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User Manual
Original Instructions
Guardmaster GuardLink Safety System
Catalog Numbers 440R-DG2R2T (DG Safety Relay); 440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D (Taps);
898D-418U-DM2 (Terminator); 440S-GLTAPBRK
x
(Bracket); 440R-ENETR (EtherNet/IP Network Interface)
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.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Overview
GuardLink System Design
Installation
Table of Contents
Preface
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 1
What Is a GuardLink System? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Single Wire Safety (SWS) Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Output Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GuardLink Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GuardLink Transition from Safe State to Operational State . . . 17
GuardLink Transition from Operational State to Safe State . . . 17
GuardLink Fault Reset Command . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Guard Locking with GuardLink Systems . . . . . . . . . . . . . . . . . . . . 18
Guard Locking Application Example. . . . . . . . . . . . . . . . . . . . . . . . 19
Chapter 2
System Current Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Voltage Drop Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chapter 3
DIN Rail Mounting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Terminal Block Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . 33
Terminal Block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Terminal Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 3
Table of Contents
4
Power, Ground, and Wire
Configuration
Status Indicators
Pulse Testing Functions
Opto-link Communications
Chapter 4
Wiring Requirements and Recommendation . . . . . . . . . . . . . . . . . . . . 37
Terminal Assignment and Function. . . . . . . . . . . . . . . . . . . . . . . . . 38
Tap Pin Assignment and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Power Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Multiple Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DG Safety Relay Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
GuardLink Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Devices with OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Voltage-free Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SWS Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
13/14 and 23/24 Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chapter 5
Configuration Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Configuration Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Push Buttons on the Front of DG Safety Relay . . . . . . . . . . . . . . . 54
AOP in the Studio 5000 Environment . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 6
DG Safety Relay Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Chapter 7
EMSS SmartTap Pulse Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Chapter 8
Arrangement with 440R-ENETR Interface. . . . . . . . . . . . . . . . . . . . . . 60
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Table of Contents
440R-ENETR Network Interface
Add-on Profile
Safety Function Calculations
Specifications
Configuration Examples
Chapter 9
Add a 440R-ENETR Interface to the Project . . . . . . . . . . . . . . . . . . . . 61
Add Relays to the 440R-ENETR Interface . . . . . . . . . . . . . . . . . . . . . . 63
Change the Order of the Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Select Lock Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Studio 5000 Code Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Lock and Unlock Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
GuardLink Fault Reset Commands . . . . . . . . . . . . . . . . . . . . . . . . . 81
Chapter 10
Appendix A
Appendix B
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 5
Table of Contents
Regulatory Approvals
Appendix C
Waste Electrical and Electronic Equipment (WEEE). . . . . . . . . . . . 117
Compliance to European Union Directives. . . . . . . . . . . . . . . . . . . . . 117
Machine Safety Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Performance Level/Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Index
6 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Preface
This user manual is a reference guide for the GuardLink™ safety system, plug-in modules, and accessories. It describes the procedures that you use to install, wire, and troubleshoot your relay. This manual explains how to install and wire your relay and gives you an overview of the GuardLink safety system
Who Should Use This Manual
Use this manual if you are responsible for the design, installation, programming, or troubleshooting of control systems that use the GuardLink safety system.
You must have a basic understanding of electrical circuitry and familiarity with safety-related control systems. If you do not, obtain the proper training before using this product.
Summary of Changes
This manual contains new and updated information as indicated in the following table.
Topic
Updated bracket catalog number on front cover
Updated the Tap Installation section
Updated pin description table for Figure 25
Updated the Add Relays to the 440R-ENETR Interface section
Page
Definitions
Publication AG-7.1
contains a glossary of terms and abbreviations that are used by Rockwell Automation to describe industrial automation systems. The following is a list of specific terms and abbreviations that are used in this manual.
• Electrical Mechanical Safety Switch (EMSS) A type of tap that interfaces with safety devices that have redundant voltage-free contacts.
The tap generates pulse tests to detect short circuits to the DC power supply, short circuits to the DC common, and shorts circuits between the two contacts.
• GuardLink Control, Lock, and Unlock (CLU) Signal This signal is either static or dynamic. When static, this signal is LO when the system is operational and HI when a demand is placed on the safety system. The signal is dynamic when an unlock command is issued to Power to
Release guard locking devices.
• GuardLink Operational State All taps on the GuardLink circuit indicate that their associated safety device is ready for the machine to operate.
• GuardLink Safe State One or more of the taps on the GuardLink circuit indicate that their associated safety device is not ready for the machine to operate.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 7
Preface
8
• GuardLink Safety Signal A known dynamic safety signal in operational mode and a two-way communication signal that the DG safety relay initiates to determine the status of the taps in the safe state.
• HI The ON state of the output of a logic block or the state of an input to a logic block or a voltage level to be above the turn-on threshold.
• LO Logic state of being OFF or a voltage level to be below the turn-off threshold.
• N/C - No connection
• N.C. (Normally Closed) A voltage-free electrical contact whose normal state (that is, no pressure or electrical potential applied) is in the closed position.
• N.O. (Normally Open) A voltage-free electrical contact whose normal state (that is, no pressure or electrical potential applied) is in the open position.
• Output Signal Switching Device (OSSD) Generally a pair of solidstate signals that are pulled up to the DC source supply. The signals are pulse-tested for short circuits to the DC power supply, short circuits to the DC common and shorts circuits between the two signals.
• Reaction Time The time between the true states of one input to the
ON state of the output.
• Recovery Time The time that is required for the input to be in the LO state before returning to the HI state.
• Response Time The time between the trigger of one input to the OFF state of the output.
• Safety Function The complete process from sensing the action (for example, open a safety gate) to executing the final output device (for example, turning off a pair of contactors).
• Single Wire Safety (SWS) A unique unidirectional safety-rated signal that is sent over one wire to indicate a safety status and command the initiation of a safety function. The SWS can be used in Category 4,
Performance Level e, per ISO 13849-1 and safety integrity level (SIL) 3, per IEC 62061 and IEC 61508.
• Status Indicators The status indicators on the front face of the DG
safety relay and the taps are bicolor. Table 1 shows how the status
indicators are used in this publication.
Table 1 - Status Indicator State
Symbol Description
Green indicator is OFF
Red indicator is OFF
Green indicator is OFF
Red indicator is ON
Symbol Description
Green indicator flashes with certain frequency
Red indicator is OFF
Green indicator is OFF
Red indicator flashes with certain frequency
Green indicator is ON
Red indicator is OFF
Green indicator is ON
Red indicator is ON
Green indicator flashes with certain frequency
Red indicator flashes with certain frequency
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Additional Resources
Preface
• Tap A connection in a GuardLink circuit that associates a safety device to the GuardLink circuit.
• Voltage-free Contacts Electrical contacts that have no voltage that is applied to them. These contacts are typically N.O. or N.C. contacts that change state due to a mechanical (for example, someone pressing a push button) or electromechanical (for example, solenoid operated) stimulus.
These documents contain additional information concerning related products from Rockwell Automation.
Resource
NEMA Standard 250 and IEC 60529
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1
Product Certifications website, http:// www.rockwellautomation.com/global/certification/ overview.page
Industrial Automation Glossary, publication AG-7.1
Description
Provides explanations of the degrees of protection that is provided by different types of enclosure.
Provides general guidelines for installing a Rockwell
Automation industrial system.
Provides declarations of conformity, certificates, and other certification details.
A glossary of industrial automation terms and abbreviations.
You can view or download publications at http://www.rockwellautomation.com/global/literature-library/overview.page
.
To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 9
Preface
Notes:
10 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Chapter
1
Overview
What Is a GuardLink System?
A GuardLink system is a collection of components to simplify a series connection of safety devices while achieving the highest industrial safety rating. The system has these important features:
• Simplifies the connection of series connected safety devices.
• Facilitates the scalability of the safety series connections.
• Provides diagnostic information about each device in the system without having to run a separate status wire back to the machine control system.
• Allows the simultaneous or individual lock and unlock of guard locking interlocks in the series connected system. No need for an additional wire from the machine control system to lock and unlock the safety gate.
• Helps ease communication to the machine control system over
EtherNet/IP. Communication includes sending non-safety commands to the devices and receiving status information back from the safety devices.
Figure 1 on page 12 shows the basic components of a typical application. The
GuardLink tap has M12 quick disconnect terminations to facilitate wiring with cordsets and patchcords. The DG safety relay can accommodate one or two GuardLink circuits or a combination of GuardLink and individual safety devices.
Each GuardLink circuit can accommodate up to 32 taps. The DG safety relay operates and monitors two safety contactors and has a monitored manual reset.
A typical GuardLink system consists of the following:
• One DG (dual GuardLink) Guardmaster® safety relay (GSR)
• One GuardLink SmartTap for each safety device
• One terminator for each GuardLink circuit
• Patchcords and cordsets
• An optional Ethernet interface
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 11
Chapter 1 Overview
Taps
12
Figure 1 - Typical GuardLink System
Each DG safety relay can accommodate up to two GuardLink circuits, each containing up to 32 devices.
One DG safety relay
One GuardLink tap for each safety device.
One terminator for each
GuardLink circuit.
Cordsets and patchcords
RR
Single Wire Safety for Expansion
Output monitoring
One optional Ethernet interface
(Required if guard locking is used)
Taps create nodes in the GuardLink circuit. A safety device is connected to each tap. Two types of taps are available:
• Taps that interface with devices having voltage-free safety contacts
• Taps that interface with devices that have OSSD signals
Each type is available in an 8-pin and 5-pin device connection version.
The taps are intended to be mounted on the machine, near the location of the device it monitors. The different types and versions can be connected in any order and can be mixed.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
DG Safety Relay
Overview Chapter 1
The DG safety relay is the host of the GuardLink system. By using a sequence of push buttons on the front face, the DG safety relay can be configured for many types of safety applications. The DG safety relay can do the following:
• Monitor up to two GuardLink circuits, two safety devices or a combination
• Use Single Wire Safety (SWS) input and output for expansion
• Execute Stop Categories 0 or 1 (immediate and delayed outputs)
• Monitor the status of output safety devices, like contactors
• Be configured for automatic or monitored manual reset
• Be configured to initiate a lock function for guard locking with a
GuardLink circuit
• Be configured to initiate an unlock function for guard locking with a
GuardLink circuit
Safety Device Inputs
The DG safety device inputs can be configured in one of the following arrangements:
• One GuardLink circuit
• Two GuardLink circuits
• One GuardLink circuit and one safety device
• Two safety devices
• One safety device
The DG safety relay applies AND logic to all used inputs. Unused inputs are ignored.
Single Wire Safety (SWS) Input
The DG safety relay then applies AND logic to the SWS input if configured for use. The single wire safety input is ignored if not included in the configuration.
Output Monitoring
The DG safety relay monitors the status of external safety output devices. After all safety inputs are satisfied, the DG safety relay checks the monitoring input terminal. If 24V is present, the DG safety relay proceeds to execute the reset function.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 13
Chapter 1 Overview
14
Reset
The DG safety relay reset function can be applied one of three ways:
• Automatic reset (no connection needed)
• Monitored manual reset by a momentary push button that is connected to an input terminal
• With an Ethernet interface, the machine control system can initiate the reset function.
The DG safety relay allows both an input terminal and the machine control system to perform the monitored manual reset function. The reset signal must transition from LO to HI and back to LO within a window of 0.25…3 seconds.
The reset occurs on the trailing edge. When using a programmable logic controller (PLC) to generate the reset signal, use a narrower window
(0.26…2.99 s) for more reliable reset action.
ATTENTION: The reset function must not be used to start or restart the machine.
, the DG safety relay has one GuardLink circuit and one safety device input. The EtherNet/IP interface reports status information to the machine control system. The DG safety relay monitors the status of the two output contactors and uses monitored manual reset to energize the contactors.
Figure 2 - One GuardLink Circuit and One Safety Device
GuardLink circuit - one tap for each safety device
Safety device (E-stop, mechanical interlock, light curtain, scanner, OSSD interlocks)
EtherNet/IP interface
DG safety relay
RR
Monitored
Manual
Reset
Output monitoring
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Overview Chapter 1
Figure 3 shows an example of a DG safety relay operating as the equivalent of a
, the DG safety relay is configured to accept two input devices, control and monitor two contactors with a manual reset input.
The 440R-ENETR interface reports the status to the machine control system.
The machine control system can also initiate a reset command.
Figure 3 - Two Safety Devices
Two safety devices (E-stops, mechanical interlocks, light curtains, scanners, OSSD interlocks)
RR
Cordsets or patchcords
DG safety relay
Optional
EtherNet/IP interface
GuardLink Principle of
Operation
The GuardLink circuit is a continuous chain of safety devices that are connected in series with only four wires. Two wires provide power and ground to the taps and devices.
The third wire (GuardLink Safety Signal) performs the diagnostics on the taps and the devices that are connected to each tap while in the safe state. It also carries the dynamic safety signal while in an operational state.
The fourth wire (CLU) provides the lock/unlock commands to guard locking devices on the circuit.
GuardLink State
The GuardLink chain can be in one of four states:
• Initialization
• Safe
• Operational
• Fault
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 15
Chapter 1 Overview
Initialization State
The initialization state starts when power is applied to the GuardLink circuit and ends when the GuardLink circuit enters the safe state. If no errors exist, the
GuardLink circuit transitions to the safe state; the initialization state cannot transition to the operational state.
During initialization, the DG safety relay establishes and verifies the validity of the circuit by checking the following items:
• All devices set their node number
• Not more than 32 devices exist
• The firmware of the taps is compatible with the DG safety relay firmware.
• The DG safety relay detects node type and position automatically.
When a 440R-ENETR interface is used, it acquires the node types and positions from the DG safety relay. The 440R-ENETR interface validates the correct type and position against the setup that is provided by the Studio 5000® Add-On-Profile (AOP). If validation is not successful, the 440R-ENETR interface reports an error.
• Validates a terminator is attached to the GuardLink circuit.
Safe State
The GuardLink safety signal commands the DG safety relay to a safe state, which turns all safety outputs OFF. The GuardLink safety signal monitors the circuit for changes of state from the taps.
The CLU signal is HI (if guard locking devices are not used) or sending a dynamic unlock signal (if guard locking devices are used). The taps indicate this state by a solid red Link indicator.
Operational State
The GuardLink operational state is described as the GuardLink safety signal that generates a specific dynamic signal to the DG safety relay and the CLU signal being LO. The state of the DG safety relay safety outputs can be OFF or
ON. The state depends on the configuration, other safety device inputs, the feedback monitoring input, and the reset input.
16 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Overview Chapter 1
Fault State
The DG safety relay and the taps have two fault states: recoverable and non-recoverable. When a fault occurs, the taps and DG safety relay are in a safe state. Diagnostic information is provided by the indicators. The DG safety relay also sends diagnostic information to the EtherNet/IP interface.
Recoverable faults can be cleared by cycling the faulted input devices. Nonrecoverable faults require the power to the cycled and can also require troubleshooting and correction of the fault. When an EtherNet/IP interface is used, the machine control system can issue a fault reset (equivalent to a power cycle).
GuardLink Transition from Safe State to Operational State
When the GuardLink signal is in the safe state, the DG safety relay holds the
CLU signal in the high or dynamic unlocking state. The DG safety relay puts all taps in the safe state. For the GuardLink signal to return to the operational state, the DG safety relay must know that all taps are ready to go to the operational state. If the taps are ready to go, the CLU signal is set to LO.
Now that the CLU is set to LO, the last tap generates the safety signal. Each successive upstream device verifies that the previous device is in a safe state, confirms that its own device is in a safe state, and sends an inverted safe state signal to the next device.
When the DG safety relay receives the safety signal, the GuardLink circuit is in an operational state, and the DG safety relay continues with the evaluation of the other inputs, output monitoring, and reset inputs.
GuardLink Transition from Operational State to Safe State
Once an input device has a demand on its safety function, the tap stops sending the safety signal. When the DG safety relay no longer detects the safety signal, the CLU signal is set to HI to make all taps enter the safe state.
GuardLink Fault Reset Command
Devices with OSSD outputs can sometimes go to a fault state that requires power cycling. The Ethernet interface can be used to send a fault reset signal from the machine control system to individual or all devices. This reset signal cycles the power to the device connected to the specified tap.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 17
Chapter 1 Overview
18
OSSD Tap
The OSSD tap is designed to specifically interface with safety products that generate OSSD outputs. The OSSD tap does not perform testing on the
OSSD signals as the input device must perform the test.
The OSSD tap is looking to see if the outputs of the connected device are energized or de-energized. If the outputs are de-energized, then the tap goes to a safe state, and the input indicator is red. If the outputs of the device are energized, then the tap shows a solid or flashing green input indicator.
If the OSSD tap inputs are not the same state for three or more seconds, then the tap enters a recoverable fault state. Both inputs must go to LO and then back to HI to recover.
EMSS Tap
The EMSS tap is designed to interface with two voltage-free contacts. The tap applies 24V to one side of the contact on both channels and looks for the 24V on the monitoring input. These contacts are pulse tested by the tap, see
Testing Functions on page 57 for pulse details.
The tap is looking to see if both contacts are closed or open. When the contacts open, the tap goes to a safe state, and the input indicator is red. When the contacts close, the tap goes to an operational state, which turns the input indicator either solid or flashing green.
The EMSS tap has a 10 second simultaneity window. If one contact opens, the second contact must open within 10 seconds. Similarly, if one contact closes, the second contact must close within 10 seconds. If the simultaneity window requirement is not met, the tap goes to a recoverable fault state. To recover, both contacts must be cycled open and then closed again within 10 seconds.
Guard Locking with GuardLink Systems
Only Power-to-Release guard locking devices can be connected to the
GuardLink taps. When guard locking devices are connected, a 440R-ENETR interface must be used. The lock and unlock commands can only be issued to the guard locking devices through the 440R-ENETR interface.
When an unlock request is issued, the DG safety relay turns off OUT X
(terminal X2) immediately and starts the off-delay timer. When the off-delay timer expires, the DG safety relay issues an unlock command to the GuardLink circuit and turns off its safety outputs (terminals 13/14 and 23/24).
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Overview Chapter 1
When multiple guard locking devices are installed on a GuardLink system, the
DG safety relay inserts a short delay between commands to each successive device to minimize the momentary inrush current to the solenoids. The device closest to the DG safety relay receives the command first. The device furthest away from the DG safety relay receives the command last.
The delay between commands is between 135…300 ms. When a few guard locking devices are used, the delay is 135 ms. As more guard locking devices are included in the circuit, the delay increases. When 32 guard locking devices are used, the delay can be up to 300 ms between each device.
Figure 4 shows an example timing diagram. The delay switch is set to
position 5 (1 second delay). The first guard unlocking command starts at
1000 ms. The second unlock signal occurs at 1135 ms. The third unlock signal occurs at 1270 ms. If 32 guard locking devices are installed, the last one receives the unlock command at 10,600 ms.
