED turns on and off when the reset button
is pressed and released, then look for an
open monitoring circuit Y1/Y2. Go to the
Monitoring Circuit.

MSR131 Toubleshooting Guide Rev C.doc Page 16 of 22 December 27, 2005

 Step R2
Use an oscilloscope to measure the reset signal. Place a small resistor; 10 ohms will work, in series with
S33/S34. Connect the oscilloscope leads across the resistor. Trigger the scope to capture the single shot. The
reset signal of an 115VAC powered MSR131 is 70mA and lasts for 34mS. For a 24V DC powered MSR131, the
reset current is 55mA and lasts for 44ms.

34mS 44mS

55mA

70mA

115V AC Powered MSR131 24VDC Powered MSR131

a) FAQ: How soon after the inputs are closed can the reset button be pressed?
100ms. When monitored manual reset is used, the reset contacts cannot be closed until at least 100ms after the
inputs are satisfied.

MSR131 Toubleshooting Guide Rev C.doc Page 17 of 22 December 27, 2005

8) Monitoring Circuit
Operation
The MSR131 provides two terminals for monitoring of external devices. The typical purpose of the monitoring
circuit is to assure the status of external devices, prior to energizing the safety outputs. In the examples below,
the output contactors (on left) and the interlock solenoid (on right) must be in the non-actuated position before
the MSR131 safety outputs can be energized. The MSR131 requires this circuit to be closed before energizing
its safety outputs. After the safety outputs are energized, the monitoring circuit is not used.

+V -V

A1 Circuit Protection A2 A1 Circuit Protection A2

S11 AC AC
24VDC S11
24VDC
(+) (-) (+) (-)
S11 S11
PWR PWR
S21 Y30 S21 Y30
Inputs Inputs
Y31 Y35 Y35
Closed Y31 Closed
Output Output
Y32 Y32
Active Active
X1 S33 X1 S33
Reset Reset
X2 Start Start S34 Start S34
X2 Start
Logic Logic
X3 Y2 Y2
X3
X4 Y1 X4 Y1
S22 S22 Guardlocking Interlock
CH2 CH2 CH2 CH2
S52 CH2 S52 CH2
& &
CH1 CH1 CH1 CH1
S12 CH1 S12 CH1
CH1 CH2 CH1 CH2
13 14 K1 13 14
23 24 K2
23 24
33 34 33 34
41 42 41 42
51 52 51 52

L1
L2
L3
M
K1 K2

Monitoring Output Devices (Contactors) Monitoring Input Devices (Guardlocking Interlock)

When CH1 closes, voltage is applied to S33. When the reset circuit, S33/S34 is closed, voltage is then applied to
Y2. If the monitoring circuit is closed, the voltage is then applied to Y1 to allow completion of the monitoring
function. The monitoring signal is short in duration (see Step M2). The Y1/Y2 circuit is opened as soon as the
external devices (ie. contactors) are energized.

MSR131 Toubleshooting Guide Rev C.doc Page 18 of 22 December 27, 2005

 Step M1
Measure the voltages at the terminals under the conditions of the inputs and outputs, shown below.

Automatic Reset
Inputs Outputs Y2/S21 Y1/S21 Status & Action
Both Open De-energized 0VDC 0VDC MSR131 working OK
Both Closed De-energized 24VDC 0VDC When CH1 closes, voltage is applied to Y2
through the reset circuit (S34) and the Start
LED is on. Since voltage is at Y2, look for
an open circuit from Y2 to Y1.
Both Closed Energized 24VDC 24VDC MSR131 working OK

Monitored Reset
Inputs Outputs Y2/S21 Y1/S21 Status & Action
Both Open De-energized 0VDC 0VDC MSR131 working OK
Both Closed De-energized 0VDC 0VDC Voltage is applied to Y2 by the closing of
the reset contact. Look for an open circuit in
the reset circuit. . Go to the Reset Circuit.
Both Closed De-energized 24VDC 0VDC Voltage is applied to Y2 by the closing of
the reset contact. Look for an open circuit in
the Y2/Y1 circuit.

Step M2
Use an oscilloscope to measure the monitoring signal current. Place a small resistor; 10 ohms will work, in
series with Y2/Y1. Connect the oscilloscope leads across the resistor. Trigger the scope to capture the single
shot. The monitoring current of an 115VAC powered MSR131 is 65mA and lasts for 34mS. The source of the
monitoring current is S33. The current enters S34 and is split. Approximately 5mA is used by the MSR131, and
the remaining 65mA is diverted to the monitoring circuit.

34mS

650mv/10 ohms = 65mA

MSR131 Toubleshooting Guide Rev C.doc Page 19 of 22 December 27, 2005

9) Output Circuits
The output circuits are redundant voltage-free, electromechanical contacts. Initial contact resistance should be less
than 1 ohm. Over the life of the contacts, resistance may go up, but should remain less than a couple ohms. Follow
the steps below using the figure below as a guide.

