Rockwell Automation 1440-RMA00-04RC User Manual

Installation Instructions

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XM-440 Master Relay Module

Catalog Number

1440-RMA00-04RC

Top ic Pa ge

Environment and Enclosure 3

European Hazardous Location Approval 4

North American Hazardous Location Approval 5

Mount the Module 6

Module Indicators 7

Self-Test 8

Reset Switch 8

Install the XM Serial Configuration Utilit y Software 9

Specifications 10

Additional Resources 12

XM-440 Master Relay Module

IMPORTANT

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.

Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow
ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

2 Rockwell Automation Publication ENMON-IN440I-EN-P - February 2014

Environment and Enclosure

ATTENTION: This equipment 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 not intended for use in residential environments and may not provide adequate protection to radio
communication services in such environments.

This equipment is supplied as open-type equipment. It must be mounted within an enclosure that is suitably designed for
those specific environmental conditions that will be present and appropriately designed to prevent personal injury resulting
from accessibility to live parts. The enclosure must have suitable flame-retardant properties to prevent or minimize the spread
of flame, complying with a flame spread rating of 5VA or be approved for the application if nonmetallic. The interior of the
enclosure must be accessible only by the use of a tool. Subsequent sections of this publication may contain additional
information regarding specific enclosure type ratings that are required to comply with certain product safety certifications.

In addition to this publication, see the following:

• Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

• NEMA Standard 250 and IEC 60529, as applicable, for explanations of the degrees of protection provided by enclosures

XM-440 Master Relay Module

, for additional installation requirements

ATTENTION: To comply with UL/CSA restrictions and the CE Low Voltage Directive (LVD), all connections to this equipment must be
powered from a single source compliant with the following:

• A Listed Class 2 power supply, or a Listed ITE safety extra low voltage (SELV) power supply with the 1440-5AFUSEKIT fuse kit, or a
protected extra low voltage (PELV) power supply certified to 60950 with the 1440-5AFUSEKIT fuse kit.

(1)

• The same power source must power any device to which the module is connected via its side connector

circuits that include: power, XMbus, 4…20 mA outputs, and setpoint multiplier circuits.

(1) Power transmission across the XM module side connector must not exceed 3 A.

(2) These circuits are all functionally isolated, but do not have adequate insulation to satisfy the isolation requirements of some electrical safety

(2)

or any of its non-isolated

standards. Therefore the ground requirements for the circuits, specified in the individual user’s manuals, must still be applied.

Prevent Electrostatic Discharge

ATTENTION: This equipment is sensitive to electrostatic discharge, which can cause internal damage and affect normal

operation. Follow these guidelines when you handle this equipment:

• Touch a grounded object to discharge potential static.

• Wear an approved grounding wriststrap.

• Do not touch connectors or pins on component boards.

• Do not touch circuit components inside the equipment.

• Use a static-safe workstation, if available.

• Store the equipment in appropriate static-safe packaging when not in use.

Rockwell Automation Publication ENMON-IN440I-EN-P - February 2014 3

XM-440 Master Relay Module

IMPORTANT

ATTENTION: The serial communication port is intended only for temporary local-programming purposes and not intended

for permanent connection. The serial cable and power connections are not to exceed 3.0 m (9.84 ft):

• This product is intended to be mounted to a well-grounded mounting surface, such as a metal panel or DIN rail. For DIN rail
mounting, use zinc plated yellow-chromate steel DIN rail to assure proper grounding. The use of other DIN rail materials
(for example, aluminum or plastic) that can corrode, oxidize, or are poor conductors, can result in improper or intermittent
grounding. Secure DIN rail to the mounting surface approximately every 200 mm (7.8 in.) and use end-anchors
appropriately.

• Do not remove or replace a terminal base unit while power is applied. Interruption of the backplane can result in
unintentional operation or machine motion.

• This module is designed so you can remove and insert it under power. However, when you remove or insert the module
with power applied, I/O attached to the module can change states due to its input/output signal changing conditions. Take
special care when using this feature.

Install the overlay slide label to protect the serial connector and electronics when the serial port is not in use.

