Allen-Bradley Guardmaster DG Safety Relay and GuardLink System User Manual
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Guardmaster DG Safety Relay and GuardLink System Catalog Numbers 440R-DG2R2T (DG Safety Relay); 440S-SF8D, 440S-SLF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D, 440S-MLF8D, 440S-PF5D, 440S-PF5D4 (Taps); 898D-418U-DM2 (Terminator); 440S-GLTAPBRKx (Bracket); 440R-ENETR (EtherNet/IP Network Interface) User Manual Original Instructions Guardmaster DG Safety Relay and GuardLink System User Manual 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. These 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). The following icon may appear in the text of this document. Identifies information that is useful and can help to make a process easier to do or easier to understand. 2 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Table of Contents Who Should Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Chapter 1 Overview GuardLink System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Safety Device Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Single Wire Safety (SWS) Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Output Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 GuardLink Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 GuardLink State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 GuardLink Transition from Safe State to Operational State . . . . . . . . . . . . . . . . . . 17 GuardLink Transition from Operational State to Safe State . . . . . . . . . . . . . . . . . . 17 GuardLink Fault Reset Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 OSSD Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 EMSS Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Passive Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Passive Power Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Guard Locking with GuardLink Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Guard Locking Application Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Chapter 2 GuardLink System Design Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 System Current Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Voltage Drop Consideration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Tap Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Case 1: Includes Guard Locking Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Case 2: No Guard Locking Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Terminator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Tap Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Chapter 3 Installation Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 DIN Rail Mounting and Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Terminal Block Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Terminal Block Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Terminal Block Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Tap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 3 Table of Contents Enclosure Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Help Prevent Excessive Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Chapter 4 Power, Ground, and Wire Wiring Requirements and Recommendation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Terminal Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Terminal Assignment and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Tap Pin Assignment and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Power Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Multiple Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 DG Safety Relay Input Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 GuardLink Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Devices with OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Voltage-free Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Single Wire Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 SWS Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Safety Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 13/14 and 23/24 Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Chapter 5 Configuration Config/Set Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Configuration Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Sel./Save Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Configuration Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Configuration Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Delay Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Buttons on the Front of DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 AOP in the Studio 5000 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Update Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Chapter 6 Status Indicators 4 DG Safety Relay Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Tap Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Table of Contents Chapter 7 Pulse Testing Functions Pulse Testing for Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 EMSS Tap Pulse Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Chapter 8 Opto-link Communications Optical Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Arrangement with 440R­ENETR Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Chapter 9 Safety Function Calculations GuardLink System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 SISTEMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Appendix A Specifications DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Appendix B Configuration Examples Configuration 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Configuration 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Configuration 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Configuration 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Configuration 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Configuration 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Configuration 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Configuration 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Configuration 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Configuration 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Configuration 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Configuration 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Configuration 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Configuration 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Configuration 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Configuration 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Configuration 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Configuration 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Configuration 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Configuration 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Appendix C Regulatory Approvals Agency Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 DG Safety Relay Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 SIL Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Performance Level/Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Tap Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 SIL Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Performance Level/Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 5 Table of Contents CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 UKCA Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Appendix D DG Safety Relay Indicator Fault Codes Determine a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Clear a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Appendix E ControlFLASH Firmware Update Download Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 DMK Extraction Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Firmware Update Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 ControlFLASH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 6 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Preface This user manual is a reference guide for the GuardLink® safety system, plug-in modules, and accessories. It describes the procedures 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 Use this manual if you are responsible for the design, installation, programming, or troubleshooting of control systems that use the GuardLink safety system. Who Should Use This Manual 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. Download Firmware, AOP, EDS, and Other Files Download firmware, associated files (such as AOP, EDS, and DTM), and access product release notes from the Product Compatibility and Download Center at rok.auto/pcdc. Summary of Changes This publication contains the following new or updated information. This list includes substantive updates only and is not intended to reflect all changes. Topic Updated step 10 and step 12 Updated Verification Added Update Firmware Updated Table 17 Updated Figure 51 Updated Figure 52 Updated Figure 53 Updated Figure 54 Updated Figure 55 Updated Figure 56 Updated Figure 57 Updated Figure 58 Updated Figure 59 Updated Figure 60 Updated Figure 64 Updated Figure 65 Updated Figure 69 Updated Figure 70 Updated Declaration of Conformity Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Page 54 55 56 68 72 73 74 75 76 77 78 79 80 81 85 86 90 91 95 7 Preface Definitions Publication AG-7.1 contains a glossary of terms and abbreviations that Rockwell Automation uses to describe industrial automation systems. The following is a list of specific terms and abbreviations that are used in this manual. Term Device Cable Drop Cable Electrical Mechanical Safety Switch (EMSS) GuardLink Control, Lock, and Unlock (CLU) Signal GuardLink Operational State GuardLink Safe State GuardLink Safety Signal HI Link Cable LO N/C N N.C. (Normally Closed) N.O. (Normally Open) Output Signal Switching Device (OSSD) Reaction Time Recovery Time Response Time Safety Function Single Wire Safety (SWS) Status Indicators Tap Trunk Cable Voltage-free Contacts 8 Definition A multi-conductor cable that connects a safety device to the J3 connection of a tap. The device cable is also referred to as a drop cable. See Device Cable. 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. 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 guard locking devices. All taps on the GuardLink circuit indicate that their associated safety device is ready for the machine to operate. One or more of the taps on the GuardLink circuit indicate that their associated safety device is not ready for the machine to operate. 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. 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. A 4-conductor cable that connects the DG relay to the J1 connection of the first tap and from the J2 to the J1 connections of the subsequent taps. The link cable is also referred to as a trunk cable. Logic state of being off or a voltage level to be below the turn-off threshold. No connection A voltage-free electrical contact whose normal state (that is, no pressure or electrical potential applied) is in the closed position. A voltage-free electrical contact whose normal state (that is, no pressure or electrical potential applied) is in the open position. Generally a pair of solid-state 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. The time between the true states of one input to the on state of the output. The time that is required for the input to be in the LO state before returning to the HI state. The time between the trigger of one input to the off state of the output. The complete process from sensing the action (for example, open a safety gate) to execution of the final output device (for example, turning off a pair of contactors). 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. The status indicators on the front face of the DG safety relay and the taps are bicolor. Table 1 on page 9 shows how the status indicators are used in this publication. A connection in a GuardLink circuit that associates a safety device to the GuardLink circuit. See Link Cable. 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. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Preface Table 1 - Status Indicator State Symbol Description Symbol Green indicator is off Red indicator is off Green indicator flashes with certain frequency Red indicator is off Green indicator is off Red indicator is on Green indicator is on Red indicator is on Green indicator is off Red indicator flashes with certain frequency Green indicator flashes with certain frequency Red indicator flashes with certain frequency Green indicator is on Red indicator is off Additional Resources Description These documents contain additional information concerning related products from Rockwell Automation. Resource NEMA Standard 250 and IEC 60529 Guardmaster EtherNet/IP Network Interface User Manual, publication 440R-UM009 Description Provides explanations of the degrees of protection that is provided by different types of enclosure. A detailed description of module functionality, configuration, installation procedure, and information on how to use the Guardmaster® EtherNet/IP™ Network Interface (catalog number 440R-ENETR). A glossary of industrial automation terms and abbreviations. Provides general guidelines for installing a Rockwell Automation industrial system. Industrial Automation Glossary, publication AG-7.1 Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Integrated Architecture Builder (IAB), Software that provides advanced selection assistance and a https://www.rockwellautomation.com/en-us/ support/product/product-selection-configuration/ graphical interface for designing GuardLink systems. integrated-architecture-builder.html Provides declarations of conformity, certificates, and other Product Certifications website, certification details. rok.auto/certifications. You can view or download publications at rok.auto/literature. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 9 Preface Notes: 10 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 1 Overview 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 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 tap for each safety device One terminator for each GuardLink circuit Patchcords and cordsets An optional Ethernet interface Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 11 Chapter 1 Overview Figure 1 - Typical GuardLink System Each DG safety relay can accommodate up to two GuardLink circuits, each containing up to 32 devices. INPUT INPUT INPUT GuardLinkenabled Devices INPUT Downstream Upstream One DG Safety Relay INPUT LNK2 NS 2 3 8 B C 4 5 6 8 9 0 1 4 7 5 6 8 9 0 1 PWR/Fault OUT IN 1 IN 2 OUT X IN X Reset FB INPUT PWR INPUT INPUT INPUT Passive Tap for GuardLink-enabled Devices Standard Safety Devices 33 34 43 44 A1 A2 S11 S12 PWR/Fault INPUT Passive Power Tap for Extra Power One Terminator for each GuardLink Circuit Logic IN OUT 33 34 43 44 Config/Set DG Reset Sel./Save . 