Related Manuals for Allen-Bradley Guardmaster
Summary of Contents for Allen-Bradley Guardmaster
- Page 1 User Manual Original Instructions Guardmaster Safety Relays Catalog Numbers 440R-S13R2, 440R-S12R2, 440R-D22R2, 440R-D22S2, 440R-EM4R2, 440R-EM4R2D...
- Page 2 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.
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Page 3: Table Of Contents
Table of Contents Preface Summary of Changes ......... . . 7 Who Should Use This Manual? . - Page 4 Table of Contents Reset and Monitor Input ........29 Automatic/Manual Reset .
- Page 5 Table of Contents Chapter 9 Application and Wiring Examples CI Safety Relay (Cat. No. 440R-S13R2)......53 DI Safety Relay (Cat. No. 440R-D22R2) ......54 DIS Safety Relay (Cat. No. 440R-D22S2) .
- Page 6 Table of Contents Appendix A Specifications General............89 Environmental .
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Page 7: Preface
Preface This manual is a reference guide for the family of Guardmaster® Safety Relays (GSR). It describes the procedures that you use to install, wire, and troubleshoot your relay. This manual also gives an overview of the operation of safety relays. -
Page 8: Additional Resources
ACTIVE or ON. This signal is also referred to as the logic link signal. Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Description Guardmaster EtherNet/IP™ Network Interface User Describes procedures that you use to install, wire, Manual, publication 440R-UM009 configure, troubleshoot, and use EtherNet/IP modules. -
Page 9: Overview
Chapter Overview The Guardmaster safety relay (GSR) family is a group of advanced general- purpose and special-purpose safety relays. This user manual addresses the CI, DI, DIS, EM, EMD, and SI safety relays from this family of relays. Hardware Features... -
Page 10: Multi-Position Switches
Chapter 1 Overview Multi-position Switches Most safety relays are configured by adjusting multi-position switches to set their functionality. The switches are on the front face of the relay so you can see the set position during, and after, configuration. During the configuration process, status indicators on the front face of the relay confirm the switch settings. -
Page 11: Em Safety Relay (Cat. No. 440R-Em4R2)
Overview Chapter 1 EM Safety Relay The EM safety relay is an expansion module with four immediately operated electromechanical relay outputs. The only input to the EM safety relay is an (Cat. No. 440R-EM4R2) SWS input. The EM safety relay is designed to expand the outputs of the GSR family of host relays. - Page 12 Chapter 1 Overview Notes: Rockwell Automation Publication 440R-UM013E-EN-P - March 2017...
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Page 13: Installation
Chapter Installation All safety relays in this manual have the same dimensions (Figure Mounting Dimensions Figure 2 - Dimensions [mm (in.)] 22.5 (0.88) 113.6 (4.47) 119.14 (4.69) DIN Rail Mounting and Safety relays mount onto 35 mm DIN rails: 35x7.5x1 mm (EN 50022-35x7.5). Removal 1. -
Page 14: Spacing
Chapter 2 Installation Spacing Safety relays can be mounted directly next to other safety relays. When the EtherNet/IP module is used, the safety relay must be mounted within 10 mm (0.4 in.) of its neighboring module to maintain effective communication. Maintain a space of 50.8 mm (2 in.) above, below, and in front of the relay for adequate ventilation. -
Page 15: Prevent Excessive Heat
Installation Chapter 2 This equipment is supplied as open-type equipment. The relays must be mounted within an enclosure that is suitably designed for those specific environmental conditions that are present and appropriately designed to help prevent personal injury as a result of accessibility to live parts. The enclosure must have suitable flame-retardant properties to help prevent or minimize the spread of flame, in compliance with a flame spread rating of 5VA, V2, V1, V0 (or equivalent) if non-metallic. - Page 16 Chapter 2 Installation Notes: Rockwell Automation Publication 440R-UM013E-EN-P - March 2017...
