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

Chapter 3 Safety Mats - Two Zones

05

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

09

17

K2

K1

K4

K3

440C-CR30-22BBB

24V Com

+ 24V DC

Mat

E-Stop E-Stop

Mat

K1 K2 K3 K4

K2

K1

K4

K3

Reset

Zone 1

Zone 1 Zone 2

Zone 2

Zone 1
O

Zone 2
O

Reset

COMI-02 I-03

COMI-00 I-01

2080-IQ4OB4

-24DC O-02 O-03

+24DC O-00 O-01

L1 L2 L3L1 L2 L3

M1 M2

Schematic

Figure 8 - Schematic

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

Safety Mats - Two Zones Chapter 3

Connected Components
Workbench

Figure 9 - Connected Components Workbench Example

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 15

Chapter 3 Safety Mats - Two Zones

Circuit Status

Operational Sequence

Example Bill of Materials

No presence is sensed on both mat systems. All four contactors are off, and both
motors (hazards) are off. The system is ready for reset.

Press Reset 1 to enable the start of Zone 1. Press Reset to enable the start of
Zone2.

To gain access to either zone, the operator steps on the mat or presses the E-stop
button. Both devices initiate an immediate stop command to its associated
hazard. An indicator at Plug-in terminal P200 and P201 show when someone or
something is on the mat or if the E-stop is pressed for that zone.

If the operator enters Zone 1, then only Zone 1 stops and Zone 2 continues to
run. If the operator enters Zone 2, then both zones stop.

After leaving the Zone 2, the operator must press the reset button to enable the
restart of Zone 2. After leaving Zone 1, the operator must press the reset buttons
for both Zone 1 and 2 to enable the restart the machine.

Table 7 - Bill of Materials

Item Product Description Qty

1 2080-IQ4OB4 4-ch Digital Input/Output Combination Module 1

2 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

3 800FM-P4MN3R 800F Pilot Light

Rd. Metal (IP66, 4/13, IP66), red, standard pack (Qty. 1)

4 800FM-MT44 800F Non-illuminated Mushroom Operators

Twist-to-release, 40 mm, round metal (Type 4/13, IP66), red,
standard pack (Qty. 1)

4.1 800F-ALM Metal Latch 2

4.2 800F-X01S 22.5 mm PB No Latch
Screw contact block, 1 N.C. self-monitoring

5 440F-M2036BYNN Safety Mat

Yellow, 1000 x 1800 mm, two 4.5 m (15 ft) 2-wire cables, exit out “B”
corners, no trim, no controller

6 440F-T2036 Trim Kit

Standard trim, 1000 x 1800 mm

7 100S-C09EJ14BC MCS 100S-C Safety Contactor

9A, 24V DC (with elec. coil), bifurated contact

8 800FM-P7MN3W 800F Pilot Light

Rd. metal (IP66, 4/13, IP66), clear, standard pack (Qty. 1)

1

2

2

4

2

2

4

2

Safety Rating

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

The safety function that is initiated by the E-stops can meet up to Cat 4, PLe and
SIL3 per IEC61508 and SIL CL3 per IEC 62061.

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

Chapter 4

Enabling Switch (GripSwitch) with Jog Function

The GripSwitch is a hold-to-run enabling device. While holding the GripSwitch
in the center (enabled) position, the operator then presses and holds the jog
switch to operate the PowerFlex drive for a specified duration.

This example requires a two-position selector switch. The position of the selector
switch determines whether the gate switch is used or the GripSwitch is used.

