Rockwell Automation 2030-MLXxxx-SYSx User Manual

System Multiplexer / Permissive Module

(Cat 2030-MLXxxx-SYSx)

ATTENTION: Hazardous Voltage or other forms of energy could be present.
To avoid serious injury or death:
Prior to beginning the installation and wiring process, ensure that all forms of energy to the installation site have been properly turned OFF and locked

out. Follow NFPA 70E requirements.

ATTENTION: This device is a component in a safety system. Do not defeat , tamper with, bypass or alter. Severe injury to personnel could result.

Only qualified service technicians must perform service or maintenance. Resealing of the device is the responsibility of the person or organization

Specifications

Overview

The System Multiplexer / Permissive Module will allow a Remote Lockout Station (RLS) to control up to four ElectroGuard® systems simultaneously. If
there is a need to control more than four

Multiplexer / Permissive Module will accept up to six RLS inputs. A maximum of 60 RLSs can be supported by using six 10 port Expansion Modules. The
System Multiplexer / Permissive Module is also available with a "Permissive" option. The "Permissive" option allows the machine controlling the process or
drive system to bring the machine or process to a predeternined stopping point prior to removal of power by the ElectroGuard® system. Once the
ElectroGuard® system isolates the energy the machine control can not re-energize the ElectroGuard®.

performing the service or maintenance.

Description Specification

Open Style Dimensions H x W x D

Degree of Protection (By enclosure type designator)

Consult local Allen-Bradley distributor for information regarding
dimensions of enclosed type Expansion Modules

Input Voltage Rating

LED Status Indicator Terminal Blocks

- Torque

4-Port

C = NEMA Type 4X
F = NEMA Type 4
H = IP54

24V DC

24V LED

10.56in x 23in x 6.69in (271.39 x 584.2 x 169.93)

J = NEMA Type 12

N = OPEN STYLE

(Supplied from ElectroGuard® Control Module)

#18 -14 AWG 0.8 -2.1 mm

W = IP65

4 – 5 lb-in. 0.5 - .6 Nm
Operating Ambient Temperature 0…+40° C (+32…+104° F)
Storage Ambient Temperature -10…+60° C (+14…140° F)
Storage Relative Humidity 5…95%, non-condensing

Weight

Agency Certification

Input Frequency, PER1 (7-10)

ElectroGuard® systems the System Multiplexer / Permissive Module can be daisy chained. The System

4-Port

UL, cUL, TUV EN954

28 lb (12.7 kg)

-1 Category 4,

10 - 200 Hz, 10 - 90% duty cycle

2

TUV EN60204

Connector Plugs - Wire Size

-1

Section 1.
Replacement of System Multiplexer / Permissive Module Installed In an Existing Enclosure

To replace an System Multiplexer / Permissive Module that is already installed in an enclosure, perform the following steps:

1. Verify the power to the ElectroGuard® has been turned OFF and locked out.

2. Open the enclosure that contains the System Multiplexer / Permissive Module.

3. Unplug all of the connector plugs attached to the System Multiplexer / Permissive Module. To remove a connector plug, grasp it firmly by its strain
relief & pull straight down.

IMPORTANT: Before installing the replacement System Multiplexer / Permissive Module, remove all of the factory supplied connector plugs from the new module.
They are not used when replacing a previously installed System Multiplexer / Permissive Module.

4. Loosen, but do not remove, the four bolts attaching the module to the enclosure mounting plate.
5A. To remove module mounted vertically -

· Remove the two upper attachment bolts

· Lift the module upward to clear the lower two bolts

· Remove the module from the enclosure
5B. To remove module mounted horizontally -

· Support the module

· Remove the two right side attachment bolts

· Slide the module to the right and remove it from the enclosure
6A. To Install replacement module vertically -

· Lift module into enclosure, slide down onto the two lower bolts and hold it in place

· Insert two upper attachment bolts

· Torque the module attachment bolts to 50-60 lb-in. (5.6-6.8 Nm)
6B. To install replacement module horizontally -

· Lift module into enclosure, slide it to the left and hold it in place

· Insert the two right side attachment bolts

· Torque the module attachment bolts to 50-60 lb-in. (5.6-6.8 Nm)

IMPORTANT: The Control Module and System Multiplexer / Permissive Module connector plugs and ports, with the exclusion of HV connector in the Control Module,
are factory keyed. This is done to ensure correct plug installation after maintenance or servicing which may have required the removal of any of the connector plugs.
Installing an RLS connector plug into a port with non-matching keying may damage the connector as well as the Control Module or System Multiplexer / Permissive
Module port (see Fig. 2 for keying information).

