Rockwell Automation Allen-Bradley Guardmaster 440C-CR30, Allen-Bradley Guardmaster 440C-CR30-22BBB, Allen-Bradley 440C-CR30-22BBB Wiring Diagram

Wiring Diagram

Guardmaster 440C-CR30 Configurable Safety Relay

Catalog Numbers 440C-CR30-22BBB

Important User Information

IMPORTANT

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).

Allen-Bradley, Connected Components Workbench, Control Tower, Guardmaster, GuardShield, Lifeline, PHOTOSWITCH, PowerFlex, Rockwell Software, SensaGuard, Trojan, and Zero-Force Touch Buttons are
trademarks of Rockwe ll Automation, Inc.

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

Preface

Additional Resources

These documents contain additional information concerning related products
from Rockwell Automation.

Resource Description

Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1

Product Certifications website, http://www.ab.com

Provides general guidelines for installing a Rockwell
Automation industrial system.

Provides declarations of conformity, certificates, and
other certification details.

You can view or download 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.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 3

Preface

Notes:

4 Rockwell Automation Publication 440C-WD001A-EN-P - November 2014

Preface

Cat 1 Stop with Guardlocking
Interlock (TLS-ZR or 440G-LZ)

Cat 1 Stop with GuardShield Light
Curtain, T-15 Interlock, E-Stop, and
PowerFlex 525

Table of Contents

Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Chapter 1

Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

PowerFlex PF525 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 2

Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

PowerFlex PF525 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Safety Mats - Two Zones

Enabling Switch (GripSwitch) with
Jog Function

Chapter 3

Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chapter 4

Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 1

Table of Contents

Chapter 5
Muting 2-Sensor L-Type
Unidirectional

Muting 2-Sensor T-Type Bidirectional

Muting 4-sensor T-type Bidirectional

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Machine Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Connected Components Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Circuit Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Example Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Safety Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chapter 6

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Machine Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Connected Components Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Circuit Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Example Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Safety Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Chapter 7

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Machine Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Connected Components Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Circuit Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Example Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Safety Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Chapter 8
Single-wire Safety

2 Rockwell Automation Publication 440C-WD001A-EN-P - November 2014

Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Connected Components Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Circuit Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Example Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Safety Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Chapter 9

Table of Contents

Lifeline Cable Pull

Two-hand Control

Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Chapter 10

Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 3

Table of Contents

Notes:

4 Rockwell Automation Publication 440C-WD001A-EN-P - November 2014

Chapter 1

Cat 1 Stop with Guardlocking Interlock
(TLS-ZR or 440G-LZ)

This example application shows how to configure the CR30 for a Guardlocking
application that requires a Category 1 stop function.

A TLS-ZR guardlocking interlock, which has OSSD outputs, locks a guard to
prevent full body access to the hazard. A PowerFlex® 525 is controlling a motor
that is considered the hazard. A selector switch requests access to the hazard area.
A push button locks access to the hazard. The CR30 performs the logic that
monitors the interlock and the drive, and allows access to the hazard under safe
conditions.

For partial body access, the 440G-LZ can be substituted for the TLS-ZR.

Product Overview

Figure 1 - Overview

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 5

Chapter 1 Cat 1 Stop with Guardlocking Interlock (TLS-ZR or 440G-LZ)

05

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

09

17

+24 VDC

24V DC Com

Reset

Red

Pink

Green
White
Blue

Grey

Yellow

Brown

Safety
Gate

Safety

TLS-ZR
440G-TZS21UPRH
889D-F8AC-2

440C-CR30-22BBB

Gate
Unlocked

Gate
Lock/
Unlock

Gate control

power supply

Gate control

circuit

M

4 Gnd

S1
S2

1 Stop

L1 L2 L3

PowerFlex

525

2 Start

R5

R6

RTS

UWV

Schematic

Figure 2 - Schematic

PowerFlex PF525 Settings

Ta b l e 1 shows a list of some of the parameter settings for this application. The list

is not a complete list of the parameters for the PF525. You may set many other

parameters to make this application successful.

