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Chapter
4
Power, Ground, and Wire
Wiring Requirements and
Recommendation
DG Safety Relay
WARNING: Before you install and wire any device, disconnect power to the system.
WARNING: Calculate the maximum possible current in each power and common wire. Observe all electrical codes that dictate the maximum current allowable for each wire size. Current above the maximum rating can cause wiring to overheat, which can cause damage.
• Allow for at least 50 mm (2 in.) between I/O wire ducts or terminal strips and the relay.
• Route incoming power to the relay by a path separate from the device wiring. Where paths must cross, their intersection must be perpendicular.
• Do not run signal or communications wiring and power wiring in the same conduit. Route wires with different signal characteristics by separate paths.
• Separate wiring by signal type. Bundle wiring with similar electrical characteristics together.
• Separate input wiring from output wiring.
• Label wiring to all devices in the system. Use tape, shrink-tubing, or other more dependable means to label wire. Use colored insulation as well to identify wiring by signal characteristics. For example, use blue for
DC wiring and red for AC wiring.
Wire Size
Each terminal can accommodate copper wire with size from 0.2…2.5 mm2
(24…14 AWG). Use copper that can withstand 60/75 °C (140/167 °F).
Terminal Torque
Torque terminals to 0.4 N•m (4 lb•in).
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 37
Chapter 4 Power, Ground, and Wire
38
Terminal Assignment and Function
The relays have four terminals: two on the top and two on the bottom. As
shown in Figure 19 , the X2 and X4 terminal markings apply to the terminals
further back. The X1 and X3 terminals apply to the terminals closest to the front.
Figure 19 - DG Terminal Identification
X1 X2
S12 S22 S32 S42
A1 A2 S11 S21
PWR/Fault
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
C onfig/S et
DG
Reset
Sel./Save
.14
.
0.2.4.6
Time
}X2
}X1
X1 X2 X3 X4
13 14 23 24
}X3
}X4
X3 X4
Some of the terminals can be configured for multiple functions. Table 7 lists
the functions available for each terminal.
Table 7 - Terminal Assignments and Functions
13
14
X3
X4
S32
S42
X1
X2
23
24
Terminal Function
A1
A2
+24V Supply (+10%, -15%)
0V Common
S11
S21
S12
S22
Pulse Test Output
Pulse Test Output
GuardLink Safety or Safety N.C.
GuardLink CLU or Safety N.C.
GuardLink Safety or Safety N.C.
GuardLink CLU or Safety N.C.
SWS In or OSSD In
SWS Out or OSSD Out
Standard Input (Feedback)
Standard Input (Reset)
Redundant Positive-Guided Relay Output 1
Redundant Positive Guided Relay Output 2
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Power, Ground, and Wire Chapter 4
Tap Pin Assignment and
Function
Each tap has three M12 quick disconnect connectors ( Figure 20 ). The system
is designed to use premanufactured patchcords to facilitate installation, modification, and troubleshooting. The link connectors are 4-pin. The device connectors are either 5-pin or 8-pin.
Figure 20 - Tap Connection Identification
INPUT
J3 GuardLink Device Connection
8-Pin M12 Female or
5-Pin M12 Female
J1 GuardLink Link In
4-Pin M12 Male
J2 GuardLink Link Out
4-Pin M12 Female
The link connections carry the power and command signals. Figure 21
shows the functions of each pin. When using Allen-Bradley® Guardmaster patchcords and safety devices, you do not need to be concerned about the pin assignments, the system is connect and go.
Figure 21 - Link Connections
2: GuardLink Safety 2: GuardLink Safety
Pin
1
2
3
4
1: +24V DC
3: 0V DC
J1 Link In (Male)
4: GuardLink CLU
Function
+24V Supply (+10%, -15%)
GuardLink Safety Signal
0V DC, the reference for the 24V supply
GuardLink Control Lock Unlock (CLU) Signal
1: +24V DC
4: GuardLink CLU
J2 Link Out (Female)
3: 0V DC
4
5
2
3
Pin
1
6
7
8
Figure 25 show the functions that are assigned to the 8-pin and
5-pin quick-disconnect connections for safety devices.