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Page 17: Power, Ground, And Wire
Chapter Power, Ground, and Wire Wiring Requirements and ATTENTION: Before you install and wire any device, disconnect power to the Recommendation system. ATTENTION: Calculate the maximum possible current in each power and common wire. Observe all electrical codes that dictate the maximum current allowable for each wire size. -
Page 18: Terminal Assignments
Chapter 3 Power, Ground, and Wire Terminal Assignments Safety relays have four terminals: two on the top and two on the bottom. As shown in Figure 5, the X2 and X4 terminal markings apply to the rear terminals. The X1 and X3 terminals apply to the front terminals. Figure 5 - Terminal Identification S12 S22 AP S54 A1 A2 P12 P22... -
Page 19: Ground The Relay
Power, Ground, and Wire Chapter 3 Table 1 lists the terminal functions. Many of the terminals perform common functions on multiple relays. Table 1 - Terminal Assignments and Functions Terminal Function Applies To +24V Supply (+10%, -15%) 24V Common Pulse Test Output for Channel 1 CI, DI, DIS, and SI Pulse Test Output for Channel 2 CI, DI, DIS, and SI... -
Page 20: Connect A Power Supply
Chapter 3 Power, Ground, and Wire Connect a Power Supply An external 24V DC power supply source must provide power for safety relays. To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with safety extra low voltage (SELV) or protected extra low voltage (PELV) must power the safety relays. - Page 21 Power, Ground, and Wire Chapter 3 Table 2 - Safety Devices with Mechanical Contacts Rockwell Automation Safety Device Product Example s Contact Availability E-stop push buttons 800F, 800T 1 N.C., 2 N.C., self-monitoring Tongue-operated interlock switches Trojan™, MT-GD2, Cadet™, Elf™ 1 N.C., 2 N.C.
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Page 22: Devices With Ossd Output
Chapter 3 Power, Ground, and Wire Devices with OSSD Output Devices, such as the GuardShield™ safety light curtains, SafeZone™ laser scanners, SensaGuard™ interlock switch, TLS-Z and 440G-LZ guard locking switches, and Bulletin 442G Multifunction Access Box (MAB) have current-sourcing PNP semiconductor outputs (OSSD), which send their own pulse-tested safety signals through their outputs. -
Page 23: Safety Mats
A status indicator must inform you that the OSSD device is faulted. Safety Mats Guardmaster (and similar) safety mats can be connected to safety relays. These mats use parallel metal-plate technology. Stepping on the mat shorts the top metal plate to the bottom metal plate. With the proper connections, safety relays detect the presence of an object on the mat and turn off their outputs. -
Page 24: Safedge Safety Edges
Capacitance Effect on page 71 for further information. TIP Older Allen-Bradley Guardmaster MSR relays could be tickled by tapping on the safety mat, which generated fast cycles. This activity caused the relay to fault because the fast cycles violated the recovery time specification. GSR relays have a 20 ms recovery time, so this fault is not likely to occur. -
Page 25: Safety Outputs
Power, Ground, and Wire Chapter 3 Figure 13 - Safedge Operating Principle Wires on Flexible Wire Cores Conductive both ends (Ch1 and Ch2) Rubber Compression creates a low resistance from Ch1 to Ch2 Non-conductive Rubber Figure 14 shows the typical wire connections. With the proper connection, GSR relays detect the compression of the edge and turn off their outputs. -
Page 26: Electromechanical Outputs
Chapter 3 Power, Ground, and Wire Electromechanical Outputs Internally, the CI, DI, EM, EMD, and SI safety relays have two positive-guided relays that are connected in series to form the safety outputs. One side of the contact must be connected to a voltage supply (see Specifications on page 89 for appropriate ratings). -
Page 27: Surge Suppressors
Power, Ground, and Wire Chapter 3 Surge Suppressors Because of the potentially high current surges that occur when switching inductive load devices, such as motor starters and solenoids, the use of surge suppression to help protect and extend the operating life of the relays is required. -
Page 28: Single Wire Safety Input And Output
Chapter 3 Power, Ground, and Wire Single Wire Safety Input and The Single Wire Safety (SWS) feature allows a safety relay to expand the safety function to additional safety relays using one wire, provided all safety relays Output have the same voltage supply reference. The CI and SI safety relays only have SWS outputs (terminal L11). -
Page 29: Auxiliary Output
Power, Ground, and Wire Chapter 3 Auxiliary Output Each safety relay has an auxiliary output. The auxiliary output is not a safety rated output; it is a low current output that is designed to indicate that the safety output status is OFF. The auxiliary output is in the opposite state of the safety outputs. - Page 30 Chapter 3 Power, Ground, and Wire Figure 20 - Typical Reset/Monitoring Circuits EM or 24V DC Com Circuit Circuit Circuit Circuit Circuit Circuit Circuit Description In automatic/manual reset, a direct connection can be made to 24V DC. Output devices are monitored with their normally closed contacts. This circuit can only be used in automatic/manual reset.