This application has four distinct safety-related functions:

1. Interlock 'Logic' Drive

2. Enabling Switch 'Logic' Drive

3. Selector switch 'Logic' Drive

Product Overview

4. Jog Switch 'Logic' Drive

Figure 10 - Overview

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 17

Chapter 4 Enabling Switch (GripSwitch) with Jog Function

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

8 Jog

7 Clear Fault

RTS

UWV

24V Com

Brown

Blue

White

Red

Yellow

SensaGuard

Integrated

Latch

Grey

GripSwitch

Gate Switch

Pink

Jog

Gate
Open

GripSwitch

12

7

8

34

Schematic

Figure 11 - Schematic

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

Enabling Switch (GripSwitch) with Jog Function Chapter 4

Connected Components
Workbench

Figure 12 - Connected Components Workbench Example

Circuit Status

Logic Level B1 block is an XOR, rather than a simple OR. The Selector switch
chooses either the gate interlock switch or GripSwitch. If a short circuit to 24V
occurs on terminal 5, and the gate closed behind the operator, the GripSwitch
would be bypassed if the simple OR block were used. To avoid a potential bypass
situation, an XOR block is used. The SOF1 output block turns off if both the
gate switch and GripSwitch were both on.

The SOF2 jog output is only enabled when the GripSwitch is both selected and
enabled. Therefore, when the Selector switch is set to the gate switch, the jog
button is disabled. The jog parameter is set to 50 (50 x 50 ms), which is

2.5seconds. When the jog switch is held down, the PF525 jogs the motor for 2.5
seconds. If the jog button is released sooner than 2.5 seconds, the motor stops
immediately.

The safety gate is closed. The selector switch is set to Gate Switch. The
GripSwitch is off and the Jog switch is off. The PF525 is off.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 19

Chapter 4 Enabling Switch (GripSwitch) with Jog Function

Operational Sequence

Example Bill of Materials

Table 8 - Operational Sequence

Action Taken Results

1. Press the drive Stop button. This clears faults in the drive. Fault F059 may be present,

due to its safety inputs being off.

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

production processes. Normally, the motor would be
stopped by the machine control system.

3. Rotate the Selector switch to GripSwitch. The operator must hold the GripSwitch in the center

position to prevent the drive from going to a fault
condition.

4. Open the guard (opens the gate interlock switch). The operator can access the hazard area.

5. Grab the GripSwitch and squeeze to the center ON

position.

6. Momentarily press the jog button. This clears the F059 fault on the PpwerFlex 525.

7. Press and hold the jog button. The PF525 turns on the motor for 2.5 seconds.

To get the PF525 to jog again, the operator can release the
jog button and then depress it again.

8. Set the selector switch to Gate Switch.

9. Press the Stop button. This clears the F059 fault on the PF525.

10.The PF525 is ready for normal producti on operations.

Table 9 - Bill of Materials

Item Product Description Qty

1 2080-IQ4OB4 4-ch Digital Input/Output Combination Module 1

2 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

3 800FM-P4MN3R 800F Pilot Light

Rd. metal (IP66, 4/13, IP66), red, standard pack (Qty. 1)

4 800FM-MT44 800F Non-illuminated Mushroom Operators

Twist-to-release, 40 mm, round metal (Type 4/13, IP66), red,
standard pack (Qty. 1)

4.1 800F-ALM Metal Latch

4.2 800F-X01S 22.5 mm Push Button
No latch, screw contact block, 1 N.C. self-monitoring

5 440F-M2036BYNN Safety Mat

Yellow, 1000 x 1800 mm, two 4.5 m (15 ft) 2-wire cables, exit out “B”
corners, no trim, no controller

6 440F-T2036 Trim Kit

Standard trim, 1000 x 1800 mm

7 100S-C09EJ14BC MCS 100S-C Safety Contactor

9 A, 24V DC (with elec. coil), bifurated contact

8 800FM-P7MN3W 800F Pilot Light

Rd. metal (IP66, 4/13, IP66), clear, standard pack (Qty. 1)

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

Enabling Switch (GripSwitch) with Jog Function Chapter 4

Safety Rating

This application has four distinct safety-related functions:

1. Interlock -> Logic -> Drive
The safety function that is performed by the gate switch can meet the
requirements up to Cat 3 PLd per ISO13849-1, SIL CL2 per IEC62061,
and SIL 2 per IEC61508.