Table 1 - Parameter Settings

Parameter Name Value Unit/Description

P042 Decel Time 3 Seconds

P045 Stop Mode 0 Stop and Clear Fault

P046 Start Source 2 Digital Input Terminal Block

P047 Speed Reference 11Drive Pot

T081 Relay 2 2 Motor Running

6 Rockwell Automation Publication 440C-WD001A-EN-P - November 2014

T105 Safety Open En 1 Fault Disable

Motor is receiving power from the drive.

Cat 1 Stop with Guardlocking Interlock (TLS-ZR or 440G-LZ) Chapter 1

Connected Components
Workbench™

Figure 3 - Connected Components Workbench Example

Circuit Status

Operational Sequence

The gate switch is closed and locked. The safety signals to the PF2525 drive are
off, and the drive is disabled. The motor is off.

Table 2 -

Action Taken Results

1. Momentarily press the reset button. The safety outputs at terminal 17, 18 and 19 turn ON.

2. Press the drive Start button. The motor turns ON. The drive can now be used for normal

3. Rotate the Unlock request to the Unlock (closed)
position.

4. Open the gate switch. The operator can access the hazard area.

5. Close the gate.

6. Rotate the Unlock switch to the locked (open) position. This locks the gate and the safety system is ready for reset.

production processes.
The speed of the motor is controlled by the Drive Pot,

located on the front of the PF525.

The power is immediately removed from terminals 17,
and the drive executes a ramp to stop command in 3
seconds (P042 is configured for 3s).

After a 5 second delay, the gate switch is unlocked and the
safety outputs to the drive open.

Go to Step 1.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 7

Chapter 1 Cat 1 Stop with Guardlocking Interlock (TLS-ZR or 440G-LZ)

Example Bill of Materials

Table 3 -

Item Product Description Qty

1 440C-CR30-22BBB Guardmaster® 440C-CR30 Software Configured Safety Relay

PLe SIL 3, 22 Safety I/O, embedded serial port, USB programming
port, 2 plugin slots, 24V DC

2440G-TZS21UPRH Guard Locking Switch - TLS-Z GD2

Solenoid Voltage: 24V AC/DC
Contacts (Safety and Aux): 2 x PNP (0.2A max.), 1 x PNP (0.2A max.)
Actuator: Fully-flex
Conduit Entry: 8-pin micro (M12)

2.1 889D-F8AC-5 DC Micro (M12) Cordset
Female, straight, 8-pin, PVC cable, yellow, unshielded, 22 AWG, IEC

color coded, no connector, 5 m (16.4 ft)

3 800FM-P4MN3R 800F Pilot Light

Metal (IP66, 4/13, IP66), red, standard pack

4 800FM-SM22MX10 800F 2-position Selector Switch

Metal, maintained, black, standard knob, standard orientation,
1 N.O. contact block, standard pack

5 800FM-F611MX10 800F Push Button

Metal, flush, blue, R, metal latch mount, 1 N.O. contact, 0 N.C.
contacts, standard, standard pack

6 24B-V2P5A104AA-ND-P3 PowerFlex 525 Pre-engineered FasTrac, with Embedded

EtherNet/IP™ and Safety

120VAC, 1-phase, 0.5 Hp, 0.4 kW normal duty; 0.5 Hp, 0.4 kW heavy
duty, Type 1 / IP20, no filter, without bypass, without reactor, motor
circuit protector (-P3)

7 800FM-F301 800F Push Button

Metal, flush, green, START, standard pack

8 800FM-E402 800F Push Button

Metal, extended, red, STOP, standard pack

1

1

1

1

1

1

1

1

1

Safety Rating

The safety function that is performed by the guard locking interlock meets the
safety performance requirements of SIL CL2 per IEC 61061:2012 and SIL 2 per
IEC 61508:2005 and has a Category 3 structure that can be used in systems
requiring Performance Levels up to PLd per ISO 13849-1: 2006. The circuit
executes a Category 1 stop.