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Page 31: Automatic/Manual Reset
Power, Ground, and Wire Chapter 3 Automatic/Manual Reset Use automatic reset when the risk assessment does not require additional manual intervention to reset the safety system. Automatic reset is often used with partial body access or where an additional control is implemented in the machine control system to start the hazardous portion of the machine after the safety inputs are closed. -
Page 32: Monitor With Expansion Relays
Chapter 3 Power, Ground, and Wire The signal can be created with a momentary push button or programmatically created with logic controller. Figure 23 shows example wire connections for the reset. The schematic also shows an example monitoring the mechanically linked, normally closed contacts of two contactors. -
Page 33: Retriggerable Input
Power, Ground, and Wire Chapter 3 Retriggerable Input The B1 and B2 inputs determine the type of timing function. • B1 and B2 open: Off-delay non-retriggerable or on-delay • B1 connected to B2: Off-delay retriggerable • B1 connected to 24V DC: Jog The EMD safety relay has a retriggerable input. - Page 34 Chapter 3 Power, Ground, and Wire Notes: Rockwell Automation Publication 440R-UM013E-EN-P - March 2017...
- Page 35 Chapter Configuration The multi-position, rotary switches on the front face of a GSR relay determine its functionality. The configuration method of a GSR relay must provide means to help protect against manipulation and maintain integrity of the configuration. The rotary switches accommodate a small screwdriver to turn the switch to the desired switch position.
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Page 36: Switch Adjustment
Chapter 4 Configuration Switch Adjustment These safety relays have multi-position switches on their front face. Use a small screwdriver to set the switches to the desired setting. TIP Make note of the mechanical stop location. Figure 25 - Configuration Switch Adjustment Mechanical Stops Screwdriver... -
Page 37: Emd Safety Relay
Configuration Chapter 4 EMD Safety Relay The EMD safety relay has two switches. The combination of the switch settings determines the functionality and the duration. During configuration, the Time switch determines the duration of the Range switch. Figure 26 Table 7 show the setting options for the Range and Time switch. -
Page 38: Configuration Process
Chapter 4 Configuration Configuration Process Configuration is a five-step process. The process requires the wiring to be completed and the inputs closed. During the configuration process, GSR relays send out test pulses to determine how it is wired and then configures the internal parameters to match the application. - Page 39 Configuration Chapter 4 Figure 27 - EMD Expansion Relay Status Indicators Flashing in Configuration Mode B1 - Indicates that the RANGE Switch is set to 3. 0.5s Flash Pause Logic IN - Indicates that the TIME Switch is set to 4 5.
- Page 40 Chapter 4 Configuration Notes: Rockwell Automation Publication 440R-UM013E-EN-P - March 2017...