0.2. Time 4 7 4.6.8 A 2 3 7 2 3 9 0 1 S12 S22 S32 S42 A1 A2 S11 S21 12.14 LNK1 .10. MS IP: 192. 168. 1. ABC A1 A2 LNK1 INPUT 5 6 X1 X2 X3 X4 13 14 23 24 13 14 23 24 Cordsets and Patchcords EM L12 L11 X32 13 14 23 24 LNK2 1607-XT Single Wire Safety for Expansion On-Machine™ Power Supply R Output Monitoring One Optional Ethernet Module (Required for Guard Locking) Taps Taps create nodes in the GuardLink circuit. A safety device is connected to each tap. The following types of taps are available: • • • • GuardLink-enabled taps that interface with devices having voltage-free safety contacts GuardLink-enabled taps that interface with devices that have OSSD signals Passive taps that interface with devices that are GuardLink-enabled Passive power taps that interface with devices that are GuardLinkenabled and add power to the link GuardLink-enabled taps are available in an 8-pin and 5-pin device connection version. Passive style taps are only available in a 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. 12 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 1 DG Safety Relay Overview 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-UM015H-EN-P - November 2022 13 Chapter 1 Overview 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. In Figure 2, 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 R Monitored Manual Reset Output monitoring 14 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 1 Overview Figure 3 shows an example of a DG safety relay operating as the equivalent of a DI safety relay. In Figure 3, 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) Cordsets or patchcords DG safety relay R 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-UM015H-EN-P - November 2022 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 steady 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. Fault State The DG safety relay and the taps have two fault states: recoverable and nonrecoverable. 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). 16 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 1 Overview 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 devices. This reset signal effectively cycles the power to the device connected to the specified tap. Communication with all downstream devices is lost until the tap completes the reset. 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. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 17 Chapter 1 Overview 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. The tap pulse tests these contacts, see Pulse Testing Functions on page 59 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. Passive Tap The passive tap is designed to interface with safety rated devices that have built-in GuardLink technology. The passive tap simply passes the GuardLink signals to and from the device. The passive tap does not operate with safety devices that have OSSD or EMSS outputs. Passive Power Tap The passive power tap has two significant features: • • 18 The passive power tap acts as a passive tap by passing the GuardLink signals directly to devices with built-in GuardLink technology, and The passive power tap allows additional power to be introduced into the GuardLink circuit to compensate for voltage drops resulting from long cable lengths and numerous devices in the circuit. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 1 Overview Guard Locking with GuardLink Systems Both Power to Release and Power to Lock guard locking devices can be connected to GuardLink taps. Power to Release switches must be connected to Power to Release taps, and Power to Lock switches must be connected to Power to Lock taps (see Table 2). 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. Table 2 - Guard Locking Taps Locking Operation Power to Release Power to Lock Switch Outputs EMSS contacts OSSD EMSS contacts OSSD Tap 440S-MF8D 440S-SF8D 440S-MLF8D 440S-SLF8D When a GuardLink circuit has both Power to Release and Power to Lock devices, a lock command that is sent to all devices causes both PTR and PTL devices to a locked state. An unlock command sent to all devices causes both PTR and PTL devices to an unlocked state. 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). 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 on page 20 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. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 19 Chapter 1 Overview Figure 4 - Unlock Command Timing Diagram Unlock Commands to Guard Locking Devices 32 5 4 3 2 1 OUT (13/14, 23/24) OUT X (X2) Unlock Request 0 1000 1135 1270 1405 Time [ms] 1540 10,600 Guard Locking Application Example Figure 5 on page 21 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. The SensaGuard switches allow immediate access to the machine. Additional risk reduction measures must be provided to help prevent access to the hazards during the timing period. Because guard locking is used, a 440R-ENETR interface must be included in the application. An HMI and PLC initiate the unlock and lock control commands. 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. 20 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 1 Overview Figure 5 - Guard Locking Application Example Schematic and Logic Schematic Logic 440N-Z21SS3PH SensaGuard Interlock 440G-LZS21SPRH Guard Locking Safety Switch 440G-TZS21UPRH Guard Locking Safety Switch SMF Level 440N-Z21SS2JN9 SensaGuard Interlock IN 1 LOGIC Level INPUT INPUT INPUT 440S-SF8D 440S-SF8D SOF Level INPUT 440S-SF8D 440S-SF5D 898D-418U-DM2 Terminator +24V DC R R FB FB OUT X OUT 14/24 K1 Start K2 Host PC Stop Reset Ethernet DC ok HMI PLC 1606-XLP95E N L S11 S21 S12 S22 A1 13 X32 13 23 X4 A1 24 X3 Status EM 440R-EM4R2 A2 L12 L11 14 23 33 43 L1 L2 L3 TIME Control B Status C DG 440R-ENETR 440R-DG2R2T S32 S42 X1 4.0.2 .4.6. 2428V A .12.1 + + 8.10 + 9 X2 A2 14 K1 24 34 K2 100S Contactors K2 44 Ethernet Feedback OUT X SWS Immediate Acting Loads 24V DC Com K1 M Table 3 - Guard Locking Application Example Configuration Indicator Function OUT Safety Functions Configuration ID: 0x6A IN 1 Input Type GuardLink IN 2 Input Type Not used OUT X Output Type SWS IN1 IN X Input Mode SWS Disabled Reset Reset Type Monitored Manual FB Reset Assignment • SOF Circuit Status The gates that the SensaGuard interlock switches monitor 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 off the motor and immediate acting loads. 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 An equivalent machine-controlled system can replace the Start/Stop circuit to start or restart the hazards after the safety system is reset. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 21 Chapter 1 Overview • 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 that 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. 22 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 2 GuardLink System Design Design Considerations 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 Current flowing through each node Cable lengths Wire size Power requirements for each tap 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. The Integrated Architecture® Builder (IAB) by Rockwell Automation (see Additional Resources on page 9) is a software tool that uses a graphical interface to facilitate the design of GuardLink and other Rockwell Automation® systems. The IAB features allow you to: • • • • • • • Select available safety devices and the appropriate tap automatically selects. Adjust all cable lengths and voltage drops automatically calculate. Click and drag devices to desired positions. Specify supply voltage. Easily add additional power supplies. Generate a bill of materials. Generate a summary report of the design. 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-UM015H-EN-P - November 2022 23 Chapter 2 GuardLink System Design Figure 6 - Tap Connections SafetyDevice Device 22 D2 Safety SafetyDevice Device 1 1 D1 Safety Safety Safety Device Device 33 D3 Device Device Cable Cable Fuse Fuse 4 A4 A SLO-BLO SLO-BLO I1 R1 INPUT J1 LinkLink Cable Cable L1 ++ - Vs=24V Power Power Supply Supply Device Cable Device Cable J3 VJ1 T1 R2 I2 J2 VJ2 Link Link Cable Cable L2 Device DeviceCable Cable J3 INPUT J1 T2 I3 J2 J3 R3 Link Cable Link Cable L3 INPUT J1 T3 J2 Terminator Terminator VJ3 System Current Calculation Item D1, D2, D3 I1, I2, I3 Description Safety devices Current in the link cable (A) IT1, IT2, IT3 Current required by a tap (A) ID1, ID2, I1D3 Current required by a safety device (A) L1, L2, L3 Length of link cable (m) R1, R2, R3 Resistance of wire (Ω) T1, T2, T3 VJ1, VJ2, VJ3 Taps Voltage at tap connector (V) The GuardLink circuit current must be calculated to determine whether a significant voltage drop occurs to a safety device. The total system current, I1, 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. I1 = IT1 + ID1 + I2 The current in each segment of the GuardLink circuit is calculated in a similar fashion. I2 = IT2 +ID2 + I3 I3 = IT3 + ID3 The total system current, I1, is therefore the sum of the device currents plus the sum of the tap currents. I1 = ∑ IT + ∑ ID Voltage Drop Consideration 24 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. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 2 GuardLink System Design 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 (0.823 mm2) cordsets and patchcords is (0.02095 ohms/m (0.00664 ohms/ft). The wire resistance of the cordset from the power supply to tap 1 (R1) is: R1 = 0.02095 * L1 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 (VJ1) is: VJ1 = 2 * I1 * R1 The tap has a small voltage from connector J1 to J2. The typical voltage at connector J2 (VJ2) drop through the tap from J1 to J2 is: VJ2 = VJ1 - (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. VJ3 = VJ1 - 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 TLS-ZR guard locking switch voltage drop is 0.29V when locked and 0.31V when unlocked. 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. If the power supply voltage is set to 24V, and the cable is the recommended 18 AWG (0.823 mm2), 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 do not adversely affect the performance of the GuardLink circuit. The operating voltage specification of the tap is 20.4…26.4V. In the example that is shown in Table 4, 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 Table 5 on page 27). Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 25 Chapter 2 GuardLink System Design IMPORTANT Table 4 assumes the following: • Supply voltage = 24V • Link cable wire gauge = 18 AWG (0.823 mm2) • Link wire resistance = 0.02095 ohms/m Table 4 - Voltage Calculation at 24V Supply Tap 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 26 Cable Length [m (ft)] 15 (49.2) 15 (49.2) 15 (49.2) 15 (49.2) 15 (49.2) 15 (49.2) 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) Safety Device SensaGuard™ Ser A SensaGuard Ser A Lite Lock 440G-LZ 800F E-stop Lifeline™ 4 Lifeline 5 TLSZR-GD2 PL e TLSZR-GD2 PL e Lite Lock 440G-LZ SensaGuard Ser A SensaGuard Ser A Mechanical Switch Mechanical Switch — — Tap + Device Current (mA) 81 81 135 40 40 81 135 135 135 81 81 40 40 0 0 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Total Current (mA) 1105 1024 943 808 768 728 647 512 377 242 161 80 40 0 0 J1 Voltage (V) 23.24 22.54 21.90 21.34 20.82 20.32 19.88 19.53 19.27 19.10 18.99 18.94 18.91 — — J3 Voltage Typical (V) 22.84 22.14 21.50 20.94 20.42 19.92 19.48 19.13 18.87 18.70 18.59 18.54 18.51 — — Chapter 2 GuardLink System Design The example in Table 4 on page 26 can be corrected in one of two ways: • • 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. Where voltage drops below 20.4V DC on the link, a passive power tap (440S-PF5D4) can be added to bring the voltage on the link back to within the necessary specification. IMPORTANT Table 5 assumes the following: • Supply voltage = 26V • Link cable wire gauge = 18 AWG (0.823 mm2) • Link wire resistance = 0.02095 ohms/m Table 5 - Voltage Calculation at 26V Supply Tap 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Cable Length [m (ft)] 15 (49.2) 15 (49.2) 15 (49.2) 15 (49.2) 15 (49.2) 15 (49.2) 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) Safety Device SensaGuard Ser A SensaGuard Ser A Lite Lock 440G-LZ 800F E-stop Lifeline 4 Lifeline 5 TLSZR-GD2 PL e TLSZR-GD2 PL e Lite Lock 440G-LZ SensaGuard Ser A SensaGuard Ser A Mechanical Switch Mechanical Switch — — Tap + Device Current (mA) 81 81 135 40 40 81 135 135 135 81 81 40 40 0 0 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Total Current (mA) 1105 1024 943 808 768 728 647 512 377 242 161 80 40 0 0 J1 Voltage (V) 25.24 24.54 23.90 23.34 22.82 22.32 21.88 21.53 21.27 21.10 20.99 20.90 20.91 — — J3 Voltage Typical (V) 25.84 24.14 23.50 23.94 22.42 21.92 21.48 21.13 20.87 20.70 20.59 20.54 20.51 — — 27 Chapter 2 GuardLink System Design Tap Cabling The GuardLink system is designed with the intent to minimize wiring by using quick-disconnect patchcords, while also allowing some manual wiring to terminals, when pinout incompatibilities exist. The preferred cables are the Bulletin 889D hardware (red jacket, PVC, unshielded, with epoxy coat). You can use any jacket color, however, the red is the preferred color to indicate a safety circuit. To minimize the voltage drop due to wire resistance, the preferred wiring gauge for the link cable is 18 AWG (0.823 mm2). Visit https://www.rockwellautomation.com/en-us/products/hardware/allenbradley/connection-devices/cables-and-cordsets/dc-micro--m12-/dc-microcordsets-and-patchcords.html for other options, like right-angle connectors, stainless-steel couplings, and shielded cables. To maintain the integrity of the GuardLink signal, the wiring distance between GuardLink-enabled devices is important. There are two application cases: • • Case 1: Includes Guard Locking Devices Case 2: No Guard Locking Devices For both cases, the wiring distance between the taps and the safety device is limited to 10 m (32.8 ft). Proper wiring requires at least 22 AWG (0.33 mm2) wire size for 5-conductor cables and for 8-conductor cables. Case 1: Includes Guard Locking Devices When the GuardLink circuit includes one or more guard locking devices, the maximum distance between GuardLink-enabled devices is 30 m (98.4 ft). If the distance between devices is greater than 30 m (98.4 ft), you must insert a GuardLink-enabled tap at a max of every 30 m (98.4 ft). If a device is not needed at a particular location, use a shorting plug for the device connection. Figure 7 on page 29 shows an example GuardLink circuit that includes at least one guard locking device. Tap 1 is a GuardLink-enabled tap that can be connected to a guard locking or a non-guard locking device. Tap 2 is a passive tap, which is connected to a GuardLink-enabled device. IMPORTANT At the time of this user manual release, the only GuardLink-enabled device is the 440G-MZ guard locking switch. Figure 7 on page 29 shows tap 3 as a safety device with terminal block connections. In this case, a cordset is used to connect the safety device to the tap. The safety device can be a guard locking or non-guard locking device. Since the GuardLink circuit has at least one guard locking switch, the maximum distance between GuardLink-enabled devices is 30 m (98.4 ft). When a passive tap is used, the cable length includes both the length of the link cable and the length of the device cable. 