Application Examples. Rockwell Automation Allen-Bradley 440GMZS20UNLJ, Allen-Bradley 440G-MZS20SNLJ, Allen-Bradley 440G-MZS20UNRJ, Allen-Bradley 440G-MZS20SNRJ
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Chapter
7
Application Examples
The following application and wiring examples are intended to show how the
440G-MZ safety switch products can be applied. If you are the user or the designer, you may require variations to these examples to meet your specific requirements.
Wire to GLP Safety Relay
The GLP safety relay is designed to operate with Power to Release (PTR) switches. To use a Power to Lock (PTL) switch, you must use an interposing relay on the lock command at GLP terminal 51. In the example shown in
, the GLP safety relay allows the gate to be unlocked when the motor is running at a Safely-limited Speed.
Figure 12 - GLP and 440G-MZ Safety Switch Schematic
+24V DC, Class 2, PELV
Reset
& Lock
Request
SLS
Request
to PAC
440G-MZS20*NR*
Unlock
Request
800FM-MT44
Reset
Safety
Status to PAC
K300
Status to PAC
Stop/Start/SLS
from PAC
Kinetix® 300 Drive
Brown
889D-F5NC-X
X 1 4 X 2 4
Gry
51 A1 S 4 4 S 5 4 Y32 L12
LOGIC SL1 SL2
GLP 3 5 8
440R-GL2S2P
S 1 2 S 2 2 L61 A2 AP P12 P22 L 1 1
Blue
Blue
872C-D8NP18-E5
Blue
Black
800FM-MT44
S11 S12 S21 S22 A1 13 23
DI
LOGIC
4
440R-D22R2
S32 S42 L11 L12 A2 14
S34
24 Y32
Safe Torque-off
(STO)
Connector with
Wiring Header
4
5
6
1
2
3
+24V DC
COM
Status
Safety Input 1
Safety COM
Safety Input 2
24V DC COM
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 31
Chapter 7 Application Examples
Circuit Status as Shown
The gate is open and unlocked. The motor is off. The GLP safety relay is ready for reset. The GLP safety relay has a Logic setting of 3: (Safely-limited Speed with Logic IN OFF), a Safely-limited Speed (SLS1) setting of 5 (5 Hz) and a maximum (SLS2) speed setting of 8 (2000 Hz). The safety outputs (X14 & X24), the single wire safety output (L11), and the auxiliary output (Y32) are OFF.
IMPORTANT Start the GLP logic configuration from “0” to configure X14 and X24 for use as safety outputs.
Starting
Close the gate and press Reset to lock the gate and turn on the GLP safety outputs. Press Start to turn the motor ON.
Safely-limited Speed
A normal production stop is performed by pressing Stop. Access through the safety gate is initiated by pressing Gate Unlock Request. The Y32 output of the
GLP safety relay turns ON, which makes an SLS request to the PAC. The PAC commands the Kinetix® drive to bring the motor to a safe slow speed. When the proximity sensors detect the speed has dropped below the Safely-limited
Speed (5 Hz), the gate becomes unlocked. The operator can enter the machine cell, as the motor continues to run at the safe slow speed. After you leave the cell and close the gate, press Reset to lock the gate and return the machine to production speeds.
The circuit meets the safety requirements up to Category 3, Performance
Level d in accordance with ISO 13849-1 and SIL CL 2 in accordance with
IEC 62061.
32 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Chapter 7 Application Examples
Wire to GLT Safety Relay
The GLT safety relay is designed to operate with PTR switches. To use a PTL switch, you must use an interposing relay on the lock command at terminal 51 of the GLT safety relay.
In this example shown in
, the GLT safety relay sends an immediate command to the drive to turn OFF. After 8 seconds, the GLT safety relay turns off its safety outputs and unlocks the gate. The risk assessment must determine adequate time delay for the machine to achieve a safe state before unlocking the gate.
