Guardmaster Safedge
Pressure Sensitive Safety
Edge System Installation and
User Manual
Bulletin Number 440F
User Manual
Original Instructions
Page 2
Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual 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.
WA RN I NG : 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.
IMPORTANTIdentifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
2Rockwell Automation Publication 440F-UM002B-EN-P - August 2020
Rockwell Automation Publication 440F-UM002B-EN-P - August 20203
Page 4
Product Overview
SAFEDGE™
RUN
STOP
OPEN
Safedge™ Pressure Sensitive Safety Edge System
Control Unit
Supply Voltage 230/110VAC (see selector)
50-60Hz or 24V AC/DC
IP65 Hoseproof, Dust tight
Safety Contacts 250V 2A N/O
Aux Contacts 250V 2A N/C
GuardEdge™ Prole Voltage 12V DC
EN ISO 13849-1 Cat. 3, EN 1760-2
System response time 13mS
See user manual for further information
ISOLATE POWER BEFORE OPENING
R
PRESSURE SENSITIVE EDGE SYSTEM
CONTROL UNIT Pt. No. 440F-C251P
MADE IN THE GERMANY
A1
A2
+
-
Z2
Z1
13
14
23
24
31
32
MC
MC
Isolate before opening
(A1/A2) 110/230V AC selectable
(+/-) 24V AC/DC
440F-C251D
PRODUCT OF THE DOMINICAN REP.
SAFEDGE
Control unit
ISO 13849-1
ISO 13856-2
OPEN
STOP
RUN
Z2
Z1
-
-
-
X2
X1
14
13
22
21
RUN
OPEN
STOP
SAFEDGE
Control unit
SECD252
Surface MountingDIN Rail Mounting
IMPORTANTRead this manual in full before installation. After installation, this
manual must be retained in a safe and accessible place.
Chapter 1
System DescriptionThe Safedge system consists of up to 50 meters of profile, a cable connector, a
Storage and HandlingStorage
4Rockwell Automation Publication 440F-UM002B-EN-P - August 2020
The Safedge™ sensitive edge sensing system is ideal as a safety sensor in
applications like power operated doors, automated vehicles, and moving
machinery beds, for use when objects are detected by touch. It can provide a
continuous line of high sensitivity touch sensing along or around practically
anything.
terminating resistor, a “C” rail and a control unit. The control unit can monitor
lengths of up to 50 m (164 ft). All profiles have the same principle of operation.
This manual covers the use of the parts of the Safedge system. If joints or
corners are required, contact your supplier. Suitably trained and qualified
personnel must complete all installation work in accordance with statutory
requirements for safety. For further assistance, please contact your supplier.
The Safedge control unit and profiles should be stored within the temperature
range of -10…+55°C (-14…+131°F).
Page 5
Chapter 1 Product Overview
Handling and Transport
The Safedge control unit and profile should be transported within the
temperature range of -10…+55°C (-14…+131°F) and should not be subjected to
any impact or heavy loads. The original packaging should be used to give
protection from excessive flexing.
Always unpack carefully and avoid damage that can result from rough handling or
the use of knives, box cutters, and so on.
Safedge Selection
The following are the most important factors t h a t influence the selection
of a suitable pressure-sensitive edge or pressure-sensitive bar for a specific
application.
•Category and performance level according to ISO 13849-1 as required for
the application. These are based on the following:
- the risk assessment for the particular application
- the requirements of a relevant type-C standard.
•Hazard speed
The speed at which the hazardous surface is moving. Normally, one
surface is moving and the other is stationary. The maximum possible
speed should be considered as the hazard speed. If both surfaces are
moving, special consideration is required.
•Stopping travel of hazardous parts
The distance traveled by the hazardous surfaces after the output signal
switching device to the machine control system gives a stop signal. This
travel depends on the hazard speed, the response time of the machine
control system and the efficiency of the machine braking system. This
travel can be calculated and/or measured. Where appropriate, a suitable
safety factor should be used to account for brake deterioration,
measurement tolerances, and so on.
•
Recovery of the sensor after deformation
On applications where the time between successive actuations of the
sensor is less than 30 s. A sensor should be selected that recovers
sufficiently for normal operation within thetime available.
Selection Procedure
After deciding the category and the performance level according to ISO
the procedure is as
1. Determine the required operating speed and maximum hazard speed.
If the maximum hazard speed is not given, it should be measured or
calculated. The point in thetravel at which the maximum speed occurs
depends on the drive mechanism.
The maximum operating speed of the device should be greater than the
maximum hazard speed.
Rockwell Automation Publication 440F-UM002B-EN-P - August 20205
follows.