7.

Reattach the existing wired connector plugs to their mating keyed connector ports, ensure they are fully inserted into the

Permissive Module

8. Close the enclosure and turn ON the power to the ElectroGuard®.

9. Commission the unit per Chapter 3 (Revision 2030_UM003A_EN_P or later) of the ElectroGuard® User Manual.

connector ports.

System Multiplexer /

Section 2

Installation of an Enclosed System Multiplexer / Permissive Module

To install a factory or customer enclosed System Multiplexer / Permissive Module, perform the following steps:

1. Determine a suitable location for mounting the System Multiplexer / Permissive Module enclosure.

2. Based on the enclosure selected, locate and mark the necessary mounting bolt hole locations on the mounting surface. Drill and tap as needed
for mounting bolts suitable for the support of the enclosed System Multiplexer / Permissive Module.

IMPORTANT: Before mounting an enclosed System Multiplexer / Permissive Module and based upon installation requirements, the openings for conduit or cable
fittings should be made to the enclosure.
If enclosure is customer supplied, conduit or cable fitting openings should be made before installing the open style System Multiplexer / Permissive Module in the
enclosure. This should be done to avoid contaminating the module with fabricating debris.
If enclosure is factory supplied, the System Multiplexer / Permissive Module should be removed from the enclosure, prior to making any openings for conduit or
cable fittings, to help avoid module contamination (see Section 1 for instructions on removing the System Multiplexer / Permissive Module from an enclosure).

3. Support the enclosure while aligning it with the mounting bolt holes.

4. Install enclosure mounting bolts and tighten to torque required for mounting bolt size selected.

5. Mount the System Multiplexer / Permissive Module inside the enclosure (see Section 1 for instructions on installing the System Multiplexer /
Permissive in an enclosure).

6. Select which System Multiplexer / Permissive Module connector plugs will require wiring (see Table 1 and Figures 1 and 3).

Figure 1
Connectors in
4 Port System Multiplexer /
Permissive Module

Table 1

RLS_A
RLS_B

RLS_C
RLS_D

RLS_E
RLS_F

EXB1
EXB2

EXB3
EXB4

PLC1EXB
PLC2EXB

PER1
PER2

System Multiplexer / Permissive Module Connectors

Connector

RLS S#_A thru RLS S#__F

EXB1 THRU EXB4 System Multiplexer / Permissive Module

PLC1EXB

PER1

The connectors at System Multiplexer / Permissive Module are "Keyed" in order to uniquely identify each connector, in the event they are
removed and re-inserted (See Figure 2).

Description Function

System Multiplexer / Permissive Module Remote
Lockout Station

Connectors to ElectroGuard® Systems (See
Section 3)

Remote Lockout Station status to customer
remote PLC (See Section 5)

Permissive inputs from the PLC and safety relay
output status

Connects Remote Lockout Station to
System Multiplexer / Permissive Module.

Interconnects the System Multiplexer /
Permissive Module to the Control Modules
in ElectroGuard® Systems, or to series
connected System Multiplexer / Permissive
Module.

Connects RLS auxiliary signals to Remote
PLC or optional Remote I/O or
Communication Modules.

The permissive input allows the machine
controlling the process or drive system to
bring the machin or process to a
predetermined stopping point prior to
removal of power by the
system. Output terminals provide the
status of safety relays SR1 and SR7.

ElectroGuard

Figure 2
Keying of RLS Connectors at System Multiplexer / Permissive Module

T

B

P

L
U
G

T

B

P

L
U
G

RLS_A RLS_C RLS_E

123456789

RLS_B

123456789

10 1 2 3 4 5 6 7 8 9

G
N
D

RLS_D

123456789

10

G
N
D

123456789

10

G
N
D

123456789

10

G
N
D

RLS_F

10

G
N
D

10

G
N
D

1234567 9

1234

PER1

PLC1 EXB

5

67 9

8

10

1234567 9
G
N
D

101112

8

1 2 3 4 5 6 7 9 10 11 12

PER2

PLC2 EXB

8

10

G
N
D

G
N
D

8

®

EXB1

123456789

T

B

P
L
U
G

10

G
N
D

EXB3

123456789

EXB2

10

G
N
D

123456789

T

B

P
L
U
G

10

G
N
D

EXB4

123456789

10

G
N
D

7. Follow the specified System Multiplexer / Permissive Module Connector's section (Table 1) to wire connectors.

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Section 2 (Cont'd)

Installation of an System Multiplexer / Permissive Module

System Multiplexer / Permissive Module Cable Specifications

IMPORTANT: · Cable must have copper conductors only.