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Page 41: Indicators During Powerup
Chapter Status Indicators Indicators During Powerup The status indicators provide operating status and diagnostic information. Indicators During Normal Table 9 - Status Indicators (Normal Operation) Operation Status Indicator Models State Description Solid green Normal operation. Non-recoverable fault. See Table 11 on page Flashing red Correct fault and cycle power PWR/Fault... -
Page 42: Indicators During Diagnostics
Chapter 5 Status Indicators Indicators During Diagnostics See the following tables: Table Page PWR/Fault Status Indicator Is Solid Red PWR/Fault Status Indicator Is Flashing Red PWR/Fault Status Indicator Is Green with Flashing Red Rockwell Automation Publication 440R-UM013E-EN-P - March 2017... -
Page 43: Pulse Testing For Inputs
Chapter Pulse Testing Functions Safety relays use pulse testing of inputs and outputs to verify that the safety function is performed when called upon. Pulse testing for the inputs must be used with devices with mechanical contacts like E-stop push buttons, tongue operated interlock switches, and limit switches. -
Page 44: Di, Dis, And Si Safety Relays
Chapter 6 Pulse Testing Functions DI, DIS, and SI Safety Relays The pulse test sequence for the DI, DIS, and SI safety relays are shown in Figure 29. The sequence is repeated every 13.6 ms. Figure 29 - Pulse Test Sequence for DI, DIS, and SI Safety Relays 13.6 16.8 22.5... -
Page 45: Off Delay, Non-Retriggerable
Chapter EMD Safety Relay Timing Functions The EMD safety relay has three functions that use timing: • Off delay • On delay • Jog The off-delay timing depends on whether the function is retriggerable. During the timing cycle, the Logic IN status indicator flashes. Off Delay, Non-retriggerable With input B1 open, the off-delay function is not retriggerable. -
Page 46: Case 2
Chapter 7 EMD Safety Relay Timing Functions Case 2 4. The logic link signal at terminal L12 turns on, and the safety outputs turn on within the specified reaction time. 5. The logic link signal turns off and the off-delay timer starts. 6. -
Page 47: Case 2
EMD Safety Relay Timing Functions Chapter 7 Case 2 4. The logic link signal at terminal L12 turns on, and the safety outputs turn on within the specified reaction time. 5. The logic link signal turns off, and the off-delay timer starts. 6. -
Page 48: Jog
Chapter 7 EMD Safety Relay Timing Functions The jog function has two timers: an on-timer and an off-timer. The Range and Time switch settings set the on-timer during configuration. The on-timer starts when both the B1 terminal is connected to 24V DC and the logic link signal at terminal L12 is on. -
Page 49: Case 2
EMD Safety Relay Timing Functions Chapter 7 Case 2 8. The B1 signal turns on before the logic link signal. 9. The logic link signal turns on. The jog on-timer starts, and the safety outputs turn on. 10. The B1 signal turns off before on-timer elapses. The safety outputs turn off immediately and the off-timer starts. - Page 50 Chapter 7 EMD Safety Relay Timing Functions Notes: Rockwell Automation Publication 440R-UM013E-EN-P - March 2017...