13849-1,
Page 6
Chapter 1 Product Overview
2.
Determine the required minimum overtravel distance.
Determine the stopping travel of the hazardous parts. If this distance is
not given, it should be measured and/or calculated. The stopping travel
multiplied by a suitable safety factor of at least 1, 2 gives the required
minimum overtravel for the application. Where other factors exist, such
as a braking system that is subject to deterioration, a higher safety
factor should be used.
A simple way to measure the stopping distance is to temporarily fit a
position detection at a position close to where the maximum hazard
speed occurs. Normally, closed contacts of this position detection
should be connected into the machine control stop circuit at the point at
he o
which t
utput signal switching devices would be connected. The
machine should be run several times in the worst anticipated conditions
and the distance that is traveled beyond the actuating point of the
position detection measured. The maximum distance that is measured
should be regarded as the stopping distance.
3. Determine the maximum permissible force.
When available, the maximum permissible force should be taken from a
type-C standard for the specific machine or be in accordance with the
risk assessment. The risk assessment should consider the body parts
and types of persons to be protected, for example, children or elderly
persons. The speed, shape, and material of the sensor and maximum
pressure that the device exerts should also be considered. The maximum
permissible force should be as low as possible.
4. Select the device.
Using the force/distance relationship data or diagrams that are
provided by the manufacturer, select the safeguard with the required
maximum operating speed that provides at least the required minimum
overtravel distance before the maximum permissible force is reached.
If a pressure-sensitive edge or pressure-sensitive bar with sufficient
overtravel cannot be found, it can then be necessary to improve the
stopping performance of the machine.
6Rockwell Automation Publication 440F-UM002B-EN-P - August 2020
Page 7
Safedge Profiles
30(1.18)
36 (1.41)
68 (2.67)
28.5 (1.12)
12.5 (0.48)
9
(0.35)
24.5 (0.96)
2 (0.08)
28 - 30
(1.10-1.18)
25 (0.98)
14 (0.55)
43 (1.69)
17 (0.67)
30 (1.18)
36 (1.41)
68 (2.67)
29 (1.14)
28.5 (1.10)
12.5
(0.48)
24.5 (0.96)
2 (0.08)
Cushion factor 5 mm (0.20 in.)
440F-E0110S
440F-E0110R : Red prole
440F-E0110N: Increased resistance
25 (0.98)
14 (0.55)
43 (1.69)
28.5(1.12)
440F-E0310S
Cushion factor 41 mm (1.60 in.)
440F-E0510S
Cushion factor 5 mm (0.20 in.)
with sealing lip
440F-E0210S
Cushion factor 41 mm (1.60 in.)
with sealing lip
440F-E0804S
Cushion factor 19 mm (0.75 in.)
with sealing lip
g. 1g. 2g. 3g. 4
fig. 5fig. 6
Cushion fac tor 19 mm (0.75 in.)
440F-E1610S
440F-E1610N : Increased resistance
"C" rail-aluminium C112/A
440F-R1212
Suitable for attaching all the
Safedge proles.
25
(0.98)
"C" rail-zinc coated steel C112/S
440F-R1112
Suitable for attaching all the
Safedge proles.
25
(0.98)
"C" rail PVC
C112/PB = Black 440F-R1212PB
C112/PR = Red440F-R1212PR
25
C112/PY = Yellow 440F-R1212PY
(0.98)
Suitable for attaching all the Safedge
proles. Available in 3 colors.
"C" rail-aluminium C112/A3
440F-R1215
Ideal when external xing of "C" rail is
required. Accepts all proles.
25 (0.98)
"C" rail-aluminium C112/A4
440F-R1216
This deeper rail allows cables to run
through channel under Safedge prole.
Accepts all proles.
"C" rail-aluminium C112/A2
440F-R1214
Ideal when external xing of "C" rail is
required. Accepts all proles.
25
(0.98)
Rockwell Automation Publication 440F-UM002B-EN-P - August 20207
Page 8
Chapter 1 Product Overview
Conductive
Rubber
Non-conductive Rubber
Flexible Wire
Cores
Flexible copper
cores send the
signal to the
evaluator
90°
45°
45°
Contact
Zone
A Safedge system consists of the following components:
•Pressure sensitive profiles, which act as sensors.