28 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 2 GuardLink System Design Figure 7 - Example Guard Locking Circuit GuardLinkenabled Guard Locking Safety Device Guard Locking or Non-guard Locking Safety Device 889D-F5NCDM-x 5­wire Patchcord or 889D-F8NBDM-x 8­wire Patchcord 10 m (32.8 ft) length, max 889D-F5NCDM-x 5­wire Patchcord 10 m (32.8 ft) length, max INPUT INPUT White Black Brown DG Safety Relay Blue ++ - - 24V Power Supply GuardLink-enabled Tap Guard Locking or Non-guard Locking Safety Device INPUT Passive Tap 889D-F4NE-30 Wire Cordset 30 m (98.4 ft) length, max 889D-M5NC-x 5­wire Cordset or 889D-M8NB-x 8­wire Cordset 10 m (32.8 ft) length, max GuardLink-enabled Tap 898D-418U-DM2 Terminator 30 m (98.4 ft) length, max between GuardLink-enabled Devices (includes link and device cables) All lengths 30 m (98.4 ft) length, max Case 2: No Guard Locking Devices Figure 8 shows an example of a GuardLink circuit with no guard locking devices. When the GuardLink circuit excludes any guard locking devices, the maximum distance between 2…32 GuardLink-enabled devices is 100 m (328.1 ft). The distance from the DG relay to the first tap is limited to 30 m (98.4 ft). If a passive power tap is used with a shorting plug, the total length between the two neighboring GuardLink-enabled taps is 100 m (328.1 ft). Figure 8 - Example of a Non-guard Locking Circuit Non-guard Locking Safety Device 889D-F5NCDM-x 5­wire Patchcord 10 m (32.8 ft) length, max 889D-F5NCDM-x 5­wire Patchcord or 889D-F8NBDM-x 8­wire Patchcord 10 m (32.8 ft) length, max INPUT White Black Brown DG Safety Relay Blue ++ - - 24V Power Supply GuardLink-enabled Tap 889D-F4NE-30 Wire Cordset 30 m (98.4 ft) length, max 898D-41KU-DM2 Shorting Plug PWR INPUT Passive Power Tap Two 889D-F4MEDM-x 4-wire Patchcord 100 m (328 ft) length, max 889D-M5NC-x Non-guard 5­wire Cordset or Locking Safety Device 889D-M8NB-x 8­wire Cordset 10 m (32.8 ft) length, max INPUT GuardLink-enabled Tap 898D-418U-DM2 Terminator Link 1: 30 m (98.4 ft) length, max Links 2…32: 100 m (328 ft) length, max Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 29 Chapter 2 GuardLink System Design Terminator The terminator (Figure 9), must be installed on the J2 connector of 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. To help troubleshoot a GuardLink system, reduce the number of taps in the GuardLink circuit by relocating the terminator. After relocation, cycle power to the DG safety relay to allow the DG safety relay to relearn how many taps are connected. If the 440R-ENETR interface is used, then it must also be power cycled, and its AOP must be updated. Figure 9 - Terminator — Catalog Number 898D-418U-DM2 Tap Replacement 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. When a GuardLink tap is replaced with another type of tap, which is removed or added to the circuit; cycle power to the DG safety relay to allow the DG safety relay to relearn how many and what types of taps are connected. If the 440RENETR interface is used, then it must also be power cycled, and its AOP must be updated. Response Time 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 10 on page 31 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. 30 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 2 GuardLink System Design Figure 10 - Response Time Example Calculation SensaGuard Opens Tap 1 Tap 2 Tap 3 Tap 4 Upstream Tap 5 Tap 6 Downstream DG Safety Relay Single Wire Safety Out 100S-C09EJ Safety Contactors The safety system response time for the system that is shown in Figure 10 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 Response Time [ms] DG Output 13/14, 23/24 DG Output SWS (X2) Component SensaGuard (1) Tap 4 Tap 3 Tap 2 Tap 1 DG Safety Relay 100S Contactor (2) Total 54.0 54.0 5.0 0.035 0.035 0.035 60.0 5.0 0.035 0.035 0.035 55.0 50.0 0.0 169.105 114.105 (1) See publication 440N-IN018. (2) See publication 100-TD013. IMPORTANT Figure 10 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. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 31 Chapter 2 GuardLink System Design Notes: 32 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 3 Installation The DG safety relay uses the same housing as GSR modules. The module dimensions are shown in Figure 11, while Figure 12 shows the tap dimensions. Figure 11 - 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 119.14 (4.69) Config/Set DG Reset Sel./Save 4. .2 Time .4.6. 12.1 0 8.10. Mounting Dimensions X1 X2 X3 X4 13 14 23 24 Figure 12 - Tap Dimensions [mm (in.)] 14 (0.55) 57 (2.24) 2X Ø5.4 (0.21) for M5 screws (Ø9.8 (0.38) max screw head) 19.25 (0.76) M12 X 1 thread 17 (0.67) 9 (0.35) 38.5 (1.51) 79.64 (3.14) Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 33 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 13). 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 13 - 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. 34 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 3 Terminal Block Removal and Replacement Installation 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 Figure 14, insert the screwdriver into the slot and pry up. Figure 14 - 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 key (Figure 15). Figure 15 - Orange-colored Keyway Orange inserts match keys Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 35 Chapter 3 Installation Tap Installation The tap can be installed directly with two M5 screws. In Figure 16, the 38.5 mm (1.5 in.) wide tap fits neatly on a standard 40 mm (1.6 in.) aluminum extrusion construction profile. Figure 16 - Mounting Directly on 40 mm (1.6 in.) Profile INPUT 40 mm (1.6 in.) M5 Screws Figure 17 shows an optional quick mounting bracket, catalog number 440S-GLTAPBRKx(a), is available to facilitate installation and removal. The tap snaps into place and can be easily removed to install patchcords and cordsets. Figure 17 - Quick-release Mounting Bracket Quick Release Clip Recessed Mounting Holes (x6) Figure 18 shows the dimensions of the quick-release mounting bracket. Figure 18 - Mounting Bracket Dimensions 6 x Ø5.4 (0.21) for M5 screws (Ø11 (0.43) max screw head) 38.5 (1.51) 22 (0.87) 20 (0.79) 76.6 (3.01) 25 (0.98) 11 (0.43) 19.6 (0.77) (a) x = 1 (to order one bracket), or 5 (for a package of five brackets). 36 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 3 Installation Figure 19 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 19 - Mounting Options with Quick-release Bracket Across Profile In-line with Profile 20 mm (0.79 in.) Profile Enclosure Considerations 30 mm (1.18 in.) Profile 45 mm (1.77 in.) Profile 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 can 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-UM015H-EN-P - November 2022 37 Chapter 3 Installation Help 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 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, it can be necessary to use air conditioning to help protect against heat buildup within the enclosure. Taps The taps have no spacing requirements. 38 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 4 Power, Ground, and Wire Wiring Requirements and Recommendation 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 the wiring to overheat, which can cause damage. • • • • • • DG Safety Relay 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-UM015H-EN-P - November 2022 39 Chapter 4 Power, Ground, and Wire Terminal Assignment and Function The relays have four terminals: two on the top and two on the bottom. As shown in Figure 20, 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 20 - DG Terminal Identification S12 S22 S32 S42 A1 A2 S11 S21 PWR/Fault OUT IN 1 IN 2 OUT X IN X Reset FB X1 X2 X3 X4 }X2 }X1 Config/Set DG Reset Sel./Save 12.1 Time .4.6. 4. 0.2 8.10. X1 X2 X3 X4 13 14 23 24 }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 Terminal A1 A2 S11 S21 S12 S22 S32 S42 X1 X2 X3 X4 13 14 23 24 40 Function +24V Supply (+10%, -15%) 0V Common 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-UM015H-EN-P - November 2022 Chapter 4 Tap Pin Assignment and Function Power, Ground, and Wire The taps have three or four M12 quick disconnect connectors (Figure 21). 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 21 - Tap Connection Identification J3 Device INPUT J1 Link In J4 Power In PWR J3 Device INPUT J2 Link Out J1 Link In J2 Link Out Passive Power GuardLink-enabled and Passive The link connections carry the power and command signals. Figure 22 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 22 - J1 and J2 Link Connections on All Taps 2: GuardLink Safety 2: GuardLink Safety 1: +24V DC 1: +24V DC 4: GuardLink CLU 4: GuardLink CLU 3: 0V DC J1 Link In (Male) Pin 1 2 3 4 3: 0V DC J2 Link Out (Female) Function +24V Supply (+10%, -15%) GuardLink Safety Signal 0V DC, the reference for the 24V supply GuardLink Control Lock Unlock (CLU) Signal Figure 23...Figure 26 show the functions that are assigned to the 8-pin and 5-pin quick-disconnect connections for safety devices. These figures include tables with the wire colors of the recommended cordset that can be used where a patchcord cannot. Figure 23 - J3 8-Pin OSSD (Female) Connector on 440S-SF8D and 440S-SLF8D Taps 2: +24V DC 3: Lock/Unlock Command 1: Aux 8: Safety OSSD A+ 7: 0V 6: Safety OSSD B Pin 1 2 3 4 5 6 7 8 4: 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, no pulse test) Safety OSSD channel A Safety OSSD channel B 0V DC, the reference for the 24V supply Safety OSSD channel A+ (24V DC, no pulse test) Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Cordset Wire Color White Brown Green Yellow Gray Pink Blue Red 41 Chapter 4 Power, Ground, and Wire Figure 24 - J3 8-Pin EMSS (Female) Connector on 440S-MF8D and 440S-MLF8D Taps 2: Lock/Unlock Command 3: Aux Contact 8: Safety Contact A 1: Aux Contact 4: Safety Contact B 7: 0V 5: Safety Contact A 6: Safety Contact B Pin 1 2 3 4 5 6 7 8 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 Cordset Wire Color White Brown Green Yellow Gray Pink Blue Red Figure 25 - J3 5-pin OSSD (Female) Connector on 440S-SF5D Tap 2: Safety OSSD A 5: Aux 1: +24V DC 3: 0V 4: Safety OSSD B Pin 1 2 3 4 5 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 Cordset Wire Color Brown White Blue Black Gray Figure 26 - J3 5-pin EMSS (Female) Connector on 440S-MF5D Tap 2: Safety Contact A 5: Safety Contact B 1: Safety Contact A 4: Safety Contact B Pin 1 2 3 4 5 42 3: N/C Function 24V output for safety contact channel A Safety contact channel A 0V DC (the reference for the power supply) Safety contact channel B 24V output for safety contact channel B Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Cordset Wire Color Brown White Blue Black Gray Chapter 4 Power, Ground, and Wire Figure 27 - J3 5-pin GuardLink-enabled (Female) Connector on 440S-PF5D and 440S-PF5D4 Taps 2: GuardLink Safety In 5: GuardLink CLU 1: 24V DC 3: 0V DC (GND) 4: GuardLink Safety Out Pin 1 2 3 4 5 Function +24V DC GuardLink Safety In 0V DC (the reference for the 24V supply) GuardLink Safety Out GuardLink CLU Cordset Wire Color Brown White Blue Black Gray Figure 28 - J4 4-pin Power In (Male) Connector on 440S-PF5D4 Tap 2: N/C 1: +24V DC 3: 0V DC (GND) 4: N/C Pin 1 2 3 4 Function +24V DC No Connection 0V DC (the reference for the 24V supply) No Connection Cordset Wire Color Brown White Blue Black 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 29 shows the wiring connections that are required to create a shorting plug. IMPORTANT For 5-pin OSSD taps, a shorting plug (Cat. No. 898D-418U-DM) can be used in place of the terminal chamber (Cat. No. 871A-TS5-DM). For 8­pin taps, a shorting plug (Cat. No. 898D-81RU-DM) can be used in place of the terminal chamber (Cat. No. 871A-TS8-DM1). For passive taps, a shorting plug (Cat. No. 898D-41KU-DM2) can be used in place of the terminal chamber (Cat. No. 871A-TS5-DM). Figure 29 - Shorting Plug Schematics Use 898D-81RU-DM or 871A-TS8-DM1 for 8-pin OSSD and EMSS taps 1 2 3 4 5 6 7 8 Use 898D-418U-DM or 871A-TS5-DM for 5-pin OSSD taps 1 2 3 4 5 Use 871A-TS5-DM for 5-pin EMSS taps 1 2 3 4 5 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Use 898D-41KU-DM2 or 871A-TS5-DM for 5-pin Passive taps 1 2 3 4 5 43 Chapter 4 Power, Ground, and Wire Power Supply Connection Many Bulletin 1606 power supplies are protected extra low voltage (PELV), safety extra low voltage (SELV), and Class 2-compliant. DG Safety Relay To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with a PELV or, under certain conditions, a SELV per IEC 60204-1 must power the DG safety relay. For the USA, a PELV supply is required, per NFPA 79. Figure 30 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 30 - 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 Config/Set DG Reset Sel./Save . .2. Time 4.6.8 12.14 0 .10. X1 X2 X3 X4 13 14 23 24 Taps To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with a PELV or, in certain circumstances, a 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 44 In the USA, use of a 4 A fuse or circuit breaker in place of a Class 2 power supply is not acceptable. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 4 Power, Ground, and Wire Figure 31 shows the power connections to the power tap. Power is connected only to the first tap. Figure 31 - Tap Power Connections GuardLink First Tap GuardLink First Tap Pin 1: +24V DC Pin 1: +24V DC 4A Pin 3: 0V DC + + Pin 3: 0V DC + + DC ok DC ok 2428V 2428V 1606-XLE240EN N 1606-XLP95E L N PELV for IEC Compliance L Class 2 for USA Compliance Multiple Power Supplies When a passive power tap is included in the GuardLink circuit, only the primary power supply must be connected to the protective earth. The passive power tap must not be connected to the protective earth to avoid ground loops. Figure 32 shows an example with a 1606-XLP95E primary power supply and a 1607-XT100D1A On-Machine™ power supply for the passive power tap. The 1606-XLP95E power supply has a protective earth connection, while the 1607-XT100D1A does not. IMPORTANT To avoid potential exposure to harmful voltage (greater than 50V), do not use more than seven passive power taps on a GuardLink circuit. Figure 32 - Multiple Power Supplies on One GuardLink Circuit PWR INPUT INPUT S12 S22 S32 S42 A1 A2 S11 S21 PWR/Fault OUT IN 1 IN 2 OUT X IN X Reset FB Config/Set DG Reset + + DC ok 2428V 1606-XLP95E Sel./Save 12.14 Time 4.6.8 . 