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Page 51: Ci Safety Relay (Cat. No. 440R-S13R2)
Chapter Internal Circuit Block Diagrams The figures in this chapter show the internal circuit block diagrams of each safety relay. CI Safety Relay Figure 36 - CI Safety Relay Circuit Diagram (Cat. No. 440R-S13R2) DI Safety Relay Figure 37 - DI Safety Relay Circuit Diagram (Cat. No. 440R-D22R2) DIS Safety Relay Figure 38 - DIS Safety Relay Circuit Diagram... -
Page 52: Em Safety Relay (Cat. No. 440R-Em4R2)
Chapter 8 Internal Circuit Block Diagrams EM Safety Relay Figure 39 - EM Safety Relay Circuit Diagram (Cat. No. 440R-EM4R2) EMD Safety Relay Figure 40 - EMD Safety Relay Circuit Diagram (Cat. No. 440R-EM4R2D) SI Safety Relay Figure 41 - SI Safety Relay Circuit Diagram (Cat. No. 440R-S12R2) Rockwell Automation Publication 440R-UM013E-EN-P - March 2017... -
Page 53: Application And Wiring Examples
Chapter Application and Wiring Examples The application and wiring examples in this chapter show you how to put the inputs and outputs together to create an operating safety system. These circuit diagrams are examples; many features are interchangeable between relays. Publication SAFETY-WD001 provides additional application and wiring... -
Page 54: Di Safety Relay (Cat. No. 440R-D22R2)
Chapter 9 Application and Wiring Examples Figure 43 shows a CI safety relay monitoring a light curtain with two OSSD outputs. The CI safety relay is set to automatic/manual reset (AM). The auxiliary signal (terminals 41/41) informs the PLC that the safety system is OFF or ON. -
Page 55: Dis Safety Relay (Cat. No. 440R-D22S2)
Application and Wiring Examples Chapter 9 Figure 45, a DI safety relay monitors a safety mat and non-contact interlock with OSSD outputs. Make note of the specific wiring for the mat. Also, during configuration and for each power-up, the mat must be clear and the interlock closed. -
Page 56: Em Safety Relay (Cat. No. 440R-Em4R2)
Chapter 9 Application and Wiring Examples The DIS safety relay monitors two devices with OSSD outputs in Figure 47 The DIS safety relay logic setting is 6: (IN1 AND IN2) OR L12 with automatic reset. The output terminals 34 and 44 are designed to tolerate higher capacitance loads (but lower resistive load) as compared to terminals 14 and Figure 47 - High Capacitive Load 24V DC... -
Page 57: Emd Safety Relay (Cat. No. 440R-Em4R2D)
Application and Wiring Examples Chapter 9 EMD Safety Relay The EMD safety relay in Figure 49 is configured for a 5 second off-delay. The single wire safety signal from terminals L11 to L12 instructs the EMD safety (Cat. No. 440R-EM4R2D) relay to turn on and off. When the E-stop is pressed, the CI safety relay turns off immediately and the EMD safety relay turns off 5 seconds later. -
Page 58: Si Safety Relay (Cat. No. 440R-S12R2)
Chapter 9 Application and Wiring Examples The EMD safety relay in Figure 51 is configured for a maximum of a 100-second jog. The single wire safety signal from terminals L11 to L12 enables the EMD safety relay. When enabled, the jog switch can be pressed and held closed to turn on the EMD safety relay outputs. -
Page 59: Ethernet Communication
Chapter Ethernet Communication The DI, DIS, EM, EMD, and SI safety relays are equipped with optical communication via an optical link. With an optical link, diagnostic data can be read from these relays and transferred to other devices over EtherNet/IP with the catalog number 440R-ENETR EtherNet/IP module. -
Page 60: Web Page
Chapter 10 Ethernet Communication Web Page The catalog number 440R-ENETR EtherNet/IP module maintains its own web page (Figure 54). To access the web page, connect an Ethernet cable to your computer, open a web browser, and type in the IP address of the ENETR module. -
Page 61: Troubleshooting
Chapter Troubleshooting This chapter explains a systematic approach to determine the likely cause of the GSR safety relay being in a faulted state or not operating properly. It describes the procedures that you use to troubleshoot your relay. Tools Needed To troubleshoot your GSR relay, you need the following tools. -
Page 62: Follow These Steps
Chapter 11 Troubleshooting Follow These Steps To diagnose the condition of the GSR relay, follow the steps in Figure Figure 56 - Troubleshooting Flowchart Start Flashing OUT indicator Go to Step 5 Go to Step 1 flashing green? (page (page PWR/Fault indicator solid green? Go to Step 2... -
Page 63: View The Pwr/Fault Status Indicator (Step 1)
Troubleshooting Chapter 11 View the PWR/Fault Status The first troubleshooting step is to examine the PWR/Fault status indicator on the front of your GSR module. See Figure 57 for status indicator location. Indicator (Step 1) TIP The PWR/Fault status indicator is located in the same position on all GSR modules. - Page 64 Chapter 11 Troubleshooting Table 11 - PWR/Fault Status Indicator Is Flashing Red Indicator Description Model Possible Causes Corrective Action • The relay is shipped from the factory with no Flashing red The GSR relay is in configuration. Continue with the configuration process. Rotate the switches to 1 time configuration mode.