Figure 4 - Unlock Command Timing Diagram
32
5
4
3
2
OUT (13/14, 23/24)
1
OUT X (X2)
Unlock Request
0 1000 1135 1270 1405 1540
Time [ms]
10,600
Guard Locking Application Example
Figure 5 on page 20 shows a typical guard locking application example. The
DG safety relay has four taps on the GuardLink circuit:
• First tap — SensaGuard™ integrated-latch interlock switch
• Second tap — 440G-LZ guard locking interlock switch
• Third tap — TLS –ZR guard locking switch
• Fourth tap — SensaGuard flat-pack interlock switch
The TIME switch on the DG safety relay is set to position 9, which provides a
5 second delay to allow the motor to coast to a full stop.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 19
Chapter 1 Overview
Schematic
+24V DC
+ +
DC ok
1606-XLP95E
N L
24V DC Com
INPUT
440S-SF8D
The SensaGuard switches allow immediate access to the machine. Additional risk reduction measures must be provided to prevent access to the hazards during the timing period.
Because guard locking is used, a 440R-ENETR interface must be included in the application. The unlock and lock control commands are initiated by an
HMI and PLC. The PLC sends the command to the 440R-ENETR interface.
Over the optical bus, the 440R-ENETR interface instructs the DG safety relay to generate the unlock and lock commands through the GuardLink circuit.
The DG and EM safety relays report status information over the optical bus back to the PLC through the 440R-ENETR interface.
Figure 5 - Guard Locking Application Example Schematic and Logic
Logic
440N-Z21SS3PH
SensaGuard
Interlock
440G-LZS21SPRH
Guard Locking
Safety Switch
440G-TZS21UPRH
Guard Locking
Safety Switch
440N-Z21SS2JN9
SensaGuard
Interlock
SMF Level IN 1
LOGIC Level
INPUT
440S-SF8D
INPUT
440S-SF8D
INPUT
440S-SF5D 898D-418U-DM2
Terminator
SOF Level
R R
FB FB
OUT X OUT 14/24
K1
Start K2
Host PC
HMI
Reset
Stop
Ethernet
PLC
Ethernet
A
+
B
C
440R-ENETR
S11 S21 S12 S22
TIME
Control
Status
DG
440R-DG2R2T
S32 S42 X1
.14
0.12
.
0.2.4.6
9
X2
A1
A2
13 23 X4
14 24 X3
OUT X
SWS
A1 X32 13 23 33 43
Immediate
Acting
Loads
Status
EM
440R-EM4R2
A2 L12 L11 14 24 34 44
K1 K2
100S
Contactors
Feedback
L1 L2 L3
M
K1
K2
Table 2 - Guard Locking Application Example Configuration
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x6A
IN1
GuardLink
Not used
SWS
SWS Disabled
Monitored Manual
SOF
20 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Overview Chapter 1
• Circuit Status
The gates monitored by the SensaGuard interlock switches are closed.
The guard locking switches are closed and locked. The DG and EM safety relays are OFF and ready for reset.
• Starting
Press the Reset button to energize the DG and EM safety relays. Their output contacts close. Press the Start button to start the motor via contactors K1 and K2 and energize the two immediate acting loads.
• Stopping
Press the Stop button to turn the motor and immediate acting loads off.
The immediate acting loads and contactors K1 and K2 de-energize immediately, and the motor coasts to a stop. This action does not unlock the guard locking switches.
IMPORTANT The Start/Stop circuit can be replaced by an equivalent machine controlled system to start or restart the hazards after the safety system is reset.
• SensaGuard Switches
Opening either SensaGuard interlock turns off the DG and EM safety relays. The EM safety relay turns off K1 and K2 immediately, and the motor coasts to a stop. With the Time switch on the DG safety relay set to 9, the 13/14 and 23/24 outputs on the DG safety relay turn off after
5 seconds. This action does not unlock the guard locking switches.
• Unlock the Guard Locking Switches
Use the HMI to unlock the guard locking switches. The EM safety relay turns off K1 and K2 immediately, and the motor coasts to a stop. After
5 seconds, both the 13/14 and 23/24 outputs of the DG safety relay turn off the immediate acting loads and the guard locking switches are unlocked.
IMPORTANT The outputs of the DG safety relay (13/14 and 23/24) turn off and the unlock command occurs after the time delay expires. The immediate acting loads must remove the hazards they control quickly before you can open the gate and reach the hazard.
• Restart
Close the safety gates. If the gates were unlocked, use the HMI to initiate a lock command. Both gates are locked and the GuardLink circuit is satisfied. Press the Reset button. Press the Start button to energize the immediate acting loads and turn on the motor.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 21
Chapter 1 Overview
Notes:
22 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Chapter
2
GuardLink System Design
The design of a GuardLink circuit requires knowledge of the power requirements of the input devices and the length of the link cables. A voltage drop occurs across each tap. The cumulative voltage drop determines the number of taps that can be included in the circuit.
The GuardLink system makes it easy to monitor multiple devices over long distances when multiple access points to the hazardous area are required.
The DG safety relay monitors the GuardLink system. The GuardLink system can provide diagnostic information on each access point back to the machine control system.
The GuardLink system must be designed considering these factors:
• Voltage available at each node • Wire size
• Current flowing through each node • Power requirements for each tap
• Cable lengths • Safety device power requirements
The GuardLink system is designed to operate on a 24V DC system. The maximum continuous current on the link circuit must not exceed 4 A; the taps and link cables are rated for 4 A continuous.
Figure 6 on page 24 identifies three tap connections: T1, T2, and T3. The
voltage and safety signals are sourced to connection J1. J2 is connected to downstream taps. J3 of each tap is connected to a safety device.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 23
Chapter 2 GuardLink System Design
Figure 6 - Tap Connections
D1 Safety Device 1
D2 Safety Device 2
Fuse
SLO-BLO™
+ + - -
Vs=24V
Power
Supply
I1
R1
Link Cable
L1
VJ1
J1
T1
INPUT
J3
Device Cable
J2
I2
Link Cable
L2
R2
VJ2 VJ3
J1
T2
INPUT
J3
Device Cable
J2
I3
Link Cable
L3
R3
Table 3 - Key for
Item
D1, D2, D3
I
1
, I
2
, I
3
I
T1
, I
I
D1
, I
T2
D2
, I
, I
T3
1D3
L
1
R
1
, L
, R
2
2
, L
, R
3
3
T1, T2, T3
V
J1
, V
J2
, V
J3
Description
Safety devices
Current in the link cable (A)
Current required by a tap (A)
Current required by a safety device (A)
Length of link cable (m)
Resistance of wire (Ω)
Taps
Voltage at tap connector (V)
J1
INPUT
T3
J2
D3
J3
Device Cable
Safety Device 3
Terminator
System Current Calculation
The GuardLink circuit current must be calculated to determine whether a significant voltage drop occurs to a safety device.
The total system current, I
1
, is the sum of the current required by the first tap plus the current required by the device that is connected to the first tap plus the current required by the downstream circuit. The total system current must not exceed 4 A, continuous.
I
1
= I
T1
+ I
D1
+ I
2
The current in each segment of the GuardLink circuit is calculated in a similar fashion.
I
2
= I
T2
+I
D2
+ I
3
I
3
= I
T3
+ I
D3
The total system current, I
1 sum of the tap currents.
, is therefore the sum of the device currents plus the
I
1
= Σ I
T
+ Σ I
D
24 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
GuardLink System Design Chapter 2
Voltage Drop Consideration
With the potential of using up to 32 taps and long cable lengths between taps, the voltage available to the safety devices at connector J3 must be calculated.
The voltage available to the safety device has two components:
• The voltage drop due to the wire resistance of the cables
• The voltage drop within the tap
The resistance of the recommended 18 AWG cordsets and patchcords is
(0.0218 ohms/m (0.00664 ohms/ft). The wire resistance of the cordset from the power supply to tap 1 (R
1
) is:
R
1
= 0.0218 * L
1
The wire resistance must be considered for both the power and ground; therefore the voltage drop is multiplied by two. The voltage at connector J1 of tap T1 (V
J1
) is:
V
J1
= 2 * I
1
* R
1
The tap has a small voltage from connector J1 to J2. The typical voltage at connector J2 (V
J2
) drop through the tap from J1 to J2 is:
V
J2
= V
J1
- (2 * 0.028V)
The voltage available at connector J3 is dependent on the device that is connected to J3. The typical voltage drop from J1 to J3 is 0.4V when the device uses 50 mA.
V
J3
= V
J1
- 0.4V (typical)
IMPORTANT The voltage drop from J1 to J3 can be as high as 1.2V with a maximum load of 500 mA at the highest rated ambient temperature.
The taps consume 25 mA when OFF. The EMSS taps consume an additional
15 mA (7.5 mA per channel) when the contacts are closed. The OSSD taps consume an additional 6 mA (3 mA per channel), when the outputs are ON.
A spreadsheet can be used to calculate the voltage available to the safety device.
Table 4 on page 26 shows the voltage available to the safety device of a number
of different devices. Assuming that the power supply voltage is set to 24V, and the cable is the recommended 18 AWG, the voltage available to the safety devices is shown in the right-hand column.
When guard locking devices are used in the circuit, the taps and wiring components are subjected to momentary surges in current. With the sequential operation of the lock/unlock command, the momentary surges should not adversely affect the performance of the GuardLink circuit.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 25
Chapter 2 GuardLink System Design
The operating voltage specification of the tap is 20.4…26.4V. In the example that is shown in
, the voltage at J1 of tap 6 has fallen below the lowest supply voltage specification of 20.4V DC. This system is not feasible, and remedial action must be taken (see
).
IMPORTANT
assumes the following:
• Supply voltage = 24V
• Link cable wire gauge = 18 AWG
• Link wire resistance = 0.0218 ohms/m
Table 4 - Voltage Calculation at 24V Supply
14
15
12
13
10
11
8
9
6
7
4
5
2
3
Tap
1
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
0 (0)
0 (0)
Cable Length
[m (ft)]
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
Safety Device
SensaGuard Ser A
SensaGuard Ser A
Lite Lock 440G-LZ
800F E-stop
LifeLine 4
LifeLine 5
TLSZR-GD2 PLe
TLSZR-GD2 PLe
Lite Lock 440G-LZ
SensaGuard Ser A
SensaGuard Ser A
Mechanical Switch
Mechanical Switch
—
—
40
0
81
40
0
135
135
135
81
Tap + Device
Current (mA)
81
81
135
40
40
81
161
80
40
0
0
647
512
377
242
Total Current
(mA)
1105
1024
943
808
768
728
18.81
18.75
18.73
—
—
19.73
19.36
19.10
18.92
J1 Voltage
(V)
23.22
22.49
21.82
21.25
20.70
20.19
18.41
18.35
18.33
—
—
19.33
18.96
18.70
18.52
J3 Voltage
Typical (V)
22.82
22.09
21.42
20.85
20.30
19.79
26 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
GuardLink System Design Chapter 2
To remedy the example in Table 4 , the supply voltage can be increased from
24V to 26V as shown in Table 5 . Now, all 13 taps meet the minimum voltage
specification of 20.4V at connector J1.
IMPORTANT
assumes the following:
• Supply voltage = 26V
• Link cable wire gauge = 18 AWG
• Link wire resistance = 0.0218 ohms/m
14
15
12
13
10
11
8
9
6
7
4
5
2
3
Tap
1
Table 5 - Voltage Calculation at 26V Supply
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
0 (0)
0 (0)
Cable
Length
[m (ft)]
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
15 (49.2)
Safety Device
SensaGuard Ser A
SensaGuard Ser A
Lite Lock 440G-LZ
800F E-stop
LifeLine 4
LifeLine 5
TLSZR-GD2 PLe
TLSZR-GD2 PLe
Lite Lock 440G-LZ
SensaGuard Ser A
SensaGuard Ser A
Mechanical Switch
Mechanical Switch
—
—
40
0
81
40
0
135
135
135
81
Tap + Device
Current (mA)
81
81
40
81
135
40
161
80
40
0
0
647
512
377
242
Total Current
(mA)
1105
1024
943
808
768
728
20.81
20.75
20.73
—
—
21.73
21.36
21.10
20.92
J1
Voltage
(V)
25.22
24.49
23.82
23.25
22.70
22.19
20.41
20.35
20.33
—
—
21.33
20.96
20.70
20.52
J3 Voltage
Typical (V)
25.82
24.09
23.42
22.85
22.30
21.79
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 27
Chapter 2 GuardLink System Design
Tap Cabling
The GuardLink system was designed with the intent of minimizing wiring by using quick-disconnect patchcords, while also allowing some manual wiring to terminals, when pinout incompatibilities exist.
Figure 7 shows the recommended cable options for the various stages of a
GuardLink system (to show the cable options only two taps are required, a full system has 32 taps). These cables are red-colored, PVC, unshielded, with epoxy-coated hardware. Although any color jacket can be used, the red color is preferred to indicate a safety circuit.
Visit ab.rockwellautomation.com/Connection-Devices/DC-Micro-Cordsetsand-Patchcords for other options, like right-angle connectors, stainless steel couplings, and shielded cables.
To maintain the safety integrity of the GuardLink signal, the wiring distance between taps is limited to 30 m (98.4 ft) and requires 18 AWG (0.82 mm2) wire. If the distance between devices is greater than 30 m (98.4 ft), then a tap must be inserted at least every 30 m (98.4 ft). A field-attachable quickdisconnect can be wired as a shorting plug for the device connection. The wiring distance between taps and the safety device is limited to 10 m (32.8 ft), and requires at least 24 AWG (0.2 mm2) wire size.
Figure 7 - Recommended Cable Options (1)
Safety Device
889D-F5NCDMx
5-wire Patchcord or
889D-F8NBDMx
8-wire Patchcord
10 m (32.8 ft) length, max
INPUT
889D-M5NCx
5-wire Cordset or
889D-M8NBx
8-wire Cordset
10 m (32.8 ft) length, max
Safety Device
INPUT
White
DG
Safety
Relay
Black Brown Blue
+ + - -
24V
Power
Supply
889D-F4NEx
4-wire Cordset
30 m (98.4 ft) length, max
889D-F4NEDMx
4-wire Patchcord
30 m (98.4 ft) length, max
889D-418-DM2
Terminator
28
(1) Replace the x with 0M3 (0.3 m [0.984 ft]), 0M6 (0.6 m [1.968 ft]), 1 (1 m [3.28 ft]), 2 (2 m [6.56 ft]), 5 (5 m [16.4 ft]), 10 (10 m
[32.8 ft]), 15 (15 m [9.2 ft]), 20 (20 m [65.6 ft]), or 30 (30 m [98.4 ft]) for standard cable lengths.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Terminator
GuardLink System Design Chapter 2
The terminator (
Figure 8 ), must be installed on the last tap to complete the
link connection. The terminator contains internal electrical components specifically for a GuardLink system; other terminators cannot be used as substitutes.
Figure 8 - Terminator — Catalog Number 898D-418U-DM2
Tap Replacement
Response Time
A GuardLink tap can be replaced with the same type of tap while the link is powered. When the connections are remade; the GuardLink circuit recovers automatically.
The GuardLink circuit has a fast response time. When a safety device opens, the tap responds within 5 ms. The GuardLink safety signal then travels upstream to the DG safety relay, which takes an additional 35 µs through each upstream tap.
Figure 9 shows an example GuardLink safety circuit with six taps. In this
example, a SensaGuard rectangular flat pack interlock, which is connected to
Tap 4, opens.
Figure 9 - Response Time Example Calculation
SensaGuard
Opens
Tap 1 Tap 2 Tap 3
Upstream
Tap 4 Tap 5
Downstream
Tap 6
DG Safety Relay
Single Wire Safety Out
100S-C09EJ
Safety
Contactors
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 29
Chapter 2 GuardLink System Design
The safety system response time for the system that is shown in Figure 9
is
listed in Table 6 . The time from when the SensaGuard interlock opens to the
time when the 100S contactors drop out is 169.105 ms. The time from when the SensaGuard interlock opens to the time when the SWS signal turns OFF is
114.105 ms.
Table 6 - Example Response Time Calculation
Component
SensaGuard
(1)
Tap 4
Tap 3
Tap 2
Tap 1
DG Safety Relay
100S Contactor
(2)
Total
(1) See publication 440N-IN008 .
(2) See publication 100-TD013 .
DG Output
13/14, 23/24
54.0
5.0
0.035
0.035
0.035
60.0
50.0
169.105
Response Time [ms]
DG Output
SWS (X2)
54.0
5.0
0.035
0.035
0.035
55.0
0.0
114.105
IMPORTANT
and Table 6 show only a portion of a complete safety system.
Additional time (for example, for motor stopping time and the response time of additional components that are connected to the SWS signal) must be considered.
30 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Chapter
3
Installation
Mounting Dimensions
The DG safety relay uses the same housing as GSR modules. The module
dimensions are shown in Figure 10 , while Figure 11
shows the tap dimensions.
Figure 10 - DG Safety Relay Dimensions [mm (in.)]
22.5
(0.88)
113.6 (4.47)
S12 S22 S32 S42
A1 A2 S11 S21
PWR/Fault
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Co nfig/S
DG Reset
Sel./Save et
.14
.
0
.2.4.6
Time
X1 X2 X3 X4
13 14 23 24
119.14
(4.69)
Figure 11 - Tap Dimensions [mm (in.)]
14
(0.55)
57 (2.24)
2X 5.4 (0.21) FOR M5 SCREWS
( 9.8 (0.38) MAX. SCREW HEAD)
19.25 (0.76)
M12 X 1 THREAD
9 (0.35)
38.5 (1.51) 79.64 (3.14)
17 (0.67)
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 31
Chapter 3 Installation
DIN Rail Mounting and
Removal
The DG safety relay easily mounts onto 35 mm (1.4 in.) DIN rails:
35 x 7.5 x 1 mm (1.4 x 0.3 x 0.04 in.) (EN 50022 - 35x7.5).
1. Hold the top at an angle ( Figure 12
).
2. Slide down until the housing catches the rail.
3. Swing the bottom down and give a little push until the latch clips onto the rail.
Figure 12 - DIN Rail Mounting
2
1
3
DIN Rail Latch
DIN Rail
Removal
To remove the DG safety relay, use a screwdriver to pry the DIN rail latch downwards until it is in the unlatched position. Then, swing the module up.
Spacing
The DG safety relay can be mounted next to other GSR safety relays. When the GSR Ethernet interface is used, the GSR module must be mounted within
10 mm (0.39 in.) of the module next to it to maintain effective communications.
Maintain 50 mm (2 in.) of space above, below, and in front of the relay for adequate ventilation.
32 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Installation Chapter 3
Terminal Block Removal and
Replacement
Terminal blocks can be removed and replaced following these instructions.
Terminal Block Removal
DG safety relays have removable terminal blocks. Use a screwdriver as a lever to remove the blocks. As shown in
, insert the screwdriver into the slot and pry up.
Figure 13 - DG Terminal Removal
1.
Insert 2.
Pry Up
Terminal Block Replacement
The terminal blocks are keyed to help prevent a block from being inserted into an incorrect location. The orange-colored insert provides the orientation of the
Figure 14 - Orange-colored Keyway
Orange inserts match keys
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 33
Chapter 3 Installation
Tap Installation
The tap can be installed directly with two M5 screws. In
38.5 mm (1.5 in.) wide tap fits neatly on a standard 40 mm (1.6 in.) aluminum extrusion construction profile.
Figure 15 - Mounting Directly on 40 mm (1.6 in.) Profile
INPUT 40 mm
(1.6 in.)