0.2. .10. X1 X2 X3 X4 13 14 23 24 N L 100…240V AC 889N-F3AFC-6F 100…240V AC PE When using the passive power tap, ground only the primary power supply to the protective earth. 889D-F4AENM-2 1607-XT100D1A 24V 3.8A On-Machine Power Supply Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 45 Chapter 4 Power, Ground, and Wire Figure 33 shows two power supplies used to power two GuardLink circuits that are connected to one DG relay. In this example, the DG relay receives power from a Class 2 power supply (PS1), which can provide 3.9 A at 24.5V DC. As a result, the current available for the GuardLink circuit is reduced by the amount of current (15 mA) required to operate the DG relay. The 0V of both power supplies must be connected together to provide a common reference for the DG relay. The 0V must also be connected to the protective earth (PE) at only one point, to avoid nuisance ground faults. Figure 33 - Multiple Power Supplies on Two GuardLink Circuits INPUT 3.75A at 24.5V INPUT 3.9A at 24.5V S12 S22 S32 S42 A1 A2 S11 S21 PWR/Fault OUT IN 1 IN 2 OUT X IN X Reset FB Config/Set DG Reset Sel./Save 12.14 + + + DC ok DC ok 24… 28V 24… 28V 1606-XLP95E 1606-XLP95E N L PS1 N L PS2 Time .4.6. . .2 0 + 8.10. X1 X2 X3 X4 13 14 23 24 PE 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 34 shows the connections for the GuardLink circuits; the wire colors apply when the recommended cordsets are used. Figure 34 - GuardLink Connections White Black Brown S12 Safety S22 CLU S32 Safety S42 CLU Blue Black A1 INPUT White Blue Brown +24V DC Input 1 A2 Input 2 DG Safety Relay 24V Com 46 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 INPUT 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 35. Figure 35 - Wiring to Devices with OSSD Outputs +24V DC Device 2 Device 1 A1 A1 A2 A2 S12 S22 Input 1 A1 A2 S32 S42 Input 2 DG Safety Relay 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 36 shows the recommended wiring for dual-channel and singlechannel, voltage-free contacts. Voltage-free contacts can be connected to either Input 1, Input 2, or both inputs. Figure 36 - Wiring to Voltage-free Contacts S21 Pulse Testing Outputs S11 Device 1 Device 2 S12 S22 Input 1 S32 S42 Input 2 DG Safety Relay S21 Pulse Testing Outputs S11 Dual Channel Single Wire Safety Device 1 Device 2 S12 S22 Input 1 S32 S42 Input 2 DG Safety Relay Single Channel The DG safety relay has the Single Wire Safety (SWS) capability to expand the safety function (both input and output). Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 47 Chapter 4 Power, Ground, and Wire SWS Connections The 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 37 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 that Relay 1 starts 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 37 - SWS Connection Example +24V DC +24V DC +24V DC +24V DC +24V DC A1 A1 A1 A1 A1 GSR Relay 1 DI A2 L12 L11 GSR Relay 2 DG A2 X1 X2 GSR Relay 3 DG A2 X1 X2 GSR Relay 4 EM A2 L12 L11 GSR Relay 5 EMD A2 L12 L11 SWS SWS SWS 24V DC Com (the relays must have a common reference) Figure 38 shows the characteristics of the 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 38 - SWS Waveform Terminals X1 and X2 24V 0V Safety Output Wiring 48 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). Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 4 Power, Ground, and Wire 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 39. See Specifications on page 67 for the voltage and current ratings of these relays. To maintain safety integrity, the safety relay contacts must be the last device that is connected to the actuator (K1 and K2 in this example). All other devices must be connected between the power supply and the safety relay contacts. If the voltage supply of the outputs exceeds the voltage supply of the relay, then the low-voltage wiring must be separated from the high-voltage wiring. Figure 39 - Output Connections of the DG Safety Relay V supply Other Devices 13 23 Safety Relay Output 14 24 K1 K2 V common 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 40 on page 50 shows an output with a suppression device. This example is a safety-related circuit, the surge protection must not be connected across (in parallel with) the safety relay outputs. 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 OSSD safety outputs. 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. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 49 Chapter 4 Power, Ground, and Wire Figure 40 - Surge Protection Examples Metal oxide varistors for V AC supply K1 K2 Diodes for V DC supply K1 V common K2 V common Table 8 lists the recommended surge suppressors for some commonly used safety control relays and contactors. Table 8 - Surge Suppressor Recommendations Safety Control Relay or Contactor 100S-C09QJxxxBC (1) 100S-C09EJxxxBC 700S-CFBxxxQJBC 700S-CFBxxxEJBC 700S-DCPxxxDZ24 700S-DCPxxxZ24 700S-PxxxA1 700S-PxxxA2 Coil Voltage Suppressor 24V DC Electronic Coil — 24V DC 199-FSMZ-1 120V AC 240V AC 199-FSMA10 199-FSMA11 (1) The QJ coil drops out faster than the EJ coil and is preferred when response time is important. The B bifurcated auxiliary contacts are recommended, as the safety monitoring current is typically on the order of a few milliamps. 50 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 5 Configuration 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 the length of time the push button is pressed. • • Config/Set Push Button Short: The button is pressed less than 1 second. Long: The button is pressed for longer than 3 seconds, but shorter than 10 seconds. Run Mode Button Press Function The indicators show the configuration of the DG safety relay. • Press once to see the configuration (see Table 9 on page 53). Short • Press a second time to see the time delay setting (see Table 10 on page 54). • Press a third time to see the status of the wiring terminals again (see Table 12 on page 57). After about 20 seconds of inactivity, the indicators revert to the wiring terminal status. The DG safety relay enters Configuration mode. The 13/14, 23/24, and X2 outputs turn off, if they are on. Long 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 the EtherNet/IP™ interface. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 51 Chapter 5 Configuration 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 You can cycle through the configuration and can switch between the function of the blinking Short indicator. See Table 9 on page 53 for indicator descriptions. Close the changes; you leave the configuration mode without saving the changes. The PWR/Fault Long indicator flashes green at a 1 Hz rate. Upon release, the indicators revert to the wiring terminal status. Sel./Save Push Button Run Mode Button Press Function The status indicators display the following: Short • 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. Reset 52 If you press both buttons simultaneously for longer than 3 seconds, the DG safety relay performs a power cycle. The same can be accomplished if you remove and reapply power to terminal A1. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 5 Configuration Steps Configuration Before starting to configure the DG safety relay, review the configuration functions in Table 9. The configuration examples in Appendix B on page 71 help you select the correct configuration. Table 9 - Configuration Status Indicator Function OUT Number of Safety Functions IN 1 Indicator Color and Setting Indicator Color and Setting Indicator Color and Setting Activate two Safety Functions (IN1 and IN2) Activate one Safety Function (only IN1) — Input Type IN1 Activate GuardLink Input function on IN1 Activate OSSD or EMSS Input function on IN1 — IN 2 Input Type IN2 Activate GuardLink Input function on IN2 Activate OSSD or EMSS Input function on IN2 OUT X Output Type Activate SWS Output on X2 Activate OSSD Output on X2 — IN X Input Mode Activate SWS or OSSD Input on X1, depends on the previous step (SWS Input if OUT X is SWS Out, OSSD Input if OUT X is OSSD.) Disable Input on X1 — Reset Reset Type Manual Monitored Reset Automatic Reset — FB Reset Assignment Reset on the Output function Reset only on IN 1 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 steady red, steady 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 - go to step 5. 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. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 53 Chapter 5 Configuration 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, the PWR/Fault indicator flashes green and the other indicators 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 Table 10). 12. After you adjust the off-delay setting to the desired setting, the configuration process is complete. 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 steady red for about 5 seconds, and then turns steady green again. Now, the other status indicators reflect the status of the wiring terminals (see Table 12 on page 57). IMPORTANT Delay Setting To close the configuration without saving your settings: • Long press the Config/Set button, then short press the Config/Set button. Then, you must either press and hold both the Config/Set and Sel./Save buttons for 3 seconds to perform a reset or cycle power to the DG safety relay. • Wait longer than 60 seconds without any additional changes. The delay is set by the 16 position switch as described in Table 10. 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 10 - Delay Switch Settings Position 0 1 2 3 4 5 6 7 54 Delay Immediate 100 ms 200 ms 300 ms 500 ms 1s 1.5 s 2s Position 8 9 10 11 12 13 14 15 Delay 3s 5s 8s 10 s 15 s 20 s 25 s 30 s Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 5 Configuration Table 11 shows how the status indicators confirm the delay setting. The bottom three indicators flash at 1 Hz. The flashing pauses for 4 seconds and then repeats. The number of flashes is equal to the delay switch setting. Table 11 - 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 Verification You can verify the configuration of the DG safety relay in two ways: • • The buttons on the front of the DG safety relay The Add-on Profile (AOP) in the Studio 5000® environment 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 4 seconds and then repeats. 3. Short press the Config/Set push button one last time to return to the running status indication. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 55 Chapter 5 Configuration 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 publication 440R-UM009 for details. After the initial configuration, record the Config value. This value can then be compared in the future to detect changes. Update Firmware Use ControlFLASH™ software to update the firmware (see ControlFLASH Firmware Update on page 101). For information on how to download, install, and use or ControlFLASH software, see the following publications: • • CFP-QS001 1756-UM105 The firmware that is packaged with the software installation is the initial release of the controller firmware. Subsequent firmware revisions to address anomalies are released during the life of a product. 56 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 6 Status Indicators DG Safety Relay Status Indicators Table 12 describes the status of the DG safety relay status indicators during normal operation. Table 12 - DG Indicators during Normal Operation Indicator PWR/Fault OUT IN 1 State Off Steady red Steady green Flashing green 1 Hz Flashing red 1 Hz Green Red Green Red Flashing red 1 Hz Green Red IN 2 OUT X IN X Reset FB Flashing red 1 Hz Off Green Red Flashing red 1X Alternate flashing green/red Green Red Off Green Flashing green 1 Hz Flashing red 1 Hz Green Off 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 - See Appendix D on page 97 to determine the fault. 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, incorrect configuration, fault on a tap, or short circuit of input S12 or S22 to power or ground. Input circuits at S32 and S42 are closed Input circuits at S32 and S42 are open Input signal missing, incorrect configuration, or short circuit from S11 or S21 to 24V or to 0V. If short circuit, remove short circuit and cycle the input device to clear fault. Input circuit is disabled OSSD output/SWS output at X2 is on OSSD output/SWS output at X2 is off Wiring short from terminal X2 to 24V or to 0V when X2 is configured as SWS. Wiring short from terminal X2 to 0V when X2 is configured as OSSD. 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-UM015H-EN-P - November 2022 57 Chapter 6 Status Indicators Tap Status Indicators Figure 41 shows the location of the tap indicators. The GuardLink® enabled tap has a device input indicator. The passive power tap has an indicator to indicate power. Both passive taps do not have an indicator for the input device nor Link indicators. For the passive taps, you must observe the indicator on the device to determine its status. Table 13 provides a description of the status for each indicator. Figure 41 - Tap Indicators Input indicator DC Power indicator INPUT No indicator PWR Link indicator GuardLink-enabled Tap INPUT INPUT Passive Power Tap Passive Tap Table 13 - Tap Indicators Indicator Input Link Power State Description The input device is in the operational state with no demand on its safety Steady green 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 Flashing green at 1 Hz 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. Steady red 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 Flashing red at 1 Hz inputs did not change simultaneously. Try cycling the input device again. Cycle power to GuardLink circuit if necessary. Steady green The tap is transmitting the safety signal. Steady red GuardLink safety signal is off. Or terminator is missing. at tap or input device. Flashing red at 1 Hz Fault Correct fault and cycle power to the GuardLink system. No communication to DG safety relay. Input is configured for OSSD/EMSS; Off recheck the configuration. Input is in faulted state. Correct fault and/or cycle power to the DG safety relay and GuardLink circuit. Steady green Power applied Off No power applied Figure 42 shows an example with seven taps; five GuardLink-enabled taps and two passive taps. The link indicators are steady red, which indicates a safe (off) state. The flashing green indicators show that the devices are operational. The steady red input indicator at tap 3 shows that the device has tripped. To determine if the devices connected to the passive taps (5 and 7) are tripped, you must examine the indicators on the device. Figure 42 - Tripped Device with Steady Red Status Indicators 1 2 3 4 5 6 7 DG Safety Relay Tripped Device 58 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Possible Tripped Device Possible Tripped Device Chapter 7 Pulse Testing Functions 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 Testing for Inputs Pulse tests for the inputs are generated on terminals S11 and S21 of the DG safety relay. Figure 43 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 43 - Pulse Test Sequence for DG Safety Relay S21 24V 0V 15.3 0.3 S11 24V 0V 0 0.6 15 15.6 Time [ms] Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 59 Chapter 7 Pulse Testing Functions EMSS Tap Pulse Tests The EMSS GuardLink®-enabled tap generates pulse tests to detect short circuit conditions. The waveforms are shown in Figure 44. 