8 Rockwell Automation Publication 440C-WD001A-EN-P - November 2014

Chapter 2

Cat 1 Stop with GuardShield™ Light Curtain, T-15
Interlock, E-Stop, and PowerFlex 525

This example application shows how to configure the CR30 for a guarding
application that requires a Category 1 stop function.

A light curtain is used where an operator frequently accesses the hazard area. A
mechanical tongue interlock switch is mounted on a gate where infrequent access
to the hazard. Both the light curtain and gate are located far enough away from
the hazard so the operator cannot reach the hazard until it has reached a safe state.

An E-stop button is also available at the control panel. Any of the three devices
must cause the machine to go to a safe OFF state.

Product Overview

Figure 4 - Overview

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 9

Chapter 2 Cat 1 Stop with GuardShield™ Light Curtain, T-15 Interlock, E-Stop, and PowerFlex 525

05

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

09

17

+24 VDC

Gate control

power supply

Gate control

circuit

M

4 Gnd

S1
S2

1 Stop

L1 L2 L3

PowerFlex

525

2 Start

RTS

UWV

24V Com

1

2
6
5

3

7
3

Pink

Receiver

Brown

Brown

Transmitter

Grey

Blue

Green

Blue

111221

22

Schematic

Figure 5 - Schematic

PowerFlex PF525 Settings

Ta b l e 4 shows a list of some of the parameter settings for this application. The list

is not a complete list of the parameters for the PF525. You may set many other
parameters to make this application successful.

Table 4 - Parameter Settings

Parameter Name Value Unit/Description

P042 Decel Time 1 Seconds

P045 Stop Mode 0 Stop and Clear Fault

P046 Start Source 2 Digital Input Terminal Block

P047 Speed Reference 1 1 Drive Pot

T081 Relay 2 2 Motor Running

Motor is receiving power from the drive.

T105 Safety Fault En 0 Fault Enable

10 Rockwell Automation Publication 440C-WD001A-EN-P - November 2014

Cat 1 Stop with GuardShield™ Light Curtain, T-15 Interlock, E-Stop, and PowerFlex 525 Chapter 2

Connected Components
Workbench

Figure 6 - Connected Components Workbench Example

Circuit Status

Operational Sequence

The light curtain is clear. The gate switch is closed. The E-stop is reset. The
CR30 safety outputs at terminal 17, 18, and 19 are ON. The PF525 shows an
F059 fault. The motor is off.

Table 5 - Operational Sequence

Action Taken Results

1. Press the drive Stop button. The F059 Fault on the PF25 is cleared. The motor is ready

2. Press the drive Start button. The motor turns ON. The drive can now be used for normal

3. Do any of the following actions:

– Block the light curtain,
– Open the gate switch, or
– Press the E-stop.

4. Do the opposite action from Step 2:

– Clear the light curtain,
– Close the gate switch, or
– Release the E-stop.

to run.
Normally, the motor would be stopped by the machine

control system, which is not shown in the schematic.

production processes.
The speed of the motor is controlled by the Drive Pot,

located on the front of the PF525.

The power is immediately removed from terminals 17,
and the drive executes a ramp to stop command in 1
seconds (P042 is configured for 1s). One second later,
terminals 18 and 19 turn off, and the PF525 executes a
safe torque off function. The PF525 shows an F059 fault in
its display.

The CR30 safety outputs at terminal 17, 18 and 19 are ON.
The PF525 still shows an F059 fault. The motor remains
off.