Profile Model No.Profile
440F-EA b c d e 440F-E0110S
440F-EB b c d e440F-E0110R
440F-EC b c d e440F-E0110N
440F-ED b c d e440F-E0510S
440F-EE b c d e440F-E1610S
440F-EF b c d e440F-E1610N
440F-GF b c d e440F-E0804S
440F-EH b c d e440F-E0310S
440F-EI b c d e440F-E0210S
440F-EJ b c d e440F-E0510S
440F-EK b c d e440F-E0804S
440F-EL b c d e440F-E0210S
440F-EM b c d e440F-E0118S
440F-EN b c d e440F-E1111S
440F-E0 b c d e440F-E1111S
where:
b: indicates with or without “c” rail for mounting
c: indicates location of cable entrance
d: indicates the termination of the profile and cable length
e: indicates the length of the profile in mm and is a five-digit number
•Control units, which evaluate the sensor signal:
Control Unit Model No.Description
440F-C251PEnclosure of surface mounting
440F-C251DEnclosure for DIN rail mounting
440F-C252DEnclosure for DIN rail mounting
IMPORTANTAll “C” rails are supplied without mounting holes. The “C” rail (440F-
R1212) can be supplied curved to meet most applications.
Each profile uses a combination of non-conductive rubber and a flexible wirecored conductive rubber, which is bonded together to form various energy
absorbing profiles. The profile has no rigid internal parts that can break
through or cause fatigue failures after prolonged use. The maximum operating
voltage of the profile is 12V DC; operators are therefore not exposed to
potentially dangerous voltage should the profile be accidentally cut or sheared.
The copper wire core throughout the length of the profile helps ensure that
there is no significant build-up of resistance over long lengths.
8Rockwell Automation Publication 440F-UM002B-EN-P - August 2020
Figure 1 - Profile Operation and Contact Zone
Page 9
Chapter 1 Product Overview
The Safedge control unit monitors the circuit through the profile. When 6KΩ
resistance (that is, normal run conditions) is detected, the control unit
produces a signal to the machine control circuit. When the profile is pressed,
from any direction through 90° as shown in Figure 1 on page 8
conductive rubber strip compresses and touches the middle conductive
rubber, which creates a “short circuit” which drops the overall resistance. The
control unit monitors this action and initiates the machine shutdown. Any
single fault in the profile or the wiring connections to the profile is detected; in
that case the control unit outputs go to a safe (OFF) state.
Individual profiles connect to each other via wires, axial connectors or
standard 90° connectors. Two wires connect the profiles to the control units.
The control unit has fully cross-monitored safety relays; it is therefore possible
to configure the unit to detect an external contactor fault.
Compliance with the requirements of EN ISO 13856-2:2013 is achieved for the
control unit regarding electrical faults and can be met for the associated part
of the machine control system. B10d for profile is 10,000.
The Safedge system complies with the requirements of the European EMC
Directive. Normal operation under interference conditions likely in industrial
environments is assured, as it has been tested and certified.
, the top
Installation of the Safedge
System
Faults are excluded per ISO 13849.
•Edges must be installed in an environment that does not cause
degradation of profile material.
•Edges must be properly sealed to help prevent non-conductive fluids
from filling the profile cavity that would prevent pressing the profile.
•Profile must be connected to qualified controller.
IMPORTANTSpecial measures may be required in the presence of abnormally high
levels of EMI. For example, near welding or induction heating equipment
or near radio transmitters or transceivers.
ATTENTION: Because fault exclusion is used, Safedge systems can achieve
up to PLd Cat. 3.
Each application/installation user shall determine required PL level. The
system as installed must meet required PL level.
IMPORTANTOnly use 440F-A0020 cyanoacrylate.
This type of cyanoacrylate adhesive achieves a lasting sealing and high
protection in accordance with the IP65 rating.
Rockwell Automation Publication 440F-UM002B-EN-P - August 20209
Page 10
Chapter 1 Product Overview
"C" RAIL
CABLE CONNECTOR
CLOSING CAP
TO CONTROL UNIT
OR NEXT PIECE
OF PROFILE
CONNECTOR
WITH RESISTOR
Installation of “C” Rail
Mounting the “C” Rail
Holes drilled on
installation
(Fasteners not
supplied)
1. Cut the Safedge profile to length.
2. When using the 440F-A1302 closing cap with sealing lip, the profile base must
3. The shaded areas must be roughened with emery/sand paper.
Assembly and Installation of the Safedge Profile
Profiles without coasting chamber should be cut with rubber shears.
Profiles with coasting chamber should be cut with a fine tooth saw.
be cut back to a length of 12 mm (0.46 in.). The cut must be precisely made to
verify that the profile base is completely trimmed off, leaving a flush surface.
12
10Rockwell Automation Publication 440F-UM002B-EN-P - August 2020
Page 11
4. The closing caps are molded with four grommets, each with a rubber plug.
ATTENTION: The narrow side (wedge) of the connector must show
outwards.