Figure 22 - J3 8-Pin OSSD (Female) Connector
2: +24V DC
1: Aux
3: Lock/Unlock Command
8: Safety OSSD A+
4: Safety OSSD B+
7: 0V
6: Safety OSSD B
5: Safety OSSD A
Function
The auxiliary status output signal is not used by the tap
+24V Supply (+10%, -15%)
The Lock/Unlock command to the device
Safety OSSD channel B+ (24V DC)
Safety OSSD channel A
Safety OSSD channel B
0V DC, the reference for the 24V supply
Safety OSSD channel A+ (24V DC)
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 39
Chapter 4 Power, Ground, and Wire
Figure 23 - J3 8-Pin EMSS (Female) Connector
2: Lock/Unlock Command
1: Aux Contact
3: Aux Contact
8: Safety Contact A
4: Safety Contact B
7: 0V
6: Safety Contact B
5: Safety Contact A
6
7
4
5
8
2
3
Pin
1
Function
Auxiliary (non-safety) contact
Lock/Unlock command
Auxiliary (non-safety) contact
24V output for safety contact channel B
Safety contact channel A
Safety contact channel B
0V DC, the reference for the Lock/Unlock command
24V output for safety contact channel A
Figure 24 - J3 5-pin OSSD (Female) Connector
2: Safety OSSD A
5: Aux
1: +24V DC
3: 0V
4: Safety OSSD B
3
4
5
Pin
1
2
Function
The +24V power supply to the device
Safety OSSD channel A
0V DC, the reference for the power supply
Safety OSSD channel B
The auxiliary status signal is not used by the tap
Figure 25 - J3 5-pin EMSS (Female) Connector
2: Safety Contact A
5: Safety Contact B
1: Safety Contact A
3: N/C
4: Safety Contact B
3
4
5
Pin
1
2
Function
24V output for safety contact channel A
Safety contact channel A
No connection
Safety contact channel B
24V output for safety contact channel B
40 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Power, Ground, and Wire Chapter 4
Bulletin 871A field-attachable quick-disconnect connectors can be used as shorting plugs during installation, troubleshooting, and for long distances.
When the distance between taps exceeds 30 m (98.4 ft), a tap must be inserted into the GuardLink system at least every 30 m (98.4 ft). A shorting plug must then be added to the J3 connector.
Figure 26 shows the wiring connections
that are required to create a shorting plug.
IMPORTANT For 5-pin OSSD taps, a shorting plug (catalog number 898D-418U-DM) can be used in place of the terminal chamber (catalog number 871A-TS5-DM).
For 8-pin taps, a shorting plug (catalog number 898D-81RU-DM2) can be used in place of the terminal chamber (catalog number 871A-TS8-DM1).
Figure 26 - Shorting Plug Schematics
Use 871A-TS8-DM1 or 898D-81RU-DM2 for 8-pin OSSD and EMSS taps
Use 871A-TS5-DM or
898D-418U-DM for 5-pin OSSD taps
6
7
4
5
1
2
3
8
1
2
3
4
5
Use 871A-TS5-DM for
5-pin EMSS taps
1
2
3
4
5
Power Supply Connection
Many Bulletin 1606 power supplies are SELV, PELV, and Class 2-compliant.
DG Safety Relay
To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with protected extra low voltage (PELV) or, under certain conditions, a safety extra low voltage (SELV) per IEC 60204-1 must power the
DG safety relay.
For the USA, a PELV supply is required, per NFPA 79.
Figure 27 shows the power supply connections for the DG safety relay.
Connect terminal A1 to +24V DC. Terminal A2 must be connected to the common of a 24V supply.
Figure 27 - DG Power Supply Connections
Connect +24V DC to Terminal A1 Connect 24V Common to Terminal A2
S12 S22 S32 S42
A1 A2 S11 S21
PWR/Fault
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
C onfig/S et
DG Reset
Sel./Save
14.