M5 Screws
Figure 16 shows an optional quick mounting bracket, catalog number
440S-GLTAPBRK cordsets.
x (1) , is available to facilitate installation and removal. The tap snaps into place and can be easily removed to install patchcords and
Figure 16 - Quick-release Mounting Bracket
Quick Release Clip
34
Recessed Mounting Holes (x6)
Figure 17 shows the dimensions of the quick-release mounting bracket.
Figure 17 - Mounting Bracket Dimensions
6 x 5.4 (0.21) Ø for M5 screws
(11 (0.43) Ø max. screw head)
38.5
(1.51)
20
(0.79)
76.6 (3.01)
11
(0.43)
22
(0.87)
25
(0.98)
19.6
(0.77)
(1) Replace the x with 1 to order one bracket and replace with a 5 for a package of five brackets.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Installation Chapter 3
Figure 18 shows some of the mounting options with the quick release bracket.
The bracket can be mounted on various sizes of profile and can mount in-line or across the profile.
Figure 18 - Mounting Options with Quick-release Bracket
In-line with Profile Across Profile
20 mm Profile 30 mm Profile 45 mm Profile
Enclosure Considerations
Consider the following when choosing your DG safety relay and tap enclosure.
DG Safety Relay
The DG safety relay is intended for use in a Pollution Degree 2 industrial environment, in overvoltage Category II applications (as defined in
IEC 60664-1), at altitudes up to 2000 m (6562 ft) without derating. This equipment is considered Group 1, Class A industrial equipment according to
IEC/CISPR 11. Without appropriate precautions, there can be difficulties with electromagnetic compatibility in residential and other environments due to conducted and radiated disturbances.
The DG safety relay is supplied as open-type equipment. It 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 that results from accessibility to live parts. The enclosure must have suitable flame-retardant properties to help prevent or minimize the spread of flame that complies with a flame spread rating of 5VA, V2, V1, V0 (or equivalent) if non-metallic. The interior of the enclosure must be accessible only by the use of a tool. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications.
Other helpful publications can be found in Additional Resources on page 9
.
Taps
Taps are intended to be mounted on the machine and are rated for Pollution
Degree 3.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 35
Chapter 3 Installation
Prevent Excessive Heat
Consider the following to help prevent excessive heat for your DG safety relay and tap.
DG Safety Relay
For most applications, normal convective cooling keeps the DG safety relay within the specified operating range. Verify that the specified temperature range is maintained. Proper spacing of components within an enclosure is usually sufficient for heat dissipation.
In some applications, other equipment inside or outside the enclosure produce a substantial amount of heat. In this case, place blower fans inside the enclosure to help with air circulation and to reduce hot spots near the controller.
Additional cooling provisions can be necessary when high ambient temperatures are encountered. Do not bring in unfiltered outside air. Place the controller in an enclosure to help protect it from a corrosive atmosphere.
Harmful contaminants or dirt can cause improper operation or damage to components. In extreme cases, you may need to use air conditioning to help protect against heat buildup within the enclosure.
Taps
The taps have no spacing requirements.
36 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Chapter
4
Power, Ground, and Wire
Wiring Requirements and
Recommendation
DG Safety Relay
WARNING: Before you install and wire any device, disconnect power to the system.
WARNING: 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. Current above the maximum rating can cause wiring to overheat, which can cause damage.
• Allow for at least 50 mm (2 in.) between I/O wire ducts or terminal strips and the relay.
• Route incoming power to the relay by a path separate from the device wiring. Where paths must cross, their intersection must be perpendicular.
• Do not run signal or communications wiring and power wiring in the same conduit. Route wires with different signal characteristics by separate paths.
• Separate wiring by signal type. Bundle wiring with similar electrical characteristics together.
• Separate input wiring from output wiring.
• Label wiring to all devices in the system. Use tape, shrink-tubing, or other more dependable means to label wire. Use colored insulation as well to identify wiring by signal characteristics. For example, use blue for
DC wiring and red for AC wiring.
Wire Size
Each terminal can accommodate copper wire with size from 0.2…2.5 mm2
(24…14 AWG). Use copper that can withstand 60/75 °C (140/167 °F).
Terminal Torque
Torque terminals to 0.4 N•m (4 lb•in).
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 37
Chapter 4 Power, Ground, and Wire
38
Terminal Assignment and Function
The relays have four terminals: two on the top and two on the bottom. As
shown in Figure 19 , the X2 and X4 terminal markings apply to the terminals
further back. The X1 and X3 terminals apply to the terminals closest to the front.
Figure 19 - DG Terminal Identification
X1 X2
S12 S22 S32 S42
A1 A2 S11 S21
PWR/Fault
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
C onfig/S et
DG
Reset
Sel./Save
.14
.
0.2.4.6
Time
}X2
}X1
X1 X2 X3 X4
13 14 23 24
}X3
}X4
X3 X4
Some of the terminals can be configured for multiple functions. Table 7 lists
the functions available for each terminal.
Table 7 - Terminal Assignments and Functions
13
14
X3
X4
S32
S42
X1
X2
23
24
Terminal Function
A1
A2
+24V Supply (+10%, -15%)
0V Common
S11
S21
S12
S22
Pulse Test Output
Pulse Test Output
GuardLink Safety or Safety N.C.
GuardLink CLU or Safety N.C.
GuardLink Safety or Safety N.C.
GuardLink CLU or Safety N.C.
SWS In or OSSD In
SWS Out or OSSD Out
Standard Input (Feedback)
Standard Input (Reset)
Redundant Positive-Guided Relay Output 1
Redundant Positive Guided Relay Output 2
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Power, Ground, and Wire Chapter 4
Tap Pin Assignment and
Function
Each tap has three M12 quick disconnect connectors ( Figure 20 ). The system
is designed to use premanufactured patchcords to facilitate installation, modification, and troubleshooting. The link connectors are 4-pin. The device connectors are either 5-pin or 8-pin.
Figure 20 - Tap Connection Identification
INPUT
J3 GuardLink Device Connection
8-Pin M12 Female or
5-Pin M12 Female
J1 GuardLink Link In
4-Pin M12 Male
J2 GuardLink Link Out
4-Pin M12 Female
The link connections carry the power and command signals. Figure 21
shows the functions of each pin. When using Allen-Bradley® Guardmaster patchcords and safety devices, you do not need to be concerned about the pin assignments, the system is connect and go.
Figure 21 - Link Connections
2: GuardLink Safety 2: GuardLink Safety
Pin
1
2
3
4
1: +24V DC
3: 0V DC
J1 Link In (Male)
4: GuardLink CLU
Function
+24V Supply (+10%, -15%)
GuardLink Safety Signal
0V DC, the reference for the 24V supply
GuardLink Control Lock Unlock (CLU) Signal
1: +24V DC
4: GuardLink CLU
J2 Link Out (Female)
3: 0V DC
4
5
2
3
Pin
1
6
7
8
Figure 25 show the functions that are assigned to the 8-pin and
5-pin quick-disconnect connections for safety devices.
Figure 22 - J3 8-Pin OSSD (Female) Connector
2: +24V DC
1: Aux
3: Lock/Unlock Command
8: Safety OSSD A+
4: Safety OSSD B+
7: 0V
6: Safety OSSD B
5: Safety OSSD A
Function
The auxiliary status output signal is not used by the tap
+24V Supply (+10%, -15%)
The Lock/Unlock command to the device
Safety OSSD channel B+ (24V DC)
Safety OSSD channel A
Safety OSSD channel B
0V DC, the reference for the 24V supply
Safety OSSD channel A+ (24V DC)
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 39
Chapter 4 Power, Ground, and Wire
Figure 23 - J3 8-Pin EMSS (Female) Connector
2: Lock/Unlock Command
1: Aux Contact
3: Aux Contact
8: Safety Contact A
4: Safety Contact B
7: 0V
6: Safety Contact B
5: Safety Contact A
6
7
4
5
8
2
3
Pin
1
Function
Auxiliary (non-safety) contact
Lock/Unlock command
Auxiliary (non-safety) contact
24V output for safety contact channel B
Safety contact channel A
Safety contact channel B
0V DC, the reference for the Lock/Unlock command
24V output for safety contact channel A
Figure 24 - J3 5-pin OSSD (Female) Connector
2: Safety OSSD A
5: Aux
1: +24V DC
3: 0V
4: Safety OSSD B
3
4
5
Pin
1
2
Function
The +24V power supply to the device
Safety OSSD channel A
0V DC, the reference for the power supply
Safety OSSD channel B
The auxiliary status signal is not used by the tap
Figure 25 - J3 5-pin EMSS (Female) Connector
2: Safety Contact A
5: Safety Contact B
1: Safety Contact A
3: N/C
4: Safety Contact B
3
4
5
Pin
1
2
Function
24V output for safety contact channel A
Safety contact channel A
No connection
Safety contact channel B
24V output for safety contact channel B
40 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Power, Ground, and Wire Chapter 4
Bulletin 871A field-attachable quick-disconnect connectors can be used as shorting plugs during installation, troubleshooting, and for long distances.
When the distance between taps exceeds 30 m (98.4 ft), a tap must be inserted into the GuardLink system at least every 30 m (98.4 ft). A shorting plug must then be added to the J3 connector.
Figure 26 shows the wiring connections
that are required to create a shorting plug.
IMPORTANT For 5-pin OSSD taps, a shorting plug (catalog number 898D-418U-DM) can be used in place of the terminal chamber (catalog number 871A-TS5-DM).
For 8-pin taps, a shorting plug (catalog number 898D-81RU-DM2) can be used in place of the terminal chamber (catalog number 871A-TS8-DM1).
Figure 26 - Shorting Plug Schematics
Use 871A-TS8-DM1 or 898D-81RU-DM2 for 8-pin OSSD and EMSS taps
Use 871A-TS5-DM or
898D-418U-DM for 5-pin OSSD taps
6
7
4
5
1
2
3
8
1
2
3
4
5
Use 871A-TS5-DM for
5-pin EMSS taps
1
2
3
4
5
Power Supply Connection
Many Bulletin 1606 power supplies are SELV, PELV, and Class 2-compliant.
DG Safety Relay
To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with protected extra low voltage (PELV) or, under certain conditions, a safety extra low voltage (SELV) per IEC 60204-1 must power the
DG safety relay.
For the USA, a PELV supply is required, per NFPA 79.
Figure 27 shows the power supply connections for the DG safety relay.
Connect terminal A1 to +24V DC. Terminal A2 must be connected to the common of a 24V supply.
Figure 27 - DG Power Supply Connections
Connect +24V DC to Terminal A1 Connect 24V Common to Terminal A2
S12 S22 S32 S42
A1 A2 S11 S21
PWR/Fault
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
C onfig/S et
DG Reset
Sel./Save
14.
0
.2.4.6
Time
X1 X2 X3 X4
13 14 23 24
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 41
Chapter 4 Power, Ground, and Wire
Taps
To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with a protected extra low voltage (PELV) or, in certain circumstances, a safety extra low voltage (SELV) per IEC 60204-1 must power the tap. For IEC applications, an in-line, slow-blow 4 A fuse is recommended if the power supply can provide more than 4 A.
For the USA, a Class 2 power supply must be used. The Class 2 supply limits the current to 4 A, so an in-line fuse is not needed.
IMPORTANT In the USA, use of a 4 A fuse or circuit breaker in place of a Class 2 power supply is not acceptable.
Figure 28 shows the power connections to the power tap. Power is connected
only to the first tap.
Figure 28 - Tap Power Connections
GuardLink First Tap GuardLink First Tap
Pin 1: +24V DC Pin 1: +24V DC
4 A
Pin 3: 0V DC Pin 3: 0V DC
+ +
DC ok
+ +
DC ok
1606-XLE 240 EN
N L
PELV for IEC Compliance
1606-XLP 95 E
N L
Class 2 for USA Compliance
42 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Power, Ground, and Wire Chapter 4
Multiple Power Supplies
When separate power supplies are used for the DG safety relay and the
GuardLink circuit, the protective earth connections must be at the same point.
Figure 29 shows an example wiring diagram (catalog number
1606-XLE240EN is not Class 2 compliant; catalog number 1606-XLP-95E is
Class 2 compliant).
Figure 29 - Multiple Power Supplies — Ground PE at Same Point
INPUT
S12 S22 S32 S42
A1 A2 S11 S21
PWR/Fault
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
DG
Co nfig/S et
Reset
Sel./Save
14.
0
.2.4.6
Time
X1 X2 X3 X4
13 14 23 24
+ +
DC ok
1606-XLE240EN
N L
+ +
DC ok
1606-XLP95E
N L
Multiple power supplies must have one point common connection
DG Safety Relay Input Wiring
This section describes DG safety relay input wiring.
GuardLink Connections
Up to two GuardLink circuits can be connected to the DG safety relay. The
GuardLink safety signal must be connected to either S12 or S32 and the
GuardLink CLU signal must be connected to either S22 or S42. Figure 30
shows the connections for the GuardLink circuits; the wire colors apply when the recommended cordsets are used.
Figure 30 - GuardLink Connections
+24V DC
INPUT INPUT
24V Com
A1 S12
Safety
Input 1
S22
CLU
A2
DG Safety Relay
S32
Safety
Input 2
S42
CLU
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 43
Chapter 4 Power, Ground, and Wire
Devices with OSSD Outputs
Devices with OSSD outputs perform their own short circuit detection. The
DG can be configured to accept up to two devices with OSSD signals.
Connections of the OSSD outputs are shown in Figure 31
.
Figure 31 - Wiring to Devices with OSSD Outputs
+24V DC
A1
A2
A1
Device 1
A2
A1
Device 2
A2
S12 S22
Input 1
DG Safety Relay
S32 S42
Input 2
24V Com
Voltage-free Contacts
Devices with voltage-free contacts must use the pulse testing outputs to detect short-circuit faults between the following:
• Channels
• Channels and power
• Channels and ground
Figure 32 shows the recommended wiring for dual-channel and single-channel,
voltage-free contacts. Voltage-free contacts can be connected to either Input 1,
Input 2, or both inputs.
Figure 32 - Wiring to Voltage-free Contacts
Device 1 Device 2
Device 1 Device 2
S11 S21
Pulse
Testing
Outputs
S12
Input 1
S22
DG Safety Relay
Dual Channel
S32 S42
Input 2
S11 S21
Pulse
Testing
Outputs
S12
Input 1
S22
DG Safety Relay
Single Channel
S32 S42
Input 2
44 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Single Wire Safety
Power, Ground, and Wire Chapter 4
The DG safety relay has the Single Wire Safety capability to expand the safety function (both input and output).
SWS Connections
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 have the same voltage supply reference.
The SWS signal is unidirectional. The signal flows from L11 to L12.
There can be many variations and combinations of series and parallel connections of the SWS. Each L11 terminal can be connected to up to ten L12 terminals.
IMPORTANT Do not connect two or more L11 terminals together.
Figure 33 shows an example wiring diagram with an SWS signal. The SWS can
be connected between the DG safety relay and other relays in the GSR family
(the CI, DI, DIS, EM, EMD, and SI relays). Relay 1 has a series connection to
Relay 2. Relay 2 has a parallel connection to Relays 3 and 4. Relay 4 has a series connection to Relay 5. The safety relays must have a common power reference
(24V common). In this example, the safety function started by Relay 1 turns off all other relays if AND logic is applied to L12 on all relays.
IMPORTANT The DG safety relay terminals are marked X2 and X1; which is equivalent to terminal L12 and L11 on other GSR relays.
Figure 33 - SWS Connection Example
+24V DC +24V DC +24V DC +24V DC +24V DC
A1
A2
GSR Relay 1
DI
L12 L11
SWS
A1
A2
GSR Relay 2
DG
X1 X2
A1
GSR Relay 3
DG
A2 X1 X2
A1
A2
GSR Relay 4
EM
L12 L11
SWS SWS
24V DC Com (the relays must have a common reference)
A1
GSR Relay 5
EMD
A2 L12 L11
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 45
Chapter 4 Power, Ground, and Wire
Safety Output Wiring
Figure 34 shows the characteristics of SWS signal when it is active. It starts
with a 1 ms pulse, followed 700 µs later by a 500 µs wide pulse. This waveform is repeated every 4 ms. The tolerance of all edges is ±10%.
When inactive, the SWS signal is 0V.
Figure 34 - SWS Waveform
24V
Terminals
X1 and X2
0V
0 1 1.7 2.2
4 ms
The DG safety relay has two voltage-free, safety-related outputs (terminals
13/14 and 23/24).
13/14 and 23/24 Safety Outputs
The 13/14 and 23/24 safety outputs have redundant (two) positive-guided relays that are internally connected between each terminal. An example of the
wiring connections is shown in Figure 35
. See
Specifications on page 87 for the
voltage and current ratings of these relays.
If the voltage supply of the outputs exceeds the voltage supply of the relay, then low-voltage wiring must be separated from the high-voltage wiring.
Figure 35 - Output Connections of the DG Safety Relay
V supply
13 23
14 24
K1 K2
V common
46 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Power, Ground, and Wire Chapter 4
Surge Protection
Due to potentially high-current surges that occur when switching inductive load devices, such as motor starters and solenoids, the use of some type of surge suppression to help protect and extend the operating life of the relays is recommended. By adding a suppression device directly across the coil of an inductive device, you prolong the life of the outputs. You also reduce the effects of voltage transients and electrical noise from radiating into adjacent systems.
Figure 36 shows an output with a suppression device. We recommend that you
locate the suppression device as close as possible to the load device.
For outputs that use 24V DC, we recommend 1N4001 (50V reverse voltage) to 1N4007 (1000V reverse voltage) diodes for surge suppression for the OSSD safety outputs (
Figure 31 ). The diode must be connected as close as possible to
the load coil.
For outputs that use 120V AC or 240V AC, we recommend metal oxide varistors.
Figure 36 - Surge Protection Examples
Metal oxide varistors for V AC supply
Diodes for V DC supply
K1
V common
K2 K1
V common
K2
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 47
Chapter 4 Power, Ground, and Wire
Notes:
48 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Chapter
5
Configuration
Config/Set Push Button
The DG safety relay has two push buttons on the front faceplate. These buttons are labeled Config/Set and Sel./Save.
These push buttons allow you to do the following:
• Configure the DG safety relay to perform a safety function
• Confirm the existing safety functions
• Reset the DG safety relay
• Report the fault code
The DG safety relay has two modes of operation: run and configuration. The functions that the push buttons perform depend on the operating mode and length of time the push button is pressed.
• Short: The button is pressed less than one second.
• Long: The button is pressed for longer than three seconds, but shorter than 10 seconds.
Run Mode
Button Press Function
Short The indicators show the configuration of the DG safety relay.
• Press once to see the configuration (see
).
• Press a second time to see the time delay setting (see
• Press a third time to see the status of the wiring terminals again (see
).
After about 20 seconds of inactivity, the indicators revert to the wiring terminal status.
Long The DG safety relay enters Configuration mode. The 13/14, 23/24, and X2 outputs turn OFF, if they are ON.
After 60 seconds of inactivity, the indicators revert to the wiring terminal status. Changes to the configuration are not saved.