Figure 13 - GLT and 440G-MZ Safety Switch Schematic
+24V DC, Class 2, PELV
440G-MZ
Safety Gate Gate
Unlock
Request
Reset and
Gate Lock
Request
L1 L2 L3
PowerFlex
525
11 +24V DC
R S T
1 Stop
2 Start
440G-MZS20*NR*
Power to Release
No aux
4 Gnd
889D-F5NC-X
Brown (+24)
Gray - Lock Cmd
White - OSSD 1
Black - OSSD 2
Blue (Gnd)
24V DC Com
S 5 4 A1 S 1 1 S 1 2 51 S 4 4 Y32
LOGIC RANGE TIME
3 4 8
GLT
440R-GL2S2T
S12 S22 L61 A2 L11 L12
B2
14 24
Gate control power supply
Gate control circuit
S1
S2
U V W
M
Circuit status as shown: The gate is open and unlocked. The motor is off. The
GLT safety relay is ready for reset. The GLT safety relay has a Logic setting of
3: (Category 1 Stop), a Range setting of 4 (10 seconds) and a Time setting of 8
(80%). The Y32 output turns OFF immediately; 8 seconds later, the safety outputs turn OFF.
The safety outputs (14 and 24) and the single wire safety output (L11) are OFF and the auxiliary output (Y32) is ON.
IMPORTANT Start the GLT logic configuration from 0 to configure 14 and 24 for use with pulse testing; the PowerFlex® 525 drive can operate with pulse tested inputs to
S1 and S2.
Starting
Close the gate. Press Reset and Gate Lock Request to lock the gate and turn on the GLT safety outputs. Press Start to turn the motor ON.
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 33
Chapter 7 Application Examples
Stopping
Normal production stops are performed by pressing Stop. Access through the safety gate is initiated by pressing the Gate Unlock Request. The Y32 output of the GLT safety relay turns OFF, which commands the PowerFlex® drive to bring the motor to a stop. After the configured time delay (8 seconds) expires, the GLT safety outputs turn off, and the gate becomes unlocked. After you leave the cell and close the gate, press Reset to lock the gate and return the machine to a production state.
The circuit meets the safety requirements up to Category 3, Performance
Level d in accordance with ISO 13849-1 and SIL CL 2 in accordance with IEC
62061.
34 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Wire to DI and EMD
Safety Relay
Chapter 7 Application Examples
The 440G-MZ safety switch can be connected to the DI and EMD safety relays.
The DI safety relay monitors the safety outputs of the safety switch and the
EMD enables the gate to be unlocked after a configured delay time expires.
B1 is connected to B2 to allow for retriggering. If you open and close the E-stop and press Reset before the delay expires, the EMD timer resets.
Upon initial power-up, the safety switch must be cycled for the DI to recognize the safety switch OSSD signals.
In the example shown in
, an E-stop initiates the machine shutdown.
After an eight-second delay, the safety switch is allowed to be unlocked and the hazards that remain are turned OFF. A selector switch is required to maintain the gate in an unlock state. The risk assessment must determine adequate time delay for the machine to achieve a safe state before unlocking the gate.
Figure 14 - DI Safety Relay with EMD Safety Relay and 440G-MZ Safety Switch Schematic
+24V DC, Class 2, PELV
Brown
Reset
Brown = +24V DC
White = OSSD 1
Black = OSSD 2
Blue = 24V DC COM
Gray = Lock CMD
L1 L2 L3
440G-MZS20*NR*
E-stop
Gray
Unlock
Blue
K1
K2
White Black
Power
In 1
In 2
Out
Logic
A1
DI
A2 S11 S21 S12 S22 S32 S42
Test Out
LOGIC
2
IN1 IN 2
L12 L11 Y32 S34 13 14 23 24
A1 A2
EMD
B1
RANGE
2
B2 37
TIME
8
L12 L11 X32 17
38 47 48
37 38 47 48
17 18 27 28
18 27 28
M
K1 K2
24V DC COM
Circuit Status as Shown
The E-stop is released. The gate is open and unlocked. K1 and K2 are OFF. The
DI safety relay is configured for two inputs with monitored manual reset. The
EMD safety relay is configured for 8-second off-delay; Range setting of 2 is 10 s, Time setting of 8 is 80% of the range. The X32 terminal is ON because the
EMD safety outputs are OFF.
