Rockwell Automation Guardmaster DG Safety Relay User Manual
Guardmaster DG Safety Relay
and GuardLink System
Catalog Numbers 440R-DG2R2T (DG Safety Relay); 440S-SF8D,
440S-SLF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D,
440S-MLF8D, 440S-PF5D, 440S-PF5D4 (Taps);
898D-418U-DM2 (Terminator); 440S-GLTAPBRKx (Bracket);
440R-ENETR (EtherNet/IP Network Interface)
User Manual
Original Instructions
Guardmaster DG Safety Relay and GuardLink System User Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WA RN I NG : Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
2 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Table of Contents
Preface
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 7
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Overview What Is a GuardLink System? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DG Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Device Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Single Wire Safety (SWS) Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Output Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
GuardLink Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GuardLink State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GuardLink Transition from Safe State to Operational State . . . . . . 17
GuardLink Transition from Operational State to Safe State . . . . . . 17
GuardLink Fault Reset Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OSSD Tap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
EMSS Tap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Passive Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Passive Power Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Guard Locking with GuardLink Systems . . . . . . . . . . . . . . . . . . . . . . . 19
Guard Locking Application Example. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 2
GuardLink System Design Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
System Current Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Voltage Drop Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Tap Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Tap Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 3
Chapter 3
Installation Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIN Rail Mounting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Terminal Block Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . 33
Terminal Block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Terminal Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Tap Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Enclosure Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Taps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Prevent Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Taps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chapter 4
Power, Ground, and Wire Wiring Requirements and Recommendation . . . . . . . . . . . . . . . . . . . . . . 37
DG Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Terminal Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Terminal Assignment and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Tap Pin Assignment and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Power Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Taps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Multiple Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DG Safety Relay Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
GuardLink Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Devices with OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Voltage-free Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Single Wire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SWS Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Safety Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
13/14 and 23/24 Safety Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Chapter 5
Configuration Config/Set Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Run Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Sel./Save Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Run Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Configuration Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Delay Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Buttons on the Front of DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . 53
AOP in the Studio 5000 Environment. . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 6
Status Indicators DG Safety Relay Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Tap Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Chapter 7
Pulse Testing Functions Pulse Testing for Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
EMSS Tap Pulse Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Chapter 8
Opto-link Communications Optical Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Arrangement with 440R?ENETR Interface . . . . . . . . . . . . . . . . . . . . . . . . 60
Chapter 9
Safety Function Calculations GuardLink System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SISTEMA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Appendix A
Specifications DG Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 5
Appendix B
Configuration Examples Configuration 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Configuration 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Configuration 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Configuration 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Configuration 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Configuration 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Configuration 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Configuration 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Configuration 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Configuration 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Configuration 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Configuration 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Configuration 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Configuration 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Configuration 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Configuration 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Configuration 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Configuration 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Configuration 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Configuration 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Appendix C
Regulatory Approvals Agency Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Compliance to European Union Directives . . . . . . . . . . . . . . . . . . . . . . . . 91
Machine Safety Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DG Safety Relay Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
SIL Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Performance Level/Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Tap Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
SIL Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Performance Level/Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Appendix D
DG Safety Relay Indicator Fault
Codes
Determine a Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Clear a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
6 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Preface
This user manual is a reference guide for the GuardLink® safety system, plugin modules, and accessories. It describes the procedures that you use to install,
wire, and troubleshoot your relay. This manual explains how to install and wire
your relay and gives you an overview of the GuardLink safety system
Who Should Use This Manual
Download Firmware, AOP, EDS, and Other Files
Summary of Changes
Use this manual if you are responsible for the design, installation,
programming, or troubleshooting of control systems that use the GuardLink
safety system.
You must have a basic understanding of electrical circuitry and familiarity
with safety-related control systems. If you do not, obtain the proper training
before using this product.
Download firmware, associated files (such as AOP, EDS, and DTM), and access
product release notes from the Product Compatibility and Download Center at
rok.auto/pcdc
This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.
Top ic Page
Updated Catalog Number List.
Updated Guard Locking with GuardLink Systems section. 19
Updated Figure 7
Updated figure headings for Figure 21
Updated Table 19…Table 24 66…68
.
Front - User
Manual
.28
…Figure 27.39…41
Definitions
Publication AG-7.1 contains a glossary of terms and abbreviations that are used
by Rockwell Automation to describe industrial automation systems. The
following is a list of specific terms and abbreviations that are used in this
manual.
• Electrical Mechanical Safety Switch (EMSS) - A type of tap that
interfaces with safety devices that have redundant voltage-free
contacts. The tap generates pulse tests to detect short circuits to the DC
power supply, short circuits to the DC common, and shorts circuits
between the two contacts.
• GuardLink Control, Lock, and Unlock (CLU) Signal - This signal is
either static or dynamic. When static, this signal is LO when the system
is operational and HI when a demand is placed on the safety system.
The signal is dynamic when an unlock command is issued to guard
locking devices.
• GuardLink Operational State - All taps on the GuardLink circuit
indicate that their associated safety device is ready for the machine to
operate.
• GuardLink Safe State - One or more of the taps on the GuardLink
circuit indicate that their associated safety device is not ready for the
machine to operate.
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 7
• GuardLink Safety Signal - A known dynamic safety signal in
operational mode and a two-way communication signal that the DG
safety relay initiates to determine the status of the taps in the safe state.
• HI - The ON state of the output of a logic block or the state of an input
to a logic block or a voltage level to be above the turn-on threshold.
• LO - Logic state of being OFF or a voltage level to be below the turn-off
threshold.
• N/C - No connection
• N.C. (Normally Closed) - A voltage-free electrical contact whose normal
state (that is, no pressure or electrical potential applied) is in the closed
position.