DMM DMM
0.235 120

Amps Volts Step O3

120VAC
Power Gnd

CH1 CH2 A2
A1 K1
13 14
A1 K2 A2
23 24
A1 A2
33 34 K3

41 42

51 MSR138.1DP 52

A1 A2
K4

DMM
120 DMM
Step O1
Volts 120
Volts Step O2

Step O1
Check the supply side of the output contacts. Does the voltage at terminals 13, 23, 33 and 41 with respect to the
appropriate power supply reference (this may not be the same as A2 or S21) meet expectations?
If yes, go to Step O2.
If not, check the upstream fuses and wiring.
Step O2
With the CH1 and CH2 LEDs on, do the voltages on the load side of the safety relay meet expectations?
If yes, go to Step O3.
If not, then the output contact in the MSR131 may be worn or contaminated. To confirm this, remove the
power wires from the terminals (both the supply and load side) and use an ohm meter to measure the
contact resistance. [This is not shown in the figure above.] Cycle the inputs and measure the resistance a
few times, as the circuit may be intermittent.
Step O3
The output voltage is ok. Does the load energize?
If yes, then MSR131 works OK. EOT.
If not, the trouble resides with the wiring to the load or the load itself. The load may be disconnected or not
functioning properly. Measure the voltage at the load. Measure the current going to the load. Replace the
load, if necessary.

MSR131 Toubleshooting Guide Rev C.doc Page 20 of 22 December 27, 2005

10) Timing Requirements
Time requirements in the table below should be followed to make sure that safety circuits are monitored in a
correct manner. Incomplete de-energizing of either internal safety channels or too short time before reset will be
detected as circuit failure and requires one correct cycling of inputs before reset.

Definitions:
Response time via E-Stop: Time from opening input contacts until opening the safety outputs.
Response time via loss of supply: Time until opening the safety outputs when supply is switched off.
Recovery time: Required time after relay has de-energized before it shall be energized again.
Auto-Reset: Unit resets as soon as inputs are closed provided all internal relays have been de-energized before.
Monitored reset: Reset is only possible if reset loop S33-S34 is open before inputs are closed and will be closed
after inputs are closed for at least 200ms. This prevents automatic reset when the reset button is bridged.

All times are maximum or minimum times. Computer (PLC) controlled actuation of the reset signal must not
occur before the recovery time has elapsed and should be maintained for at least 100ms.

Time Description Time

Via E-Stop <15ms

Response time
Via loss of supply <100ms
Via E-Stop <100ms
Recovery time With monitored reset <100ms
Via loss of supply <250ms
Via Reset button <60ms
Switch-on delay Via Auto-Reset <100ms
Via supply <200ms
Reset Signal duration >100ms

11) Single Point Lesson

The following page contains a simplified “single page” troubleshooting guideline.

MSR131 Toubleshooting Guide Rev C.doc Page 21 of 22 December 27, 2005

 MSR131 Troubleshooting Guide
A1 S33 S34 S52 S11 13 23 33
X3 S11 S12 S21 S22 41 51 51 L1 (120 VAC)
This troubleshooting guide assumes that the open
24V DC Reset
MSR131 has been wired per the schematic MSR131RTP
shown. This schematic shows connections
L1 L2 L3
that demonstrate the functionality of the PWR 13 23 33 41 51 A1 S11 S12 S21 S22 S52 S11Y31 S33 S34 13 23 33 41 51
MSR131. Additional components are START closed K1
necessary to complete the safety system. MSR131RTP
CH1 IN CH1
Configuration: Dual Channel Safety Gate, Output
Active
Inputs
Closed K2
CH2
Manual Reset, Output Monitoring CH2 IN
A2 X1 X2 X3 X4 Y30 Y32 Y35 Y2 Y1 14 24 34 42 52
Maximum Allowable Input Resistance: 45 14 24 34 42 52 M
ohms K1 K2
24V Ground
X4 Y30 S31 Y32 Y35 42 52 52
A2 Y1 Y2 X1 X2 14 24 34 L2
Dual Channel Gate Interlock, Monitored Manual Reset,
Dual Channel Output, Monitored Output

CH1 CH2 S. S. S. S.
Power Start IN IN CH1 CH2 Y35 Y32 Gate Output Check
LED LED LED LED LED LED Inputs Outputs Devices
Closed Off When pressing the reset button, the Start LED turns ON, but outputs do not turn ON. Check the
monitoring loop between Y1 and Y2; it should be a closed circuit.
On Reset On On On Off Off On Off

Closed Off 1) Check the gate switch circuit going to S21 and S22; it should be a closed circuit. 2) Check
the circuit between S11 and S52; it should be a closed circuit. If the gate is opened, the CH1 IN
On Off On Off On Off Off Off LED and CH1 LED will turn off. If gate is re-closed again, CH1 IN LED will turn on.

Closed Off 1) Check the gate switch circuit going to S12 and S52. The circuit may have opened while the
gate was closed. If the gate is opened, the CH2 IN LED and CH2 LED will turn off. If the gate
On Off Off On Off On Off Off is re-closed again, CH2 IN LED with turn on.

Closed Off Check for short circuit across the inputs: S11 to S21, S11 to S22, S12 to S21, or S12 to S22.

Blinking Off Off Off Off Off Off Off

Closed Off Check the Reset button; it may be shorted or held in the closed position.

On On On On Off Off On Off

Closed Off Check power applied to A1 and A2.

Off Off Off Off Off Off Off Off

Closed Off 1) Check for power at terminals 13, 14, 23 and 24. 2) An internal component failure may have
occurred in the MSR131.
On On On On On On On On

MSR131 Toubleshooting Guide Rev C.doc Page 22 of 22