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 35
Chapter 7 Application Examples
Starting
With the Unlock switch open, close the gate. Press Reset to lock the gate and turn on the K1…K4 safety contactors.
Stopping
Stopping is initiated by pressing the E-stop. K1 and K2 contactors turn off immediately. The single wire safety signal from the DI safety relay (L11) to the
EMD safety relay (L12) also turns off immediately, and the EMD starts the offdelay timer. After 8 seconds, X32 goes to 24V. The unlock switch is enabled, and the gate can be unlocked. While the gate is unlocked, the DI safety relay cannot turn the safety outputs back ON. After you leave the cell and close the gate, open the unlock switch to lock the gate, and release the E-stop.
The circuit can meet the safety requirements up to Category 4, Performance
Level e in accordance with ISO 13849-1 and SIL CL 3 in accordance with
IEC 62061.
36 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Wire to DG Safety Relay
Chapter 7 Application Examples
The 440G-MZ safety switch can be used in GuardLink® applications. The
GuardLink system:
• Is designed to operate with Power to Release switches.
• Uses taps to connect a series of devices to one relay.
• Provides control and status information between the machine control system and the safety system.
shows four 440G-MZ safety switches that are connected on two
GuardLink circuits from one DG safety relay. The DG safety relay can accommodate up to 32 devices on each input. The devices can be a mix of many different safety devices. When guard locking devices are included in the
GuardLink system, the lock/unlock command must come from the machine control system through the 440R-ENETR module.
See publication 440R-UM015 for further details.
Figure 15 - DG Safety Relay with 440G-MZ Safety Switch Schematic
+24V DC, Class 2, PELV
440G-MZS20*NR* 440G-MZS20*NR*
889D-F5NCDM-X
440S-PFSD
889D-F5NCDM-X
440S-PFSD
889D-F4NE-X
Brown
Blue
440G-MZS20*NR* 440G-MZS20*NR*
889D-F5NCDM-X
440S-PFSD
889D-F5NCDM-X
440S-PFSD
889D-F4NE-X
Brown
Blue
Control
Status
Machine
Control
System
440R-ENETR
+
A
B
C
S12 S22 S11 S21 A1
Control
Status
TIME
DG
0
440R-DG2R2T
S32 S42 X2 X1 A2
13 23 X4
14 24 X3
K1 K2
24V DC Com
L1 L2 L3
K1
K2
M
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 37
Chapter 7 Application Examples
Wire to CR30 Safety Relay
The CR30 safety relay is a software configurable safety relay that can easily interface with the 440G-MZ safety switch. Version 10 and later of the
Connected Components Workbench™ software has a locking function that is useful for guard locking applications.
Figure 16 shows an example schematic. The CR30 safety relay monitors the
motor running signal from the PowerFlex 525 drive. When the motor is not running, the safety gate can be unlocked, and the PowerFlex 525 drive goes to a
Safe Torque Off state.
Figure 16 - CR30 Safety Relay with 440G-MZ Safety Switch Schematic
+24V DC, Class 2, PELV
Safety Gate
440G-MZS20*NR*
Power to Release
No aux
889D-F5NC-X
Brown (+24)
Black - OSSD 2
White - OSSD 1
Gray - Lock Cmd
Blue (Gnd)
24V DC Com
Lock
Unlock
PowerFlex
525
11 +24V DC
R S T
1 Stop
L1 L2 L3
Reset
2 Start
0 0 0 1 0 2 0 3 0 4
CR30
A1 A2 12 13 14
05
Motor Not Running
R5
R6
06 07 08 09 10 11
440C-CR30-22BBB
15 16 17 18 19 20 21 t081=2
4 Gnd
Gate control power supply
Gate control circuit
S1
S2
U V W
M
Figure 17 on page 39 shows an example CR30 safety relay configuration that
works with the schematic in
38 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Chapter 7 Application Examples
The safety switch OSSD outputs drive the Safe Torque Off (STO) signals of the
PowerFlex 525 drive. The STO is enabled after the gate is locked and the Reset is pressed. The PowerFlex 525 drive STO inputs can tolerate the pulse test that is generated by the CR30 outputs.