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 44 - EMSS Test Pulses 1 ms 21 ms 8 ms 60 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 8 Opto-link Communications Optical Bus The GSR family of relays uses an optical bus to communicate status information to the 440R-ENETR Guardmaster® EtherNet/IP™ network interface(a). DG safety relays have two optical buses: • • 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 45. Figure 45 - Optical Bus Ports Opto Bus 3 Opto Bus 2 (a) See publication 440R-UM009 for detailed 440R-ENETR interface information. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 61 Chapter 8 Opto-link Communications Arrangement with 440R­ENETR 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 46. Figure 46 - 440R­ENETR Interface Arrangement A1 A2 LINK1 ENETR IP: 192. 168. 1. ABC MS LNK1 LNK2 NS A B C LINK2 S12 S22 S32 S42 S12 S22 S32 S42 A1 A2 S11 S21 A1 A2 S11 S21 PWR/Fault OUT IN 1 IN 2 OUT X IN X Reset FB DG Config/Set Reset Sel./Save 9 0 1 Time 8 2 7 6 5 43 PWR/Fault OUT IN 1 IN 2 OUT X IN X Reset FB DG S12 S22 S32 S42 S12 S22 S32 S42 A1 A2 S11 S12 A1 A2 S11 S12 PWR/Fault PWR/Fault IN1 IN1 IN2 Logic IN OUT 0 LOGIC 1 8 7 6 5 4 2 3 IN2 Logic IN OUT 0 LOGIC 1 8 7 Config/Set 6 5 4 2 3 33 34 43 44 A1 A2 S11 S12 PWR/Fault 37 38 47 48 A1 A2 B1 B2 PWR/Fault B1 Logic IN Logic IN OUT 33 34 43 44 A1 Reset Sel./Save 9 0 1 Time 8 2 7 6 5 43 X1 X2 X3 X4 X1 X2 X3 X4 13 14 23 24 13 14 23 24 13 14 23 24 DI 34 44 14 24 DIS L12 L11 Y32 S34 L12 L11 Y32 S34 13 14 23 24 34 44 14 24 OUT RANGE 0 1 2 3 7 6 54 1 TIME 2 3 10 4 9 5 8 7 6 9 8 13 14 23 24 EM L12 L11 X32 13 14 23 24 EMD L12 L11 X32 17 18 27 28 The 440R­ENETR interface can monitor up to six relays of any combination. The DG safety relays must be closest to the 440R­ENETR interface. 5 mm (0.2 in.) max spacing between relays The DG safety relay requires a 440R-ENETR interface when controlling guard locking interlock switches on a GuardLink circuit. An Ethernet interface is also useful, but not required, when monitoring guarding interlocks and E-stop devices. Status and fault codes can be transferred from the DG safety relay to the machine controller and control signals can be sent from the machine controller to the DG safety relay. The status signals form the DG safety relay to the machine controller include: • • • Status of the DG safety relay terminals Status of the taps on the GuardLink circuits Fault codes of the DG safety relay or the taps. The control signals from the machine controller to the DG safety relay include: • • • Reset command to turn on the DG safety relay outputs if the inputs are satisfied. Lock and unlock commands to lock or unlock the guard locking interlocks. Fault reset to cycle power to the DG relay to clear certain faults. Tap fault reset to cycle power to the device connected to the tap to clear certain faults. See publication 440R-UM009 for details. 62 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Chapter 9 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 47 shows an example safety system to help demonstrate the process of determining the Performance Level. Figure 47 - Example Circuit for Safety System Calculation 440N-Z21SS3PH 440G-LZS21SPRH SensaGuard™ Guard Locking Interlock Safety Switch 450L-B4FN0900YD 450L-APT-PW-5 (Tx) 450L-APR-ON-5 (Rx) Light Curtain 800F-1YMD51 (800FP-LMP44) E-Stop Push Button 440G-LZ 1485P-RDR5 Tee INPUT INPUT INPUT 440S-SF8D 440S-SF8D INPUT 440S-MF5D 440S-SF5D 898D-418U-DM2 Terminator +24V DC K1 Start K2 Host PC Stop Reset K1 Ethernet DC ok HMI PLC 1606-XLP95E N L S11 S21 S12 S22 A1 Control Status C DG 440R-ENETR 440R-DG2R2T S32 S42 X1 B X32 13 23 X4 A1 14 24 X3 Status EM 440R-EM4R2 A2 L12 L11 14 K1 700S-CFB K2 Relays (AC-15) 13 4.0.2 0 X2 A2 Ethernet OUT X SWS 24V DC Com 23 33 43 L1 L2 L3 TIME .4.6. 2428V A .12.1 + + 8.10 + K2 K3 24 34 K4 44 Feedback Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 K3 100S-C09 K4 Contactors M 63 Chapter 9 Safety Function Calculations 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 48. Figure 48 - Safety Function Block Diagrams Input Logic 440N-Z21SS3PH SensaGuard Channel 1 1 440N-Z21SS3PH SensaGuard Channel 1 440G-LZS21SPRH Guard Locking Switch Channel 1 440G-LZS21SPRH Guard Locking Switch Channel 1 800FP-LMP44 E-Stop Channel 1 800FP-LMP44 E-Stop Channel 1 450L-B4FN0600YD Light Curtain Channel 1 450L-B4FN0900YD Light Curtain Channel 1 100S-C09 Contactor Channel 1 100S-C09 Contactor Channel 2 Subsystem 2 Tap 2 440S-SF8D Subsystem 3 Subsystem 4 Subsystem 5 700S-CFB Relay Channel 1 DG 440R-DG2R2T 700S-CFB Relay Channel 2 Subsystem 2 Tap 2 440S-SF8D Subsystem 3 DG 440R-DG2R2T Subsystem 4 EM 440R-EM4R2 100S-C09 Contactor Channel 1 100S-C09 Contactor Channel 2 Subsystem 2 Tap 3 440S-MF5D Subsystem 3 Subsystem 4 Subsystem 5 700S-CFB Relay Channel 1 DG 440R-DG2R2T 700S-CFB Relay Channel 2 Subsystem 2 Tap 3 440S-MF5D Subsystem 3 DG 440R-DG2R2T Subsystem 4 EM 440R-EM4R2 100S-C09 Contactor Channel 1 100S-C09 Contactor Channel 2 Subsystem 2 Tap 4 440S-SF5D Subsystem 3 Subsystem 4 Subsystem 5 700S-CFB Relay Channel 1 DG 440R-DG2R2T 700S-CFB Relay Channel 2 Subsystem 2 Tap 4 440S-SF5D Subsystem 3 DG 440R-DG2R2T Subsystem 4 EM 440R-EM4R2 450L-B4FN0900YD Light Curtain Channel 2 Subsystem 1 64 EM 440R-EM4R2 450L-B4FN0600YD Light Curtain Channel 2 Subsystem 1 8 DG 440R-DG2R2T Subsystem 4 440G-TZS21UPRH Guard Locking Switch Channel 2 Subsystem 1 7 Tap 1 440S-SF8D Subsystem 3 800FP-LMP44 E-Stop Channel 2 Subsystem 1 6 Subsystem 2 440G-LZS21SPRH Guard Locking Switch Channel 2 Subsystem 1 5 700S-CFB Relay Channel 2 440G-LZS21SPRH Guard Locking Switch Channel 2 Subsystem 1 4 DG 440R-DG2R2T 440N-Z21SS3PH SensaGuard Channel 2 Subsystem 1 3 700S-CFB Relay Channel 1 440N-Z21SS3PH SensaGuard Channel 2 Subsystem 1 2 Tap 1 440S-SF8D Output 100S-C09 Contactor Channel 1 100S-C09 Contactor Channel 2 Subsystem 2 Subsystem 3 Subsystem 4 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Subsystem 5 Chapter 9 SISTEMA Safety Function Calculations 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 on page 94. These devices will be available in a future update of the Rockwell Automation library. Figure 49 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 PL e 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 49 - SISTEMA Project - First Two Safety Functions Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 65 Chapter 9 Safety Function Calculations Figure 50 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 50 - Project Summary 66 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix A Specifications DG Safety Relay Table 14 - General Specifications — DG Safety Relay Attribute 440R-DG2R2T Dimensions, H x W x D 119.14 x 22.5 x 113.6 mm (6.49 x 0.88 x 4.47 in.) Shipping weight, approx. 225 g (0.5 lb) Wire size 0.2…2.5 mm ² (24…14 AWG) Wiring category Copper that withstands 75 °C (167 °F) Insulation-stripping length 7 mm (0.28 in.) Terminal screw torque 0.4 N•m (4 lb•in) Power supply voltage range 24V DC PELV/SELV, UL Class 1 Div. 2., 0.85…1.1 x rated voltage Power consumption 3.5 W Power on delay 5.5 s Case material Polyamide PA 6.6 Terminal protection IP20 Enclosure protection IP40 (NEMA 1) Mounting 35 mm (1.4 in.) DIN rail in enclosure that is rated to a minimum of IP54 Table 15 - Environmental Specifications — DG Safety Relay Attribute 440R-DG2R2T Temperature, operating -5…+55 °C (23…131 °F) Relative humidity 90% Vibration 10…55 Hz, 0.35 mm (1.38 in.) Shock 10 g, 16 ms Pollution level 2 Installation group Overvoltage Category III, VDE 0110-1 Impulse withstand voltage 2500V Table 16 - Pulse Test Output Specifications — DG Safety Relay Attribute 440R-DG2R2T Wiring terminals S11/S21 Continuous output current, max 100 mA Surge output current, max 0.7 A Surge output current duration, max 5 ms Residual voltage drop from P/S, max 0.6V Load capacitance, max [nF/mA load] 200/20 100/10 22/0 Off state leakage current, max < 0.1 mA Short circuit detection Yes Short circuit protection Yes Galvanic isolation: I/O from logic No Pulse test duration ≤700 µs Pulse test period 5 ms Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 67 Appendix A Specifications Table 17 - Input Devices with Voltage-free Contacts Specifications — DG Safety Relay Attribute 440R-DG2R2T Wiring terminals S12/S22 and S32/S42 On voltage, max 26.4V On voltage, min 11V Off voltage, max 5V Off current, max 2 mA On current, min at 20V DC 10 mA Galvanic isolation: I/O from logic No Off pulse that is accepted for OSSD setting without declaring the input as off Min = 0 µs Max = 700 µs Off pulse period, min 15 ms Input simultaneity Infinite Input capacitance 220 nF Table 18 - SWS Specifications — DG Safety Relay Attribute 440R-DG2R2T Wiring terminal Output - X2 Input - X1 Continuous output current, max 50 mA On state voltage drop (P/S to +), max 0.2V Surge output current, max 700 mA Surge output current duration, max 5 ms Load capacitance, max 1 µF Off state leakage current, max < 0.1 mA Short circuit detection Yes Short circuit protection Yes Galvanic isolation: I/O from logic No Fan-out (max number of connections to L11) 10 Cable length between L11 and L12 30 m (98.4 ft) Off state leakage current, max < 0.1 mA Table 19 - Safety Output Specifications — DG Safety Relay Attribute 440R-DG2R2T Wiring terminals 13/14, 23/24 Types 2 N.O. Thermic current Ith 1x6A Fuses output (external) 6 A slow blow or 10 A quick blow Switched current, min 10 mA Switched voltage, min 10V Mechanical life 10,000,000 cycles Rating UL:C300 AC-15:1.5 A / 250V AC DC13: 2 A / 24V DC (0.1 Hz) Contact material AgNi + 0.2 µ Au Reaction times Automatic reset < 100 ms Monitored manual reset < 500 ms Response time 13/14 and 23/24 safety outputs 68 35 ms SWS output 30 ms Recovery time 100 ms Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix A Tap Specifications Table 20 - General Specifications — Tap Attribute 440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D, 440S-PF5D, 440S-PF5D4, 440S-MLF8D, 440S-SLF8D Dimensions, L x W x H 79.64 x 38.5 x 17 mm (3.14 x 1.51 x 0.67 in.) Shipping weight, approx. 27.2 g (0.96 oz) Case material Red RAL 3020 unfilled ABS MG47C plastic Mounting screw torque 2.25 N•m (20 lb•in) Mounting Any orientation Table 21 - Electrical Specifications — GuardLink Enabled Tap Attribute 440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D, 440S-MLF8D, 440S-SLF8D Voltage requirements 24V DC +10%, -15% Supply over voltage protection, max 60V DC Reverse polarity protection Yes Short circuit protection OSSD supply and lock signal 700 mA GuardLink® signals 500 mA On voltage, max 26.4V On voltage, min 11V Off voltage, max 5V Off current, max 2 mA On current, min at 20V DC 10 mA Galvanic isolation: I/O from logic No Off pulse that is accepted for OSSD setting without declaring the input as off Min = 0 µs Max = 700 µs Off pulse period, min 15 ms Input capacitance 220 nF Current consumption EMSS input on 40 mA EMSS input off 25 mA OSSD input on 29 mA OSSD input off 25 mA Voltage that is supplied to OSSD device connected to the J3 connector Pin1 of 5-pin OSSD J1 supply voltage -1.2V @ 500 mA, max load, 0.4V at 50 mA load Pin 2 of 8-pin OSSD J1 supply voltage -1.2V @ 500 mA, max load, 0.4V at 50 mA load Response time EMSS tap OSSD tap 5 ms plus 35 µs for each upstream tap CLU timing between successive lock/unlock 135…300 ms Table 22 - Passive Tap Specifications Attribute 440S-PF5D Voltage requirements at J1 24V DC +10%, -15% Current consumption, max 0 mA Galvanic isolation: I/O from logic No Voltage supplied to device connected to J3 J1 supply voltage Response time 0 µs plus 30 µs for each upstream tap CLU timing between successive lock/unlock 135…300 ms Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 69 Appendix A Specifications Table 23 - Passive Power Tap Specifications Attribute 440S-PF5D4 Voltage requirements at J4 24V DC +10%, -15% Supply over voltage protection, max 60V DC Reverse polarity protection Yes Short-circuit protection Yes Current consumption, max 15 mA Galvanic isolation: I/O from logic No Voltage supplied to device connected to J3 J4 supply voltage Response time 1 µs plus 30 µs for each upstream tap CLU timing between successive lock/unlock 135…300 ms Table 24 - Environmental Specifications — Taps and Terminator Attribute Tap: 440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D, 440S-PF5D, 440S-PF5D4, 440S-MLF8D, 440S-SLF8D Terminator: 898D-418U-DM2 Temperature 70 Operating -25…+70 °C (-13…+158 °F) Storage -40…+85 °C (-40…+185 °F) Relative humidity 35…85%, not exceed 50%RH at 70 °C (158 °F) Vibration per IEC 60068-2-6 10…55 Hz, 1 mm (0.04 in.) Shock per IEC 60068-2-27 30 g, 11 ms, half-sine Pollution level per IEC 60947-5-2 3 Enclosure protection IP65, IP67 washdown according to EN 60529, UL Type 1 PR61413 Flammability UL94, DIN 752000/FMV 55302 Protection against electric shock Class III per EN 61140 Emissions CISPR 11 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 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-UM015H-EN-P - November 2022 71 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 auto detect 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. Figure 51 - Two Safety Inputs, Middle SWS, and Monitored Manual Reset Assigned to Safety Outputs Schematic Logic +24V DC SMF Level Input 1 Test Out IN X IN 2 Reset And K1 A1 IN 11 S11 S21 S12 S22 A1 13 23 X4 A1 X32 13 23 33 43 LOGIC Level K2 TIME 12.1 8.10. GSR DG CI/SI/DI/DIS 440R-DG2R2T A2 L12 L11 S32 S42 X1 .4.6. 