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Page 65: Check The Power Supply (Step 2)
Troubleshooting Chapter 11 Table 12 - PWR/Fault Status Indicator Is Green with Flashing Red Indicator Description Model Possible Causes Corrective Action The safety relay continues to operate, and the One or more of the rotary switches have changed switches can be returned to their original during operation. -
Page 66: Verify Grounding At The Power Supply
Chapter 11 Troubleshooting Verify Grounding at the Power Supply IEC 60204-1 and NFPA79 require that the 24V is supplied by a PELV-rated power supply. The 24V common must be connected to protective earth, as shown in Figure 59. The protective ground connection must only be in one location and is often best when closest to the power supply. -
Page 67: Check Voltage-Free Contacts
Troubleshooting Chapter 11 IMPORTANT The following factors affect the value that is measured at the relay inputs: • Voltage-free contacts • Pulse testing waveforms • Capacitance • Length of wire • Contact resistance • Channel sequence Table 14 shows the voltage levels that are viewed on an oscilloscope versus a digital multimeter. - Page 68 Chapter 11 Troubleshooting 2. Check the voltage at each of the inputs with the device contacts closed, as shown in Figure 61. The values must be very close to the values measured at terminals S11 and S21. a. If both channels are closed, a voltmeter must read about 19V and the IN indicator is green.
- Page 69 Troubleshooting Chapter 11 1. Check the safety inputs with the device contacts open, as shown in Figure TIP The SI safety relay does not have terminals S32 and S42. Figure 62 - Typical Voltage Measurements of the DI, DIS, and SI Relays with Contacts Open Device 1 Device 2 S32 S42...
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Page 70: Examine Pulse Test Waveforms
Chapter 11 Troubleshooting Examine Pulse Test Waveforms If you have an oscilloscope, you can examine the pulse tests. The test pulses are used to check for short-circuit conditions; the test pulses are not used to turn the inputs ON and OFF. If they are clean and square, then they are OK. The test pulses are generated on terminals S11 and S21. -
Page 71: Detect Off Pulses
Troubleshooting Chapter 11 detected, the device must shut off both OSSD outputs and go to a faulted state. A status indicator must inform you that the OSSD device is faulted. See Devices with OSSD Output on page 22 for more information. Detect Off Pulses When configured for monitored manual (or manual) reset, the GSR relay detects off pulses as described in... -
Page 72: Long Wire - Resistance Effect
Chapter 11 Troubleshooting Long Wire — Resistance Effect Long input wiring adds resistance and decreases the input signal voltage. Figure 67 shows the effects on the pulse tests. Notice that the shape of the pulses has not changed, only the amplitude. If the wiring is too long, the safety relay does not turn ON. -
Page 73: Channel Simultaneity (Discrepancy)
Troubleshooting Chapter 11 Channel Simultaneity (Discrepancy) GSR relays have infinite simultaneity (sometimes referred to as discrepancy). One channel can close (at T1) and the other channel can close much later (at T2), and the input circuit is satisfied. The order in which the channels close is not significant;... -
Page 74: Recovery Time
Chapter 11 Troubleshooting Recovery Time Recovery time is a delay time that is required, measured from when the relay outputs turned OFF until they can turn back ON again. GSR relays have a 100 ms recovery time specification (Figure 70). The GSR family of safety relays has conservative recovery time specifications. - Page 75 Troubleshooting Chapter 11 EM or EMD expansion relays have both SWS input and output signals. You must connect a wire to L12. Your application requirements determine whether L11 is used. Figure 71 shows an example of an SWS connection. Note the L11 terminal (which is the SWS output) can be connected to multiple L12 terminals (SWS input), but the L12 terminal cannot be connected to multiple L11 terminals.