IMPORTANT After changes to the hardware configuration of the DG safety relay or the
GuardLink circuit, power must be cycled to the DG safety relay, the GuardLink circuit, and to the EtherNet/IP interface.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 49
Chapter 5 Configuration
Sel./Save Push Button
Reset
Configuration Steps
Configuration Mode
When you are in the configuration mode, the duration that the Config/Set button is depressed determines what the DG safety relay reveals.
Button Press Function
Short You can cycle through the configuration and can switch between the function of the blinking indicator. See
for indicator descriptions.
Long Abort the changes; you leave the configuration mode without saving the changes. The PWR/
Fault indicator flashes green at a 1 Hz rate. Upon release, the indicators revert to the wiring terminal status.
Run Mode
Button Press Function
Short The status indicators display the following:
• Alternating flashing green indicators if optical buses are active.
• Alternating flashing red indicators if optical buses are inactive.
Long Nothing happens.
Configuration Mode
Button Press Function
Short You can jump from one configuration step to the next.
Long The new configuration is saved.
If you press both push buttons simultaneously for longer than three seconds, the DG safety relay performs a power cycle. The same can be accomplished if you remove and reapply power to terminal A1.
Before starting to configure the DG safety relay, review the configuration functions in
. The configuration examples in
help you select the correct configuration.
50 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Chapter 5
Table 8 - Configuration
Status
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Function
Number of Safety Functions
Input Type IN1
Input Type IN2
Output Type
Input Mode
Reset Reset Type
FB Reset Assignment
(1) Only available if Manual Monitored Reset is selected.
Indicator Color and Setting
Activate two Safety Functions
(IN1 and IN2)
Activate GuardLink Input function on IN1
Activate GuardLink Input function on IN2
Activate SWS Output on X2
Activate SWS or OSSD Input on
X1, depends on the previous step (SWS Input if OUT X is SWS
Out, OSSD In out if OUT X is
OSSD.)
Manual Monitored Reset
Reset on the Output function
Indicator Color and Setting
Activate one Safety Function
(only IN1)
Activate OSSD or EMSS Input function on IN1
Activate OSSD or EMSS Input function on IN1
Activate OSSD Output on X2
Disable Input on X1
Automatic Reset
Reset only on IN 1
(1)
Indicator Color and Setting
—
—
If only one Safety Function (IN1) is selected, the IN2 is disabled
—
—
—
Not used if Automatic Reset is selected
1. Long press the Config/Set button.
The PWR/Fault indicator turns green and all other indicators flash red quickly, which indicates that the DG safety relay is in Configuration mode. Shortly after release of the Config/Set button:
• The PWR/Fault status indicator flashes green at 1 Hz.
• The OUT status indicator flashes the current configuration (red or green) at 1 Hz.
• The remaining status indicators are solid red, solid green, or off.
2. Short press the Config/Set button to change the function of the OUT status indicator.
IMPORTANT If you press the Config/Set button in these steps again, the status indicator switches back and forth between red and green.
Short press the Sel./Save button to accept and go to the next step.
3. Short press the Config/Set button to change the function on the IN 1 status indicator.
Short press the Sel./Save button to accept and go to the next step.
IMPORTANT If the IN 2 indicator is off, the function is not available in this configuration. The configuration proceeds to the OUT X indicator -
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 51
Chapter 5 Configuration
52
4. Short press the Config/Set button to change the function on the IN 2 status indicator, if available.
Short press the Sel./Save button to accept and go to the next step.
5. Short press the Config/Set button to change the function on the
OUT X status indicator.
Short press the Sel./Save button to accept and go to the next step.
6. Short press the Config/Set button to change the function on the IN X status indicator.
Short press the Sel./Save button to accept and go to the next step.
7. Short press the Config/Set button to change the function on the Reset status indicator.
Short press the Sel./Save button to accept and go to the next step.
8. Short press the Config/Set button to change the function on the FB status indicator.
Short press the Sel./Save button to accept and go to the next step.
9. All indicators flash the new configuration. Use this step to confirm your configuration.
Short press the Sel./Save button to accept and go to the next step.
10. Now, you can verify and adjust the time delay. If the rotary switch is at position 0, all indicators (except the PWR/Fault) are off. If the rotary switch is in a position other than 0, then the bottom three indicators flash. The number of times the indicators flash is equal to the Time switch position.
11. Rotate the rotary switch to the desired off-delay setting (see
12. When the configuration is finished, long press the Sel./Save button to save the new configuration.
The status indicators flash their configuration while the button is held down. When the button is released, the PWR/Fault status indicator flashes green twice, turns solid red for about five seconds, and then turns solid green again. Now, the other status indicators reflect the status of the wiring terminals (see
).
IMPORTANT To abort the configuration without saving your settings:
• Long press the Config/Set button, then short press the Config/Set button. The DG safety relay returns to normal operation (Run mode) without saving the changes.
• Wait longer than 60 seconds without any additional changes.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Delay Setting
Verification
Configuration Chapter 5
The delay is set by the 16 position switch as described in Table 9 . The DG
inputs must be opened during the delay. If the inputs close before the expiration of the delay time, the delayed output remains ON and any locked guards remain locked. If the inputs are reopened the timer restarts from zero.
Table 9 - Delay Switch Settings
4
5
2
3
6
7
Position
0
1
Delay
Immediate
100 ms
200 ms
300 ms
500 ms
1 s
1.5 s
2 s
10
11
12
13
Position
8
9
14
15
Delay
3 s
5 s
8 s
10 s
15 s
20 s
25 s
30 s
shows how the status indicators confirm the delay setting. The bottom three indicators flash at 1 Hz. The flashing pauses for four seconds and then repeats. The number of flashes is equal to the delay switch setting.
Table 10 - Indicators Confirm Delay Setting
Indicator Color Status
PWR/Fault Configuration mode
OUT
IN 1
IN 2
OUT X
IN X
—
—
—
—
Reset
The number of flashes indicates the delay switch setting. For example:
0 = no flashing
5 = five flashes
FB
You can verify the configuration of the DG safety relay in three ways:
• The push buttons on the front of the DG safety relay
• The 440R-ENETR interface web page
• The Add-on-profile (AOP) in the Studio 5000 environment
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 53
Chapter 5 Configuration
Push Buttons on the Front of DG Safety Relay
While in the Run mode, short presses of the Config/Set button can verify the configuration.
IMPORTANT The PWR/Fault indicator remains green through these steps.
1. Short press the Config/Set push button.
The indicators show the configuration. Compare the colors of each indicator to your desired colors.
2. Short press the Config/Set push button again.
The indicators show the Time switch setting. If the indicators are off, then the TIME is set to zero. For a setting other than zero, the bottom three indicators flash green. The number of flashes is equal to the switch setting. The flashing pauses for four seconds and then repeats.
3. Short press the Config/Set push button one last time to return to the running status indication.
AOP in the Studio 5000 Environment
Each configuration is assigned a unique identification. The ID appears as a
decimal value in the Config field in the Controller Tags. See Studio 5000 Code
Examples on page 80 for more information. After the initial configuration,
record the Config value. This value can then be compared in the future to detect changes.
54 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Chapter
6
Status Indicators
DG Safety Relay Status
Indicators
describes the status of the DG safety relay status indicators during normal operation.
Table 11 - DG Indicators during Normal Operation
Indicator
PWR/Fault
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
State
OFF
Solid Red
Solid Green
Flashing Green 1 Hz
Flashing Red 1 Hz
Green
Red
Green
Red
Flashing Red 1 Hz
Green
Red
Flashing Red 1 Hz
OFF
Green
Red
Green
Red
OFF
Green
Flashing Green 1 Hz
Red
Green
Red
Description
No power
DG safety relay is in self-test state or idle state
Normal operation (Run mode)
Configuration mode - proceed with configuration
Fault Mode - Press the Sel./Save Button to see the fault code
Output circuits at 13/14 and 23/24 are closed
Output circuits at 13/14 and 23/24 are open
Input circuits at S12 and S22 are closed
Input circuits at S12 and S22 are open
Input signal missing or incorrect configuration
Input circuits at S32 and S42 are closed
Input circuits at S32 and S42 are open
Input signal missing or incorrect configuration
Input circuit is disabled
OSSD output/SWS output at X2 is ON
OSSD output/SWS output at X2 is OFF
Input circuit at X1 closed
Input circuit at X1 open
Input circuit is disabled
Reset button at X4 pushed
Reset at X4 required
Reset at X4 held ON. Try resetting again.
Feedback circuit at X3 closed
Feedback circuit at X3 open
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 55
Chapter 6 Status Indicators
Tap Status Indicators
the status for each indicator.
Figure 37 - Tap Indicators
Input indicator
INPUT
Link indicator
Table 12 - Tap Indicators
Indicator
Input
Link
State
Solid Green
Flashing Green at 1 Hz
Solid Red
Flashing Red at 1 Hz
Solid Green
Solid Red
Flashing Red at 1 Hz
Off
Description
The input device is in the operational state with no demand on its safety function (for example, the OSSD inputs are ON or safety contacts are closed). The tap is also in the operational state.
The input device is in the operational state (no demand on its safety) and the tap is in the safe state. One or more upstream taps are in a safe state. The CLU signal is high, so all taps are in the safe state.
OSSD inputs are OFF or safety contacts are open.
The input device is in the safe state (for example, OSSD inputs are OFF or safety contacts are open), and there are no faults with the tap.
The input device has not performed as expected; for example, both inputs did not change simultaneously. Try cycling the input device again. Cycle power to GuardLink circuit if necessary.
The tap is transmitting the safety signal.
GuardLink safety signal is OFF. Or terminator is missing.
Fault at tap or input device.
Correct fault and cycle power to the GuardLink system.
No communication to DG safety relay. Input is configured for OSSD/
EMSS; recheck the configuration. Input is in faulted state. Correct fault and/or cycle power to the DG safety relay and GuardLink circuit.
Figure 38 shows an example with five taps. The device at Tap 3 has tripped, and
the GuardLink safety signal is in a safe state. To locate the tripped device, follow the blinking green lights to the tap with the solid red device indicator.
The link indicator is solid red, which indicates a safe (OFF) state.
Figure 38 - Tripped Device with Solid Red Status Indicators
Tripped device
56 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Chapter
7
Pulse Testing Functions
Pulse Testing for Inputs
Your DG safety relay uses pulse testing of inputs with voltage free contacts to detect short circuit conditions. The test pulses are used to detect three short circuit conditions:
• Between the input terminals and +24V
• Between the input terminals and 24V common
• Between the two input terminals.
Pulse testing for the inputs must be used with devices like E-stop push buttons, tongue operated interlock switches, and limit switches that have voltage-free contacts.
The pulse-testing cannot be turned on or off and cannot be changed.
Therefore, the purpose of this chapter is informational, but it can be used during troubleshooting of a DG safety circuit.
Pulse tests for the inputs are generated on terminals S11 and S21 of the DG safety relay.
Figure 39 shows the pulse testing that is associated with the DG safety relay.
The pulse widths are either 300 µs or 600 µs wide, and the pulses are repeated every 15 ms.
Figure 39 - Pulse Test Sequence for DG Safety Relay
S21
24V
0V
0.3
15.3
S11 24V
0V
0 0.6
15 15.6
Time [ms]
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 57
Chapter 7 Pulse Testing Functions
EMSS SmartTap Pulse Tests
The EMSS SmartTap generates pulse tests to detect short circuit conditions.
The waveforms are shown in
Figure 40 . The pulses are 1 ms wide. Channel 2
pulse occurs 8 ms after Channel 1. The pulses are repeated every 21 ms. When either of the input channels goes to an open state, the pulses are turned off.
Figure 40 - EMSS Test Pulses
1 ms
21 ms
8 ms
58 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Optical Bus
Chapter
8
Opto-link Communications
The GSR family of relays use an optical bus to communicate status information to the 440R-ENETR Guardmaster Ethernet/IP network interface safety relays have two optical buses:
(1)
. DG
• Bus 2 allows communication to pass from the 440R-ENETR interface to the DI, DIS, EM, EMD. GLP, GLT, and SI safety relays (the CI safety relay does not have an optical bus).
• Bus 3 is used exclusively by the DG safety relay for GuardLink communications.
The optical bus ports are on each side of the housing, as shown in Figure 41
.
Figure 41 - Optical Bus Ports
Opto Bus 2
Opto Bus 3
(1) See publication 440R-UM009 for detailed 440R-ENETR interface information.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 59
Chapter 8 Opto-link Communications
Arrangement with
440R-ENETR Interface
Each 440R-ENETR interface can communicate with up to six GSR relays, in any combination. All DG safety relays must be located closest to the
440R-ENETR interface, as shown in
Figure 42 - 440R-ENETR Interface Arrangement
A1 A2
LINK1
MS
LNK1
LNK2
NS
ENETR
A
B
C
S12 S22 S32 S42
A1 A2 S11 S21
PWR/Fault
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Co nfig/S et
DG Reset
Sel./Save
9
0
1
Time
3
2
5 4
X1 X2 X3 X4
13 14 23 24
S12 S22 S32 S42
A1 A2 S11 S21
PWR/Fault
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Co nfig/S et
DG Reset
Sel./Save
8
9
76
0
5
1
2
4
3
Time
X1 X2 X3 X4
13 14 23 24
LINK2
S12 S22 S32 S42
A1 A2 S11 S12
PWR/Fault
IN1
IN2
Logic IN
OUT
LOGIC 0 1
8
7
6 5
4
2
3
S12 S22 S32 S42
A1 A2 S11 S12
PWR/Fault
IN1
IN2
Logic IN
OUT
LOGIC 0 1
8
7
6 5
4
2
3
A1
33 34 43 44
A1 A2 S11 S12
PWR/Fault
37 38 47 48
A1 A2 B1 B2
PWR/Fault
B1
Logic IN
OUT
33 34 43 44
Logic IN
OUT
RANGE
9
8
TIME
7
10
9
8
6
7
0
5
1
4
1
2
3
6
2
3
5
4
13 14 23 24
DI
L12 L11 Y32 S34
13 14 23 24
34 44 14 24
DIS
L12 L11 Y32 S34
34 44 14 24
13 14 23 24
EM
L12 L11 X32
13 14 23 24
EMD
L12 L11 X32
17 18 27 28
The 440R-ENETR interface can monitor up to six relays of any combination.
The DG safety relays must be closest to the 440R-ENETR interface.
5 mm (0.2 in.) max spacing between relays
60 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Chapter
9
440R-ENETR Network Interface Add-on Profile
Status and control signal can be sent from the DG safety relay to the machine control system over EtherNet/IP by using the 440R-ENETR network interface.
Add-on Profile (AOP)
To use the 440R-ENETR network interface in a Logix Designer project, you must download and install the AOP. Download firmware and associated files
(such as AOP, DTM, and EDS) from the Product Compatibility and
Download Center (PCDC) .
The DG safety relay is included with the release of Series B.
Add a 440R-ENETR Interface to the Project
With the AOP downloaded and installed, Figure 43 shows the beginning steps
to add the 440R-ENETR interface to the I/O Configuration.
1. Right-click the Ethernet identifier.
2. Click New Module.
Figure 43 - Controller Organizer
2
1
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 61
Chapter 9 440R-ENETR Network Interface Add-on Profile
The Select Module Type window appears ( Figure 44
).
3. Find the 440R-ENETR. You can search, filter, or scroll to find it.
4. Click Create to add the module to the project.
Figure 44 - Select Module Type
3
4
The New Module window opens that shows the General information
(
5. Verify that the Series, Revision, Electronic Keying, and Connection are as shown (or later).
6. Enter a name.
7. Enter a description (optional).
8. Select an IP address.
9. Click Change to add GSR relays to the project.
Figure 45 - New Module - General Tab
7
6
5
8
9
62 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Add Relays to the
440R-ENETR Interface
440R-ENETR Network Interface Add-on Profile Chapter 9
There are two ways to add relays to the Ethernet module.
• Upload relays
This preferred method requires the physical system to be complete, including relays, taps, and communications with the Ethernet Module.
• Manually enter relays
This method can be used before the physical system being complete.
This method requires you to select each relay in its specific location. If a
DG relay is used, you must also select the type of tap and its specific location in the GuardLink circuit. For more information, see
Upload Method
Verify that you have downloaded the Studio 5000 project into the controller.
1. Go offline.
2. In the Controller Organizer, click the Ethernet Module.
3. On the General tab, click the Change button.
1
3
2
4. Click the Upload button.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 63
Chapter 9 440R-ENETR Network Interface Add-on Profile
5. Expand the AB_ETHIP-1 path.
6. Select the 440R-ENETR.
7. Click OK.
5
6
7
8. After the upload is completed, click OK.
9. Confirm the changes, click Yes.
10. Click OK to close the Module Definition window.
64
9
10
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
440R-ENETR Network Interface Add-on Profile Chapter 9
11. Go on-line
12. Download the configuration to the controller.
11
12
Manual Method
Figure 46 shows the module definition and the steps necessary to add relays
that the 440R-ENETR interface monitors.
1. Right-click Relay Bus.
2. Click Add Device.
3. Click one of the devices in the list that appears. You can select multiple devices, but the DG safety relays must be together and closest to the
440R-ENETR interface. For this example, click the DG safety relay.
Figure 46 - Module Definition - Add a DG Safety Relay
2
3
1
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 65
Chapter 9 440R-ENETR Network Interface Add-on Profile
In Figure 47 , the DG safety relay has been added to Slot 1 (the relay next
to the 440R-ENETR interface). Each DG safety relay can have up to two GuardLink connections. By default, both GuardLink connections are disabled.
Figure 47 - Module Definition - DG Safety Relay Added
66
Now, you can add a tap to the GuardLink connection (
4. Right-click a GuardLink connection.
IMPORTANT A GuardLink connection can be added to either [1] or [2] or both.
5. Click Add Device.
6. Click the desired tap. The type of tap must be the same as the physical location of the selected tap. In this example, select the OSSD 8-pin.
Figure 48 - Add a Tap
5
6
4
In
Figure 49 , the OSSD 8-pin is Node 1 (7). This tap is electrically
closest to the DG safety relay.
Figure 49 - Tap 1 Is Defined as Node 1
7
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Change the Order of the
Devices
440R-ENETR Network Interface Add-on Profile Chapter 9
to add as many modules that exist in the
GuardLink chain. Remember that the order of the types of modules must be the same as the physical taps.
Repeat the process for the second GuardLink chain, if a second
GuardLink chain is used. If not, then the second input (terminals S32 and S42) automatically configures for one safety device during the configuration process.
IMPORTANT The nodes must be sequential and must not have any gaps in the positions.
The order of the devices can be modified in one of two ways.
• Change the node value to a number greater than the last node. In
, node 4 can be changed to node 8 or higher.
Figure 50 - Node Change
• Right-click the device and click Delete Device as shown in Figure 51
. A confirmation window appears. Click Yes to confirm delete.
Figure 51 - Node Delete
Once deleted, node 4 is empty. The node must be refilled with a module, or the higher numbered nodes must be renumbered to remove empty position.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 67
Chapter 9 440R-ENETR Network Interface Add-on Profile
When the nodes are established, click the OK button and confirm the module change by clicking Yes as shown in
Figure 52 - Confirm Module Change
You return to the General tab. Use the Change button to add up to six
relays. Figure 53 shows an example with three relays. Notice that the DG
safety relays are listed first.