4.0.2 X2 A2 14 24 X3 EM 440R-EM4R2 A2 L12 L11 14 K3 24 34 44 SOF Level K4 Feedback Input 2 IN X OUT X SWS 24V DC Com K1 K2 K3 R R FB FB OUT X OUT 14/24 K4 Table 25 - Configuration 1 — Hex (Dec) 72 Indicator Function OUT Safety Functions Configuration ID: 0x7F (127) IN1 and IN2 Configuration ID: 0x7B (123) IN1 and IN2 Configuration ID: 0x7D (125) IN1 and IN2 IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type SWS SWS SWS SWS IN X Input Mode SWS Enabled SWS Enabled SWS Enabled SWS Enabled Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual FB Reset Assignment SOF SOF SOF SOF Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Configuration ID: 0x79 (121) Appendix B Configuration 2 Configuration Examples In Configuration 2, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with auto detect 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. Figure 52 - Two Safety Inputs, Middle SWS, Monitored Manual Reset Assigned to Input 1, Automatic Reset Assigned to Input 2 Schematic Logic +24V DC IN X Input 1 Test Out Reset S11 S21 S12 S22 A1 13 A1 23 X4 X32 13 23 33 43 And K2 TIME LOGIC Level 12.1 .4.6. 4.0.2 8.10. GSR DG CI/SI/DI/DIS 440R-DG2R2T A2 L12 L11 S32 S42 X1 X2 A2 14 24 X3 EM 440R-EM4R2 A2 L12 L11 14 K3 OUT X SWS K1 24V DC Com K2 SOF Level FB FB Feedback OUT X OUT 14/24 Configuration ID: 0x3B (59) Configuration ID: 0x3D (61) 24 34 Input 2 IN X IN 2 R SMF Level K1 A1 IN 1 K3 44 K4 K4 Table 26 - Configuration 2 — Hex (Dec) Indicator Function OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type SWS SWS SWS SWS IN X Input Mode SWS Enabled SWS Enabled SWS Enabled SWS Enabled Monitored Manual Monitored Manual Monitored Manual Monitored Manual SMF IN1 SMF IN1 SMF IN1 SMF IN1 Reset Reset Type FB Reset Assignment Configuration ID: 0x3F (63) Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Configuration ID: 0x39 (57) 73 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 auto detect 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 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 53 - Two Safety Inputs, Middle SWS, Automatic Reset Assigned to Safety Outputs Schematic Logic +24V DC IN X Input 1 Test Out IN 2 IN 1 SMF Level K1 A1 S11 S21 S12 S22 A1 13 23 X4 A1 X32 13 23 33 43 And K2 TIME LOGIC Level 12.1 8.10. DG GSR 440R-DG2R2T CI/SI/DI/DIS A2 L12 L11 S32 S42 X1 .4.6. 4.0.2 X2 A2 14 24 X3 EM 440R-EM4R2 A2 L12 L11 14 K3 FB Feedback OUT X OUT 14/24 Configuration ID: 0x1B (27) Configuration ID: 0x1D (29) 34 Input 2 IN X OUT X SWS K1 24V DC Com K2 SOF Level FB 24 K3 44 K4 K4 Table 27 - Configuration 3 — Hex (Dec) Indicator Function OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type SWS SWS SWS SWS IN X Input Mode SWS Enabled SWS Enabled SWS Enabled SWS Enabled Reset Reset Type Automatic Automatic Automatic Automatic FB Reset Assignment Not used Not used Not used Not used 74 Configuration ID: 0x1F (31) Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Configuration ID: 0x19 (25) Appendix B Configuration 4 Configuration Examples In Configuration 4, only safety Input 1 is in use. It can either be configured for GuardLink or OSSD with auto detect 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 54 - One Safety Input, Middle SWS, Monitored Manual Reset Assigned to Safety Outputs Schematic Logic +24V DC Test Out IN X Input 1 Reset IN 1 SMF Level K1 A1 S11 S21 S12 S22 A1 13 A1 23 X4 X32 13 23 33 And 43 K2 TIME LOGIC Level 12.1 8.10. GSR DG CI/SI/DI/DIS 440R-DG2R2T A2 L12 L11 S32 S42 X1 .4.6. 4.0.2 X2 A2 14 24 X3 EM 440R-EM4R2 A2 L12 L11 14 K3 R R FB FB OUT X OUT 14/24 SOF Level 24 34 44 K4 Feedback IN X 24V DC Com OUT X SWS K1 K2 K3 K4 Table 28 - Configuration 4 — Hex (Dec) Indicator Function OUT Safety Functions IN 1 Configuration ID: 0x7A (122) Configuration ID: 0x78 (120) IN1 IN1 Input Type GuardLink OSSD/EMSS IN 2 Input Type Not used Not used OUT X Output Type SWS SWS IN X Input Mode SWS Enabled SWS Enabled Reset Reset Type FB Reset Assignment Monitored Manual Monitored Manual SOF SOF Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 75 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 auto detect 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 55 - One Safety Input, Middle SWS, Automatic Reset Assigned to Safety Outputs Schematic Logic +24V DC Test Out Input 1 SMF Level IN X IN 1 K1 A1 S11 S21 S12 S22 A1 13 A1 23 X4 X32 13 23 33 43 And K2 TIME LOGIC Level 12.1 8.10. DG GSR 440R-DG2R2T CI/SI/DI/DIS A2 L12 L11 S32 S42 X1 .4.6. 4.0.2 X2 A2 14 24 X3 EM 440R-EM4R2 A2 L12 L11 14 K3 24 34 44 SOF Level K4 Feedback IN X 24V DC Com OUT X SWS K1 K2 K3 FB FB OUT X OUT 14/24 K4 Table 29 - Configuration 5 — Hex (Dec) 76 Indicator Function OUT Safety Functions IN 1 Configuration ID: 0x1A (26) Configuration ID: 0x18 (24) IN1 IN1 Input Type GuardLink OSSD/EMSS IN 2 Input Type Not used Not used OUT X Output Type SWS SWS IN X Input Mode SWS Enabled SWS Enabled Reset Reset Type Automatic Automatic FB Reset Assignment Not used Not used Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix B Configuration 6 Configuration Examples In Configuration 6, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with auto detect 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 56 - Two Safety Inputs, First SWS Device, Manual Monitored Reset Assigned to Safety Outputs Schematic Logic +24V DC Test Out Input 1 IN 1 SMF Level Reset K1 S11 S21 S12 S22 A1 13 23 X4 A1 X32 13 23 33 And 43 K2 TIME IN 2 LOGIC Level 12.1 8.10. DG 440R-DG2R2T S32 S42 X1 .4.6. 4.0.2 X2 A2 14 24 X3 EM 440R-EM4R2 A2 L12 L11 14 K3 24 34 44 OUT X SWS 24V DC Com K1 K2 K3 R FB FB OUT X OUT 14/24 K4 Feedback Input 2 R SOF Level K4 Table 30 - Configuration 6 — Hex (Dec) Indicator Function OUT Safety Functions Configuration ID: 0x6F (111) IN1 and IN2 Configuration ID: 0x6B (107) IN1 and IN2 Configuration ID: 0x6D (109) IN1 and IN2 IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type SWS SWS SWS SWS IN X Input Mode Disabled Disabled Disabled Disabled Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual FB Reset Assignment SOF SOF SOF SOF Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Configuration ID: 0x69 (105) 77 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 auto detect 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 57 - Two Safety Inputs, First SWS Device, Monitored Manual Reset Assigned to Input 1, Automatic Reset Assigned to Input 2 Schematic Logic +24V DC IN 1 Test Out Input 1 Reset SMF Level R K1 S11 S21 S12 S22 A1 13 A1 23 X4 X32 13 23 33 43 K2 TIME 12.1 8.10. DG 440R-DG2R2T S32 S42 X1 And LOGIC Level .4.6. 4.0.2 IN 2 X2 A2 14 24 X3 EM 440R-EM4R2 A2 L12 L11 14 K3 24 34 44 K4 SOF Level OUT X SWS 24V DC Com K1 K2 K3 FB OUT X OUT 14/24 Feedback Input 2 FB K4 Table 31 - Configuration 7 — Hex (Dec) Indicator Function OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type SWS SWS SWS SWS IN X Input Mode Disabled Disabled Disabled Disabled Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual FB Reset Assignment SMF IN1 SMF IN1 SMF IN1 SMF IN1 78 Configuration ID: 0x2F (47) Configuration ID: 0x2B (43) Configuration ID: 0x2D (45) Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Configuration ID: 0x29 (41) Appendix B Configuration 8 Configuration Examples In Configuration 8, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with auto detect 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 58 - First SWS Device, Two Safety Inputs, Automatic Restart Assigned to Safety Outputs Schematic Logic +24V DC IN 1 Test Out Input 1 IN 2 SMF Level K1 S11 S21 S12 S22 A1 13 A1 23 X4 X32 13 23 33 43 And K2 TIME LOGIC Level 12.1 8.10. DG 440R-DG2R2T S32 S42 X1 .4.6. 4.0.2 X2 A2 14 24 X3 EM 440R-EM4R2 A2 L12 L11 14 K3 24 34 44 K4 SOF Level FB FB OUT X OUT 14/24 Feedback Input 2 OUT X SWS 24V DC Com K1 K2 K3 K4 Table 32 - Configuration 8 — Hex (Dec) Indicator Function Configuration ID: 0x0F (15) Configuration ID: 0x0B (11) Configuration ID: 0x0D (13) Configuration ID: 0x09 (9) OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type SWS SWS SWS SWS IN X Input Mode Disabled Disabled Disabled Disabled Reset Reset Type Automatic Automatic Automatic Automatic FB Reset Assignment Not used Not used Not used Not used Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 79 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 auto detect 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 59 - One Safety Input, First SWS, Monitored Manual Reset Assigned to Safety Outputs Schematic Logic +24V DC IN 1 Test Out Input 1 SMF Level Reset K1 S11 S21 S12 S22 A1 13 23 X4 A1 X32 13 23 33 43 K2 TIME LOGIC Level 12.1 8.10. DG 440R-DG2R2T S32 S42 X1 .4.6. 4.0.2 X2 A2 14 24 X3 EM 440R-EM4R2 A2 L12 L11 14 K3 SOF Level 24 34 44 K4 Feedback OUT X SWS 24V DC Com K1 K2 K3 R R FB FB OUT X OUT 14/24 K4 Table 33 - Configuration 9 — Hex (Dec) 80 Indicator Function Configuration ID: 0x6A (106) OUT Safety Functions IN1 IN1 IN 1 Input Type GuardLink OSSD/EMSS IN 2 Input Type Not used Not used OUT X Output Type SWS SWS IN X Input Mode SWS Disabled SWS Disabled Reset Reset Type Monitored Manual Monitored Manual FB Reset Assignment SOF SOF Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Configuration ID: 0x68 (104) Appendix B Configuration 10 Configuration Examples In Configuration 10, only safety Input 1 is in use. It can either be configured for GuardLink or OSSD with auto detect 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 60 - First SWS Device, One Safety Input, Automatic Reset Assigned to Safety Outputs Schematic Logic +24V DC IN 1 Test Out Input 1 SMF Level K1 S11 S21 S12 S22 A1 13 23 X4 A1 X32 13 23 33 43 K2 TIME LOGIC Level 12.1 8.10. DG 440R-DG2R2T S32 S42 X1 .4.6. 4.0.2 X2 A2 14 24 X3 EM 440R-EM4R2 A2 L12 L11 14 K3 SOF Level 24 34 44 K4 Feedback OUT X SWS 24V DC Com K1 K2 K3 FB FB OUT X OUT 14/24 K4 Table 34 - Configuration 10 — Hex (Dec) Indicator Function OUT Safety Functions IN 1 Configuration ID: 0x0A (10) Configuration ID: 0x08 (8) IN1 IN1 Input Type GuardLink OSSD/EMSS IN 2 Input Type Not used Not used OUT X Output Type SWS SWS IN X Input Mode SWS Disabled SWS Disabled Reset Reset Type Automatic Automatic FB Reset Assignment Not used Not used Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 81 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 auto detect 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 the 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 61 - Two Safety Inputs, No SWS, Monitored Manual Assigned to Safety Outputs Schematic Logic +24V DC L1 L2 L3 Test Out Input 1 Reset S11 S21 S12 S22 A1 23 X4 TIME 12.1 4.0.2 .4.6. DG 440R-DG2R2T S32 S42 X1 X2 IN X PowerFlex R S T Stop Start Com A2 14 24 X3 IN 1 IN 2 & LOGIC Level & Gate control power supply 8.10. Out Machine +24 Control O3 O2 System O1 O0 Com 13 SMF Level R FB SOF Level Gate control circuit OUT X OUT 14/24 Input 2 S1 S2 U V W IN X OUT X OSSD M 24V DC Com Table 35 - Configuration 11 — Hex (Dec) Indicator Function OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type OSSD OSSD OSSD OSSD 82 Configuration ID: 0x77 (119) Configuration ID: 0x73 (115) Configuration ID: 0x75 (117) Configuration ID: 0x71 (113) IN X Input Mode OSSD Enabled OSSD Enabled OSSD Enabled OSSD Enabled Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual FB Reset Assignment SOF SOF SOF SOF Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix B Configuration 12 Configuration Examples In Configuration 12, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with auto detect 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 the 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 62 - 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 L1 L2 L3 Test Out Reset S11 S21 S12 S22 A1 13 23 X4 TIME 12.1 4.0.2 .4.6. DG 440R-DG2R2T S32 S42 X1 X2 A2 14 24 X3 Input 2 IN 1 Stop Start Com IN 2 R PowerFlex R S T & LOGIC Level & SOF Level Gate control circuit FB OUT X S1 S2 IN X IN X Gate control power supply 8.10. Out +24 Machine Control O3 O2 System O1 O0 Com Input 1 SMF Level OUT 14/24 U V W OUT X OSSD M 24V DC Com Table 36 - Configuration 12 — Hex (Dec) Indicator Function OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type OSSD OSSD OSSD OSSD IN X Input Mode OSSD Enabled OSSD Enabled OSSD Enabled OSSD Enabled Monitored Manual Monitored Manual Monitored Manual Monitored Manual SMF IN1 SMF IN1 SMF IN1 SMF IN1 Reset Reset Type FB Reset Assignment Configuration ID: 0x37 (55) Configuration ID: 0x33 (51) Configuration ID: 0x35 (53) Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Configuration ID: 0x31 (49) 83 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 auto detect 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 the 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 63 - No SWS, Two Safety Inputs, Automatic Restart Assigned to Safety Outputs Schematic Logic +24V DC SMF Level IN X IN 1 IN 2 L1 L2 L3 Test Out Input 1 & PowerFlex R S T LOGIC Level S11 S21 S12 S22 A1 13 23 X4 TIME & Stop Start Com SOF Level 12.1 4.0.2 .4.6. Gate control power supply 8.10. Out +24 Machine Control O3 O2 System O1 O0 Com DG 440R-DG2R2T S32 S42 X1 X2 A2 14 24 X3 Input 2 OUT X OUT 14/24 Gate control circuit S1 S2 IN X FB OUT X OSSD U V W M 24V DC Com Table 37 - Configuration 13 — Hex (Dec) Indicator Function OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type OSSD OSSD OSSD OSSD IN X Input Mode OSSD Enabled OSSD Enabled OSSD Enabled OSSD Enabled Reset Reset Type Automatic Automatic Automatic Automatic FB Reset Assignment Not used Not used Not used Not used 84 Configuration ID: 0x17 (23) Configuration ID: 0x13 (19) Configuration ID: 0x15 (21) Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Configuration ID: 0x11 (17) Appendix B Configuration 14 Configuration Examples In Configuration 14, only safety Input 1 is in use. It can either be configured for GuardLink or OSSD with auto detect 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 the 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 64 - No SWS, One Safety Input, Monitored Manual Reset Assigned to Safety Outputs Schematic Logic +24V DC L1 L2 L3 Test Out Reset S11 S21 S12 S22 A1 13 23 X4 Stop Start Com TIME 12.1 4.0.2 A2 14 24 X3 And OUT X OSSD R SOF Level Gate control circuit S1 S2 IN X LOGIC Level Gate control power supply 8.10. DG 440R-DG2R2T S32 S42 X1 X2 IN 1 PowerFlex R S T .4.6. Out Machine +24 Control 03 02 System 01 00 Com Input 1 IN X SMF Level FB OUT X OUT 14/24 U V W M 24V DC Com Table 38 - Configuration 14 — Hex (Dec) Indicator Function OUT Safety Functions IN 1 Configuration ID: 0x72 (114) Configuration ID: 0x70 (112) IN1 IN1 Input Type GuardLink OSSD/EMSS IN 2 Input Type Not used Not used OUT X Output Type OSSD OSSD IN X Input Mode OSSD Enabled OSSD Enabled Reset Reset Type Monitored Manual Monitored Manual FB Reset Assignment SOF SOF Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 85 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 auto detect 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 the 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 65 - No SWS, One Safety Function, Automatic Reset Assigned to Safety Outputs Schematic Logic L1 L2 L3 +24V DC Test Out Input 1 PowerFlex R S T S11 S21 S12 S22 A1 23 X4 Stop Start Com TIME 12.1 4.0.2 X2 LOGIC Level Gate control power supply 8.10. DG 440R-DG2R2T S32 S42 X1 A2 14 24 X3 Gate control circuit S1 S2 IN X 24V DC Com 13 .4.6. Out +24 Machine Control 03 02 System 01 00 Com IN X OUT X OSSD IN 1 SMF Level And FB SOF Level OUT X OUT 14/24 U V W M Table 39 - Configuration 15 — Hex (Dec) 86 Indicator Function OUT Safety Functions Configuration ID: 0x12 (18) Configuration ID: 0x10 (16) IN1 IN1 IN 1 Input Type GuardLink OSSD/EMSS IN 2 Input Type Not used Not used OUT X Output Type OSSD OSSD IN X Input Mode OSSD Enabled OSSD Enabled Reset Reset Type Automatic Automatic FB Reset Assignment Not used Not used Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix B Configuration 16 Configuration Examples In Configuration 16, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with auto detect 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 66 - No SWS, Two Safety Inputs, Manual Monitored Reset Assigned to Safety Outputs Schematic Logic +24V DC Test Out Input 1 Reset S11 S21 S12 S22 A1 13 L1 L2 Machine Control System 23 X4 TIME .12.1 IN 2 L3 0.2 & LOGIC Level K1 .4.6 .8.10 In Machine +24 Control 03 System 02 01 00 Com IN 1 SMF Level DG 440R-DG2R2T S32 S42 X1 X2 A2 14 K2 24 X3 Input 2 SOF Level Feedback OUT X OSSD K1 K2 R FB OUT X M OUT 14/24 4V DC Com Table 40 - Configuration 16 — Hex (Dec) Indicator Function OUT Safety Functions Configuration ID: 0x67 (103) IN1 and IN2 Configuration ID: 0x63 (99) IN1 and IN2 Configuration ID: 0x65 (101) IN1 and IN2 Configuration ID: 0x61 (97) IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type OSSD OSSD OSSD OSSD IN X Input Mode OSSD Disabled OSSD Disabled OSSD Disabled OSSD Disabled Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual FB Reset Assignment SOF SOF SOF SOF Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 87 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 auto detect 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 67 - No SWS, Two Safety Inputs, Monitored Manual Reset Assigned to Input 1, Automatic Reset Assigned to Input 2 Schematic Logic +24V DC Reset Test Out Input 1 S11 S21 S12 S22 A1 13 23 X4 IN 2 R L1 L2 L3 & Machine Control System LOGIC Level TIME 12.1 4.0.2 K1 .4.6. 