2. Enabling Switch -> Logic -> Drive
The safety function that is performed by the enabling switch can meet the
requirements up to Cat 3 PLd per ISO13849-1, SIL CL2 per IEC62061,
and SIL 2 per IEC61508.

3. Selector switch -> Logic -> Drive
The safety function that is performed by the enabling switch can meet the
requirements up to Cat 3 PLd per ISO13849-1, SIL CL2 per IEC62061,
and SIL 2 per IEC61508.

4. Jog Switch-> Logic -> Drive
The safety function that is performed by the jog switch can meet the
requirements up to Cat 2 PLc per ISO13849-1, SIL CL1 per IEC62061,
and SIL 1 per IEC61508.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 21

Chapter 4 Enabling Switch (GripSwitch) with Jog Function

Notes:

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

Chapter 5

MS1 MS2

LC

Muting Lamp

Material

Conveyor Flow

Hazard Area Non-hazard Area

Muting 2-Sensor L-Type Unidirectional

The CR30 has a function block that supports 2-sensor L-type muting. With this
function block, the material can only move in one direction: from the hazard area
to the non-hazard area. The two muting sensors are located within the hazard
area, and the material must be large enough to block both sensors and the light
curtain. The function block contains timing parameters that allow you to
accommodate a wide range of operating speeds.

Product Overview

Machine Layout

Figure 13 - Overview

The material can only flow from the hazard area to the non-hazard area. The
material must be large enough to concurrently block muting sensor 1, muting
sensor 2, and the light curtain.

Figure 14 - Machine Layout

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 23

Chapter 5 Muting 2-Sensor L-Type Unidirectional

+24V DC

Muted

Light Curtain

24V Com

AB

Pink OSSD A

Grey OSSD B

BlueBlue

Override

Contactors
for Conveyor
Power

Muting
Lamp

05

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

09

17

K2K1

Black

Brown

Brown

Blue

Blue

K2

K1

3 4 11 3

Black

Brown

Brown

Brown

Brown

Blue

Blue

Muting

Sensor 1

Muting

Sensor 2

3 4 1

6

5

7

21

3

Schematic

The example schematic is set up to agree with the terminals shown in the
Connected Components Workbench™ and the example bill of materials.

Figure 15 - Example Schematic

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

Muting 2-Sensor L-Type Unidirectional Chapter 5

Connected Components
Workbench

Figure 16 - Connected Components Workbench Example

Circuit Status

The circuit is ready to run. The muting sensors are clear and the light curtain is
clear.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 25

Chapter 5 Muting 2-Sensor L-Type Unidirectional

LC

Muting sensor 1

Muting sensor 2

Muting lamp

t > 30ms

t > 30ms

t > 50ms

30ms <= t
t < synchronization
time

30ms <= t
t < synchronization
time

t < muting time

muted

Operational Sequence

The muting sensors and the light curtain participate in the sequence of events to
achieve the muting. The material must move past the sensors and into the light
curtain within the synchronization times, which are set in the Connected
Components Workbench function block. In addition, the material must move
through the light curtain within the muting time, which is also set in the
Connected Components Workbench function block.

Figure 17 - Operational Sequence

As the material moves out of the hazard area, it first breaks muting sensor 1
(MS1). The material continues to move and must break muting sensor 2 (MS2)
within the first synchronization time, which is set on the Connected
Components Workbench to 1 second. Then, the muting lamp turns ON and the
light curtain is muted. The material continues to move and must break the light
curtain within the second muting time, which is also set on the Connected
Components Workbench to 1 second. Finally, the material must move through
the light curtain within the muting time, which is configured on the Connected
Components Workbench to 10 seconds.

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

If the material movement exceeds one of the synchronization times or the muting
time, the conveyor stops. An operator can press and hold down the override
button for the duration of the override time. The conveyor contactors turn on
until the override time expires (or the operator releases the button).