European Hazardous Location Approval

The following applies when the product bears the Ex Marking

This equipment is intended for use in potentially explosive atmospheres as defined by European Union Directive 94/9/EC and has been found to
comply with the Essential Health and Safety Requirements relating to the design and construction of Category 3 equipment intended for use in
Zone 2 potentially explosive atmospheres, given in Annex II to this Directive.

Compliance with the Essential Health and Safety Requirements has been assured by compliance with EN 60079-0, EN 60079-15 and EN 60079-11.

WARNING: The installation of the XM-440 module includes the following warnings:

• This equipment must be mounted in an ATEX-certified enclosure with a minimum ingress protection rating of at least IP54 ( as

defined in IEC60529), and used in an environment of not more than Pollution Degree 2 (as defined in IEC 60664-1) when applied in
Zone 2 environments. The enclosure must have a tool-removable cover or door.

• This equipment must be used within its specified ratings defined by Rockwell Automation.

• Provision must be must to prevent the rated voltage from being exceeded by transient disturbances of more than 140% of the

rated voltage when applied in Zone 2 environments.

• This equipment must be used only with ATEX-certified Allen-Bradley terminal base units.

• Secure any external connections that mate to this equipment by using screws, sliding latches, threaded connectors, or other

means provided with this product.

• Do not disconnect equipment unless power has been removed or the area is known to be nonhazardous.

• Connection of the modules to barriers and/or sensors located in dangerous areas is the responsibility of the user.

• The XM-440 module must be installed in accordance with specification control sheet 48240-HAZ.

4 Rockwell Automation Publication ENMON-IN440I-EN-P - February 2014

North American Hazardous Location Approval

The following information applies when operating this equipment in
hazardous locations:

Products marked "CL I, DIV 2, GP A, B, C, D" are suitable for use in Class I Division 2
Groups A, B, C, D, Hazardous Locations and nonhazardous locations only. Each product is
supplied with markings on the rating nameplate indicating the hazardous location
temperature code. When combining products within a system, the most adverse
temperature code (lowest "T" number) may be used to help determine the overall
temperature code of the system. Combinations of equipment in your system are subject
to investigation by the local Authority Having Jurisdiction at the time of installation.

EXPLOSION HAZARD -

• Do not disconnect equipment unless power has been

removed or the area is known to be nonhazardous.

• Do not disconnect connections to this equipment
unless power has been removed or the area is known to
be nonhazardous. Secure any external connections that
mate to this equipment by using screws, sliding
latches, threaded connectors, or other means provided
with this product.

• Substitution of components may impair suitability for
Class I, Division 2.

• If this product contains batteries, they must only be
changed in an area known to be nonhazardous.

Informations sur l'utilisation de cet équipement en environnements dangereux.

Les produits marqués "CL I, DIV 2, GP A, B, C, D" ne conviennent qu'à une utilisation en
environnements de Classe I Division 2 Groupes A, B, C, D dangereux et non dangereux.
Chaque produit est livré avec des marquages sur sa plaque d'identification qui indiquent le
code de température pour les environnements dangereux. Lorsque plusieurs produits sont
combinés dans un système, le code de température le plus défavorable (code de
température le plus faible) peut être utilisé pour déterminer le code de température global
du système. Les combinaisons d'équipements dans le système sont sujettes à inspection
par les autorités locales qualif iées au moment de l'installation.

XM-440 Master Relay Module

RISQUE D’EXPLOSION –

• Couper le courant ou s'assurer que l'environnement

est classé non dangereux avant de débrancher
l'équipement.

• Couper le courant ou s'assurer que l'environnement
est classé non dangereux avant de débrancher les
connecteurs. Fixer tous les connecteurs externes
reliés à cet équipement à l'aide de vis, loquets
coulissants, connecteurs filetés ou autres moyens
fournis avec ce produit.

• La substitution de composants peut rendre cet
équipement inadapté à une utilisation en
environnement de Classe I, Division 2.

• S'assurer que l'environnement est classé non
dangereux avant de changer les piles.

WARNING: The installation of the XM-440 module includes the following warnings:

• When you insert or remove the module while power is on, an electrical arc can occur. This could cause an explosion in hazardous

location installations. Be sure that power is removed or the area is nonhazardous before proceeding.