Figure 53 - Example with Three Relays
68 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Controller Tags
440R-ENETR Network Interface Add-on Profile Chapter 9
When the Ethernet interface is added to the project, the tags that are shown in
Figure 54 appear in the Controller Tags section of the Studio 5000 project.
The Ethernet interface has both Input and Output tags. Notice the three relays
match the example from Figure 53
.
See publication 440R-UM009 for more information on Ethernet interface tags. The DG safety relay tags are described in detail in
.
Figure 54 - Ethernet Interface Tags
Select Lock Command
Figure 55 shows how to select the Lock Command for an individual tap.
1. Expand the Ethernet module output.
2. Expand the relay output.
3. Expand the GuardLink output.
4. Expand the LockCmd selections.
5. Click the desired tap.
Figure 55 - Select Lock Command
1
2
3
4
5
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 69
Chapter 9 440R-ENETR Network Interface Add-on Profile
Table 13 - DG Safety Relay Tags
Name Data Type Definition
SafetyInput01
SafetyInput02
PtS12
PtS22
PtS32
PtS42
PtS11
PtS21
PtX1
PtX2
PtX3
PtX4
Pt13_14
Pt23_24
ResetRequired1
ResetHeldOn1
NonRecoverableFault
Fault
FaultCode
Config
ValueRotarySwitch
GuardLink1
GuardLink2
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
Safety Input 1 Status - Indicates whether safety input circuit 1 is On or Off.
0 = The input channel is Off.
1 = The input channel is On.
Safety Input 2 Status - Indicates whether safety input circuit 2 is On or Off.
0 = The input channel is Off.
1 = The input channel is On.
S12 Status - Indicates whether terminal S12 of circuit IN01 is On or Off.
0 = The terminal is Off.
1 = The terminal is On.
S22 Status - Indicates whether terminal S22 of circuit IN02 is On or Off.
0 = The terminal is Off.
1 = The terminal is On.
S32 Status - Indicates whether terminal S32 of circuit IN02 is On or Off.
0 = The terminal is Off.
1 = The terminal is On.
S42 Status - Indicates whether terminal S42 of circuit IN02 is On or Off.
0 = The terminal is Off.
1 = The terminal is On.
S11 Status - Indicates whether terminal S11 is On or Off.
0 = The terminal is Off.
1 = The terminal is On.
S21 Status - Indicates whether terminal S21 is On or Off.
0 = The terminal is Off.
1 = The terminal is On.
X1 Status - Indicates whether terminal X1 is On or Off.
0 = The terminal is Off.
1 = The terminal is On.
X2 Status - Indicates whether terminal X2 is On or Off.
0 = The terminal is Off.
1 = The terminal is On.
X3 Status - Indicates whether terminal X3 is On or Off.
0 = The terminal is Off.
1 = The terminal is On.
X4 Status - Indicates whether terminal X4 is On or Off.
0 = The terminal is Off.
1 = The terminal is On.
13/14 Status - Indicates whether output relays contacts at terminals 13/14 are closed or open.
0 = The contacts are open.
1 = The contacts are closed.
23/24 Status - Indicates whether output relays contacts at terminals 23/24 are closed or open.
0 = The contacts are open.
1 = The contacts are closed.
Reset Required Indication - This indication turns On (1) when all monitored input conditions are On and the safety relay Output is
Off (0) on GuardLink circuit 1.
Reset Held On Fault - Indicates that the reset signal for IN1 was held On (1) for longer than the maximum time of 3000 ms.
0 = No fault
1 = Fault
Non-Recoverable Fault Status - Indicates whether the DG safety relay has detected unexpected internal operation.
0 = No fault
1 = Fault
BOOL
INT
Fault Status - Indicates whether the DG safety relay has detected unexpected operation of a monitored safety device.
0 = No fault
1 = Fault
Fault Code - When a fault occurs, the DG safety relay generates a value to help indicate the potential cause of the fault. See
Table 18 on page 76 for a list of fault codes.
INT
SINT
Configuration ID - Each configuration of the DG safety relay has a unique ID. This tag determines if the configuration changed.
Value of Rotary Switch - The DG safety relay provides a unique value of each position of the timer rotary switch.
AB:GSR_DG_GL:I:0 GuardLink1 Input and Output
AB:GSR_DG_GL:I:0 GuardLink2 Input and Output
70 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Table 14 - GuardLink 1 Tags
Name
Active
Data Type
BOOL
Tripped BOOL
DiagnosticActive BOOL
DiagnosticCode
Fault
FaultCode
DeviceTrip
SINT
BOOL
SINT
DINT
DeviceDiagnostic
DeviceFault
DINT
DINT
DeviceCount DINT
440R-ENETR Network Interface Add-on Profile Chapter 9
shows the tags for GuardLink1. These tags apply to input IN1, which is wiring terminals S12 and S22. GuardLink2 has the same tags, but the tags apply to input IN2, which is wiring terminals S32 and S42.
Definition
Active Status - Indicates whether the GuardLink circuit is used on IN1.
0 = IN1 is used for standard OSSD or EMSS inputs. When the Active value is zero, all remaining GuardLink tags are zero.
1 = IN1 is used as a GuardLink input.
Tripped Status - Indicates whether the GuardLink circuit is operational or in a tripped state.
0 = Operational
1 = Tripped
Diagnostic Active - Indicates whether the GuardLink circuit is in a diagnostic state.
0 = All GuardLink taps are not in a faulted (diagnostic) state.
1 = One or more GuardLink taps are in a faulted (diagnostic) state. The tap indicators are flashing red. See
for more information.
Diagnostic Code - See Table 19 on page 76
for more information.
Fault - Indicates whether the GuardLink circuit is in a fault state. See
Table 17 on page 73 for more information.
0 = No Fault
1 = Fault
Fault Code - Indicates the fault code when the GuardLink circuit is faulted. See
.
Device Trip - When all nodes are operational, DeviceTrip is the same as DeviceCount. When nodes are tripped, DeviceTrip shows a value that reflects all nodes that remain operational. Bit values of zero indicate the nodes that are tripped.
With four operational nodes, the decimal value is 15. If nodes 1 and 3 are tripped, the decimal value is 10. If only node 2 is tripped, the decimal value is 13.
Status
All Operational
Decimal
15
Bit 3
1
Bit 2
1
Nodes 1 and 3 tripped
Node 2 tripped
10
13
1
1
0
1
Device Diagnostic - Indicates the nodes whose diagnostics are active.
0 = No nodes are in diagnostics.
Bit 1
1
1
0
Bit 0
1
0
1
Device Fault - Indicates the nodes that are faulted
0 = No nodes are faulted.
For example with four nodes, a 6 means that node 1 and node 4 are faulted.
Device Count - Provides the number of nodes in the GuardLink1 circuit.
For example, a 15 means the GuardLink system has four nodes.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 71
Chapter 9 440R-ENETR Network Interface Add-on Profile
shows the 440R-ENETR interface input tags. These tags are read only and provide status of the communications to the Ethernet interface.
Table 15 - 440R-ENETR Interface Input Tags
Name
ConnectionFaulted
Data Type
BOOL
EthernetLink1Sts
EthernetLink2Sts
OpticalLinkSts
OpticalLink2Sts
OpticalLink3Sts
Relay1Connected
Relay2Connected
Relay3Connected
Relay4Connected
Relay5Connected
Relay6Connnected
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
BOOL
Definition
Connection Faulted - Indicates whether the connection to the Ethernet interface has faulted.
0 = No connection fault.
1 = Connection has faulted.
Ethernet Link1 Status - Indicates whether Link1 of the Ethernet interface is active.
0 = Link1 is not active.
1 = Link1 is active.
Ethernet Link2 Status - Indicates whether Link2 of the Ethernet interface is active.
0 = Link2 is not active.
1 = Link2 is active.
Optical Link Status - Indicates whether Optical Links from the Ethernet interface to the GSR relays are active.
0 = Optical Link is not active.
1 = Optical Link is not active.
Optical Link2 Status - Indicates whether Optical Link2 from the Ethernet interface to the GSR relays is active.
0 = Optical Link2 is not active.
1 = Optical Link2 is not active.
Optical Link3 Status - Indicates whether Optical Link3 from the Ethernet interface to the GSR relays is active.
0 = Optical Link3 is not active.
1 = Optical Link3 is not active.
Relay 1 Connected - Indicates whether a GSR relay is connected to the Ethernet interface via the optical link.
0 = Relay 1 is not connected.
1 = Relay 1 is connected.
Relay 2 Connected - Indicates whether a GSR relay is connected to the Ethernet interface via the optical link.
0 = Relay 2 is not connected.
1 = Relay 2 is connected.
Relay 3 Connected - Indicates whether a GSR relay is connected to the Ethernet interface via the optical link.
0 = Relay 3 is not connected.
1 = Relay 3 is connected.
Relay 4 Connected - Indicates whether a GSR relay is connected to the Ethernet interface via the optical link.
0 = Relay 4 is not connected.
1 = Relay 4 is connected.
Relay 5 Connected - Indicates whether a GSR relay is connected to the Ethernet interface via the optical link.
0 = Relay 5 is not connected.
1 = Relay 5 is connected.
Relay 6 Connected - Indicates whether a GSR relay is connected to the Ethernet interface via the optical link.
0 = Relay 6 is not connected.
1 = Relay 6 is connected.
72 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
440R-ENETR Network Interface Add-on Profile Chapter 9
The Ethernet interface can send commands to each of the relays that are
included in the opto-links. Table 16
lists the tags for Relay 1, where Relay 1 is a
DG safety relay. Output tags for other GSR relays can be found in publication
440R-UM009 .
Table 16 - Ethernet Output Tags for Relay 1
Name
Reset
Data Type
BOOL
FaultReset BOOL
GuardLink1 AB:GSR_DG_GL:O:0
GuardLink1.UnlockCmd
GuardLink1.LockCmd
DINT
DINT
GuardLink1.FaultResetCmd
DINT
GuardLink2 AB:GSR_DG_GL:O:0
Definition
Reset 1 - Applies a reset command to the inputs to input IN1.
0 = Clears the reset.
1 = Initiates a reset.
Fault Reset - Applies a reset command to the DG safety relay when a faulted state exists.
0 = Clears the reset.
1 = Initiates a reset.
GuardLink1 - This field contains three commands (Lock, Unlock, and Fault Reset) that can be sent to the GuardLink1 circuit of the DG safety relay.
Unlock Command - Can be used to send unlock commands to one or more guard locking interlocks.
Lock Command - Can be used to send lock commands to one or more guard locking interlocks.
Fault Reset Command - Can be used to send fault reset commands to one or more guard locking interlocks. This tag must be used when the guard locking interlock has faulted. The command cycles power to the interlock.
GuardLink2 - This field contains three commands (Lock, Unlock, and Fault Reset) that can be sent to the GuardLink2 circuit of the DG safety relay. See the description for
.
lists the fault codes for the DG safety relay.
Table 17 - DG Safety Relay Fault Codes
Fault Codes
0x0011
0x0013
0x0015
0x0017
0x0040
0x0041
0x0042
0x0043
0x0001
0x0002
0x0003
0x0004
0x0006
0x000A
0x000D
0x0010
0x0044
0x0045
0x0101
0x0102
0x0103
0x0104
0x0105
0x0106
Type
Recoverable
Recoverable
Recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Name
Test Out A stuck at
Test Out B stuck at
Power Fault
VCC Fault
Internal hard fault
Relay Contacts End of Life
Test Out Cross Fault
Terminal Fault S11
Terminal Fault S21
Terminal Fault S22
Terminal Fault S42
Terminal Fault X2
GuardLink-CH[0] no Termination
GuardLink-CH[1] no Termination
GuardLink-CH[0] not wired
GuardLink-CH[1] not wired
GuardLink-CH[0] more than 32 slave devices
GuardLink-CH[1] more than 32 slave devices
GuardLink-CH[0] Tap 1 communication error
GuardLink-CH[0] Tap 2 communication error
GuardLink-CH[0] Tap 3 communication error
GuardLink-CH[0] Tap 4 communication error
GuardLink-CH[0] Tap 5 communication error
GuardLink-CH[0] Tap 6 communication error
Description
Stuck @ 24V S11
Stuck @ 24V S21
A1 is over 27V and under 20V
3.3V is out of range
Summary of all faults
Force guided relay feedback error
Shortcut between S11 and S21
Terminal issue when configured as output like Test Out A
Terminal issue when configured as output like Test Out B
Terminal issue when configured as Guardlink
Terminal issue when configured as Guardlink
Terminal issue when configured as OSSD/SWS
No terminator detected
No terminator detected
No IAH responses
No IAH responses
More than 32 slave devices
More than 32 slave devices
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 73
Chapter 9 440R-ENETR Network Interface Add-on Profile
Table 17 - DG Safety Relay Fault Codes
0x011D
0x011E
0x011F
0x0120
0x0101
0x0102
0x0103
0x0104
0x0115
0x0116
0x0117
0x0118
0x0119
0x011A
0x011B
0x011C
0x010D
0x010E
0x010F
0x0110
0x0111
0x0112
0x0113
0x0114
Fault Codes
0x0107
0x0108
0x0109
0x010A
0x010B
0x010C
0x010D
0x010E
0x010F
0x0110
0x0111
0x0112
0x0113
0x0105
0x0106
0x0107
0x0108
0x0109
0x010A
0x010B
0x010C
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Type
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Name
GuardLink-CH[0] Tap 7 communication error
GuardLink-CH[0] Tap 8 communication error
GuardLink-CH[0] Tap 9 communication error
GuardLink-CH[0] Tap 10 communication error
GuardLink-CH[0] Tap 11 communication error
GuardLink-CH[0] Tap 12 communication error
GuardLink-CH[0] Tap 13 communication error
GuardLink-CH[0] Tap 14 communication error
GuardLink-CH[0] Tap 15 communication error
GuardLink-CH[0] Tap 16 communication error
GuardLink-CH[0] Tap 17 communication error
GuardLink-CH[0] Tap 18 communication error
GuardLink-CH[0] Tap 19 communication error
GuardLink-CH[0] Tap 20 communication error
GuardLink-CH[0] Tap 21 communication error
GuardLink-CH[0] Tap 22 communication error
GuardLink-CH[0] Tap 23 communication error
GuardLink-CH[0] Tap 24 communication error
GuardLink-CH[0] Tap 25 communication error
GuardLink-CH[0] Tap 26 communication error
GuardLink-CH[0] Tap 27 communication error
GuardLink-CH[0] Tap 28 communication error
GuardLink-CH[0] Tap 29 communication error
GuardLink-CH[0] Tap 30 communication error
GuardLink-CH[0] Tap 31 communication error
GuardLink-CH[0] Tap 32 communication error
GuardLink-CH[1] Tap 1 communication error
GuardLink-CH[1] Tap 2 communication error
GuardLink-CH[1] Tap 3 communication error
GuardLink-CH[1] Tap 4 communication error
GuardLink-CH[1] Tap 5 communication error
GuardLink-CH[1] Tap 6 communication error
GuardLink-CH[1] Tap 7 communication error
GuardLink-CH[1] Tap 8 communication error
GuardLink-CH[1] Tap 9 communication error
GuardLink-CH[1] Tap 10 communication error
GuardLink-CH[1] Tap 11 communication error
GuardLink-CH[1] Tap 12 communication error
GuardLink-CH[1] Tap 13 communication error
GuardLink-CH[1] Tap 14 communication error
GuardLink-CH[1] Tap 15 communication error
GuardLink-CH[1] Tap 16 communication error
GuardLink-CH[1] Tap 17 communication error
GuardLink-CH[1] Tap 18 communication error
GuardLink-CH[1] Tap 19 communication error
Description
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
74 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
440R-ENETR Network Interface Add-on Profile Chapter 9
Table 17 - DG Safety Relay Fault Codes
0x0217
0x0218
0x0219
0x021A
0x021B
0x021C
0x021D
0x021E
0x021F
0x0201
0x0210
0x0211
0x0212
0x0213
0x0214
0x0215
0x0216
0x011A
0x011B
0x011C
0x011D
0x011E
0x011F
0x0120
0x0200
Fault Codes
0x0114
0x0115
0x0116
0x0117
0x0118
0x0119
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Non-recoverable
Type
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Recoverable
Non-recoverable
Name
GuardLink-CH[1] Tap 20 communication error
GuardLink-CH[1] Tap 21 communication error
GuardLink-CH[1] Tap 22 communication error
GuardLink-CH[1] Tap 23 communication error
GuardLink-CH[1] Tap 24 communication error
GuardLink-CH[1] Tap 25 communication error
GuardLink-CH[1] Tap 26 communication error
GuardLink-CH[1] Tap 27 communication error
GuardLink-CH[1] Tap 28 communication error
GuardLink-CH[1] Tap 29 communication error
GuardLink-CH[1] Tap 30 communication error
GuardLink-CH[1] Tap 31 communication error
GuardLink-CH[1] Tap 32 communication error
DG safety relay is not configured
DG safety relay configuration needs FW update
Rotary switch mismatch 00
Rotary switch mismatch 01
Rotary switch mismatch 02
Rotary switch mismatch 03
Rotary switch mismatch 04
Rotary switch mismatch 05
Rotary switch mismatch 06
Rotary switch mismatch 07
Rotary switch mismatch 08
Rotary switch mismatch 09
Rotary switch mismatch 10
Rotary switch mismatch 11
Rotary switch mismatch 12
Rotary switch mismatch 13
Rotary switch mismatch 14
Rotary switch mismatch 15
Description
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No, or corrupted, communication
No configuration on DG safety relay
DG safety relay configuration needs FW update
At startup, rotary switch mismatch position must be 0
At startup, rotary switch mismatch position must be 1
At startup, rotary switch mismatch position must be 2
At startup, rotary switch mismatch position must be 3
At startup, rotary switch mismatch position must be 4
At startup, rotary switch mismatch position must be 5
At startup, rotary switch mismatch position must be 6
At startup, rotary switch mismatch position must be 7
At startup, rotary switch mismatch position must be 8
At startup, rotary switch mismatch position must be 9
At startup, rotary switch mismatch position must be 10
At startup, rotary switch mismatch position must be 11
At startup, rotary switch mismatch position must be 12
At startup, rotary switch mismatch position must be 13
At startup, rotary switch mismatch position must be 14
At startup, rotary switch mismatch position must be 15
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 75
Chapter 9 440R-ENETR Network Interface Add-on Profile
lists the fault codes for the taps.
05 (05)
06 (06)
07 (07)
08 (08)
09 (09)
10 (0A)
11 (0B)
12 (0C)
13 (0D)
14 (0E)
15 (0F)
Table 18 - Tap Fault Codes
Fault Code Decimal (Hex) Name
00 (00)
01 (01)
No fault
Channel A fault
02 (02) Channel B fault
Power error
Memory fault
Auto-detect fault
ROM fault
RAM fault
CPU fault
Test fault
Description
—
Short circuit is detected on Channel A of the monitored field device
Short circuit is detected on Channel B of the monitored field device
Power error
Internal memory fault
Failure to detect monitored field device type
Internal memory fault
Runtime memory fault.