Muting 2-Sensor L-Type Unidirectional Chapter 5

Example Bill of Materials

Table 10 - 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, protective height 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 42EF-E1EZB-F4 PHOTOSWITCH® Photoelectric Sensor

RightSight, transmitted beam, infrared, DC, 4-pin DC micro QD on
152mm (6 in.) pigtail

3.1 889D-F4AC-5 DC Micro(M12), Female, Straight
4-pin PVC, yellow, unshielded, 5 m (16.4 ft)

442EF-R9KBBV-F4 PHOTOSWITCH Photoelectric Sensor

RightSight, transmitted beam receiver, DC - dark operate, both sink
(NPN) and source (PNP), 4-pin DC micro QD on 152 mm (6 in.) pigtail

4.1 889D-F4AC-5 DC Micro(M12), Female, Straight
4-pin PVC, yellow, unshielded, 5 m (16.4 ft)

5 855T-BPM10C Control Tower™ Stack Light Mounting Base

10 cm pole mount, black housing, cap included

6 855T-B24TL7 Control Tower Stack Light

Black housing, 24V AC/DC full voltage, clear steady LED
(socket mount)

7 800FM-F1 800F Push Button

Metal, flush, white, no legend, standard pack (Qty. 1)

8 800F-MX10 Metal Latch Mount

1 N.O. contact(s), 0 N.C. contact(s), standard

9 100S-C09EJ304BC MCS 100S-C Safety Contactor

9 A, 24V DC (with elec. coil), bifurcated contact

1

1

1

1

2

2

2

2

1

1

1

1

2

Safety Rating

The 2-sensor L-type muting meets the performance requirements of Cat 4, PLe
per ISO13849-1, SIL CL3 per IEC 62061, and SIL 3 per IEC 61508.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 27

Chapter 5 Muting 2-Sensor L-Type Unidirectional

Notes:

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

Chapter 6

Muting 2-Sensor T-Type Bidirectional

The CR30 has a function block that supports 2-sensor T-type muting. With this
function block, the material can only move in either direction: from the hazard
area to the non-hazard area or reverse. The two muting sensors are arranged so
that their beams form an “X” pattern where the crossover occurs very close to the
light curtain beam. The shape of the material must be such that it breaks the
muting sensor and light curtain beams in a specific pattern. The function block
contains timing parameters that allow you to accommodate a wide range of
operating speeds.

Product Overview

Figure 18 - Overview

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 29

Chapter 6 Muting 2-Sensor T-Type Bidirectional

Hazard Area Non-hazard Area

Machine

MS1 MS2

LC

Muting Lamp

Material

Conveyor

+24V DC

Muted

Light Curtain

24V Com

AB

Pink OSSD A

Grey OSSD B

BlueBlue

Override

Contactors
for Conveyor
Power

Muting
Lamp

05

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

09

17

K2K1

Black

Brown

Brown

Blue

Blue

K2

K1

3 4 11 31 3

Black

Brown

Brown

Brown

Brown

Blue

Blue

Muting

Sensor 1

Muting

Sensor 2

3 4 1

6

5

7

21

3

Machine Layout

Schematic

The material can flow in either direction: to the hazard area from the non-hazard
area or reverse. The shape of the material must be such that it blocks both muting
sensors before it blocks the light curtain. The order in which the muting sensors
are blocked is not critical, but the synchronization time (time between blocking
one sensor and the other sensor) must be met.

Figure 19 - Machine Layout

The example schematic is set up to agree with the terminals shown in the
Connected Components Workbench and the example bill of materials.

Figure 20 - Example Schematic

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

Muting 2-Sensor T-Type Bidirectional Chapter 6

Connected Components
Workbench

Figure 21 - Connected Components Workbench Example

Circuit Status

The circuit is ready to run. The muting sensors are clear and the light curtain is
clear.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 31

Chapter 6 Muting 2-Sensor T-Type Bidirectional

Operational Sequence

The muting sensors and the light curtain participate in the sequence of events to
achieve the muting. The material must move past the sensors and into the light
curtain within the synchronization times, which are set in the Connected
Components Workbench function block. In addition, the material must move
through the light curtain within the muting time, which is also set in the
Connected Components Workbench function block.