IMPORTANT: The maximum total cable length values shown in Table 2 must not be exceeded, as this may result in unreliable operation of the ElectroGuard®.

Consider using an Expansion Module if cable lengths greater than those shown are needed (See APPENDIX C of the Manual for wiring examples).

· Cable with 600V insulation is required.

· Oil resistant cable is recommended.

· Individual conductors within the cable should be color-coded or otherwise clearly marked (see Table 1).

· Cable must have a shield with a drain wire.

· Type of wire for EXB_ to RLS connector or similar:
ALPHA wire "XTRA-GUARD®2

- Part No. 25450/9 for #14 AWG, 0.64" O.D.

- Part No. 25440/9 for #16 AWG, 0.61" O.D.

- Part No. 25430/9 for #18 AWG, 0.55" O.D.

· Type of wire for PLC1EXB connectors or similar:
ALPHA wire "XTRA-GUARD®2

- Part No. 25450/25 for #14 AWG, 0.98" O.D.

- Part No. 25440/25 for #16 AWG, 0.93" O.D.

- Part No. 25430/25 for #18 AWG, 0.80" O.D.

Table 2
Maximum Allowable Cable Lengths for RLS Connected to System Multiplexer / Permissive Module

In North America Outside of North America

Wire Guage

14 AWG

16 AWG 12,500 ft

18 AWG

Maximum
Total Cable Length

20,000 ft

7,750 ft

mm2

2.1

1.3 3,800 m

0.8

Maximum
Total Cable Length

6,100 m

2,360 m

The EXB1 connector provides control power and allows the interface to the System Multiplexer / Permissive Module from the Control Module in the
ElectroGuard® Power Panel. This is accomplished by wiring from the EXB1 connector at the System Multiplexer / Permissive Module to any one of
the RLS ports on the Control Module. The EXB2 thru EXB4 connectors allow the interface of the System Multiplexer / Permissive Module to
additional ElectroGuard® Power Panels. This is accomplished by wiring from the EXB2 thru EXB4 connectors at the System Multiplexer / Permissive
Module to any one of the RLS ports on the Control Module in the other ElectroGuard® Power Panels. See Section 3.

The EXB2 thru EXB4 connectors also allow for the series connection of up to three System Multiplexer / Permissive Modules. This is accomplished
by wiring from the EXB2 thru EXB4 connectors at the System Multiplexer / Permissive Module to the RLS_A connector of the series added System
Multiplexer Module. See Figure 7, Section 3.

Table 3
Maximum Cable Length for System Multiplexer / Permissive Module to Control Module

In North America
AWG

14

16 1.3

18

The cable lengths in Table 2 and Table 3 represent the total wire impedance allowed to help ensure proper operation of the safety monitoring relays
used in the isolation system. Consult Rockwell Automation for cable lengths when series connecting System Multiplexer / Permissive Modules.
NOTE: When series connecting the System Multiplexer / Permissive Modules, two maximum cable lengths must be taken into consideration. One
cable length is the maximum distance from the Control Module to the last series-connectedSystem Multiplexer / Permissive Module. The other cable
length is the RLS circuit length. See Appendix C of the Electro-Guard® User Manual regarding length calculation, conductor sizing and installation
scenarios.

Outside of North
America (mm2)

2.1

0.8

Maximum Distance from Control Module

1,200 ft

750 ft

475 ft

366 m

229 m

145 m

IMPORTANT: The System Multiplexer / Permissive Module can support a maximum of 60 RLSs by using six 10-port Expansion Modules.

IMPORTANT: Connector plugs provided on ElectroGuard® Control Modules and System Multiplexer / Permissive Modules are factory shipped with two jumper

wires installed (see Figure 4). These two jumper wires must be removed and discarded when wiring is performed to connect a Remote Lockout Station to the
connector plug. Failure to remove the two jumper wires prevents proper operation of the RLS "System Isolated" indicator light.

IMPORTANT: When routing the cables from the Remote Lockout Stations to the System Multiplexer / Permissive Module, care must be taken to protect the
cables from physical damage and cable must be run in conduit when outside enclosed.

IMPORTANT: Cables to the System Multiplexer / Permissive Module must not run adjacent to power conductors or be run in a line voltage wireway.

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