IMPORTANTSpread the adhesive evenly over the shaded area! Verify that no
adhesive enters the profile.
When fitting a resistor, leave the plugs intact. When making a cable
connection, select the appropriate cable exit, and remove the plug from the
grommet with a hole punch.
5. Pull the connecting cable through the hole.
6. Pierce each of the copper wires with one of the needles. Press the needle
contacts of the connector in the direction shown: wedge outwards, straight
into the copper wires.
7. Fold back the sealing lip of the cap, then:
a. Apply adhesive to shaded area of closing cap as illustrated, then affix to
edge of profile. Apply pressure for 10 seconds to enable adhesion.
b. Apply adhesive to remainder of shaded area and allow sealing lip to contact
the profile.
Chapter 1 Product Overview
8. To achieve complete seal, apply more adhesive to the Safedge profile,
especially around the grommet/cable exit and sealing lip of the closing cap.
9. The axial profile connector 440F-A0061S is used for extensions and repairs
(see previous steps) for the 440F-E0110 series of profiles only. For other types,
use straight pin connectors.
When inserting the profile into the “C” rail, a lubricant may be used to reduce
friction. When installing, do not pull on connecting cable or on rubber profile.
Sensing Surface of Safedge System
The sensing surface of the Safedge system is active along almost the full length
of the edge. The 10mm (0.4 in.) at the beginning and end are not active.
Rockwell Automation Publication 440F-UM002B-EN-P - August 202011
Page 12
Chapter 1 Product Overview
Technical Specifications
Attribute440F-C251P Surface Mount440F-C251D DIN Rail440F-C252D DIN Rail
ConformityEN 13849 PLd, Cat. 3, EN ISO 13856-2: 2013
System response time13 ms
Environmental protectionIP65
Safedge profile voltage, max12V DC (open circuit)
Operating voltage, nom4V (run condition)
Output fuse, max2 A quick acting5 A quick acting
Impulse withstand voltage2500V
Over voltageCategory 2
Contamination levelIII
Switched current/voltage, min10 mA/10V
Power consumption<6VA
Relay outputs
Utilization category
Safety inputsSafedge profile (open resistance 6 KΩ)
Status indicator 1Green: RUN
Status indicator 2Yellow: OPEN
Status indicator 3Red: STOP
Internal controlsAC voltage selector
Internal fuses
Output fuse, max—4 A on AC/2 A on DC
Ambient temp. range—control unit -10…+55 °C (-14…+131 °F)
Actuating distance6.4 mm (0.25 in.)6.6 mm (0.26 in.)8.0 mm (0.31 in.)7.8 mm (0.30 in.)9.4 mm (0.37 in.)
Response distance1.2 mm (0.05 in.)1.9 mm (0.07 in.)27.2 mm (1.07 in.)8.4 mm (0.33 in.)5.0 mm (0.20 in.)
440F-E0510S
440F-E0110R
440F-E0110S
440F-E0210S
440F-E0310S
440F-E1610N
440F-E0118S
440F-E0804S
440F-E1610S
12Rockwell Automation Publication 440F-UM002B-EN-P - August 2020
Page 13
Chapter 1 Product Overview
Distance [mm (in.)]
Vp = 10 mm/s
0.02.0
(0.08)
3.6
(0.14)
5.5
(0.22)
7.2
(0.28)
8.7
(0.34)
300
250
200
150
100
50
0
Force (N)
300
250
200
150
100
50
0
0.01.9
(0.07)
3.9
(0.15)
5.4
(0.21)
7.4
(0.29)
8.8
(0.35)
Distance [mm (in.)]
Vp = 100 mm/s
Force (N)
440F-E1111S is a cover profile only and is nonfunctioning.
•Speed, max: 100 mm/s
•Suitable for the detection of fingers
The control unit must not be mounted inside the hazard zone. Access to the
control unit is required for manual reset or for routine indicator observation,
so it must be visible when in operation. The control unit can be mounted on
either side of the power doors, as long as the only hazard is the actual doors. In
all other cases, the control unit can be mounted anywhere convenient outside
the hazard zone, with consideration for access requirements for test and
maintenance.