Figure 22 - Operational Sequence

LC

Muting sensor 1

Muting sensor 2

Muting lamp

30ms <= t
t < synchronization
time

t > 30ms

t > 50ms

muted

t < muting time

t > 30ms

30ms <= t
t < synchronization
time

As the material moves, it must block both muting sensors within their
synchronization times, which are configured in the Connected Components
Workbench function block for 3seconds. The light curtain is then muted. The
material must move through the light curtain within the specified muting time,
which is configured in the Connected Components Workbench to be 10
seconds.

If the material movement exceeds one of the synchronization times or the muting
time, the conveyor stops. An operator can press and hold down the override
button for the duration of the override time. The conveyor contactors turn on
until the override time expires (or the operator releases the button).

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

Muting 2-Sensor T-Type Bidirectional Chapter 6

Example Bill of Materials

Table 11 - 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, protective height 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 42EF-E1EZB-F4 PHOTOSWITCH Photoelectric Sensor

RightSight, transmitted beam, infrared, DC, 4-pin DC micro QD on
152mm (6 in.) pigtail

3.1 889D-F4AC-5 DC Micro(M12), Female, Straight
4-pin, PVC cable, yellow, unshielded, 5 m

442EF-R9KBBV-F4 PHOTOSWITCH Photoelectric Sensor

RightSight, transmitted beam receiver, DC - dark operate, both sink
(NPN) and source (PNP), 4-pin DC micro QD on 152 mm (6 in.) pigtail

4.1 889D-F4AC-5 DC Micro (M12), Female, Straight
4-pin, PVC cable, yellow, unshielded, 22 AWG, 5 m (16.4 ft)

5 855T-BPM10C Control Tower Stack Light Mounting Base

10 cm pole mount, black housing, cap included

6 855T-B24TL7 Control Tower Stack Light

Black housing, 24V AC/DC full voltage, clear steady LED
(socketmount)

7 800FM-F1 800F Push Button

Metal, flush, white, no legend, standard pack (Qty. 1)

8 800F-MX10 Metal Latch Mount

1 N.O. contact(s), 0 N.C. contact(s), standard

9 100S-C09EJ304BC MCS 100S-C Safety Contactor

9 A, 24V DC (with elec. coil), bifuracated contact

1

1

1

1

2

2

2

2

1

1

1

1

2

Safety Rating

The 2-sensor T-type muting meets the performance requirements of Cat 4, PLe
per ISO13849-1, SIL CL3 per IEC 62061, and SIL 3 per IEC 61508.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 33

Chapter 6 Muting 2-Sensor T-Type Bidirectional

Notes:

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

Chapter 7

Muting 4-sensor T-type Bidirectional

The CR30 has a function block that supports 4-sensor T-type muting. With this
function block, the material can only move in either direction: from the hazard
area to the non-hazard area or reverse. The four muting sensors are arranged so
that their beams cross orthogonally across the conveyor: two inside the hazard
area and two outside the hazard area. The length of the material must be such
that it breaks all four muting sensors and light curtain beams simultaneously. The
function block contains timing parameters that allow you to accommodate a
wide range of operating speeds.

Product Overview

Figure 23 - Overview

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 35

Chapter 7 Muting 4-sensor T-type Bidirectional

Hazard Area Non-hazard Area

Machine

MS1MS2MS3MS4

LC

Muting Lamp

Material

Muted LC

Conveyor

+24V DC

Muted

Light Curtain

24V Com

AB

Pink OSSD A

Grey OSSD B

BlueBlue

Override

Contactors
for Conveyor
Power

Muting
Lamp

05

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

09

17

K2K1

Black

Brown

Brown

Blue

Blue

K2

K1

3 4 11 3

Black

Brown

Brown

Brown

Brown

Blue

Blue

Muting

Sensor 3

Muting

Sensor 4

3 4 1

6

5

7

21

3

Black

Brown

Brown

Blue

Blue

3 4 11 3

Black

Brown

Brown

Blue

Blue

Muting

Sensor 1

Muting

Sensor 2

3 4 1

Machine Layout

Schematic

The material can flow in either direction: to the hazard area from the non-hazard
area or reverse. The shape of the material must be such that it blocks both muting
sensors before it blocks the light curtain. The order in which the muting sensors
are blocked is not critical, but the synchronization time (time between blocking
one sensor and the other sensor) must be met.