• If you connect or disconnect the serial cable with power applied to this module or the serial device on the other end of the cable,
an electrical arc can occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the
area is nonhazardous before proceeding.

• Be sure that power is removed or the area is nonhazardous before proceeding.

• If you connect or disconnect the XMbus cable with power applied to this module or any device on the network, an electrical arc can

occur. This could cause an explosion in hazardous location installations. Be sure that power is removed or the area is nonhazardous
before proceeding.

• If you connect or disconnect wiring while the field-side power is on, an electrical arc can occur. This could cause an explosion in
hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding.

• Wiring to or from the XM-440 module, which enters or leaves the system enclosure, must utilize wiring methods suitable for Class
I, Division 2 Hazardous Locations, as appropriate for the installation in accordance with the product drawing Without Barriers ­48240-HAZ.

Rockwell Automation Publication ENMON-IN440I-EN-P - February 2014 5

XM-440 Master Relay Module

Mount the Module

The XM® 440 module mounts on a XM-942 terminal base unit, catalog number 1440-TB-C. We recommend that you
mount the module after you have connected the wiring on the terminal base unit. Refer to the XM-942 Master Relay
Terminal Base Installation Instructions, publication GMSI10-IN022

The XM-440 module is compatible only with the XM-942 terminal base unit. Verify that the keyswitch on the terminal base unit
is at position 2 for the XM-440 module.

Do not attempt to install XM-440 modules on other terminal base units.

Do not change the position of the keyswitch after wiring the XM-942 terminal base unit.

1. Make certain the keyswitch (A) on the terminal base unit (C) is at position 2 as required for the XM-440 module.

.

2. Make certain the side connector (B) is pushed all the way to the left.

You cannot install the module unless the connector is fully extended.

3. Make sure that the pins on the bottom of the module are straight so they align properly with the connector in the

terminal base unit.

4. Position the module (D) with its alignment bar (E) aligned with the groove (F) on the terminal base unit.

5. Press firmly and evenly to seat the module in the terminal base unit.

The module is seated when the latching mechanism (G) is locked into the module.

6. Repeat the above steps to install the next module in its terminal base unit.

All grounds in the system must be tied to the same point of the same grounding electrode system.

Maintain a 2.54 cm (1 in.) minimum clearance between the module and adjacent equipment. There are no orientation
restrictions.

6 Rockwell Automation Publication ENMON-IN440I-EN-P - February 2014

Module Indicators

MASTER RELAY

1440-RMA00-04RC

Module Indicators

The XM-440 module has six status indicators, which are on top of the module.

Module Status (MS) Indicator

Color State Description

No color Off No power applied to the module.

Green Flashing red Module performing power-up self-test.

Flashing Module operating in Program mode.

Solid Module operating in Run mode.

Red Flashing • Application firmware is invalid or not loaded. Download firmware to the module.

• Firmware download is currently in progress.

Solid An unrecoverable fault has occurred. It is possible that the module must be repaired or replaced.

(1)

(2)

XM-440 Master Relay Module

(1) Program mode - Typically this occurs when the module configuration settings are being updated with the Serial Configuration Utility. In Program mode, the module does not perform its normal functions.

The alarm monitoring is stopped and the relay outputs are deactivated unless they are latched.

(2) Run mode - In Run mode, the module collects alarm status from the XM measurement modules and controls the relay outputs.

Network Status (NS) Indicator

Color State Description

No color Off Module is not online:

• Module is autobauding.

• No power applied to the module; look at Module Status indicator.

Green Flashing Module is online (DeviceNet network) but no connections are currently established.

Solid Module is online with connections currently established.

Red Flashing One or more I/O connections are in the timed-out-state.

Solid Failed communication (duplicate MAC ID or bus-off).

(1) Normal condition when the module is not a slave to an XM-440 module, programmable controller, or other master device.

(1)

Relay Indicators (four)

Color State Description

Red Off On-board relay in not activated.

Solid On-board relay is activated.

Rockwell Automation Publication ENMON-IN440I-EN-P - February 2014 7

XM-440 Master Relay Module

IMPORTANT

MASTER RELAY

1440-RMA00-04RC

Reset Switch

Self-Test

The XM-440 module performs a self-test at powerup. The self-test includes a status indicator test and a device test. During
the status indicator test, the indicators are turned on independently and in sequence for approximately 0.25 seconds.