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Page 76: Check The Reset/Monitoring Circuit (Step 5)
Chapter 11 Troubleshooting Check the Reset/Monitoring The OUT status indicator blinks green when the inputs to the GSR relay are satisfied and the GSR relay is ready to turn on its outputs. The OUT status Circuit (Step 5) indicator flashes green at a 1 Hz rate. The GSR relay is waiting for the appropriate reset signal at terminal S34. -
Page 77: Two-Handed Reset Operation
Troubleshooting Chapter 11 Two-handed Reset Operation Does your application have an E-stop mounted close to the reset button, which allows you to release the E-stop with one hand and press the reset button with the other? Does your application let you close a safety gate with one hand and press the reset button with the other hand? These configurations are not a problem with GSR relays because the reset signal can be pressed 10 ms after the relay inputs are satisfied. -
Page 78: Check The Safety Outputs (Step 6)
Chapter 11 Troubleshooting Check the Safety Outputs The GSR family of relays has two types of outputs: (Step 6) • Electromechanical outputs: CI, DI, EM, EMD, and SI safety relays • OSSD outputs: DIS safety relay Electromechanical Output Issues If the OUT status indicator is solid green, but the output device does not energize begin troubleshooting by measuring the terminal voltage. -
Page 79: Ossd Output Issues
Troubleshooting Chapter 11 Measure the Contact Resistance If the voltage at terminal 13 is the same as the supply voltage, but terminal 14 measures zero volts measure the contact resistance. SHOCK HAZARD: Turn off power before power connection is removed if +Vsupply is greater than 50V. - Page 80 Chapter 11 Troubleshooting Check the OSSD Connections Confirm that voltage is present at the relay terminals and the load. Figure 77 shows an example of the measurement points for one output channel (terminal 14). Since most safety circuits consist of two channels, repeat the checking on the second channel (terminal 24).
- Page 81 Troubleshooting Chapter 11 Figure 78 - Typical Connections to PowerFlex Drive 24V DC supply PowerFlex 525 Volts AC Drive Motor 24V common Step Description The voltage at 34 must be slightly less than the supply voltage. If not, then the DIS relay must be replaced.
- Page 82 Chapter 11 Troubleshooting The main transistor pulses are about 110 µs wide. Each channel is tested individually as shown in Figure 81. The individual pulses are about 50 µs wide. These pulse widths are provided for informational purposes; the pulses cannot be turned OFF or adjusted.
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Page 83: Auxiliary Output Issues
Troubleshooting Chapter 11 Auxiliary Output Issues Table 18 - Auxiliary Output Issues State Symptom Action My PLC does not know that the relay is OFF or my auxiliary status Measure the Auxiliary Output Terminal Voltage on page indicator does not turn ON. The voltage at terminal 41 is the same as the supply voltage. - Page 84 Chapter 11 Troubleshooting Measure the Contact Resistance The OUT status indicator is OFF, and the voltage at terminal 41 is the same as the supply voltage. However, terminal 42 measures 0V. SHOCK HAZARD: Turn off power before power connection is removed if +Vsupply is greater than 50V.
- Page 85 Troubleshooting Chapter 11 Figure 84 - Measure Y32 Voltage +24V DC CI, DI, DIS or SI PWR/Fault Volts Input Check the X32 Output When OUT status indicator is OFF, terminal X32 does not turn ON. TIP This is proper operation for the EM and EMD relays if they are in a non- recoverable faulted state.