Figure 24 - Machine Layout

The example schematic is set up to agree with the terminals shown in the
Connected Components Workbench and the example bill of materials.

Figure 25 - Schematic

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

Muting 4-sensor T-type Bidirectional Chapter 7

Connected Components
Workbench

Figure 26 - Connected Components Workbench Example

Circuit Status

Operational Sequence

The circuit is ready to run. The muting sensors are clear and the light curtain is
clear.

The muting sensors and the light curtain participate in the sequence of events to
achieve the muting. The material must move past the sensors and into the light
curtain within the synchronization times, which are set in the Connected
Components Workbench function block. In addition, the material must move
through the light curtain within the muting time, which is also set in the
Connected Components Workbench function block.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 37

Chapter 7 Muting 4-sensor T-type Bidirectional

Figure 27 - Operational Sequence

LC

Muting sensor 1 (4)

Muting sensor 2 (3)

Muting sensor 3 (2)

Muting sensor 4 (1)

Muting lamp

muted

t > 30ms

t < muting time

t > 30ms

30ms <= t
t < synchronization
time

30ms <= t
t < synchronization
time

t > 30ms

t > 50ms

As the material moves, it must block both muting sensors within their
synchronization times, which are configured in the Connected Components
Workbench function block for 3seconds. The light curtain is then muted. The
material must move through the light curtain within the specified muting time,
which is configured in the Connected Components Workbench to be 10
seconds.

If the material movement exceeds one of the synchronization times or the muting
time, the conveyor stops. An operator can press and hold down the override
button for the duration of the override time. The conveyor contactors turn on
until the override time expires (or the operator releases the button).

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

Muting 4-sensor T-type Bidirectional Chapter 7

Example Bill of Materials

Table 12 - 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, protective height 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 42EF-E1EZB-F4 PHOTOSWITCH Photoelectric Sensor

RightSight, transmitted beam, infrared, DC, 4-pin DC micro QD on
152mm (6 in.) pigtail

3.1 889D-F4AC-5 DC Micro(M12), Female, Straight
4-pin, PVC cable, yellow, unshielded, 5 m

442EF-R9KBBV-F4 PHOTOSWITCH Photoelectric Sensor

RightSight, transmitted beam receiver, DC - dark operate, both sink
(NPN) and source (PNP), 4-pin DC micro QD on 152 mm (6 in.) pigtail

4.1 889D-F4AC-5 DC Micro (M12), Female, Straight
4-pin, PVC cable, yellow, unshielded, 22 AWG, 5 m (16.4 ft)

5 855T-BPM10C Control Tower Stack Light Mounting Base

10 cm pole mount, black housing, cap included

6 855T-B24TL7 Control Tower Stack Light

Black housing, 24V AC/DC full voltage, clear steady LED
(socketmount)

7 800FM-F1 800F Push Button

Metal, flush, white, no legend, standard pack (Qty. 1)

8 800F-MX10 Metal Latch Mount

1 N.O. contact(s), 0 N.C. contact(s), standard

9 100S-C09EJ304BC MCS 100S-C Safety Contactor

9 A, 24V DC (with elec. coil), bifuracated contact

1

1

1

1

4

4

4

4

1

1

1

1

2

Safety Rating

The 2-sensor L-type muting meets the performance requirements of Cat 4, PLe
per ISO13849-1, SIL CL3 per IEC 62061, and SIL 3 per IEC 61508.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 39

Chapter 7 Muting 4-sensor T-type Bidirectional

Notes:

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

Chapter 8

Single-wire Safety

This example application focuses on the single-wire safety (SWS) feature built
into the CR30. TheCR30 has two input terminals that can be configured to use
single wire safety and two output terminals that can be configured to use single
wire safety.