The Lock_Ctrl_1 block controls the unlock command to the safety switch. The unlock Stop Time delay is set to 5 seconds, and the ULR Latch (Unlock Request) is set to ON. When an unlock request is made, the command is issued 5 seconds after the motor stops running, and the unlock request is latched ON.
Figure 17 - CR30 Configuration in CCW
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 39
Chapter 7 Application Examples
Wire to POINT Guard I/O
Module
shows a wiring example of a 440G-MZ Power to Release safety switch that is connected to a 1734 POINT Guard I/O™ module.
Figure 18 - 1734 Module and 440G-MZ Safety Switch Schematic
440G-MZ
440G-MZS20*NR*
Power to Release
No aux
889D-F5NC-X
Safety Gate
Ethernet I/P to GuardLogix®
PLC and HMI
1 7 3 4 A E N T
0 1
2
4
3
5
24V DC Com
6 7
+24V DC
1734-IB8S 1 7 3 4 O B 8 S
I0
I2
I1
I3
I4
I6
I5
I7
O0 O1
O2 O3
O4 O5
O6 O7
COM COM
T0 T1M
COM
T2
COM COM COM COM COM
T3M
COM COM COM COM
K1 K2
K1 K2
Black - OSSD 2
White - OSSD 1
Blue (Gnd)
Gray - Lock Cmd
Brown (+24)
Figure 19 shows the General tab of the 1734-AENTR module properties.
The Input Status can be set to Rack Optimization, Enhanced Rack
Optimization, or Combined Status - Power - Muting as these settings are used by the Dual Channel Input Stop (DCS) logic block to verify that the 1734-IB8S switch is operational. The Output Data must be set to Test, as the test outputs are used to generate test pulses for the output contactors, K1 and K2.
Figure 19 - 1734-AENTR Module Properties - General
40 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Chapter 7 Application Examples
Figure 20 shows the 1734-IB8S General tab. Set the Module Definition with the
following settings:
• Input Data: Safety
• Output: Test
• Input Status: Pt. Status-Power-Muting-Test Output
Figure 20 - 1734-IB8S Module Properties - General
shows the Input Configuration tab of the 1734-IB8S switch module properties.
In this example, Points 0 and 1 monitor the OSSD outputs of the 440G-MZ safety switch. The Type is set to Single and the Mode must be set to Safety.
Points 2 and 3 monitor the status of the output contactors, K1 and K2. The Type should be set to Single. Set Mode to Safety Pulse Test. Safety pulse testing is used to detect potential faults in the monitoring circuit.
Figure 21 - 1734-IB8S Module Properties - Input Configuration
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 41
Chapter 7 Application Examples
shows the Test Output tab of the 1734-IB8S module properties.
In this example, Points 0 and 1 are set to Pulse Test as these points help check the integrity of the contactors K1 and K2, to be sure they are off before the logic program energizes the contactors.
Points 2 and 3 are set to Standard. Point 2 is the LOCK command. Point 3 applies power to the safety switch. By setting it to Standard, you can programmatically turn these points OFF and ON, in case a nonrecoverable fault occurs with the switch.
Figure 22 - 1734-IB8S Module Properties - Test Output
shows the General tab of the 1734-OB8S module properties. Set the
Module Definition with the following settings:
• Input Data: None
• Output: Safety
• Input Status: Pt. Status
Figure 23 - 1734-OB8S Module Properties - General
42 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Chapter 7 Application Examples
Figure 24 shows the Output Configuration tab of the 1734-OB8S switch module
properties.
Points 0 and 1 drive the output contactors K1 and K2. For both points, Type is set to Dual, and the Mode is set to Safety Pulse Test.