The device test occurs after the status indicator test. The Module Status (MS) indicator is used to indicate the status of the
device self-test.

MS Indicator State Description

Flashing red and green Device self-test is in progress.

Solid green or flashing green Device self-test completed successfully, and the firmware is valid and running.

Flashing red Device self-test completed, the hardware is OK, but the firmware is invalid. Or, the firmware download is in progress.

Solid red Unrecoverable fault, hardware failure, or Boot Loader program corruption.

Reset Switch

WARNING: When you press the reset button while power is on, an electrical arc can occur. This could cause an explosion in

hazardous location installations. Be sure that power is removed or the area is nonhazardous before proceeding.

The XM-440 module has an external reset switch on top of the module. The Reset switch can be used to reset all latched
relays, including the relays in the Relay Expansion module when it is attached to the XM-440 module.

The Reset switch resets the relays only if the input is no longer in alarm or the condition that caused the alarm is no longer
present.

8 Rockwell Automation Publication ENMON-IN440I-EN-P - February 2014

XM-440 Master Relay Module

Install the XM Serial Configuration Utility Software

The XM Documentation and Configuration Utility CD is packaged with the XM modules. It contains the XM Serial
Configuration Utility software, a set of user guides, hazardous location installation drawings, and electronic data sheet
(EDS) files that are used by network configuration tools such as RSNetWorx™ for DeviceNet software. The user guides are
in portable document format (PDF), and must be viewed with Adobe Acrobat Reader software.

To install the XM Serial Configuration Utility software, follow these steps.

1. Insert the XM Serial Configuration Utility CD-ROM into the CD-ROM drive.

If autorun is Then

Enabled The Setup program starts automatically and the XM Serial Configuration Utility opening screen appears.

Disabled Follow these steps.

1. Click Start, and then click Run.
The Run dialog box appears.

2. In the Open box, type x:\autorun, where x is the letter of the drive containing the XM Documentation and
Configuration Utility CD-ROM.

3. Click OK.
The XM Serial Configuration Utility opening screen appears.

2. Follow the instructions that appear to install the XM Serial Configuration Utility.

3. When you are finished installing the software, remove the XM Documentation and Configuration Utility

CD-ROM from the CD-ROM drive; store it in a safe place.

Rockwell Automation Publication ENMON-IN440I-EN-P - February 2014 9

XM-440 Master Relay Module

Specifications

The following table lists the technical specifications for the XM-440 module.

Attribute XM-440

Temperature, operating
IEC 60068-2-1 (Test Ad, Operating Cold),
IEC 60068-2-2 (Test Bd, Operating Dry Heat),
IEC 60068-2-14 (Test Nb, Operating Thermal Shock)

Temperature, surrounding air, max 65 °C (149 °F)

Temperature, nonoperating
IEC 60068-2-1 (Test Ab, Unpackaged Nonoperating Cold),
IEC 60068-2-2 (Test Bb, Unpackaged Nonoperating Dry Heat),
IEC 60068-2-14 (Test Na, Unpackaged Nonoperating Thermal Shock)

Relative humidity
IEC 60068-2-30 (Test Db, Unpackaged Damp Heat)

Vibration
IEC 60068-2-6 (Test Fc, Operating)

Shock, operating
IEC 60068-2-27 (Test Ea, Unpackaged Shock)

Shock, nonoperating
IEC 60068-2-27 (Test Ea, Unpackaged Shock)

Emissions
CISPR 11 (IEC 61000-6-4)

ESD immunity
IEC 61000-4-2

Radiated RF immunity
IEC 61000-4-3

EFT/B immunity
IEC 61000-4-4

Surge Transient immunity
IEC 61000-4-5

Conducted RF immunity
IEC 61000-4-6

Enclosure type rating None (open-style)

Voltages/ranges Supply:

-20…65 °C (-4…149 °F)

-40…85 °C (-40…185 °F)