Products that have single-wire safety outputs can be connected to the inputs of
the CR30. This application example shows a CR30 and SI as the single-wire
safety inputs of a CR30. On the output side, the CR30 is driving another CR30
and an EM relay using the single-wire safety output.

Two SensaGuard™ non-contact switches with integrated latch are included in the
example to show that the SWS signals can be incorporated into the logic that is
performed by the CR30.

Product Overview

Figure 28 - Overview

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 41

Chapter 8 Single-wire Safety

+24V DC

24V Com

AB

Reset
#1

#1 #2

#1 #2

Reset
#2

SWS IN

SWS OUT

05

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

09

17

05

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

09

17

Sensa­Guard
#1

Sensa­Guard
#2

OSSD A

OSSD B

OSSD A

OSSD B

A1

L11

X32

L12 14 34 4424

13 33 4323

A2

EM
440R-EM4R2

05

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

09

17

RESET

0

MM

AM

A1

S11 S21 S12S22

Y32L11

13142324S34

A2

SI
440R-S12R2

Schematic

A partial schematic is shown in Figure 29 to highlight the SWS connections.

Figure 29 - Schematic

Connected Components
Workbench

The Connected Components Workbench shows two safety functions:

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

1. SWS In #1 & Gate #1 → SWS Out #1 (Immediate OFF).

2. SWS In #2 & Gate #2 → SWS Out #2 (Delayed OFF).

Figure 30 - Connected Components Workbench Example

Single-wire Safety Chapter 8

Circuit Status

Operational Sequence

The safety gates are closed and the SWS safety inputs are active.

Press Reset #1 to activated SWS output #1 (terminal 20).

Press Reset #2 to activate SWS output #2 (terminal 21).

Deactivating SWS In #1 on terminal 10 or opening Gate #1 turns off SWS
output #1.

Deactivating SWS In #2 on terminal 11 or opening Gate #2 turns off WS
output#2.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 43

Chapter 8 Single-wire Safety

Example Bill of Materials

Safety Rating

Table 13 - 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

2440R-S12R2 Guardmaster Single-input Safety Relay (SI)

1 dual channel universal input, 1 N.C. solid-state auxiliary outputs

3440R-EM4R2 Guardmaster Expansion Module Safety Relay (EM)

Expansion module (single-wire safe is only input), 1 N.C. solid-state
auxiliary outputs

4 440N-Z21SS2H SensaGuard

Plastic rectangular, 2 x PNP, 0.2 A, max safety output, 6 in. pigtail,
8pin micro (M12)

4.1 889D-F8AB-5 DC Micro (M12), Female, Straight
8-pin, PVC cable, yellow, unshielded, 24 AWG, IEC color coded, no

connector, 5 m (16.4 ft)

5 800FM-F611MX10 800F Push Button

Metal, flush, blue, R, metal latch mount, 1 N.O. contact(s), 0 N.C.
contact(s), standard, standard pack (Qty. 1)

3

1

1

2

2

2

The safety ratings of the two safety functions depend on additional components
that are not included in the example. The SWS portion of the circuit can be used
in applications up to Cat 4 PLe and SIL3.

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

Chapter 9

Lifeline Cable Pull

Lifeline™ cable pull switches are emergency stop devices with mechanical
contacts. The application uses pulse testing to check for potential short circuits to
24V, ground and across channels. Manual monitored reset prevents the outputs
from turning ON when Lifeline switches are reset.