Force Travel Relationship
Since the Safedge system is a contact device, a force is required to operate the
device. This force is dependent on the shape of the object that applies the force,
the speed of the object and deformation distance on the profile. To help
understand the force requirements, the European standard ISO 13856-2 2013
provides three test objects that are traveling at two speeds. Figure 2
force that is applied over the deformation distance on the surface of the
profile. The force required to operate the corners is greater than the force
required along the straight section of the profile. This force must be used as a
guideline, as the inanimate object cannot be harmed.
shows the
Figure 2 - Force vs Distance
Rockwell Automation Publication 440F-UM002B-EN-P - August 202013
Test temperature 20 °C (68 °F)/Speed:10 mm/s100 mm/s200 mm/s10 mm/s100 mm/s200 mm/s
Actuation force63.6 N76.9 N84.6 N13.5 N19.5 N20.6 N
Response travel A [mm (in.)]9.7 (0.38)9.6 (0.38)9.4 (0.37)7.3 (0.29)7.2 (0.28)6.9 (0.27)
Total deformations at 250 N B1 [mm (in.)]22.3 (0.88)19.5 (0.77)18.5 (0.73)28.1 (1.10)25.4 (1)25.4 (1)
Total deformations at 400 N B2 [mm (in.)]28.7 (1.13)27.6 (1.09)26.7 (1.05)32.4 (1.28)31.1 (1.22)30.6 (1.20)
Total deformations at 600 N B2 [mm (in.)]31.2 (1.23)29.9 (1.18)28.9 (1.14)34.9 (1.37)33.8 (1.33)32.9 (1.30)
Compensation travel at 250 N [mm (in.)]12.7 (0.50)9.9 (0.39)9.1 (0.36)20.8 (0.82)18.2 (0.72)18.4 (0.72)
Compensation travel at 400 N [mm (in.)]19.1 (0.75)17.9 (0.70)17.3 (0.68)25.0 (0.98)23.9 (0.94)23.7 (0.93)
Stopping distance, max [mm (in.)]15.9 (0.63)15.0 (0.59)14.4 (0.57)20.8 (0.82)19.9 (0.78)19.7 (0.78)
AttributeCat. No. 440F-E0310S, 440F-E0210S
Test temperature 20 °C (68 °F)/Speed:10 mm/s100 mm/s200 mm/s
Actuation force41.6 N68.5 N87.0 N
Response travel A [mm (in.)]6.8 (0.27)9.6 (0.38)8.6 (0.34)
Total deformations at 250 N B1 [mm (in.)]38.1 (1.50)21.7 (0.85)22.0 (0.87)
Total deformations at 400 N B2 [mm (in.)]44.6 (1.76)44.0 (1.73)42.5 (1.67)
Total deformations at 600 N B2 [mm (in.)]49.5 (1.95)49.2 (1.95)47.6 (1.87)
Compensation travel at 250 N [mm (in.)]31.3 (1.23)12.2 (0.48)13.4 (0.53)
Compensation travel at 400 N [mm (in.)]37.8 (1.49)34.4 (1.35)33.9 (1.33)
Stopping distance, max [mm (in.)]31.5 (1.24)28.7 (1.13)28.3 (1.11)
14Rockwell Automation Publication 440F-UM002B-EN-P - August 2020
Select the Cushion Factor
One of the important characteristics of edge systems is called cushion factor.
The cushion factor is the distance that the profile can be depressed after the
signal is generated. This characteristic is important when the profile is
mounted on automated doors.
Automated doors continue to close for some finite time after the profile sends
the initial stop signal, which is known as the system response time. The system
response time is the sum of the Safedge control unit response time, the control
Page 15
130 (5.12)
440F-C251P (surface mounted)
rail mounting
45.5 (1.79)
73
(2.87)
120 (4.72)
A1 + Z 2 M C 13 23 31
A2 --
Z 1 MC 14 24 32
35 mm DIN
440F-C251D (mounted on DIN rail)440F-C252D (mounted on DIN rail)
Control Unit
Connection Box
Coiled
Cable
Closing
Cap
Cable
Connector
Connector
with Resistor
Closing
Cap
“C” Rail
Connection Box
115 (4.53)
4 x M4 Fixing Holes
115
(4.53)
130
(5.12)
75 (2.95)
Pg16/21
Pg16/21
Chapter 1 Product Overview
system response time, and the mechanical stopping time. Systems with longer
response time should use larger cushion factors. You must validate that injury
does not occur if parts of the body get jammed, for example between the
sensing edge and the fixed part of a machine.
You might also consider a reversing option. When the profile is depressed, the
Safedge control unit sends a signal to a reversing relay. Since the reversing
relay is not a safety rated device, you must still confirm that injury does not
occur if parts of the body get jammed.
Mounting
Dimensions shown in mm (in.).
22.5
118 (4.64)
35 mm DIN
rail mounting
(0.88)
86
(3.38)
Terminal Connections
To help prevent strain on terminal connections, use connection boxes and
coiled cables.