Figure 24 - Module Properties - Output Configuration
Figure 25 on page 44 shows an example program. A Dual Channel Input Stop
function block monitors the 440G-MZ safety switch, and a Configurable
Redundant Output function block controls two contactors. This example can be used as a starting point for implementation; you must incorporate additional logic that is based on the risk assessment for the machine.
9
10
11
12
Rung Description
0
With the Test Data output setup set as Standard, an HMI input can cycle power ON and OFF to the
440G-MZ safety switch to recover from a fault, if necessary. Upon powerup, the N.C. contact automatically applies power to the 440G-MZ safety switch.
2
1
The Dual Channel Input Stop monitors the outputs of the 440G-MZ safety switch. The DCS block is set for automatic start on powerup (cold start) and automatic restart each time the switch is locked.
The output of the DCS in Rung 1 provides a tag that shows the input 440G-MZ input status is OK. This tag is used in Rung 4 to enable the Configurable Output to be reset.
3
4
5
A momentary contact from an HMI input starts a short on delay timer. HMI input must be held long enough for the timer to expire. This timer is intended to help prevent inadvertent reset. The preset value can be adjusted to suit the application.
When the timer is done, the OSF_Storage_Bit is set. When the HMI_CROUT_Actuate button in Rung 4 is released, the OSF_Storage_Bit goes LO and the OSF_Output_Bit goes HI.
When the OSF_Output_Bit goes HI, the CROUT_Actuate tag is set. The CROUT_Actuate tag is self-sealing because the OSF_Output_Bit is HI only momentarily.
6
7
8
The GMZ_Crout block is set for negative feedback. The CROUT block output cannot go HI unless the external contactor status at Feedback 1 and 2 is HI.
The two CROUT outputs turn ON the ArmorBlock® outputs, which energize the external contactors.
From an HMI input, you can lock or unlock the 440G-MZ safety switch. The HMI input must be a maintained switch.
Notify the HMI if a fault is present on the DCS block.
An HMI input can reset the DCS if a fault is present.
Notify the HMI if a fault is present on the CROUT block.
An HMI input can reset the CROUT if a fault is present.
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 43
Chapter 7 Application Examples
Figure 25 - 1734 Example Studio 5000® Program
44 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Wire to ArmorBlock
Guard I/O Module
Chapter 7 Application Examples
The 440G-MZ safety switch can be connected to a 1732ES/1732DS ArmorBlock
Guard I/O™ module by using a catalog number 889D-F5NCDM-x 5-wire patchcord. An example schematic is shown in
.
Figure 26 - ArmorBlock Schematic
1732ES-IB12XOB4
889D-F5NCDM-X
889D-E5NC-10 889D-E5NC-10
Brown (1)
K1
K2
White (2)
Black (4) Gray (5)
White (2) A1
K1
A2 Blue (3)
100S Contactors or
700S or 700-HPS Relays
Black(4) A1
K2
A2 Gray (5)
shows the General tab of the ArmorBlock module properties. The
Input Status must be set to Combined Status - Muting and the Output Data must be set to Combined.
Figure 27 - Module Properties - General
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 45
Chapter 7 Application Examples
shows the Input Configuration tab of the ArmorBlock module properties. In this example, Points 0 and 1 monitor the OSSD outputs of the safety switch. The Type should be set to Single, and the Mode must be set to
Safety.
Points 4 and 5 monitor the status of the output contactors K1 and K2. These points should also be set to Single and Safety Pulse Test. The Test Source must agree with the Test Output tab.
Figure 28 - Module Properties - Input Configuration
46
Figure 29 shows the Test Output tab of the ArmorBlock Module Properties. In
this example, Points 0 and 1 are set to Standard, which allows the program to control these points. Point 0 applies power to the 440G-MZ safety switch. By setting it to standard, you can programmatically turn this point off and on if the 440G-MZ safety switch has a fault condition. Point 1 is the lock/unlock command. In this example, the 440G-MZ safety switch is a PTR type, so 24V unlocks the switch. Points 4 and 5 are used to monitor the contactor outputs and are set to Pulse Test.