0
.2.4.6
Time
X1 X2 X3 X4
13 14 23 24
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 41
Chapter 4 Power, Ground, and Wire
Taps
To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with a protected extra low voltage (PELV) or, in certain circumstances, a safety extra low voltage (SELV) per IEC 60204-1 must power the tap. For IEC applications, an in-line, slow-blow 4 A fuse is recommended if the power supply can provide more than 4 A.
For the USA, a Class 2 power supply must be used. The Class 2 supply limits the current to 4 A, so an in-line fuse is not needed.
IMPORTANT In the USA, use of a 4 A fuse or circuit breaker in place of a Class 2 power supply is not acceptable.
Figure 28 shows the power connections to the power tap. Power is connected
only to the first tap.
Figure 28 - Tap Power Connections
GuardLink First Tap GuardLink First Tap
Pin 1: +24V DC Pin 1: +24V DC
4 A
Pin 3: 0V DC Pin 3: 0V DC
+ +
DC ok
+ +
DC ok
1606-XLE 240 EN
N L
PELV for IEC Compliance
1606-XLP 95 E
N L
Class 2 for USA Compliance
42 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Power, Ground, and Wire Chapter 4
Multiple Power Supplies
When separate power supplies are used for the DG safety relay and the
GuardLink circuit, the protective earth connections must be at the same point.
Figure 29 shows an example wiring diagram (catalog number
1606-XLE240EN is not Class 2 compliant; catalog number 1606-XLP-95E is
Class 2 compliant).
Figure 29 - Multiple Power Supplies — Ground PE at Same Point
INPUT
S12 S22 S32 S42
A1 A2 S11 S21
PWR/Fault
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
DG
Co nfig/S et
Reset
Sel./Save
14.
0
.2.4.6
Time
X1 X2 X3 X4
13 14 23 24
+ +
DC ok
1606-XLE240EN
N L
+ +
DC ok
1606-XLP95E
N L
Multiple power supplies must have one point common connection
DG Safety Relay Input Wiring
This section describes DG safety relay input wiring.
GuardLink Connections
Up to two GuardLink circuits can be connected to the DG safety relay. The
GuardLink safety signal must be connected to either S12 or S32 and the
GuardLink CLU signal must be connected to either S22 or S42. Figure 30
shows the connections for the GuardLink circuits; the wire colors apply when the recommended cordsets are used.
Figure 30 - GuardLink Connections
+24V DC
INPUT INPUT
24V Com
A1 S12
Safety
Input 1
S22
CLU
A2
DG Safety Relay
S32
Safety
Input 2
S42
CLU
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 43
Chapter 4 Power, Ground, and Wire
Devices with OSSD Outputs
Devices with OSSD outputs perform their own short circuit detection. The
DG can be configured to accept up to two devices with OSSD signals.
Connections of the OSSD outputs are shown in Figure 31
.
Figure 31 - Wiring to Devices with OSSD Outputs
+24V DC
A1
A2
A1
Device 1
A2
A1
Device 2
A2
S12 S22
Input 1
DG Safety Relay
S32 S42
Input 2
24V Com
Voltage-free Contacts
Devices with voltage-free contacts must use the pulse testing outputs to detect short-circuit faults between the following:
• Channels
• Channels and power
• Channels and ground
Figure 32 shows the recommended wiring for dual-channel and single-channel,
voltage-free contacts. Voltage-free contacts can be connected to either Input 1,
Input 2, or both inputs.
Figure 32 - Wiring to Voltage-free Contacts
Device 1 Device 2
Device 1 Device 2
S11 S21
Pulse
Testing
Outputs
S12
Input 1
S22
DG Safety Relay
Dual Channel
S32 S42
Input 2
S11 S21
Pulse
Testing
Outputs
S12
Input 1
S22
DG Safety Relay
Single Channel
S32 S42
Input 2
44 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Single Wire Safety
Power, Ground, and Wire Chapter 4
The DG safety relay has the Single Wire Safety capability to expand the safety function (both input and output).