8.10. In Machine +24 Control 03 02 System 01 00 Com IN 1 SMF Level DG 440R-DG2R2T S32 S42 X1 X2 SOF Level A2 14 24 X3 K1 K2 FB K2 OUT X OUT 14/24 Input 2 OUT X OSSD 24V DC Com M Table 41 - Configuration 17 — Hex (Dec) Indicator Function OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type OSSD OSSD OSSD OSSD IN X Input Mode OSSD Disabled OSSD Disabled OSSD Disabled OSSD Disabled Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual FB Reset Assignment SMF IN1 SMF IN1 SMF IN1 SMF IN1 88 Configuration ID: 0x27 (39) Configuration ID: 0x23 (35) Configuration ID: 0x25 (37) Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Configuration ID: 0x21 (33) Appendix B Configuration 18 Configuration Examples In Configuration 18, both safety inputs, Input 1 and Input 2, are in use. They can either be configured for GuardLink or OSSD with auto detect 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 68 - No SWS, Two Safety Inputs, Automatic Reset Assigned to Safety Outputs Schematic +24V DC Logic Test Out Input 1 L1 L2 S11 S21 S12 S22 A1 13 23 X4 Machine Control System 12.1 4.0.2 K1 8.10. DG 440R-DG2R2T S32 S42 X1 X2 A2 14 K2 24 X3 Input 2 LOGIC Level K1 K2 FB SOF Level Feedback OUT X OSSD IN 2 & TIME .4.6. In +24 Machine Control 03 02 System 01 00 Com L3 IN 1 SMF Level OUT X M OUT 14/24 24V DC Com Table 42 - Configuration 18 — Hex (Dec) Indicator Function Configuration ID: 0x07 (7) Configuration ID: 0x03 (3) Configuration ID: 0x05 (5) OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2 IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS OUT X Output Type OSSD OSSD OSSD OSSD IN X Input Mode OSSD Disabled OSSD Disabled OSSD Disabled OSSD Disabled Reset Reset Type Automatic Automatic Automatic Automatic FB Reset Assignment Not used Not used Not used Not used Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Configuration ID: 0x01 (1) 89 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 auto detect 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 69 - First SWS Device, One Safety Input, Monitored Manual Reset Assigned to Safety Outputs Schematic Logic +24V DC Test Out Input 1 Reset S11 S21 S12 S22 A1 13 L1 L2 L3 Machine Control System 23 X4 LOGIC Level TIME 12.1 4.0.2 K1 .4.6. 8.10. In Machine +24 Control 03 System 02 01 00 Com IN 1 SMF Level DG 440R-DG2R2T S32 S42 X1 X2 OUT X OSSD A2 14 24 X3 K1 K2 R SOF Level FB K2 OUT X OUT 14/24 Feedback M 24V DC Com Table 43 - Configuration 19 — Hex (Dec) 90 Indicator Function OUT Safety Functions IN 1 Input Type Configuration ID: 0x62 (98) Configuration ID: 0x60 (96) IN1 IN1 GuardLink OSSD/EMSS IN 2 Input Type Not used Not used OUT X Output Type OSSD OSSD IN X Input Mode OSSD Disabled OSSD Disabled Reset Reset Type Monitored Manual Monitored Manual FB Reset Assignment SOF SOF Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix B Configuration 20 Configuration Examples In Configuration 20, only safety Input 1 is in use. It can either be configured for GuardLink or OSSD with auto detect 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 70 - No SWS, One Safety Input, Automatic Reset Assigned to Safety Outputs Schematic Logic +24V DC Test Out Input 1 L1 L2 S11 S21 S12 S22 A1 13 23 X4 L3 Machine Control System LOGIC Level TIME 12.1 4.0.2 K1 .4.6. 8.10. In +24 Machine Control 03 02 System 01 00 Com IN 1 SMF Level DG 440R-DG2R2T S32 S42 X1 X2 OUT X OSSD SOF Level A2 14 24 X3 K1 K2 FB K2 OUT X OUT 14/24 M 24V DC Com Table 44 - Configuration 20 — Hex (Dec) Indicator Function OUT Safety Functions IN 1 Input Type Configuration ID: 0x02 (2) Configuration ID: 0x00 (0) IN1 IN1 GuardLink OSSD/EMSS IN 2 Input Type Not used Not used OUT X Output Type OSSD OSSD IN X Input Mode OSSD Disabled OSSD Disabled Reset Reset Type Automatic Automatic FB Reset Assignment Not used Not used Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 91 Appendix B Configuration Examples Notes: 92 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix C Regulatory Approvals Agency Certifications DG Safety Relay Ratings • • • • • • • UL Listed Industrial Control Equipment, certified for US and Canada. CE Marked for all applicable directives UKCA Marked for all applicable regulations RCM Marked for all applicable acts CCC Mark S-Mark KC Marked for Korea 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 45 - SIL Ratings Attribute Safety integrity level Safety integrity level claim limit [SILCL] PFHd [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 3.49 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 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 93 Appendix C Regulatory Approvals 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 can be used in safety systems meeting up to Category 4 and Performance Level PL e in accordance with ISO 13849-1. Table 46 - DG Performance Level Ratings Tap Ratings Attribute Category Performance Level MTTFd [a] 440R-DG2R2T Up to 4 Up to e DCavg [%] 97.31 SFF [%] CCF 99.06 80 92.2 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. The passive taps simply pass the GuardLink® signals to the safety device, therefore the passive taps do not have a SIL rating. Table 47 - GuardLink-enabled Tap SIL Ratings Attribute Safety integrity level Safety integrity level claim limit [SILCL] PFHd [1/h] Mode of operation Proof test interval, max [a] Safe failure fraction [%] 440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D, 440S-MLF8D, 440S-SLF8D 3 3 2.65 x 10-10 High-demand mode 20 98.68 Table 48 - GuardLink-enabled Tap Lock Command SIL Ratings Attribute Safety integrity level Safety integrity level claim limit [SILCL] PFHd [1/h] Mode of operation Proof test interval, max [a] Safe failure fraction [%] 94 440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D, 440S-MLF8D, 440S-SLF8D 2 2 1.5 x 10-9 High-demand mode 20 98.16 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix C Regulatory Approvals Performance Level/Category The Performance Level of the safety function is dependent on the structure of all devices that comprise the safety function. The GuardLink taps can be used in safety systems meeting up to Category 4 and Performance Level PL e in accordance with ISO 13849-1. The passive taps simply pass the GuardLink signals to the safety device, therefore the passive taps do not have a Category or Performance Level rating. Table 49 - GuardLink-enabled Tap Performance Level Ratings Attribute Category Performance Level MTTFd [a] DCavg [%] SFF [%] CCF Taps Up to 4 Up to e 1943.07 97.65 99.00 80 Table 50 - GuardLink-enabled Tap Lock Command Performance Level Ratings Attribute Category Performance Level MTTFd [a] DCavg [%] SFF [%] CCF Declaration of Conformity Taps Up to 2 Up to d 2159.99 92.78 98.24 80 CE Conformity This product is CE marked and is approved for installation within the European Union and EEA regions. This product is designed and tested to meet the EMC Directive 2014/30/EU, Machinery Directive 2006/42/EC 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 safety-related 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. For a comprehensive list of certifications visit: rok.auto/certifications. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 95 Appendix C Regulatory Approvals UKCA Conformity This product is UKCA marked and is approved for installation within the United Kingdom regions. This product is designed and tested to meet the 2016 No. 1091 Electromagnetic Compatibility Regulations, the 2008 No. 1597 Supply of Machinery (Safety) Regulations 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 safety-related 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. For a comprehensive list of certifications visit: rok.auto/certifications. 96 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix D DG Safety Relay Indicator Fault Codes Determine a Fault The DG safety relay performs an extensive range of internal tests to verify the performance of the safety function. When the PWR/Fault indicator is flashing red at 1 Hz, the indicators on the front of the DG safety relay can provide information on the fault. Use the following procedure to determine the fault. 1. 2. 3. 4. Press the Config/Set button. Read the flashing red indicators for the Faulted Module. Press the Config/Set button again. Read the flashing green indicators for the Fault number. If there are no flashing green indicators; the Fault ID value is 0. 5. Add the values as shown in the example in Table 51 on page 98. 6. Use the total of the values to look up the Module and Fault IDs in Table 52 on page 98. Clear a Fault Use the following recommended actions to clear a fault. 1. Where a terminal is specified, check the wiring and, if possible, measure the voltage to confirm the status at the specified terminal. 2. Where the Time Delay switch has been changed in Module 21, return the switch to its original position and cycle power. 3. Where the Time Delay switch has been changed in Module 22, simply return the switch to its original position. 4. Cycle power to the relay to clear the fault. 5. If the fault is not cleared, reconfigure the relay. 6. If the fault persists, replace the relay. An example fault is shown in Table 51 on page 98. This fault can easily be demonstrated by turning the Delay switch to a new position after the relay has been successfully configured. In this example, the rotary switch is not in position 3. Return the switch to position 3, and the fault is cleared. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 97 Appendix D DG Safety Relay Indicator Fault Codes Table 51 - Example Fault after Configuration Indicator Module Color Red Fault ID Value Color Green Value PWR/Fault 128 128 OUT 64 64 IN1 32 32 IN2 16 16 OUT X 8 8 IN X 4 4 Reset 2 2 FB 1 1 Total Value 22 3 Table 52 - Indicator Fault Codes Module 1…5 Module Description Internal Fault 6 Configuration Procedure Fault ID All 1 2 3 4 5 6 7 8 9 10 11 98 7…14 Internal Fault 15 Plausibility Tests All 1 2 3 4 5 6 7 8 11 12 13 Fault Description Various faults Status host configuration is invalid Default case configuration procedure Load type one configuration failed Device not configured Load configuration table failed Existing configuration does not match EEPROM data Load existing configuration failed Save configuration PB And CRC In EEPROM failed CRC check of copied data failed CRC check of copied data failed, invalid amount of data Compare received data CRC with co-safety processor failed Various faults Terminal S11 must be HI Terminal S21 must be HI Terminal S12 must be HI Terminal S22 must be HI Terminal S32 must be HI Terminal S42 must be HI Terminal X1 must be HI Terminal X2 must be HI Terminal S11 must be LO Terminal S21 must be LO Terminal S12 must be LO Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix D DG Safety Relay Indicator Fault Codes Table 52 - Indicator Fault Codes (Continued) Module Module Description 15 Plausibility Tests 16 Internal Fault 17 Read Inputs 18…19 Internal Fault 20 Startup Tests Fault ID 14 15 16 17 18 21 22 23 24 31 ALL 1 2 3 4 5 6 7 8 All 1 2 3 4 5 6 7 11 12 13 14 15 16 17 18 21 22 23 24 25 26 27 28 30 31 32 Fault Description Terminal S22 must be LO Terminal S32 must be LO Terminal S42 must be LO Terminal X1 must be LO Terminal X2 must be LO Feedback internal relay coil must be HI Feedback internal relay coil must be LO Terminal X4 must be HI Terminal X4 must be LO MT must be HI Various faults Default Case Terminal S22. The CLU signal has an invalid pattern Terminal S42. The CLU signal has an invalid pattern Terminal X1 SWS signal has an invalid pattern Terminal X2 SWS signal has an invalid pattern Default case call of input interpretation Default case read input once Default case mon dc once Various faults Internal main transistor is on when it must be off Internal main transistor is off when it must be on Internal main transistor is on when it must be off Terminal S11stuck at HI Terminal S21stuck at HI Terminal S12stuck at HI Terminal S32stuck at HI Terminal S11 internal test switch N.C. Terminal S21 internal test switch N.C. Terminal S12 internal test switch N.C. Terminal S22 internal test switch N.C. Terminal S32 internal test switch N.C. Terminal S42 internal test switch N.C. Terminal X1 internal test switch N.C. Terminal X2 internal test switch N.C. Terminal S11 must be LO Terminal S21 must be LO Terminal S12 must be LO Terminal S22 must be LO Terminal S32 must be LO Terminal S42 must be LO Terminal X1 must be LO Terminal X2 must be LO — Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Internal feedback relay is energized 99 Appendix D DG Safety Relay Indicator Fault Codes Table 52 - Indicator Fault Codes (Continued) 100 Module Module Description 21 Invalid Rotary Position During Power-up 22 Invalid Rotary Position During Run 23…46 Internal Fault Fault ID 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 20 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 20 All Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Fault Description Saved position is 0 Saved position is 1 Saved position is 2 Saved position is 3 Saved position is 4 Saved position is 5 Saved position is 6 Saved position is 7 Saved position is 8 Saved position is 9 Saved position is 10 Saved position is 11 Saved position is 12 Saved position is 13 Saved position is 14 Saved position is 15 Default case Saved position is 0 Saved position is 1 Saved position is 2 Saved position is 3 Saved position is 4 Saved position is 5 Saved position is 6 Saved position is 7 Saved position is 8 Saved position is 9 Saved position is 10 Saved position is 11 Saved position is 12 Saved position is 13 Saved position is 14 Saved position is 15 Rotary switch pin has short circuit Various faults Appendix E ControlFLASH Firmware Update Use the ControlFLASH™ programming tool to update the firmware in the 440R-DG2R2T safety relay. The firmware is issued as a Device Management Kit (.dmk file). A DMK is one, digitally signed file that contains the firmware. ControlFLASH authenticates the origin of the DMK and then validates the contents. This authentication provides enhanced protection against malicious threats. Download the DMK file and then run the DMK Extraction Tool; no need to install or extract the file. For more information, see publication 1756-UM105. Download Firmware Navigate to the Rockwell Automation Product Compatibility and Download Center (PCDC): rok.auto/pcdc. Type 440R in the search field. Click the search icon and select the firmware revision that you want to download. Follow the download instructions. Figure 71 - Rockwell Automation Download Website The default location of the DMK files is C:\Users\Public\Documents\Rockwell Automation\Firmware Kits. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 101 Appendix E ControlFLASH Firmware Update DMK Extraction Tool After the DMK file is downloaded, run the DMK Extraction tool. Figure 72 shows the location to launch the DMK Extraction tool. From the Windows® Start icon, expand the FLASH Programming Tools, and click the DMK Extraction Tool. Figure 72 - Select the DMK Extraction Tool Start Figure 73 shows an example of the files that the DMK Extraction Tool discovers in the default directory: C:\Program File (x86)\ControlFLASH. If necessary, use the Browse function to select another directory. Click the checkboxes next to the files that you want to extract and click Extract. Figure 73 - Select Files to Extract 102 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix E ControlFLASH Firmware Update Figure 74 shows a successful extraction and details. The firmware is ready to download into a 440R-DG2R2T safety relay. Click OK. Figure 74 - Extraction Succeeded Firmware Update Preparation The ControlFLASH firmware update performs best when the safety relays are fully operational in Run mode (not Configuration mode) with proper communications with the 440R-ENTER and the host controller. Figure 75 shows verification of proper configuration. Use Studio 5000® to open the 440R-ENETR Module Properties. Click Change, then click Upload, and review the Relay bus. If the Relay bus is accurate, click OK and leave the controller offline. Figure 75 - Verify Communications between Host computer and the DG relays Figure 76 on page 104 shows an example system with two 440R-DG2R2T safety relays located adjacent the 440R-ENETR. Multiple relays (up to six) can be updated simultaneously. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 103 Appendix E ControlFLASH Firmware Update On the 440R-ENETR, set the ABC switches to 000. The MS indicator flashes red. Cycle the power to the safety relay. After self-tests complete, the MS and NS indicators on the 440R-ENETR is steady green. The IP address does not change; the 000 setting is for firmware updates. Figure 76 - Set IP Address to 000 - Cycle Power ControlFLASH You must have ControlFLASH version 15.03 or later to download the DMK firmware to the safety relays. From the Windows Start icon, expand the FLASH Programming Tools, and click ControlFLASH (see Figure 77). Figure 77 - Start ControlFLASH Start 104 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix E ControlFLASH Firmware Update Figure 78 shows the ControlFLASH welcome window. From here, you can review the log, check the inventory of firmware releases, and change from RSLinx® Classic to FactoryTalk® Linx, if necessary. This example shows RSLinx Classic. Click Next. Figure 78 - Welcome to ControlFLASH Figure 79 shows the location of the available firmware. Select the 440R-ENETR to upgrade the firmware. Click Next. Figure 79 - Select the 440R-ENETR Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 105 Appendix E ControlFLASH Firmware Update In the example shown in Figure 80, the devices use RSLinx. In this example, 440R-ENETR is highlighted with IP address 192.168.2.78. Click OK. Figure 80 - Select the 440R-ENETR Figure 81 shows the available revisions. The latest revision of the firmware for the safety relay is 1.02.0. Figure 81 - DG FW Versions Available 106 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix E ControlFLASH Firmware Update Review the DANGER message (see Figure 82). If no danger exists, click Finish to initiate the update. Figure 82 - Review Danger Message Click Yes on the confirmation window to confirm the update. Potential Fault 1: Figure 83 shows a message that appears if the DMK Extraction tool was not used before ControlFLASH. Click Yes, then run the DMK extraction tool. Figure 83 - Failed to Validate Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 107 Appendix E ControlFLASH Firmware Update Potential Fault 2: Figure 84 shows a message that the device is not in the proper mode. Check that the IP address switches on the 440R-ENETR are set to 000. Cycle power. Figure 84 - Improper Mode Figure 85 shows a successful update. The current revision is now 2.001, the revision level of the 440R-ENETR. The safety relays are 440R-DG2R2T FW 1.02.0 Series A. Click OK. Figure 85 - Update Success As the safety relay performs the update and self-tests, watch the status indicators on the safety relay. The status indicators show a waterfall sequence, then all turn steady green. This process takes about 5 minutes. Then the safety relay resets back to its original configuration. If multiple safety relays are configured simultaneously, the next safety relay in the sequence begins its firmware update and self-test and shows the status indicator waterfall sequence. 108 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Appendix E ControlFLASH Firmware Update Cycle power to the safety relays. The indicators alternate red/orange for about 2 minutes. Return the IP address switches ABC back to their original positions and cycle power. Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 109 Appendix E ControlFLASH Firmware Update Notes: 110 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Index Numerics 13/14 safety output 49 23/24 safety output 49 440R-ENETR (Ethernet) interface arrangement 62 A agency certification 93 AOP verification 56 arrangement 440R-ENETR (Ethernet) interface 62 B bus optical 61 C cabling tap 28 calculation safety function 63 GuardLink system 63 SISTEMA 65 system current 24 certification agency 93 clear fault 97, 101 CLU signal 8 command fault reset 17 communication opto-link 61 compliance European Union directives 95 config/set configuration mode 52 push button 51 run mode 51 configuration 51 example 71 mode config/set 52 sel./save 52 steps 53 connection power supply DG safety relay 44 multiple 45 tap 44 single wire safety 48 SWS 48 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 consideration enclosure 37 voltage drop 24 contact voltage-free 8 control, lock, and unlock signal 8 ControlFLASH 101, 104 fault 107, 108 D definition 8 delay setting 54 determine fault 97, 101 device cable 8 Device Management Kit (DMK) 101 extraction tool 102 DG safety relay enclosure consideration 37 excessive heat 38 output monitoring 13 overview 13 performance level/category 94 power supply connection 44 reset 14 safety device input 13 SIL rating 93 single wire safety input 13 status indicators 57 terminal assignment 40 terminal function 40 terminal torque 39 wire size 39 dimension mounting 33 DIN rail mountingDIN rail removal 34 spacing 34 directive compliance to European Union 95 drop cable 8 E electrical mechanical safety switch 8 EMSS 8 tap 18 EMSS SmartTap pulse test 60 enclosure consideration 37 DG safety relay 37 tap 37 European Union directives compliance 95 example configuration 71 fault 98 111 Index excessive heat prevent 38 F fault clear 97, 101 determine 97, 101 example 98 fault code indicator 98 fault reset command 17 firmware download 101 FLASH Programming Tools 102 function pulse testing 59 safety 8 G ground 39 guard locking GuardLink system 19 GuardLink connectionsinput wiring 46 fault reset command 17 guard locking 19 principle of operation 15 state 15 system typical 12 what is 11 system design 23 transition (operational state - safe state) 17 transition (safe state - operational state) 17 H heat prevent excessive 38 HI 8 I indicator fault code 98 status 8, 57 DG safety relay 57 tap 58 input pulse testing 59 single wire safety 13 SWS 13 input wiring DG safety relay 46 GuardLink connections 46 OSSD output device 47 voltage-free contact 47 installation 33 tap 36 L link cable 8 112 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 LO 8 lock command timing diagram 20 M mode configuration config/set 52 sel./save 52 run config/set 51 sel./save 52 monitoring output 13 mounting dimension 33 DIN rail 34 multiple power supply connection 45 N N.C. 8 N.O. 8 N/C 8 normally closed 8 normally open 8 O operation GuardLink, principle 15 operational state GuardLink 8 optical bus 61 opto-link communication 61 OSSD 8 tap 17 OSSD output device input wiring 47 output monitoring 13 output signal switching device 8 output wiring safety 48 overview 11 DG safety relay 13 tap 12 P performance level/category DG safety relay 94 tap 95 pin assignment tap 41 pin function tap 41 power 39 Index power supply connection DG safety relay 44 multiple 45 tap 44 prevent excessive heat 38 protection surge 49 pulse test EMSS SmartTap 60 pulse testing function 59 input 59 push button config/set 51 sel./save 52 verification 55 R reaction time 8 recommendation wiring 39 recovery time 8 regulatory approval 93 removal DIN rail 34 terminal block 35 replacement tap 30 terminal block 35 requirement wiring 39 reset 14, 52 response time 8 RSLinx 105 run mode config/set 51 sel./save 52 S safe state GuardLink 8 safety device input 13 function 8 output 13/14 and 23/24 49 output wiring 48 signal, GuardLink 8 single wire 8, 47 connection 48 safety function calculation 63 GuardLink system 63 SISTEMA 65 safety switch electrical mechanical 8 sel./save configuration mode 52 push button 52 run mode 52 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 setting delay 54 signal GuardLink safety 8 SIL rating DG safety relay 93 tap 94 single wire safety 8, 47 connection 48 input 13 spacing DIN rail 34 specifications 67 - 70 electrical tap 69 environmental DG relay 67 general DG relay 67 tap 69 input device with voltage-free contacts DG relay 68 pulse test output DG relay 67 safety output DG relay 68 SWS DG relay 68 tap 69 state GuardLink 15 GuardLink operational 8 GuardLink safe 8 status indicator 9 status indicator 8 state 9 status indicators 57 DG safety relay 57 tap 58 steps configuration 53 surge protection 49 surge suppressor recommendation 50 switching device output signal 8 SWS 8, 47 connection 48 input 13 system current calculation 24 system design GuardLink 23 113 Index T tap 8 cabling 28 EMSS 18 enclosure consideration 37 excessive heat 38 installation 36 OSSD 17 overview 12 performance level/category 95 pin assignment 41 pin function 41 power supply connection 44 replacement 30 SIL rating 94 specifications 69 status indicators 58 terminal assignment DG safety relay 40 terminal block removal 35 replacement 35 terminal function DG safety relay 40 terminal torque DG safety relay 39 terminator 30 time reaction 8 recovery 8 response 8 timing diagram lock command 20 transition GuardLink (operational state - safe state) 17 GuardLink (safe state - operational state) 17 trunk cable 8 V verification 55 AOP 56 push button 55 voltage drop consideration 24 voltage-free contact 8 input wiring 47 W wire 39 wire size DG safety relay 39 wiring recommendation 39 requirement 39 safety output 48 114 Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 Guardmaster DG Safety Relay and GuardLink System User Manual Rockwell Automation Publication 440R-UM015H-EN-P - November 2022 115 Rockwell Automation Support Use these resources to access support information. Technical Support Center Knowledgebase Local Technical Support Phone Numbers Literature Library Product Compatibility and Download Center (PCDC) Find help with how-to videos, FAQs, chat, user forums, and product notification updates. Access Knowledgebase articles. Locate the telephone number for your country. Find installation instructions, manuals, brochures, and technical data publications. Download firmware, associated files (such as AOP, EDS, and DTM), and access product release notes. rok.auto/support rok.auto/knowledgebase rok.auto/phonesupport rok.auto/literature rok.auto/pcdc Documentation Feedback Your comments help us serve your documentation needs better. If you have any suggestions on how to improve our content, complete the form at rok.auto/docfeedback. Waste Electrical and Electronic Equipment (WEEE) At the end of life, this equipment should be collected separately from any unsorted municipal waste. Rockwell Automation maintains current product environmental information on its website at rok.auto/pec. Allen-Bradley, ControlFLASH, expanding human possibility, FactoryTalk, GuardLink, Guardmaster, Integrated Architecture, Lifeline, On-Machine, Rockwell Automation, RSLinx, SensaGuard, and Studio 5000 are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of ODVA, Inc. Windows is a trademark of Microsoft Corporation. Trademarks not belonging to Rockwell Automation are property of their respective companies. Rockwell Otomasyon Ticaret A.Ş. Kar Plaza İş Merkezi E Blok Kat:6 34752, İçerenkÖy, İstanbul, Tel: +90 (216) 5698400 EEE YÖnetmeliğine Uygundur Publication 440R-UM015H-EN-P - November 2022 Supersedes Publication 440R-UM015G-EN-P - November 2021 Copyright © 2022 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A. ">

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