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Page 86: Emd Expansion Relay B1/B2 Inputs (Step 7)
Chapter 11 Troubleshooting EMD Expansion Relay B1/B2 Figure 86 shows the waveform from B1 to B2. This waveform is the same as the single wire safety waveform. The waveform is present only when the output of Inputs (Step 7) the EMD expansion relay is ON. With a digital multimeter, the voltage measures 8…9V DC. -
Page 87: Terminal Block Removal And Replacement
Troubleshooting Chapter 11 Terminal Block Removal and Terminal blocks can be replaced following these instructions. Replacement Terminal Block Removal GSR relays have removable terminal blocks. Use a screwdriver as a lever to remove the blocks. As shown in Figure 87, insert the screwdriver into the slot and pry up. -
Page 88: Series, Version, And Manufacturing Date Code
Chapter 11 Troubleshooting Series, Version, and The product label differs slightly depending on when you purchased your relay. Manufacturing Date Code Current Product Label The series, firmware revision number, and manufacturing date code are identified on the safety relay label, as shown in Figure Figure 89 - Product Label - Series and Revision Identification Manufactured during... -
Page 89: General
Appendix Specifications General Table 19 - General Specifications Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI) Dimensions, HxWxD [mm (in)] 119.14 x 22.5 x 113.6 (0.88 x 4.69 x 4.47) Shipping Weight, Approx. [g (lb)] 225 (0.5) 180 (0.4) 50 (0.33) -
Page 90: Safety Inputs In, In1, And In2
Appendix A Specifications Safety Inputs IN, IN1, and IN2 Table 21 - Safety Inputs IN, IN1 and IN2 Specifications Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI) Inputs 1 NC, 1 PNP (OSSD) 2 NC, 2 PNP (OSSD) 2 NC, 2 PNP (OSSD) —... -
Page 91: B1 Input
Specifications Appendix A B1 Input Table 23 - B1 Input Specifications Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI) Wiring Terminal — — — — — Max [V] — — — — 26.4 — ON Voltage Min [V] —... -
Page 92: Auxiliary Output
Appendix A Specifications Auxiliary Output Table 25 - Auxiliary Output Specifications Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI) Wiring Terminal — Output Type 1 N.C. 1 PNP, 50 mA max Single Wire Safety Table 26 - Single Wire Safety (SWS) Specifications Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) -
Page 93: Agency Certifications
Appendix Regulatory Approvals Agency Certifications • UL Listed Industrial Control Equipment, certified for US and Canada. • CE marked for all applicable directives • C-Tick marked for all applicable acts • CCC Mark • S-Mark Compliance to European This product has the CE marking and is approved for installation within the European Union and EEA regions. -
Page 94: Sil Rating
Appendix B Regulatory Approvals The performance of the safety function is dependent on the structure of all devices that comprise the safety function. Table 27 Table 28 provide the data that must be used to represent safety relays when calculating the safety integrity level (SIL) or the Performance Level (PL). -
Page 95: Index
Index contact resistance 84 add-on profile voltage-free 67 Studio 5000 Logix Designer 60 cycling adjustment multiple-channel 73 switch 36 agency certifications 93 Studio 5000 Logix Designer 60 date code application manufacturing 88 examples 53 detect CI safety relay 53 off pulse 71 DI safety relay 54 devices DIS safety relay 55... - Page 96 48 input 33 general specifications 89 label ground 17 product (current) 88 relay 19 product (old) 88 Guardmaster safety relay long wire 72 CI 10 DI 10 DIS 10 EM 11 EMD 11 machine safety SI 11 directive 93...
- Page 97 Index mounting process dimensions 13 configuration 38 product label DIN rail 13 multiple-channel current 88 cycling 73 old 88 multi-position pulse testing switch 10 functions 43 input 43 CI safety relay 43 DI, DIS, and SI safety relay 44 OSSD outputs 44 non-retriggerable PWR/fault status indicator 63 off delay 45...
- Page 98 Index safety mat switch DI safety relay 55 adjustment 36 safety output DI safety relay 36 DIS safety relays 36 check 78 EMD safety relay 37 electromechanical output multi-position 10 issues 78 OSSD output issues 79 input 28 safety outputs output 28 specifications 92 specifications 91...
- Page 100 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, Atlas, Cadet, Elf, Ferrogard, Guardmaster, GuardShield, Kinetix, Lifeline, PowerFlex, Rockwell Automation, Rockwell Software, Rotacam, Safedge, SafeZone, SensaGuard, Sipha, Studio 5000 Logix Designer, and Trojan are trademarks of Rockwell Automation, Inc.