Product Overview

Figure 31 - Overview

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 45

Chapter 9 Lifeline Cable Pull

+24V DC

24V Com

Reset

AB

05

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

09

17

K2K1

K2

K1

12

22

11

21

32

31

44

43

12

22

11

213231

44

43

Cable

Schematic

Connected Components
Workbench

Figure 32 - Schematic

The Lifeline 4 switches are emergency stop devices. The emergency stop function
blocks are ANDed as both must be closed for the Immediate Safety Output to
turn ON. When either Lifeline switch opens, the Safety Output turns OFF
immediately.

Circuit Status

Operational Sequence

Example Bill of Materials

Both Lifeline switches are closed. The contactors are OFF.

Press the reset button to turn both contactors ON. Pull on the cable to turn the
contactors OFF.

Table 14 - 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 440E-L13043 440E Emergency Stop Device

2.1 440E-A13085 Installation Kit
75 m

3 440E-L13043 440E Emergency Stop Device

4 800FM-F611MX10 800F Push Button

5 100S-C09EJ23BC MCS 100S-C Safety Contactor

Metal, flush, blue, R, metal latch mount, 1 N.O. contact(s), 0 N.C.
contact(s), standard, standard pack (Qty. 1)

9 A, 24V DC (with elec. coil), bifurcated contact

1

Safety Rating

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

The safety rating that is initiated by either cable pull switch meets the
requirements of Cat 4 PLe and SIL3.

Chapter 10

24V Com

+24V DC

AB

05

CR30

020100 03 04

A1 15 20 21160618A2

071908 10 11

12 13 14

09

17

K2K1

K2

K1

K4

K3

S1

S2

BrownBlue

Blue

White

Black

Brown

White

Black

Grey

Grey

S3 S4

BrownBlue

White

Black

BrownBlue

White

Black

K3 K4

Two-hand Control

This application example shows the setup for two separate 2-hand controls each
that meets ISO 13851 Type IIIC. One uses mechanical outputs, and the other
uses OSSD outputs. Each of the 800Z Zero-Force Touch Buttons™ have a
normally open and normally closed contact. The two systems operate
independently of each other.

Product Overview

Schematic

Figure 33 - Overview

Figure 34 - Schematic

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 47

Chapter 10 Two-hand Control

Connected Components
Workbench

Figure 35 - Connected Components Workbench Example

Circuit Status

Operational Sequence

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

In both circuits, there are no hands on the buttons. All four output contactors are
off.

The two circuits work independently.

You must simultaneously press S1 and S2 (or S3 and S4) to turn on contactors K1
and K2 (or K3 and K4), where simultaneously means within a half second of each
other. You must maintain their hands on both buttons to maintain the contactors
in the ON state. Removing your hands from either button causes the contactors
to turn OFF.

Two-hand Control Chapter 10

Example Bill of Materials

Table 15 - 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

2800Z-GL3Q5 30.5 mm Type 4/4X/13 IP66 Zero-Force Momentary General

Purpose Touch Button

10…40V DC and 20…30V AC input, relay output - 5-pin QD

2.1 800Z-G3AH1 Plastic Mounting Kit
For 30.5 mm holes, (GP)

2.2 889N-F5AE-12F 5-Pin Straight QD Cable

30.5 mm mounting hole, 12 ft length

3800Z-G3AG2 Guard

Black, 22.5 mm/30.5 mm mounting, (GP)

4800Z-GP3Q4 30.5 mm Type 4/4X/13 IP66 Zero-Force Momentary General

Purpose Touch Button

10…30V DC, PNP (sourcing output), 4-pin QD

4.1 800Z-G3AH1 Plastic Mounting Kit
For 30.5 mm holes, (GP)

4.2 889D-F4AE-5 4-Pin Straight QD Micro Cable

30.5 mm mounting hole, 12 ft length

5 100S-C09EJ23BC MCS 100S-C Safety Contactor

9 A, 24V DC (with elec. coil), bifurcated contact

1

Safety Rating

Although the wiring is a little different, both 2-hand control systems meet
ISO13851 Type IIIC.

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 49

Chapter 10 Two-hand Control

Notes:

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

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Publication 440C-WD001A-EN-P - November 2014

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