SWS Connections
The Single Wire Safety (SWS) feature allows a safety relay to expand the safety function to additional safety relays using one wire, provided all safety relays have the same voltage supply reference.
The SWS signal is unidirectional. The signal flows from L11 to L12.
There can be many variations and combinations of series and parallel connections of the SWS. Each L11 terminal can be connected to up to ten L12 terminals.
IMPORTANT Do not connect two or more L11 terminals together.
Figure 33 shows an example wiring diagram with an SWS signal. The SWS can
be connected between the DG safety relay and other relays in the GSR family
(the CI, DI, DIS, EM, EMD, and SI relays). Relay 1 has a series connection to
Relay 2. Relay 2 has a parallel connection to Relays 3 and 4. Relay 4 has a series connection to Relay 5. The safety relays must have a common power reference
(24V common). In this example, the safety function started by Relay 1 turns off all other relays if AND logic is applied to L12 on all relays.
IMPORTANT The DG safety relay terminals are marked X2 and X1; which is equivalent to terminal L12 and L11 on other GSR relays.
Figure 33 - SWS Connection Example
+24V DC +24V DC +24V DC +24V DC +24V DC
A1
A2
GSR Relay 1
DI
L12 L11
SWS
A1
A2
GSR Relay 2
DG
X1 X2
A1
GSR Relay 3
DG
A2 X1 X2
A1
A2
GSR Relay 4
EM
L12 L11
SWS SWS
24V DC Com (the relays must have a common reference)
A1
GSR Relay 5
EMD
A2 L12 L11
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 45
Chapter 4 Power, Ground, and Wire
Safety Output Wiring
Figure 34 shows the characteristics of SWS signal when it is active. It starts
with a 1 ms pulse, followed 700 µs later by a 500 µs wide pulse. This waveform is repeated every 4 ms. The tolerance of all edges is ±10%.
When inactive, the SWS signal is 0V.
Figure 34 - SWS Waveform
24V
Terminals
X1 and X2
0V
0 1 1.7 2.2
4 ms
The DG safety relay has two voltage-free, safety-related outputs (terminals
13/14 and 23/24).
13/14 and 23/24 Safety Outputs
The 13/14 and 23/24 safety outputs have redundant (two) positive-guided relays that are internally connected between each terminal. An example of the
wiring connections is shown in Figure 35
. See
Specifications on page 87 for the
voltage and current ratings of these relays.
If the voltage supply of the outputs exceeds the voltage supply of the relay, then low-voltage wiring must be separated from the high-voltage wiring.
Figure 35 - Output Connections of the DG Safety Relay
V supply
13 23
14 24
K1 K2
V common
46 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018
Power, Ground, and Wire Chapter 4
Surge Protection
Due to potentially high-current surges that occur when switching inductive load devices, such as motor starters and solenoids, the use of some type of surge suppression to help protect and extend the operating life of the relays is recommended. By adding a suppression device directly across the coil of an inductive device, you prolong the life of the outputs. You also reduce the effects of voltage transients and electrical noise from radiating into adjacent systems.
Figure 36 shows an output with a suppression device. We recommend that you
locate the suppression device as close as possible to the load device.
For outputs that use 24V DC, we recommend 1N4001 (50V reverse voltage) to 1N4007 (1000V reverse voltage) diodes for surge suppression for the OSSD safety outputs (
Figure 31 ). The diode must be connected as close as possible to
the load coil.
For outputs that use 120V AC or 240V AC, we recommend metal oxide varistors.
Figure 36 - Surge Protection Examples
Metal oxide varistors for V AC supply
Diodes for V DC supply
K1
V common
K2 K1
V common
K2
Rockwell Automation Publication 440R-UM015C-EN-P - April 2018 47
Chapter 4 Power, Ground, and Wire
Notes:
48 Rockwell Automation Publication 440R-UM015C-EN-P - April 2018

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