Rockwell Automation Publication 440F-UM002B-EN-P - August 202015
Page 16
Installation and Wiring
440F-C251P (surface mounted)
4.3
4.7
4.6
4.54.4
+
Z1 X1 13 21
Z2 X2
-
14 22
440F-C251D (mounted on DIN rail)440F-C251D (mounted on DIN rail)
IMPORTANTWiring must be in accordance with the [British] National Electric Code
and applicable local codes and ordinances. Carefully follow the
instructions on page 17
Electrical ConnectionsFigure 3 - Safedge Control Unit
STOP
RED
for correct installation.
RUN
OPEN
GREEN
YELLOW
LED INDICATION
4.7
Z1 Z2 MC MC
Chapter 2
4.6
110V
4.1
230V
L
+--
N
31 32 13 14 23 24
ve ve
SUPPLY FUSE
500 mA
4.34.44.5
A1 + Z 2 MC 13 23 31
4.3
4.1
A2
4.7
-- Z1 MC 14 24 32
4.2
SUPPLY
FUSE
500 mA
STOP (RED)
OPEN (YELLOW)
RUN (GREEN)
110V
230V
4.2
See table on page 17 for callout explanations.
SAFETY FUSES
2A
4.5
4.4
4.6
16Rockwell Automation Publication 440F-UM002B-EN-P - August 2020
Page 17
(1)
Uses 6K8 resistor
(yellow)
Item
(1) From Figure 3 on page 16.
Description
Main selector switch: If using a 110V AC or a 230V AC supply, set the voltage selector switch before turning on the power. The default factory setting of the
4.1
unit is 230V AC.
Main input terminal LN PE (A1, A2, PE): If using a 110V AC or 230V AC supply, the power supply should be wired together with a protective earth (ground) to the
4.2
terminals shown. The size of the protective earth (PE, ground) wire should at least be equal to that of the supply wire. Also check the main selector switch. If
these terminals are used, ignore the following items.
24V AC/DC input terminal +ve and -ve or + and -: If a 24V AC/DC supply is used, the supply should be connected to these terminals, verifying that the correct
polarity is observed.
4.3
Do not make any connections to the terminals of main input terminal. When a 24V AC or DC supply is used, it must be isolated from the main supply in
accordance with international electrical safety practice (IEC 364-4-41). One pole should be grounded to the earth. For 24V DC, the negative pole should be
grounded. With 24V AC, the ground of the power supply should be connected to the negative terminal.
Aux. Output terminals 31 and 32 or 21 and 22 in 440F-C: This terminal provides an auxiliary normally closed contact (that is closed when the green RUN
4.4
status indicator is off) which is suitable for indication or for alarm devices. As it is an auxiliary, it must not be connected to the safety circuit.
Safety Output terminals 13, 14, 23 and 24: These terminals are volt-free contacts for connection to the machine safety circuits—in other words, they are
connected in series with the machine contactor control circuit (max rating 2 A at 250V AC). Both of these safety circuits are internally fused but must also be
4.5
externally protected with a 2 A quick-acting fuse. If you are using only one contactor, terminals 13 and 24 are required and terminals 14 and 23 should be
jumpered together. For two contactors with two independent control circuits (that is a dual channel system), use 13-14 for one contactor and 23-24 for the
other. For two contactors, also see Applications
Reset terminal MC-MC or X1 - X2 on the 440F-C2522: These terminals are used for a number of different functions (the surface mount version is supplied
with jumpers, while the DIN rail version is supplied without a jumper).
Without the jumper, the terminals can be connected to positively guided normally closed auxiliary contacts on the machine contactors to provide monitoring of
the contactors in dual channel control systems. If one contactor fails to isolate the power at de-energization of its control coil, the Safedge™ system does not
allow the other contactor to be energized until the fault has been rectified. Fit a jumper between these terminals on the DIN rail unit if this function is not
required.
4.6
This terminal is also used for auto/manual reset. If the MC-MC terminal remains jumpered or connected only to the normally closed contact of the contactor,
the unit is in automatic reset mode. In automatic reset mode, the output is achieved solely by removal of the actuating force. The output is also achieved at
power up of the actuator (when there is no actuation force present). If a spontaneous restart can generate a risk, based on the result of a risk assessment to
ISO12100, then this mode must not be used. See IEC60204-1 and EN ISO13849-1.
For manual reset mode, a normally open spring return (not latching) push button must be connected across the MC-MC terminals or in series with the normally
closed contactors. When the actuating force is removed, the unit does not operate until the button is pressed. The button also has to be pressed after
powering up the control unit.
Profile connection to control units: These terminals are used to connect the profile to the:
• Z1 = Brown (inner conductor)
• Z2 = White (outer connector)
4.7
See Applications
A profile must be terminated with a 6KΩ resistor (yellow) for series connection. If two profiles are connected directly to Z1 and Z2 (in parallel), each profile
should be terminated with a 15K resistor (blue).