5…95% noncondensing

2 g @ 10…500 Hz

15 g

20 g

Class A

4 kV contact discharges
8 kV air discharges

10V/m with 1 kHz sine-wave 80% AM from 80…2000 MHz
10V/m with 200 Hz 50% Pulse 100% AM at 900 MHz
10V/m with 200 Hz 50% Pulse 100% AM at 1890 MHz
3V/m with 1 kHz sine-wave 80% AM from 2000…2700 MHz

±2 kV at 5 kHz on power ports
±1 kV at 5 kHz on relay and shielded signal ports
±1 kV at 5 kHz on XMbus port

±1 kV line-earth(CM) on relay ports
±2 kV line-earth(CM) on shielded signal ports
±2 kV line-earth(CM) on XMbus port

10V rms with 1 kHz sine-wave 80% AM from 150 kHz…80 MHz

24V DC, 0.2A max, Class 2/SELV

Relay:
250V AC, 50/60 Hz, 3 A resisitive

Power dissipation 3.4 W max

External over-current protection 440-5AFUSEKIT for SELV/PELV power sources

Isolation voltage 250V (continuous), Basic Insulation Type, relay to relay and to all other circuits

Type tested at 1500V AC for 60 s

10 Rockwell Automation Publication ENMON-IN440I-EN-P - February 2014

XM-440 Master Relay Module

Attribute XM-440

Wiring cate gory

Wire type Signal connections : shielded

Pilot duty rating Relay ports: Not rated

North American temp code T4A

IEC temp code T4

(1) Use this Conductor Category information for planning conductor routing. Refer to Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1.

(1)

2 - on relay and shielded signal ports
3 - on Serial and power ports
2 - on XMbus ports

Power and relay connections: unshielded

Certifications

Certification
(when product is marked)

c-UL-us UL Listed Industrial Control Equipment, certified for US and Canada. See UL File E234338.

c-CSA-us CSA Certified Process Control Equipment for Class I, Division 2 Group A,B,C,D Hazardous Locations, certified for US and Canada. See CSA File 150115.

CE European Union 2004/108/EC EMC Directive, compliant with:

C-Tick Australian Radiocommunications Act, compliant with:

Ex European Union 94/9/EC ATEX Directive, compliant with:

KC Korean Registration of Broadcasting and Communications Equipment, compliant with:

(1)

Description

• EN 61326-1; Meas./Control/Lab., Industrial Requirements

• EN 61000-6-2; Industrial Immunity

• EN 61000-6-4; Industrial Emissions

• EN 61131-2; Programmable Controllers (Clause 8, Zone A & B)

European Union 2006/95/EC LVD, compliant with:

• EN 61131-2; Programmable Controllers (Clause 11)

• AS/NZS CISPR 11; Industrial Emissions

• EN 60079-15; Potentially Explosive Atmospheres, Protection "n"

• EN 60079-11; Explosive Atmospheres, Protection "i"

• EN 60079-0; General Requirements

• II 3 G Ex nAC [ic] IIC T4X Gc

when used at or below 60V AC or 75V DC

• Article 58-2 of Radio Waves Act, Clause 3

(1) See the Product Certification link at http://www.rockwellautomation.com for Declarations of Conformity, Certificates, and other certification details.

Rockwell Automation Publication ENMON-IN440I-EN-P - February 2014 11

Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat:6 34752 İçerenköy, İstanbul, Tel: [phone]

Additional Resources

For more information on the products described in this publication, use these resources.

Resource Description

1440 XM Monitoring Modules Specifications Technical Data, publication 1440-TD001

XM-440 Master Relay Module User Guide, publication GMSI10-UM009

Provides technical specifications for the 1440 series of monitoring modules.

Provides information about how to install and configure the XM-440 Master Relay
Module, along with technical specifications and DeviceNet information and objects for
the module.

You can view or download Rockwell Automation publications at http:/www.rockwellautomation.com/literature/

. To
order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales
representative.

Allen-Bradley, Rockwell Software, Rockwell Automation, XM, RSNetWorx, and LIST EN.THINK.SOLVE. are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication ENMON-IN440I-EN-P - February 2014 PN-210604

Supersedes Publication ENMON-IN440H-EN-P - October 2012 Copyright © 2014 Rockwell Auto mation, Inc. All rights reserved. Pr inted in the U.S.A.