Go to Step 1.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 11

Chapter 2 Cat 1 Stop with GuardShield™ Light Curtain, T-15 Interlock, E-Stop, and PowerFlex 525

Example Bill of Materials

Table 6 - Bill of Materials

Item Product Description Qty

1 440C-CR30-22BBB Guardmaster 440C-CR30 Software Configured Safety Relay

PLe SIL 3, 22 Safety I/O, embedded serial port, USB programming
port, 2 plugin slots, 24V DC

2 440L-P4K1760YD GuardShield Safety Light Curtain

Res 30 mm, Pt Ht 1760 mm, 88 beams

2.1 889D-F4AC-5 DC Micro (M12)
Female, straight, 4-pin, PVC cable, yellow, unshielded,

22 AWG, 5 m (16.4 ft)

2.2 889D-F8AB-5 DC Micro (M12)
Female, straight, 8-pin, PVC cable, yellow, unshielded,

24 AWG, 5 m (16.4 ft)

3 440K-T11287 Tongue Switch - Trojan™ T15

Contacts (safety and aux): 2 N.C., BBM
Preference: N/A
Actuator: Fully-flex
Model Type: GD2 front entry
Conduit Entry: 1/2in NPT conduit

4 800FM-LMT64 800F Illuminated Mushroom Operators

Illuminated, twis t-to-release, 60 mm, round metal (Type 4/13, IP66),
red, standard pack (Qty. 1)

5 800F-X01L 22.5 mm Push Button

No latch, screw contact block, 1 N.C.L.B.

6 800F-ALM Metal Latch 1

7 800F-X01S 22.5 mm PB

No latch, screw contact block, 1 N.C. self-monitoring

8 800F-N3R Integrated LED

Latch mount, 24V AC/DC, red LED

9 800F-X10 22.5 mm Push Button

No latch, screw contact block, 1 N.O.

10 800FM-F301 800F Push Button

Metal, flush, green, START, standard pack (Qty. 1)

11 800FM-E402 800F Push Button

Metal, extended, red, STOP, standard pack (Qty. 1)

12 24B-V2P5A104AA-ND-P3 PowerFlex 525 Pre-engineered FasTrac, with Embedded

EtherNet/IP and Safety

120V AC, 1-phase, 0.5 Hp, 0.4 kW normal duty; 0.5 Hp, 0.4 kW heavy
duty, Type 1 / IP20, no filter, without bypass, without reactor, motor
circuit protector (-P3)

1

1

1

1

1

1

1

1

1

1

1

1

1

Safety Rating

The safety function that is initiated by the light curtain can meet up to Cat 3 PLd
per IS013849-1, SIL CL2 per IEC 62061, and SIL 2 per IEC 61508. It does not
achieve Cat 4 PLe due to the rating of the PF5252 drive

The safety function that is initiated by the gate interlock switch can meet up to
Cat 3 PLd per IS013849-1, SIL CL2 per IEC 62061, and SIL 2 per IEC 61508
when using fault exclusion as described in ISO 14119.

The safety function that is initiated by the E-stop can meet up to Cat 3 PLd per
IS013849-1, SIL CL2 per IEC 62061, and SIL 2 per IEC 61508.

12 Rockwell Automation Publication 440C-WD001A-EN-P - November 2014

Chapter 3

Safety Mats - Two Zones

This application demonstrates two zones using safety mats and E-stop push
buttons. Each zone is controlled by a safety mat and an E-stop push button. In
this example, a sequential manufacturing process has two zones. If an operator
enters the first zone, that zone stops while the second zone continues to function.
If an operator enters zone 2, then both zones 1 and 2 must stop. An indicator
lamp shows which zone is not operating, and the user is allowed to enter for
normal production type operations.

The safety mats for each zone can be single mats or multiple mats that are
connected in series. The safety mats must be connected to pulse tested outputs to
operate properly with the CR30. In this example, the Zone 1 mats use pulses
from 12 and 13 and Zone 2 uses pulses from 16 and 17.

Product Overview

The two E-stop buttons use the same test pulses, from terminals 14 and 15 - this
arrangement is preferred. Alternatively, the E-stops can be powered directly by
the 24V DC supply, but powering directly from 24V does not provide cross
channel fault detection.

Note: The outputs of the CR30 are driving 100S contactors. Due to the
inrush current limitations of the CR30, the CR30 can only switch the
100S-C09EJ contactors. The CR30 cannot switch the C43EJ contactors.

Figure 7 - Overview

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 13