Chapter 2 Installation and Wiring
on page 19.
on page 19.
Profile ConnectionConnect in Series
Installations that involve several profiles are normally connected in series.
Connect in Parallel
A maximum of two profiles can be connected in parallel to facilitate the wiring
of certain applications.
Uses 15K resistor (blue)
Rockwell Automation Publication 440F-UM002B-EN-P - August 202017
Page 18
Commissioning and Sequence of Operation
When the unit is installed, check the following sequence of operation.
Manual Reset Mode1. Turn on the power.
a. No status indicators illuminate.
2. Press the reset switch
a. The green RUN status indicator illuminates.
b. Safety contacts close.
c. Auxiliary contacts open.
d. Contactors energize.
3. Press the profile.
a. The green RUN status indicator turns off.
b. The red STOP status indicator illuminates.
c. Safety contacts open.
d. Auxiliary contacts close.
e. Contactors de-energize.
4. Release the profile.
a. The red STOP status indicator turns off.
b. System has returned to step 1
5. If profile is pressed before reset
a. The red STOP status indicator illuminates each time that the profile is
pressed but the safety contacts do not energize.
Chapter 3
.
Automatic Reset Mode1. Turn on the power.
a. The green RUN status indicator illuminates.
b. Safety contacts close.
c. Auxiliary contacts open.
d. Contactors energize.
2. Press the profile.
a. The green RUN status indicator turns off.
b. The red STOP status indicator illuminates.
c. Safety contacts open.
d. Auxiliary contacts close.
e. Contactors de-energize.
3. Release the profile.
a. System has returned to step 1
IMPORTANT • Terminal block tightening torque rating is 7 in•lb, suitable for wire sizes 16 AWG.
•Use 16 AWG min.
• Use copper conductors only.
• Temperature rating of field wiring must not be less than ambient.
18Rockwell Automation Publication 440F-UM002B-EN-P - August 2020
.
Page 19
Comparative Properties
Series Terminated, Safedge Input, Manual Reset,
Dual Channel Output, Monitored Output
Series Terminated, Cascaded, Safedge Input, Automatic Reset,
Dual Channel Output, No Output Monitoring
Parallel Terminated, Safedge Input, Manual Reset,
Single Channel Output, Monitored Output
Series Terminated, Safedge Input, Automatic Reset,
Single Channel Output, No Output Monitoring
Z1X1
Z2
-
X2
+
440F-C252D
24V Ground
14
13
21
L1K1L2 L3
22
K1
M
Safedge
+24V DC
Reset
Z1X1
Z2
-
X2
+
440F-C252D
14
13
21
L1K1L2K2L3
22
K1
M
Safedge
+24V DC
24V Ground
Safedge
Reset
Z1X1
Z2
N
X2
L
440F-C251D
440F-C251P
L1
N
14
24
13
23 31
L1K1L2K2L3
42
K1K2
M
Safedge
-
+Ve
Ve
Z1X1
Z2
-
X2
+Ve
440F-C251D
440F-C251P
14
24
13
23 31
L1K1L2K2L3
42
K1K2
M
Safedge
24VDC
24V Ground
Ve
L
N
Z1
Z2
+
-
Brown
White
The wiring diagram on the left shows a 110/230V AC application with one
contactor (with profile pressed). The right side of the illustration above
shows a 110/230V AC application with two contactors, contactor monitoring
and START/STOP circuit (also with profile pressed).
440F-E0804S, 440F-E0310S, 440F-E0210S, and 440F-E0118S
EPDM Profiles
Tensile strength (reinforced) mPA2620
Resilience (20 °C [68 °F])FairGood
Low temperature flexibilityFairGood
Resistance to sunlightGoodGood
Resistance to heat agingGoodGood
Resistance to oxidationFairGood
Resistance to ozoneFairGood
Resistance to H
2OGoodGood
Resistance to dilute acidsFairGood
Resistance to concentrated acidsFairGood
Resistance to oils and greasesGoodPoor
440F-E1111S is a cover profile only and is nonfunctioning.
IMPORTANTProfile must be selected according to intended environment.
Applications
Rockwell Automation Publication 440F-UM002B-EN-P - August 202019
Page 20
Maintenance and Service
Chapter 4
Troubleshooting
Maintenance
SymptomProbable CauseCheck
The yellow OPEN status indicator
illuminates.
No status indicators illuminate even
if profile is pressed.
No status indicators illuminate
unless profile is pressed and then
the red STOP status indicator
illuminates.
Unit appears to work correctly but
there is no output.