Internal memory fault
Internal test fault
Voltage fault
OSSD fault
Power error
Channel A and Channel B cross fault
Integrity fault Internal memory fault
Safety signal shutdown No response on GuardLink
Recommended Action
—
Check wiring
Functionally test the monitored device
Check wiring
Functionally test the monitored device
Evaluate supply voltage
Power cycle the unit
If error persists, replace unit
Check wiring
Power cycle the device
Power cycle the unit
If error persists, replace unit
Power cycle the unit
If error persists, replace unit
Power cycle the unit
If error persists, replace unit
Power cycle the unit
If error persists, replace unit
Power cycle the unit
If error persists, replace unit
Check wiring
Functionally test the monitored device
Power cycle the unit
If error persists, replace unit
Check that the installation meets specification
lists the diagnostic codes for the taps.
Table 19 - Tap Diagnostic Codes
Diagnostic Code Decimal (Hex) Name
00 (00) No diagnostic
01 (01)
02 (02)
Safety signal timeout
Safety signal invalid
03 (03)
04 (04)
64 (40)
65 (41)
Reset input is held on
Power low warning
Device startup func. Test
Device fault, func. test
Description
—
Safety signal timeout, check status of downstream device
Safety signal invalid
Reset input is held on
Power out of specification
Perform a functional test of the device (cycle between safe and active state)
Perform a functional test of the device (cycle between safe and active state)
76 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
I/O Faulted
440R-ENETR Network Interface Add-on Profile Chapter 9
The following figures show how to remedy the I/O Faulted status on the
EtherNet/IP interface.
An exclamation mark in a small yellow triangle indicates a fault on the
EtherNet/IP interface in the Controller Organizer panel.
Figure 56 - I/O Faulted Identified
With an EtherNet/IP connection, do the following:
1. Go offline.
2. Click the change button.
Figure 57 - Go Offline and Change
1
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
2
77
Chapter 9 440R-ENETR Network Interface Add-on Profile
3. Click Upload to upload the configuration that is in the EtherNet/IP interface into the project.
Figure 58 - Upload
Next, you must select the upload path.
4. Expand your Ethernet connection.
5. Select your Ethernet interface.
6. Click OK. The upload begins immediately.
Figure 59 - Upload Path Selection
4
5
6
78 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
440R-ENETR Network Interface Add-on Profile Chapter 9
7. Click OK when upload is complete.
Figure 60 - Upload Complete
8. Click Yes to confirm the change.
9. Click OK.
Figure 61 - Confirm Change to Module Definition
8 9
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 79
Chapter 9 440R-ENETR Network Interface Add-on Profile
10. Go online to Run mode.
11. Download the new configuration to the controller.
Figure 62 - Run and Download
10
11
The process is complete. The EtherNet/IP interface no longer shows an I/O
Fault.
Studio 5000 Code Examples
The following are examples of code that you encounter in the Studio 5000 environment.
Lock and Unlock Commands
Figure 63 shows sample code to lock and unlock guard locking switches.
Rung 9 uses an HMI input to unlock all switches in the GuardLink circuit.
First, we move a zero into the LockCmd to clear out any previous lock commands. Then, we move a -1 into the UnlockCmd. The -1 is converted to a
1 for each tap. If a tap is not a guard locking switch, then the command is ignored.
Rung 10 uses an HMI input to lock all switches in the GuardLink circuit. First, we move a zero into the UnlockCmd to clear out any previous unlock commands. Then, we move a -1 into the LockCommand. The -1 is converted to a 1 for each tap. If a tap is not a guard locking switch, then the command is ignored.
Rungs 11 and 12 provide an example of unlocking and locking a specific switch. In this case, we move a 4, which is the third tap, instead of a -1.
80 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Figure 63 - Lock and Unlock Commands
440R-ENETR Network Interface Add-on Profile Chapter 9
GuardLink Fault Reset Commands
Figure 64 shows sample code to reset devices on the GuardLink circuit.
Rung 16 uses an HMI input to reset all devices in the GuardLink circuit. First, we move a zero into the FaultResetCmd to clear out any previous commands.
Then, we move a -1 into the FaultResetCmd. The -1 is converted to a 1 for each tap. The reset is equivalent to cycling the power to each tap and device.
Rung 17 uses an HMI input to reset one tap and device. First, we move a zero into the FaultResetCmd to clear out any previous commands. Then, we move a four into the FaultResetCmd to reset the third tap and device.
Figure 64 - GuardLink Fault Reset Commands
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 81
Chapter 9 440R-ENETR Network Interface Add-on Profile
Notes:
82 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Chapter
10
Safety Function Calculations
GuardLink System
The GuardLink system typically consists of multiple taps and input devices.
When calculating the Performance Level or the safety integrity level, the safety function must only consider the input device, the associated tap, the DG and
EM safety relays, and the output devices driven by the safety relays. Figure 65
shows an example safety system to help demonstrate the process of determining the Performance Level.
Figure 65 - Example Circuit for Safety System Calculation
440N-Z21SS3PH
SensaGuard
Interlock
440G-LZS21SPRH
Guard Locking
Safety Switch
800F-1YMD51
(800FP-LMP44)
E-Stop Push Button
450L-B4FN0900YD
450L-APT-PW-5 (Tx)
450L-APR-ON-5 (Rx)
Light Curtain
440G-LZ
+24V DC
+ +
DC ok
1606-XLP95E
N L
INPUT
440S-SF8D
INPUT
440S-SF8D
INPUT
440S-MF5D
1485P-RDR5
Tee
INPUT
440S-SF5D
898D-418U-DM2
Terminator
K1
Start K2
Host PC
HMI
Reset
Stop
K1 K2
Ethernet
PLC
Ethernet
A
+
B
C
440R-ENETR
S11 S21 S12
Control
Status
DG
440R-DG2R2T
S32 S42 X1
S22
TIME
2.1
0.1
4.
0.2.4.
0
X2
A1
A2
OUT X
SWS
13 23 X4
14 24 X3
K1 K2
A1 X32 13 23 33 43
Status
EM
440R-EM4R2
A2 L12 L11 14 24 34
700S-CFB
Relays (AC-15)
44
K3 K4
100S-C09
Contactors
Feedback
L1 L2 L3
M
K3
K4
24V DC Com
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 83
Chapter 10 Safety Function Calculations
84
2
440N-Z21SS3PH
SensaGuard
Channel 1
440N-Z21SS3PH
SensaGuard
Channel 2
Subsystem 1
3
440G-LZS21SPRH
Guard Locking Switch
Channel 1
440G-LZS21SPRH
Guard Locking Switch
Channel 2
Subsystem 1
4
440G-LZS21SPRH
Guard Locking Switch
Channel 1
440G-LZS21SPRH
Guard Locking Switch
Channel 2
Subsystem 1
5
800FP-LMP44
E-Stop
Channel 1
800FP-LMP44
E-Stop
Channel 2
Subsystem 1
6
800FP-LMP44
E-Stop
Channel 1
440G-TZS21UPRH
Guard Locking Switch
Channel 2
Subsystem 1
7
450L-B4FN0600YD
Light Curtain
Channel 1
450L-B4FN0600YD
Light Curtain
Channel 2
Subsystem 1
8
450L-B4FN0900YD
Light Curtain
Channel 1
450L-B4FN0900YD
Light Curtain
Channel 2
Subsystem 1
This system has eight safety functions; two functions for each input device.
One function is for the DG outputs, and the second is for the expansion
module outputs. The safety Function Block Diagrams are shown in Figure 66 .
Figure 66 - Safety Function Block Diagrams
Input Logic
440N-Z21SS3PH
SensaGuard
Channel 1
1
Tap 1
440S-SF8D
DG
440R-DG2R2T
440N-Z21SS3PH
SensaGuard
Channel 2
Subsystem 1 Subsystem 2 Subsystem 3
Output
700S-CFB
Relay
Channel 1
700S-CFB
Relay
Channel 2
Subsystem 4
Tap 1
440S-SF8D
Subsystem 2
Tap 2
440S-SF8D
Subsystem 2
Tap 2
440S-SF8D
Subsystem 2
Tap 3
440S-MF5D
Subsystem 2
Tap 3
440S-MF5D
Subsystem 2
Tap 4
440S-SF5D
Subsystem 2
Tap 4
440S-SF5D
Subsystem 2
DG
440R-DG2R2T
Subsystem 3
DG
440R-DG2R2T
Subsystem 3
DG
440R-DG2R2T
Subsystem 3
DG
440R-DG2R2T
Subsystem 3
DG
440R-DG2R2T
Subsystem 3
DG
440R-DG2R2T
Subsystem 3
DG
440R-DG2R2T
Subsystem 3
EM
440R-EM4R2
Subsystem 4
EM
440R-EM4R2
Subsystem 4
EM
440R-EM4R2
Subsystem 4
EM
440R-EM4R2
Subsystem 4
700S-CFB
Relay
Channel 1
700S-CFB
Relay
Channel 2
Subsystem 4
100S-C09
Contactor
Channel 1
100S-C09
Contactor
Channel 2
Subsystem 5
100S-C09
Contactor
Channel 1
100S-C09
Contactor
Channel 2
Subsystem 5
700S-CFB
Relay
Channel 1
700S-CFB
Relay
Channel 2
Subsystem 4
100S-C09
Contactor
Channel 1
100S-C09
Contactor
Channel 2
Subsystem 5
700S-CFB
Relay
Channel 1
700S-CFB
Relay
Channel 2
Subsystem 4
100S-C09
Contactor
Channel 1
100S-C09
Contactor
Channel 2
Subsystem 5
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
SISTEMA
Safety Function Calculations Chapter 10
SISTEMA is a free program that is used to determine the safety function values per ISO 13849. Many devices are preloaded into a
Rockwell Automation library. The DG relay and taps were loaded into a local library, based on the safety data in
Appendix C . These devices will be available
in a future update of the Rockwell Automation library.
Figure 67 shows the first two safety functions. To generate the remaining
functions, you can simply copy and paste these functions back into the project and then change the input device.
To achieve a PLe rating and a 20-year mission time, the system is limited to
65,000 operations each year. The limiting component is the 100S contactors, which are driving the motor load. The E-stop has a limitation of 12,000 operations per year.
Figure 67 - SISTEMA Project - First Two Safety Functions
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 85
Chapter 10 Safety Function Calculations
Figure 68 shows a summary of the project. Each safety function has a required
Performance Level of “e”, and each safety function has achieved that level.
Figure 68 - Project Summary
86 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
DG Safety Relay
Appendix
A
Specifications
Table 20 - General Specifications — DG Safety Relay
Attribute
Dimensions, H x W x D
Shipping weight, approx.
Wire size
Wiring category
Insulation stripping length
Terminal screw torque
Power supply voltage range
Power consumption
Power on delay
Case material
Terminal protection
Enclosure protection
Mounting
440R-DG2R2T
119.14 x 22.5 x 113.6 mm (6.49 x 0.88 x 4.47 in.)
225 g (0.5 lb)
0.2…2.5 mm ² (24…14 AWG)
Copper that withstands 75 °C (167 °F)
7 mm (0.28 in.)
0.4 N•m (4 lb•in)
24V DC PELV/SELV, UL Class 1 Div. 2., 0.85…1.1 x rated voltage
3.5 W
5.5 s
Polyamide PA 6.6
IP20
IP40 (NEMA 1)
35 mm (1.4 in.) DIN rail in enclosure that is rated to a minimum of IP54
Table 21 - Environmental Specifications — DG Safety Relay
Attribute
Temperature, operating
Relative humidity
Vibration
Shock
Pollution level
Installation group
Impulse withstand voltage
440R-DG2R2T
-5…+55 °C (23…131 °F)
90%
10…55 Hz, 0.35 mm
10 g, 16 ms
2
Overvoltage Category III, VDE 0110-1
2500V
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 87
Appendix A Specifications
Table 22 - Pulse Test Output Specifications — DG Safety Relay
Attribute
Wiring terminals
Continuous output current, max
Surge output current, max
Surge output current duration, max
Residual voltage drop from P/S, max
Load capacitance, max [nF/mA load]
Off state leakage current, max
Short circuit detection
Short circuit protection
Galvanic isolation: I/O from logic
Pulse test duration
Pulse test period
Yes
Yes
No
≤700 µs
5 ms
440R-DG2R2T
S11/S21
100 mA
0.7 A
5 ms
0.6V
200/20
100/10
22/0
< 0.1 mA
Table 23 - Input Devices with Voltage-free Contacts Specifications — DG Safety Relay
Attribute
Wiring terminals
ON voltage, max
ON voltage, min
OFF voltage, max
OFF current, max
ON current, min at 20V DC
Galvanic isolation: I/O from logic
Off pulse that is accepted for OSSD setting without declaring the input as
OFF
Off pulse period, min
Input capacitance
440R-DG2R2T
S12/S22 and S32/S42
26.4V
11V
5V
2 mA
10 mA
No
Min = 0 µs
Max = 700µs
15 ms
220 nF
88 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Table 24 - SWS Specifications — DG Safety Relay
Attribute
Wiring terminal
Continuous output current, max
ON state voltage drop (P/S to +), max
Surge output current, max
Surge output current duration, max
Load capacitance, max
Off state leakage current, max
Short circuit detection
Short circuit protection
Galvanic isolation: I/O from logic
Fan-out
(Max number of connections to L11)
Cable length between L11 and L12
Off state leakage current, max
Short circuit detection
Short circuit protection
440R-DG2R2T
Output - X2
Input - X1
50 mA
0.2V
700 mA
5 ms
1 µF
< 0.1 mA
No
Yes
No
10
30 m (98.4 ft)
< 0.1 mA
Yes
Yes
Table 25 - Safety Output Specifications — DG Safety Relay
Attribute
Wiring terminals
Types
Thermic current I th
Fuses output (external)
Switched current, min
Switched voltage, min
Mechanical life
Rating
440R-DG2R2T
13/14, 23/24
2 N.O.
1 x 6 A
6 A slow blow or 10 A quick blow
10 mA
10V
10,000,000 cycles
UL:C300
AC-15:1.5 A / 250V AC
DC13: 2 A / 24V DC (0.1 Hz)
AgNi + 0.2 µ Au Contact material
Reaction times
Automatic reset
Monitored manual reset
Response time
13/14 and 23/24 safety outputs
SWS output
Recovery time
<100 ms
<500 ms
35 ms
30 ms
100 ms
Specifications Appendix A
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 89
Appendix A Specifications
Tap
Table 26 - General Specifications — Tap
Attribute
Dimensions, L x W x H
Shipping weight, approx.
Case material
Mounting screw torque
Mounting
440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D
79.64 x 38.5 x 17 mm (3.14 x 1.51 x 0.67 in.)
27.2 g (0.96 oz)
Red RAL 3020 unfilled ABS MG47C plastic
2.25 N•m (20 lb•in)
Any orientation
Table 27 - Electrical Specifications — Tap
Attribute
Voltage requirements
Supply over voltage protection, Max
Reverse polarity protection
Short circuit protection
OSSD supply and lock signal
GuardLink signals
ON voltage, max
ON voltage, min
OFF voltage, max
OFF current, max
ON current, min at 20V DC
Galvanic isolation: I/O from logic
Off pulse that is accepted for OSSD setting without declaring the input as
OFF
440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D
24V DC +10%, -15%
60V DC
Yes
700 mA
500 mA
26.4V
11V
5V
2 mA
10 mA
No
Min = 0 µs
Max = 700 µs
Off pulse period, min
Input capacitance
Current consumption
EMSS input ON
15 ms
220 nF
EMSS input OFF
OSSD input ON
40 mA
25 mA
29 mA
OSSD input OFF 25 mA
Voltage that is supplied to OSSD device connected to the J3 connector
Pin1 of 5-pin OSSD
Pin 2 of 8-pin OSSD
Response Time
EMSS SmartTap
J1 supply voltage -1.2V @ 500 mA, max load, 0.4V at 50 mA load
J1 supply voltage -1.2V @ 500 mA, max load, 0.4V at 50 mA load
5 ms plus 35 µs for each upstream tap
OSSD SmartTap
CLU timing between successive lock/ unlock
135…300 ms
90 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Specifications Appendix A
Table 28 - Environmental Specifications — Tap and Terminator
Attribute Tap: 440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D
Terminator: 898D-418U-DM2
Temperature
Operating
Storage
Relative humidity
Vibration per IEC 60068-2-6
Shock per IEC 60068-2-27
Pollution level per IEC 60947-5-2
Enclosure protection
Flammability
Protection against electric shock
Emissions
-25…+70 °C (-13…+158 °F)
-40…+85 °C (-40…+185 °F)
35…85%, not exceed 50%RH at 70 °C (158 °F)
10…55 Hz, 1 mm
30 g, 11 ms, half-sine
3
IP65, IP67 washdown according to EN 60529, UL Type 1 PR61413
UL94, DIN 752000/FMV 55302
Class III per EN 61140
CISPR 11
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 91
Appendix A Specifications
Notes:
92 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Appendix
B
Configuration Examples
This appendix contains examples of configurations. Each example contains the following:
• Schematic
This diagram shows the major connections. The input devices are not shown because of multiple configuration options.
• Logic diagram
This diagram shows the safety monitoring function (SMF), the logic level, and the safety output function (SOF).
• Configuration table
This table shows potential examples of configuration for the corresponding schematic and logic diagram. Each configuration also shows the color of the status indicators during configuration. If in Run mode, a short press of the Config/Set button also shows these indicators.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 93
Appendix B Configuration Examples
Configuration 1
In Configuration 1, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN X (terminal X1) is configured for SWS In; this input is ANDed with IN 1 and IN 2.
The output OUT X (terminal X2) is configured for SWS Out and can drive any other SWS compatible device. In this example, the SWS out is driving an
EM safety relay. OUT X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.
The relay configuration is considered a middle SWS as it requires an SWS input and provides an SWS output.
The Reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all inputs of the safety function are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
94 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Examples Appendix B
Figure 69 - Two Safety Inputs, Middle SWS, and Monitored Manual Reset Assigned to Safety Outputs
Schematic Logic
+24V DC
Test Out Input 1 Reset
K1
24V DC Com
A1
GSR
CI/SI/DI/DIS
A2 L12 L11
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23 X4
14 24 X3
Input 2
IN X OUT X
SWS
K1 K2
A1 X32 13 23 33 43
K3 K4
K2
EM
440R-EM4R2
A2 L12 L11 14 24 34 44
Feedback
K3
K4
Table 29 - Configuration 1
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x7F
IN1 and IN2
GuardLink
GuardLink
SWS
SWS Enabled
Monitored Manual
SOF
Configuration ID: 0x7B
IN1 and IN2
GuardLink
OSSD/EMSS
SWS
SWS Enabled
Monitored Manual
SOF
Configuration ID: 0x7D
IN1 and IN2
OSSD/EMSS
GuardLink
SWS
SWS Enabled
Monitored Manual
SOF
Configuration ID: 0x79
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
SWS
SWS Enabled
Monitored Manual
SOF
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 95
Appendix B Configuration Examples
Configuration 2
In Configuration 2, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN X (terminal X1) is configured for SWS In. This input is ANDed with IN 1 and IN 2.
The output OUT X (terminal X2) is configured for SWS Out and can drive any other SWS compatible device. In this example, the SWS out is driving an
EM safety relay. OUT X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.
The relay configuration is considered a middle SWS as it requires an SWS input and provides an SWS output.