Figure 29 - Module Properties - Test Output
Figure 30 shows the Output Configuration tab of the ArmorBlock module
properties. Points 0 and 1 drive the output contactors K1 and K2. The point
Types are set to Dual, and the Modes are set to Safety.
Figure 30 - Module Properties - Output Configuration
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Chapter 7 Application Examples
Figure 31 on page 48 shows an example program. A Dual Channel Input Stop
function block monitors the 440G-MZ safety switch, and a Configurable
Redundant Output function block controls two contactors. This example can be used as a starting point for implementation; you must incorporate additional logic that is based on the risk assessment for the machine.
9
10
11
12
Rung Description
0
With the Test Data output setup set as Standard, an HMI input can cycle power ON and OFF to the
440G-MZ safety switch to recover from a fault, if necessary. Upon powerup, the N.C. contact automatically applies power to the 440G-MZ safety switch.
1
The Dual Channel Input Stop monitors the outputs of the 440G-MZ safety switch. The DCS block is set for automatic start on powerup (cold start) and automatic restart each time the switch is locked.
2
3
4
The output of the DCS in Rung 1 provides a tag that shows the input 440G-MZ input status is OK. This tag is used in Rung 4 to enable the Configurable Output to be reset.
A momentary contact from an HMI input starts a short on delay timer. HMI input must be held long enough for the timer to expire. This timer is intended to help prevent inadvertent reset. The preset value can be adjusted to suit the application.
When the timer is done, the OSF_Storage_Bit is set. When the HMI_CROUT_Actuate button in Rung 4 is released, the OSF_Storage_Bit goes LO and the OSF_Output_Bit goes HI.
5
6
7
When the OSF_Output_Bit goes HI, the CROUT_Actuate tag is set. The CROUT_Actuate tag is self-sealing because the OSF_Output_Bit is HI only momentarily.
The GMZ_Crout block is set for negative feedback. The CROUT block output cannot go HI unless the external contactor status at Feedback 1 and 2 is HI.
The two CROUT outputs turn ON the ArmorBlock outputs, which energize the external contactors.
8
From an HMI input, you can lock or unlock the 440G-MZ safety switch. The HMI input must be a maintained switch.
Notify the HMI if a fault is present on the DCS block.
An HMI input can reset the DCS if a fault is present.
Notify the HMI if a fault is present on the CROUT block.
An HMI input can reset the CROUT if a fault is present.
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 47
Chapter 7 Application Examples
Figure 31 - Example Studio 5000 Program
48 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Chapter 7 Application Examples
Wire to MSR55P Back EMF
Safety Relay
A PowerFlex 525 drive controls the speed and direction of the motor. The
MSR55P safety relay allows access to the hazard after the motor has achieved its standstill settings. The DI safety relay monitors the guard locking switch and the E-stop push button.
The DI safety relay enables the drive to restart after the gate is closed and locked and the E-stop is released.
Figure 32 - MSR55P Back EMF Relay Schematic
+24V DC Class 2 PELV
L1L2 L3
R S T
Reset
Unlock
Vm -Monitoring
voltage ts - time Setting
(delay)
Status
to PAC
PowerFlex
525
1 Stop
2 Start
Safety Gate
440G-MZS20*NR*
Power to Release
No aux
889D-F5NC-X
Brown (+24)
Black - OSSD 2
White - OSSD 1
Gray - Unlock Request
Blue (Gnd)
24V DC Com
S11S21 S22 S12 A1 L12 Y32 S34
LOGIC
2
DIS
440R-D22S2
S32 S42 L11 A2 34 44 14 24
A1 11 23 33 43 53
MSR55P
440R-S35014
A3 X1 X2
Vm
X3
7
3 t s
A2 12 24 34 44 54 ON ERR A4 L1 L2 L3
ON status
ON status
Error status
Fuses*
4 Gnd
Gate Control
Power Supply
S1
S2
Gate control
circuit
U V W
M
3~
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 49
Chapter 7 Application Examples
Notes:
50 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

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