Machine does not stop when profile
is pressed. The green RUN status
indicator goes off.
Machine does not stop when profile
is pressed. The green RUN status
indicator stays on.
Open circuit in profile or
connecting wiring
Supply failure.
Failure to reset.
Blown fuse. Damaged or
incorrect wiring. Fault on
Safedge™ causes the outputs
to fail safe
Incorrect external connections
Do not allow the use of the machine.
Replace controller.
Verify that Z1-Z2 terminals are secure.
Check cable for breaks.
Check profile for damage.
Make sure that voltage selector switch is
set correctly. Check supply fuse. Verify
that supply voltage is present.
If contactor monitoring is used, verify that
each contactor is functioning correctly.
Confirm that MC-MC terminals are secure.
Check that link is in place and that Reset
button functions correctly.
Check output fuses. Inspect all wiring for
damage. Check for movement on any
internal relays.
Replace controller.
Inspect all wiring to contactors for
mistakes.
Carefully read this section, in full, before attempting any maintenance work.
ATTENTION: During maintenance operations, disconnect the prime mover of
the machine before working on the Safedge system. Observe all applicable
electrical safety precautions.
Profile Cleaning
The profiles should be kept clean of deposits such as swarf (fine metallic filings
or shavings that are removed by cutting, grinding, or any other mechanical
process), debris, and other foreign materials to help prevent damage or deadzones. It is permissible to use warm water and a mild detergent to clean the
surface area.
20Rockwell Automation Publication 440F-UM002B-EN-P - August 2020
Page 21
Chapter 4 Maintenance and Service
Routine Maintenance Inspection and Test
This inspection and test is recommended weekly or after repair.
IMPORTANTDo not use solvents.
1. Stop the machine, clean the profile or profiles and allow them to dry off.
Inspect the surface of the profile for damage. Any damage that punctures
the profile could let material or liquid in. It must be dealt with
immediately.
2. Check that all end caps, corners, and joints are secure and free from
damage. Damaged parts must be replaced immediately.
3. Test the profile operation. Two people may be required, one to press the
profile and one to observe the operation of the control unit. On systems
that use manual reset mode, the Reset button must be pressed
continuously. Check that the green RUN status indicator is illuminated
when the profile is not pressed and that the red STOP status indicator is
illuminated when it is. Start the machine, press the profile and check that
the machine stops immediately.
If these checks reveal any problem, do not allow use of the machine until the
problems are rectified. Record all inspections and tests in a written log.
Thorough Examination and Test
This examination and test is recommended twice yearly or after repair
ATTENTION: Suitably trained and qualified personnel are required for
this examination and test.
1. Conduct tests as listed in Routine Maintenance Inspection and Test
2. Isolate the power source to the machine and Safedge system. Observe
usual electrical safety precautions.
3. Inspect the profile and components thoroughly for mechanical damage.
4. Disconnect the wires to the profile at terminals Z1-Z2.
5. Connect the wires from the profile to the input of an ohmmeter. One
person should press the profile with one hand at every point on the strip.
The resistance should measure 6KΩ ±10% when the profile is not
pressed, and no greater than 1K when it is.
If these checks reveal any problems, do not allow the use of the machine until
they are rectified.
Record the inspection and test in a written log (see Written Log
on page 23).
.
Rockwell Automation Publication 440F-UM002B-EN-P - August 202021
Page 22
Chapter 4 Maintenance and Service
Repair
Before working on a Safedge system or machine control system, isolate the
power source to the machine and Safedge system. Observe all applicable
electrical safety precautions.
User repairs are limited to replacement with new Safedge system parts. In the
event of any problems, the units should be returned to the supplier.
Any repairs to the connecting wires should be made using heat shrink butt
splice connectors.
After replacing any part of the system, the inspection and test procedures
detailed in the Routine Maintenance Inspection and Test
Examination and Test on page 21 must be conducted with special attention
given to those parts replaced.
IMPORTANTTampering with component parts invalidates warranty. Warranty is
invalid if quality seal is broken on the DIN rail (440F-C251D) control unit.
and Thorough
IMPORTANTAfter maintenance or repair operations, all fastenings, cable protection,
and so on, must be correctly refitted. Failure to do so, or the use of nonapproved parts can result in the Safedge system failing to achieve its
specified performance.
22Rockwell Automation Publication 440F-UM002B-EN-P - August 2020
Page 23
Routine Inspection and Test
Written Log
DateInspected byComments
Appendix A
Rockwell Automation Publication 440F-UM002B-EN-P - August 202023
Page 24
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At the end of life, this equipment should be collected separately from any unsorted municipal waste.
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