The Reset mode is configured for manual monitored reset that is assigned to
Input 1. After a demand of the safety function by Input 1, the outputs are enabled when all safety inputs are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
After a demand of the safety function by Input 2 or IN X, the outputs are enabled when the IN 2 and IN X safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.
96 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Examples Appendix B
Figure 70 - Two Safety Inputs, Middle SWS, Monitored Manual Reset Assigned to Input 1, Automatic Reset Assigned to Input 2
Schematic Logic
+24V DC
Test Out Input 1 Reset
K1
24V DC Com
A1
GSR
CI/SI/DI/DIS
A2 L12 L11
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23 X4
14 24 X3
Input 2
IN X OUT X
SWS
K1 K2
A1 X32 13 23 33 43
K3 K4
K2
EM
440R-EM4R2
A2 L12 L11 14 24 34 44
Feedback
K3
K4
SMF Level
LOGIC Level
SOF Level
IN X
OUT X
IN 1
R
&
FB
OUT 14/24
IN 2
Table 30 - Configuration 2
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x3F
IN1 and IN2
GuardLink
GuardLink
SWS
SWS Enabled
Monitored Manual
SMF IN1
Configuration ID: 0x3B
IN1 and IN2
GuardLink
OSSD/EMSS
SWS
SWS Enabled
Monitored Manual
SMF IN1
Configuration ID: 0x3D
IN1 and IN2
OSSD/EMSS
GuardLink
SWS
SWS Enabled
Monitored Manual
SMF IN1
Configuration ID: 0x39
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
SWS
SWS Enabled
Monitored Manual
SMF IN1
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 97
Appendix B Configuration Examples
Configuration 3
In Configuration 3, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN X (terminal X1) is configured for SWS In. This input is ANDed with IN 1 and IN 2.
The output OUT X (terminal X2) is configured for SWS Out and can drive any other SWS compatible device. In this example, the SWS out is driving an
EM safety relay. OUT X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.
The relay configuration is considered a middle SWS as it requires an SWS input and provides an SWS output.
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
The Reset mode is configured for automatic and assigned to the safety outputs.
After a demand of the safety function by any input, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.
Figure 71 - Two Safety Inputs, Middle SWS, Automatic Reset Assigned to Safety Outputs
Schematic
+24V DC
Test Out Input 1
K1
A1
GSR
CI/SI/DI/DIS
A2 L12 L11
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23 X4
14 24 X3
A1 X32 13 23 33 43
EM
440R-EM4R2
A2 L12 L11 14 24 34 44
Feedback
24V DC Com
Table 31 - Configuration 3
Input 2
IN X OUT X
SWS
K1 K2 K3 K4
K2
K3
K4
Logic
SMF Level
LOGIC Level
SOF Level
IN X IN 1
&
FB
OUT X OUT 14/24
IN 2
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x1F
IN1 and IN2
GuardLink
GuardLink
SWS
SWS Enabled
Automatic
Not used
Configuration ID: 0x1B
IN1 and IN2
GuardLink
OSSD/EMSS
SWS
SWS Enabled
Automatic
Not used
Configuration ID: 0x1D
IN1 and IN2
OSSD/EMSS
GuardLink
SWS
SWS Enabled
Automatic
Not used
Configuration ID: 0x19
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
SWS
SWS Enabled
Automatic
Not used
98 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Examples Appendix B
Configuration 4
In Configuration 4, only safety Input 1 is in use. It can either be configured for
GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN X (terminal X1) is configured for SWS In. This input is ANDed with IN 1.
The output OUT X (terminal X2) is configured for SWS Out and can drive any other SWS compatible device. In this example, the SWS out is driving an
EM safety relay. OUT X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.
The relay configuration is considered a middle SWS as it requires an SWS input and provides an SWS output.
The Reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all inputs of the safety function are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
Figure 72 - One Safety Input, Middle SWS, Monitored Manual Reset Assigned to Safety Outputs
Schematic
+24V DC
Test Out Input 1 Reset
K1
A1
GSR
CI/SI/DI/DIS
A2 L12 L11
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23 X4
14 24 X3
A1 X32 13 23 33 43
EM
440R-EM4R2
A2 L12 L11 14 24 34 44
K2
K3
K4
Feedback
24V DC Com
IN X OUT X
SWS
K1 K2 K3 K4
Logic
SMF Level
LOGIC Level
SOF Level
IN X IN 1
&
R
FB
OUT X OUT 14/24
Table 32 - Configuration 4
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x7A
IN1
GuardLink
Not used
SWS
SWS Enabled
Monitored Manual
SOF
Configuration ID: 0x78
IN1
OSSD/EMSS
Not used
SWS
SWS Enabled
Monitored Manual
SOF
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 99
Appendix B Configuration Examples
Configuration 5
In Configuration 5, only safety Input 1 is in use. It can either be configured for
GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN X (terminal X1) is configured for SWS In. This input is ANDed with IN 1.
The output OUT X (terminal X2) is configured for SWS Out and can drive any other SWS compatible device. In this example, the SWS out is driving an
EM safety relay. OUT X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.
The relay configuration is considered a middle SWS as it requires an SWS input and provides an SWS output.
The Reset mode is configured for automatic/manual and assigned to the safety outputs. After a demand of the safety function by any input, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present.
A reset operation is not required.
Figure 73 - One Safety Input, Middle SWS, Automatic Reset Assigned to Safety Outputs
Schematic
+24V DC
Test Out Input 1
K1
A1
GSR
CI/SI/DI/DIS
A2 L12 L11
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23 X4
14 24 X3
A1 X32 13 23 33 43
EM
440R-EM4R2
A2 L12 L11 14 24 34 44
Feedback
IN X OUT X
SWS
K1 K2 K3 K4
K2
K3
K4
24V DC Com
Table 33 - Configuration 5
Logic
SMF Level
LOGIC Level
SOF Level
IN X
OUT X
IN 1
&
FB
OUT 14/24
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x1A
IN1
GuardLink
Not used
SWS
SWS Enabled
Automatic
Not used
Configuration ID: 0x18
IN1
OSSD/EMSS
Not used
SWS
SWS Enabled
Automatic
Not used
100 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Examples Appendix B
Configuration 6
In Configuration 6, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN 1 (terminal X1) is disabled; there is no connection to terminal
X1.
The output OUT X (terminal X2) is configured for SWS Out. SWS Out can drive any other SWS compatible device. In this example, the SWS out is driving an EM safety relay. OUT X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.
The relay configuration is considered a first SWS as it does not require SWS input and provides an SWS output.
The Reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all safety inputs are
ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
Figure 74 - Two Safety Inputs, First SWS Device, Manual Monitored Reset Assigned to Safety Outputs
Schematic Logic
+24V DC
Test Out Input 1 Reset
SMF Level
K1
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23
14 24
X4
X3
A1 X32 13 23 33 43
EM
440R-EM4R2
A2 L12 L11 14 24 34 44
K2
K3
K4
LOGIC Level
SOF Level
Input 2 Feedback
24V DC Com
SWS
OUT X
K1 K2 K3 K4
IN 1
&
R
FB
OUT X OUT 14/24
IN 2
Table 34 - Configuration 6
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x6F
IN1 and IN2
GuardLink
GuardLink
SWS
Disabled
Monitored Manual
SOF
Configuration ID: 0x6B
IN1 and IN2
GuardLink
OSSD/EMSS
SWS
Disabled
Monitored Manual
SOF
Configuration ID: 0x6D
IN1 and IN2
OSSD/EMSS
GuardLink
SWS
Disabled
Monitored Manual
SOF
Configuration ID: 0x69
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
SWS
Disabled
Monitored Manual
SOF
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 101
Appendix B Configuration Examples
Configuration 7
In Configuration 7, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN 1 (terminal X1) is disabled; there is no connection to terminal
X1.
The output Out X (terminal X2) is configured for SWS Out. SWS Out can drive any other SWS compatible device. In this example, the SWS out is driving an EM safety relay. Output Out X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.
The Reset mode is configured for manual monitored reset and is assigned to
Input 1. After a demand of the safety function by Input 1, the outputs are enabled when all safety inputs are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
After a demand of the safety function by Input 2, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.
Figure 75 - Two Safety Inputs, First SWS Device, Monitored Manual Reset Assigned to Input 1, Automatic Reset Assigned to Input 2
Schematic Logic
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
+24V DC
Test Out Input 1 Reset
K1
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23
14 24
X4
X3
A1 X32 13 23 33 43
EM
440R-EM4R2
A2 L12 L11 14 24 34 44
Feedback Input 2
SWS
OUT X
24V DC Com
Table 35 - Configuration 7
K1 K2 K3 K4
K2
K3
K4
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x2F
IN1 and IN2
GuardLink
GuardLink
SWS
Disabled
Monitored Manual
SMF IN1
Configuration ID: 0x2B
IN1 and IN2
GuardLink
OSSD/EMSS
SWS
Disabled
Monitored Manual
SMF IN1
SMF Level
LOGIC Level
SOF Level
IN 1
R
OUT X
FB
OUT 14/24
Configuration ID: 0x2D
IN1 and IN2
OSSD/EMSS
GuardLink
SWS
Disabled
Monitored Manual
SMF IN1
&
IN 2
Configuration ID: 0x29
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
SWS
Disabled
Monitored Manual
SMF IN1
102 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Examples Appendix B
Configuration 8
In Configuration 8, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN 1 (terminal X1) is disabled; there is no connection to terminal
X1.
The output Out X (terminal X2) is configured for SWS Out. SWS Out can drive any other SWS compatible device. In this example, the SWS out is driving an EM safety relay. Output Out X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.
The relay configuration is considered a first SWS as it does not require SWS input and provides an SWS output.
The Reset mode is configured for automatic manual and assigned to the safety outputs. After a demand of the safety function by any input, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present.
A reset operation is not required.
Figure 76 - First SWS Device, Two Safety Inputs, Automatic Restart Assigned to Safety Outputs
Schematic Logic
+24V DC
Test Out Input 1 SMF Level
K1
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23
14 24
X4
X3
A1 X32 13 23 33 43
EM
440R-EM4R2
A2 L12 L11 14 24 34 44
K2
K3
K4
LOGIC Level
SOF Level
Input 2 Feedback
24V DC Com
SWS
OUT X
K1 K2 K3 K4
IN 1
&
FB
OUT X OUT 14/24
IN 2
Table 36 - Configuration 8
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x0F
IN1 and IN2
GuardLink
GuardLink
SWS
SWS Enabled
Automatic
Not used
Configuration ID: 0x0B
IN1 and IN2
GuardLink
OSSD/EMSS
SWS
SWS Enabled
Automatic
Not used
Configuration ID: 0x0D
IN1 and IN2
OSSD/EMSS
GuardLink
SWS
SWS Enabled
Automatic
Not used
Configuration ID: 0x09
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
SWS
SWS Enabled
Automatic
Not used
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 103
Appendix B Configuration Examples
Configuration 9
In Configuration 9, only safety Input 1 is in use. It can either be configured for
GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN 1 (terminal X1) is disabled; there is no connection to terminal
X1.
The output Out X (terminal X2) is configured for SWS Out. SWS Out can drive any other SWS compatible device. In this example, the SWS out is driving an EM safety relay. Output Out X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.
The relay configuration is considered a first SWS as it does not require SWS input and provides an SWS output.
The Reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all inputs of the safety function are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
Figure 77 - One Safety Input, First SWS, Monitored Manual Reset Assigned to Safety Outputs
Schematic Logic
+24V DC
Test Out Input 1 Reset SMF Level
K1
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23
14 24
X4
X3
A1 X32 13 23 33 43
EM
440R-EM4R2
A2 L12 L11 14 24 34 44
K2
K3
K4
LOGIC Level
SOF Level
Feedback
24V DC Com
SWS
OUT X
K1 K2 K3 K4
IN 1
&
R
FB
OUT X OUT 14/24
Table 37 - Configuration 9
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x6A
IN1
GuardLink
Not used
SWS
SWS Disabled
Monitored Manual
SOF
Configuration ID: 0x68
IN1
OSSD/EMSS
Not used
SWS
SWS Disabled
Monitored Manual
SOF
104 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Examples Appendix B
Configuration 10
In Configuration 10, only safety Input 1 is in use. It can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN 1 (terminal X1) is disabled; there is no connection to terminal
X1.
The output Out X (terminal X2) is configured for SWS Out. SWS Out can drive any other SWS compatible device. In this example, the SWS out is driving an EM safety relay. Output Out X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.
The relay configuration is considered a first SWS as it does not require SWS input and provides an SWS output.
The Reset mode is configured for automatic and assigned to the safety outputs.
After a demand of the safety function by any input, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.
Figure 78 - First SWS Device, One Safety Input, Automatic Reset Assigned to Safety Outputs
Schematic
+24V DC
Test Out Input 1
K1
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23
14 24
X4
X3
A1 X32 13 23 33 43
EM
440R-EM4R2
A2 L12 L11 14 24 34 44
K2
K3
K4
Feedback
24V DC Com
SWS
OUT X
K1 K2 K3 K4
Logic
SMF Level
LOGIC Level
SOF Level
FB
IN 1
&
FB
OUT X OUT 14/24
Table 38 - Configuration 10
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x0A
IN1
GuardLink
Not used
SWS
SWS Disabled
Automatic
Not used
Configuration ID: 0x08
IN1
OSSD/EMSS
Not used
SWS
SWS Disabled
Automatic
Not used
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 105
Appendix B Configuration Examples
Configuration 11
In Configuration 11, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The output type for OUT X (terminal X2) is configured for OSSD, and input
IN X (terminal X1) is enabled. In this mode, IN X accepts a 24V DC input signal and output OUT X can be used as an immediate switching safety output to initiate a stop function of a drive. The 2-channel safety output 14/24 can drive the safety circuit for a Safe Torque Off with a delay time to perform a
Stop Category 1 function.
The Reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all inputs of the safety function are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
Figure 79 - Two Safety Inputs, No SWS, Monitored Manual Assigned to Safety Outputs
Schematic Logic
+24V DC SMF Level IN X IN 1 IN 2
Machine
Control
System
Out
+24
O3
O2
O1
O0
Com
Test Out Input 1
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
DG
440R-DG2R2T
S32 S42 X1 X2
A1
A2
13 23
14 24
X4
X3
Input 2
Reset
L1 L2 L3
PowerFlex
R S T
Stop
Start
Com
Gate control power supply
Gate control circuit
S1
S2
U V W
LOGIC Level
SOF Level
&
&
R
FB
OUT X OUT 14/24
IN X OUT X
OSSD M
24V DC Com
Table 39 - Configuration 11
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x77
IN1 and IN2
GuardLink
GuardLink
OSSD
OSSD Enabled
Monitored Manual
SOF
Configuration ID: 0x73
IN1 and IN2
GuardLink
OSSD/EMSS
OSSD
OSSD Enabled
Monitored Manual
SOF
Configuration ID: 0x75
IN1 and IN2
OSSD/EMSS
GuardLink
OSSD
OSSD Enabled
Monitored Manual
SOF
Configuration ID: 0x71
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
OSSD
OSSD Enabled
Monitored Manual
SOF
106 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Examples Appendix B
Configuration 12
In Configuration 12, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The output type for OUT X (terminal X2) is configured for OSSD, and input
IN X (terminal X1) is enabled. In this mode, IN X accepts a 24V DC input signal and output OUT X can be used as an immediate switching safety output to initiate a stop function of a drive. The 2-channel safety output 14/24 can drive the safety circuit for a Safe Torque Off with a delay time to perform a
Stop Category 1 function.
The Reset mode is configured for manual monitored reset and is assigned to
Input 1. After a demand of the safety function by Input 1, the outputs are enabled when all safety inputs are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
After a demand of the safety function by Input 2, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.
Figure 80 - Two Safety Inputs, No SWS, Monitored Manual Reset Assigned to Input 1, Automatic Reset Assigned to Input 2 and IN X
Schematic Logic
+24V DC
Test Out Input 1
Reset
SMF Level IN X IN 1
R
IN 2
Machine
Control
System
Out
+24
O3
O2
O1
O0
Com
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23
14 24
X4
X3
Input 2
IN X OUT X
OSSD
L1 L2 L3
PowerFlex
R S T
Stop
Start
Com
Gate control power supply
Gate control circuit
S1
S2
U V W
LOGIC Level
SOF Level
&
&
FB
OUT X OUT 14/24
M
24V DC Com
Table 40 - Configuration 12
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x37
IN1 and IN2
GuardLink
GuardLink
OSSD
OSSD Enabled
Monitored Manual
SMF IN1
Configuration ID: 0x33
IN1 and IN2
GuardLink
OSSD/EMSS
OSSD
OSSD Enabled
Monitored Manual
SMF IN1
Configuration ID: 0x35
IN1 and IN2
OSSD/EMSS
GuardLink
OSSD
OSSD Enabled
Monitored Manual
SMF IN1
Configuration ID: 0x31
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
OSSD
OSSD Enabled
Monitored Manual
SMF IN1
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 107
Appendix B Configuration Examples
Configuration 13
In Configuration 13, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The output type for OUT X (terminal X2) is configured for OSSD, and input
IN X (terminal X1) is enabled. In this mode, IN X accepts a 24V DC input signal and output OUT X can be used as an immediate switching safety output to initiate a stop function of a drive. The 2-channel safety output 14/24 can drive the safety circuit for a Safe Torque Off with a delay time to perform a
Stop Category 1 function.
The Reset mode is configured for automatic and assigned to the safety outputs.
After a demand of the safety function by any input, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.
Figure 81 - No SWS, Two Safety Inputs, Automatic Restart Assigned to Safety Outputs
Schematic Logic
+24V DC SMF Level
IN X IN 1 IN 2
Test Out Input 1
L1 L2 L3
PowerFlex
R S T
&
LOGIC Level
&
Machine
Control
System
Out
+24
O3
O2
O1
O0
Com
S11 S21 S12 S22 A1
TIME
.14
.
0.2.4.6
DG
440R-DG2R2T
S32 S42 X1 X2 A2
13 23
14 24
X4
X3
Stop
Start
Com
Gate control power supply
SOF Level
Input 2
Gate control circuit
S1
S2
U V W
FB
OUT X OUT 14/24
IN X OUT X
OSSD
24V DC Com
M
Table 41 - Configuration 13
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x17
IN1 and IN2
GuardLink
GuardLink
OSSD
OSSD Enabled
Automatic
Not used
Configuration ID: 0x13
IN1 and IN2
GuardLink
OSSD/EMSS
OSSD
OSSD Enabled
Automatic
Not used
Configuration ID: 0x15
IN1 and IN2
OSSD/EMSS
GuardLink
OSSD
OSSD Enabled
Automatic
Not used
Configuration ID: 0x11
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
OSSD
OSSD Enabled
Automatic
Not used
108 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Examples Appendix B
Configuration 14
In Configuration 14, only safety Input 1 is in use. It can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The output type for OUT X (terminal X2) is configured for OSSD, and input
IN X (terminal X1) is enabled. In this mode, IN X accepts a 24V DC input signal and output OUT X can be used as an immediate switching safety output to initiate a stop function of a drive. The 2-channel safety output 14/24 can drive the safety circuit for a Safe Torque Off with a delay time to perform a
Stop Category 1 function.
The Reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all inputs of the safety function are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
Figure 82 - No SWS, One Safety Input, Monitored Manual Reset Assigned to Safety Outputs
Schematic Logic
+24V DC
Test Out Input 1
Reset
L1 L2 L3
PowerFlex
R S T
SMF Level
IN X IN 1
&
Machine
Control
System
Out
+24
O3
O2
O1
O0
Com
S11 S21 S12 S22 A1
DG
440R-DG2R2T
S32 S42 X1
TIME
.14
.
0.2.4.6
X2 A2
13 23
14 24
X4
X3
Stop
Start
Com
Gate control power supply
LOGIC Level
SOF Level
&
Gate control circuit
S1
S2
U V W
R
FB
OUT X OUT 14/24
IN X OUT X
OSSD
24V DC Com
M
Table 42 - Configuration 14
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x72
IN1
GuardLink
Not used
OSSD
OSSD Enabled
Monitored Manual
SOF
Configuration ID: 0x70
IN1
OSSD/EMSS
Not used
OSSD
OSSD Enabled
Monitored Manual
SOF
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 109
Appendix B Configuration Examples
Configuration 15
In Configuration 15, only safety Input 1 is in use. It can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The output type for OUT X (terminal X2) is configured for OSSD, and input
IN X (terminal X1) is enabled. In this mode, IN X accepts a 24V DC input signal and output OUT X can be used as an immediate switching safety output to initiate a stop function of a drive. The 2-channel safety output 14/24 can drive the safety circuit for a Safe Torque Off with a delay time to perform a
Stop Category 1 function.
The Reset mode is configured for automatic and assigned to the safety outputs.
After a demand of the safety function by any input, the outputs are enabled when the Input 1 safety input is ACTIVE and the feedback signal is present. A reset operation is not required.
Figure 83 - No SWS, One Safety Function, Automatic Reset Assigned to Safety Outputs
Schematic Logic
+24V DC
Machine
Control
System
Out
+24
O3
O2
O1
O0
Com
24V DC Com
Test Out Input 1
S11 S21 S12 S22 A1 13 23 X4
DG
440R-DG2R2T
S32 S42 X1
TIME
.14
.
0.2.4.6
X2 A2 14 24 X3
IN X OUT X
OSSD
L1 L2 L3
PowerFlex
R S T
Stop
Start
Com
Gate control power supply
Gate control circuit
S1
S2
U V W
M
SMF Level
LOGIC Level
SOF Level
IN X
&
IN 1
&
FB
OUT X OUT 14/24
Table 43 - Configuration 15
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x12
IN1
GuardLink
Not used
OSSD
OSSD Enabled
Automatic
Not used
Configuration ID: 0x10
IN1
OSSD/EMSS
Not used
OSSD
OSSD Enabled
Automatic
Not used
110 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Examples Appendix B
Configuration 16
In Configuration 16, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN X (terminal X1) is disabled. The output type for OUT X
(terminal X2) is configured for OSSD and can be used as a status output or to drive another control device.
The reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all safety inputs are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
Figure 84 - No SWS, Two Safety Inputs, Manual Monitored Reset Assigned to Safety Outputs
Schematic Logic
+24V DC
SMF Level
IN 1 IN 2
Test Out Input 1
Reset L1 L2 L3
&
Machine
Control
System
In
+24
O3
O2
O1
O0
Com
S11 S21 S12 S22 A1
DG
440R-DG2R2T
S32 S42 X1
TIME
.14
.
0.2.4.6
X2 A2
Input 2
OUT X
OSSD
13 23 X4
14
K1
24
K2
X3
Feedback
Machine Control
System
M
K1
K2
LOGIC Level
SOF Level
OUT X
R
FB
OUT 14/24
24V DC Com
Table 44 - Configuration 16
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x67
IN1 and IN2
GuardLink
GuardLink
OSSD
OSSD Disabled
Monitored Manual
SOF
Configuration ID: 0x63
IN1 and IN2
GuardLink
OSSD/EMSS
OSSD
OSSD Disabled
Monitored Manua
SOF
Configuration ID: 0x65
IN1 and IN2
OSSD/EMSS
GuardLink
OSSD
OSSD Disabled
Monitored Manual
SOF
Configuration ID: 0x61
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
OSSD
OSSD Disabled
Monitored Manual
SOF
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 111
Appendix B Configuration Examples
Configuration 17
In Configuration 17, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN X (terminal X1) is disabled. The output type for OUT X
(terminal X2) is configured for OSSD and can be used as a status output or to drive another control device.
The Reset mode is configured for manual monitored reset and is assigned to
Input 1. After a demand of the safety function by Input 1, the outputs are enabled when all safety inputs are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
After a demand of the safety function by Input 2, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.
Figure 85 - No SWS, Two Safety Inputs, Monitored Manual Reset Assigned to Input 1, Automatic Reset Assigned to Input 2
Schematic Logic
+24V DC
Test Out Input 1
Reset
SMF Level
IN 1
R
L1 L2 L3
Machine Control
System LOGIC Level
&
Machine
Control
System
In
+24
O3
O2
O1
O0
Com
24V DC Com
S11 S21 S12 S22 A1
DG
440R-DG2R2T
S32 S42 X1
TIME
.14
.
0.2.4.6
X2 A2
Input 2
13 23
14 24
X4
X3
OUT X
OSSD
K1 K2
M
K1
K2
SOF Level FB
OUT X OUT 14/24
IN 2
Table 45 - Configuration 17
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x27
IN1 and IN2
GuardLink
GuardLink
OSSD
OSSD Disabled
Monitored Manual
SMF IN1
Configuration ID: 0x23
IN1 and IN2
GuardLink
OSSD/EMSS
OSSD
OSSD Disabled
Monitored Manua
SMF IN1
Configuration ID: 0x25
IN1 and IN2
OSSD/EMSS
GuardLink
OSSD
OSSD Disabled
Monitored Manual
SMF IN1
Configuration ID: 0x21
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
OSSD
OSSD Disabled
Monitored Manual
SMF IN1
112 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Examples Appendix B
Configuration 18
In Configuration 18, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN X (terminal X1) is disabled. The output type for OUT X
(terminal X2) is configured for OSSD and can be used as a status output or to drive another control device.
The reset mode is configured for automatic and assigned to the safety outputs.
After a demand of the safety function by any input, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.
Figure 86 - No SWS, Two Safety Inputs, Automatic Reset Assigned to Safety Outputs
Schematic
+24V DC
Machine
Control
System
In
+24
O3
O2
O1
O0
Com
Test Out Input 1
L1 L2 L3
S11 S21 S12 S22
TIME
.14
.
0.2.4.6
A1
DG
440R-DG2R2T
S32 S42 X1 X2 A2
Input 2
13 23
14 24
X4
X3
Feedback
OUT X
OSSD
K1 K2
Machine Control
System
M
K1
K2
Logic
SMF Level
LOGIC Level
SOF Level
IN 1
&
FB
OUT X OUT 14/24
IN 2
24V DC Com
Table 46 - Configuration 18
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x07
IN1 and IN2
GuardLink
GuardLink
OSSD
OSSD Disabled
Automatic
Not used
Configuration ID: 0x03
IN1 and IN2
GuardLink
OSSD/EMSS
OSSD
OSSD Disabled
Automatic
Not used
Configuration ID: 0x05
IN1 and IN2
OSSD/EMSS
GuardLink
OSSD
OSSD Disabled
Automatic
Not used
Configuration ID: 0x01
IN1 and IN2
OSSD/EMSS
OSSD/EMSS
OSSD
OSSD Disabled
Automatic
Not used
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 113
Appendix B Configuration Examples
Configuration 19
In Configuration 19, only safety Input 1 is in use. It can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN X (terminal X1) is disabled. The output type for OUT X
(terminal X2) is configured for OSSD and can be used as a status output or to drive another control device.
The reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all inputs of the safety function are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.
Figure 87 - First SWS Device, One Safety Input, Monitored Manual Reset Assigned to Safety Outputs
Schematic Logic
+24V DC
SMF Level
Test Out Input 1 Reset
L1 L2 L3
IN 1
&
Machine
Control
System
In
+24
O3
O2
O1
O0
Com
S11 S21 S12 S22 A1
DG
440R-DG2R2T
S32 S42 X1
TIME
.14
.
0.2.4.6
X2 A2
13 23
14 24
X4
X3
Machine Control
System
K1
K2
LOGIC Level
SOF Level R
FB
Feedback
OUT X OUT 14/24
OUT X
OSSD
K1 K2
M
24V DC Com
Table 47 - Configuration 19
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x62
IN1
GuardLink
Not used
OSSD
OSSD Disabled
Monitored Manual
SOF
Configuration ID: 0x60
IN1
OSSD/EMSS
Not used
OSSD
OSSD Disabled
Monitored Manual
SOF
114 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Configuration Examples Appendix B
Configuration 20
In Configuration 20, only safety Input 1 is in use. It can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.
The input IN X (terminal X1) is disabled. The output type for OUT X
(terminal X2) is configured for OSSD and can be used as a status output or to drive another control device.
The reset mode is configured for automatic and assigned to the safety outputs.
After a demand of the safety function by any input, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.
Figure 88 - No SWS, One Safety Input, Automatic Reset Assigned to Safety Outputs
Schematic
+24V DC
Test Out Input 1
L1 L2 L3
Logic
SMF Level
IN 1
Machine Control
System
LOGIC Level
&
Machine
Control
System
In
+24
O3
O2
O1
O0
Com
S11 S21 S12 S22 A1
DG
440R-DG2R2T
S32 S42 X1
TIME
.14
.
0.2.4.6
X2 A2
OUT X
OSSD
13 23
14 24
K1 K2
X4
X3
M
K1
K2
SOF Level
FB
OUT X OUT 14/24
24V DC Com
Table 48 - Configuration 20
Indicator
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
Function
Safety Functions
Input Type
Input Type
Output Type
Input Mode
Reset Type
Reset Assignment
Configuration ID: 0x02
IN1
GuardLink
Not used
OSSD
OSSD Enabled
Automatic
Not used
Configuration ID: 0x00
IN1
OSSD/EMSS
Not used
OSSD
OSSD Enabled
Automatic
Not used
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 115
Appendix B Configuration Examples
Notes:
116 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Appendix
C
Regulatory Approvals
Agency Certifications
• UL Listed Industrial Control Equipment, certified for US and Canada.
• CE Marked for all applicable directives
• RCM marked for all applicable acts
• CCC Mark
• S-Mark
• KC marked for Korea
Waste Electrical and
Electronic Equipment (WEEE)
At the end of its life, this equipment should be collected separately from any unsorted municipal waste.
Compliance to European
Union Directives
This product has the CE Marking and is approved for installation within the
European Union and EEA regions. It has been designed and tested to meet the following directives.
• Electromagnetic compatibility EMC Directive 2014/30/EU
• Low Voltage Directive 2014/35/EU
• Machinery Directive 2006/42/EC
Machine Safety Directive
This product is designed and tested to meet the European Council Directive
2006/42/EC on machinery and the following standards.
• IEC/EN 61508 - Functional safety of electrical/electronic/ programmable electronic safety-related systems
• IEC/EN 62061 - Safety of machinery - Functional safety of safetyrelated electrical, electronic, and programmable electronic control systems
• EN ISO 13849-1 - Safety of machinery — Safety-related parts of control systems — Part 1: General principles for design
This product is intended for use in an industrial environment.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 117
Appendix C Regulatory Approvals
DG Safety Relay Ratings
SIL Rating
The DG safety relay meets the requirements of SIL in accordance with IEC/
EN 61508 and SIL CL 3 in accordance with IEC/EN 62061.
Table 49 - SIL Ratings
Attribute
Safety integrity level
Safety integrity level claim limit [SILCL]
PFH d
[1/h]
Mode of operation
Safety-related subsystems
Hardware fault tolerance
Proof test interval, max [a]
Safe failure fraction [%]
Diagnostic coverage [%]
440R-DG2R2T
3
3
1.92 x 10 -8
High-demand mode
Type B (use of programmable / complex components)
HFT = 1 (dual channel system)
HFT = 0 (single channel system)
20
98.9
97.12
Performance Level/Category
The Performance Level of the safety function is dependent on the structure of all devices that comprise the safety function.
The DG safety relay is capable of being used in safety systems meeting up to
Category 4 and Performance Level PLe in accordance with ISO 13849-1.
Table 50 - DG Performance Level Ratings
Attribute
Category
Performance Level
MTTF d
[a]
DC avg
[%]
SFF [%]
CCF
440R-DG2R2T
Up to 4
Up to e
92.2
97.31
99.06
80
118 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Tap Ratings
Regulatory Approvals Appendix C
SIL Rating
The tap modules can be used in systems that require up to SIL 3 in accordance with IEC/EN 61508 and SIL CL 3 in accordance with EN 62061. A comprehensive analysis of the components that comprise the safety system function determines the actual performance rating.
Table 51 - Tap SIL Ratings
Attribute
Safety integrity level
Safety integrity level claim limit [SILCL]
PFH d
[1/h]
Mode of operation
Proof test interval, max [a]
Safe failure fraction [%]
440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D
3
3
2.65 x 10
-10
High-demand mode
20
98.68
Table 52 - Tap Lock Command SIL Ratings
Attribute
Safety integrity level
Safety integrity level claim limit [SILCL]
PFH d
[1/h]
Mode of operation
Proof test interval, max [a]
Safe failure fraction [%]
440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D
2
2
1.5 x 10
-9
High-demand mode
20
98.16
EMC Directive
This product is designed and tested to meet the European Council Directive
2014/30/EU on Electromagnetic Compatibility (EMC) and the following standards:
• EN 55011: Industrial, scientific, and medical equipment - Radio frequency disturbance characteristics - Limits and methods of measurement CISPR 11:2009 (Modified)
• EN 61000-6-2: Generic Standards - Immunity for Industrial
Environments
• EN 61000-6-7: Electromagnetic compatibility (EMC) Generic standards. Immunity requirements for equipment that is intended to perform functions in a safety-related system (functional safety) in industrial locations.
• EN 61326-3-1: Electrical equipment for measurement, control, and laboratory use - EMC requirements - Part 3-1: Immunity requirements for safety-related systems and for equipment that is intended to perform safety-related functions (functional safety) - General industrial applications
This product is intended for use in an industrial environment.
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 119
Appendix C Regulatory Approvals
Notes:
120 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Numerics
13/14 safety output
23/24 safety output
440R-ENETR (Ethernet) interface add relay
add to project
Add-on Profile
arrangement
input tag
output tag - relay 1
A
add
440R-ENETR (Ethernet) interface
relay
Add-on Profile
440R-ENETR (Ethernet) interface
agency certification
AOP
verification
arrangement
440R-ENETR (Ethernet) interface
B
bus optical
C
cabling tap
calculation safety function
GuardLink system
SISTEMA
system current
certification agency
change order of devices
CLU signal
code example
Studio 5000
command fault reset
GuardLink fault reset
lock
unlock
communication opto-link
compliance
European Union directives
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 config/set configuration mode
push button run mode
configuration
example
mode config/set
sel./save
steps
connection power supply
DG safety relay
multiple
tap
single wire safety
SWS
consideration enclosure
voltage drop
contact voltage-free
control, lock, and unlock signal
controller tag
D
definition
delay setting
device change order
DG safety relay enclosure consideration
excessive heat fault code
output monitoring
overview
performance level/category
power supply connection
reset
safety device input
SIL rating
single wire safety input
status indicators
terminal assignment
terminal function terminal torque
wire size
diagnostic code tap
dimension mounting
DIN rail mountingDIN rail removal spacing
directive compliance to European Union
machine safety
Index
121
Index
122
E
electrical mechanical safety switch
EMC directive tap
EMSS
tap
EMSS SmartTap pulse test
enclosure consideration
DG safety relay
tap
European Union directives compliance
example code (Studio 5000)
configuration
excessive heat prevent
F
fault code
DG safety relay
tap
fault reset command
fault reset command
faulted
I/O
function pulse testing
safety
G
ground
guard locking
GuardLink system
GuardLink connectionsinput wiring
fault reset command
,
guard locking
principle of operation
state
system typical
what is
system design
transition (operational state - safe state)
transition (safe state - operational state)
GuardLink1 tag
H
heat prevent excessive
HI
I
I/O faulted
indicator status
DG safety relay
tap
input pulse testing
single wire safety
SWS
input tag
440R-ENETR (Ethernet) interface
input wiring
DG safety relay
GuardLink connections
OSSD output device
voltage-free contact
installation
tap
L
LO
lock command
timing diagram
M
machine safety directive
manual method
mode configuration config/set
sel./save
run config/set
sel./save
monitoring output
mounting dimension
DIN rail
multiple power supply connection
N
N.C.
N.O.
N/C
normally closed
normally open
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Index
O
operation
GuardLink, principle
operational state
GuardLink
optical bus
opto-link communication
OSSD
tap
OSSD output device input wiring
output monitoring
output signal switching device
output tag -relay 1
440R-ENETR (Ethernet) interface
output wiring safety
overview
DG safety relay
tap
P
performance level/category
DG safety relay
pin assignment tap
pin function tap
power
power supply connection
DG safety relay
multiple
tap
prevent excessive heat
protection surge
pulse test
EMSS SmartTap
pulse testing function
input
push button config/set
sel./save
verification
R
reaction time
recommendation wiring
recovery time
regulatory approval
relay manual
,
upload
removal
DIN rail
terminal block
replacement tap
terminal block
requirement wiring
reset
response time
run mode config/set
sel./save
S
safe state
GuardLink
safety device input
function
output
13/14 and 23/24
output wiring
signal, GuardLink
single wire
connection
safety function calculation
GuardLink system
SISTEMA
safety switch electrical mechanical
sel./save configuration mode
push button
run mode
setting signal delay
GuardLink safety
SIL rating
DG safety relay
tap
single wire safety
connection
input
spacing
DIN rail
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 123
Index
124 specifications
electrical tap
environmental
DG relay
tap
general
DG relay
tap
input device with voltage-free contacts
DG relay
pulse test output
DG relay
safety output
DG relay
SWS tap
DG relay
state
GuardLink
GuardLink operational
GuardLink safe
status indicator
status indicator
state
status indicators
DG safety relay
tap
steps configuration
Studio 5000 code example
surge protection
switching device output signal
SWS
connection
input
system current calculation
system design
GuardLink
T
tag controller
GuardLink1
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 tap
cabling
diagnostic code
EMC directive
EMSS
enclosure consideration
excessive heat
fault code
installation
OSSD
overview
pin assignment
pin function
power supply connection
replacement
SIL rating
specifications
status indicators
terminal assignment
DG safety relay
terminal block removal
replacement
terminal function
DG safety relay
terminal torque
DG safety relay
terminator
time reaction
recovery
response
timing diagram lock command
transition
GuardLink (operational state - safe state)
GuardLink (safe state - operational state)
U
unlock command
upload method
V
verification
AOP
push button
voltage drop consideration
voltage-free contact
input wiring
W
wire
wire size
DG safety relay
wiring recommendation
requirement
safety output
.
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Publication 440R-UM015C-EN-P – April 2018
Superseded Publication 440R-UM015B-EN-P – January 2018 Copyright © 2018 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
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