• N.O. (Normally Open) - A voltage-free electrical contact whose normal
state (that is, no pressure or electrical potential applied) is in the open
position.
• Output Signal Switching Device (OSSD)- Generally a pair of solid-state
signals that are pulled up to the DC source supply. The signals are
pulse-tested for short circuits to the DC power supply, short circuits to
the DC common and shorts circuits between the two signals.
• Reaction Time - The time between the true states of one input to the
ON state of the output.
• Recovery Time - The time that is required for the input to be in the LO
state before returning to the HI state.
• Response Time - The time between the trigger of one input to the OFF
state of the output.
• Safety Function - The complete process from sensing the action (for
example, open a safety gate) to executing the final output device (for
example, turning off a pair of contactors).
• Single Wire Safety (SWS) - A unique unidirectional safety-rated signal
that is sent over one wire to indicate a safety status and command the
initiation of a safety function. The SWS can be used in Category 4,
Performance Level e, per ISO 13849-1 and safety integrity level (SIL) 3,
per IEC 62061 and IEC 61508.
• Status Indicators - The status indicators on the front face of the DG
safety relay and the taps are bicolor. Table 1
shows how the status
indicators are used in this publication.
Table 1 - Status Indicator State
Symbol Description Symbol Description
Green indicator is OFF
Red indicator is OFF
Green indicator is OFF
Red indicator is ON
Green indicator is OFF
Red indicator flashes with certain
frequency
Green indicator is ON
Red indicator is OFF
• Tap - A connection in a GuardLink circuit that associates a safety device
to the GuardLink circuit.
• Voltage-free Contacts - Electrical contacts that have no voltage that is
applied to them. These contacts are typically N.O. or N.C. contacts that
change state due to a mechanical (for example, someone pressing a
push button) or electromechanical (for example, solenoid operated)
stimulus.
8 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Green indicator flashes with certain frequenc y
Red indicator is OFF
Green indicator is ON
Red indicator is ON
Green indicator flashes with certain frequenc y
Red indicator flashes with certain frequency
Additional Resources
These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
NEMA Standard 250 and IEC 60529
Guardmaster EtherNet/IP Network Interface User
Manual, publication 440R-UM009
Industrial Automation Glossary, publication AG-7.1
Industrial Automation Wiring and Grounding
Guidelines, publication 1770-4.1
Product Certifications website,
rok.auto/certifications.
You can view or download publications at rok.auto/literature
Provides explanations of the degrees of protection that is
provided by different types of enclosure.
A detailed description of module functionality, configuration,
installation procedure, and information on how to use the
Guardmaster® EtherNet/IP™ Network Interface (catalog
number 440R-ENETR).
A glossary of industrial automation terms and abbreviations.
Provides general guidelines for installing a Rockwell
Automation industrial system.
Provides declarations of conformity, certificates, and other
certification details.
.
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 9
Notes:
10 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Overview
Chapter 1
What Is a GuardLink System?
A GuardLink® system is a collection of components to simplify a series
connection of safety devices while achieving the highest industrial safety
rating. The system has these important features:
• Simplifies the connection of series connected safety devices.
• Facilitates the scalability of the safety series connections.
• Provides diagnostic information about each device in the system without
having to run a separate status wire back to the machine control system.
• Allows the simultaneous or individual lock and unlock of guard locking
interlocks in the series connected system. No need for an additional wire
from the machine control system to lock and unlock the safety gate.
• Helps ease communication to the machine control system over
EtherNet/IP™. Communication includes sending non-safety commands
to devices and receiving status information back from the safety devices.
Figure 1 on page 12
GuardLink tap has M12 quick disconnect terminations to facilitate wiring with
cordsets and patchcords. The DG safety relay can accommodate one or two
GuardLink circuits or a combination of GuardLink and individual safety
devices.
Each GuardLink circuit can accommodate up to 32 taps. The DG safety relay
operates and monitors two safety contactors and has a monitored manual
reset.
shows the basic components of a typical application. The
A typical GuardLink system consists of the following:
• One DG (dual GuardLink) Guardmaster® safety relay (GSR)
• One tap for each safety device
• One terminator for each GuardLink circuit
• Patchcords and cordsets
• An optional Ethernet interface
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 11
Chapter 1 Overview
R
INPUTPWR
INPUT
1607-XT
INPUT
INPUT INPUT INPUT INPUT
INPUTINPUT INPUT
INPUT
NS
LNK2
LNK1
MS
4
3
2
1
0
5
6
7
8
9
A2A1
LNK2
LNK1
IP: 192. 168. 1. ABC
4
3
2
1
0
5
6
7
8
9
4
3
2
1
0
5
6
7
8
9
A
B
C
33 34 43 44
A1 A2 S11 S12
PWR/Fault
Logic IN
OUT
L12 L11 X32
13 14 23 24
EM
13 14 23 24
33 34 43 44
S12 S22 S32 S42
A1 A2 S11 S21
X1 X2 X3 X4
13 14 23 24
OUT
IN 1
IN X
Reset
FB
Cong/Set
Sel./Save
DG
Reset
Time
OUT X
IN 2
PWR/Fault
0
.
2
.
4
.
6
.
8
.
1
0
.
1
2
.
1
4
.
Each DG safety relay can accommodate
up to two GuardLink circuits, each
containing up to 32 devices.
Standard Safety Devices
GuardLink
Enabled
Devices
One Terminator for
each GuardLink Circuit
Passive Power Tap
for Extra Power
Single Wire Safety for Expansion
Output Monitoring
One Optional Ethernet Module (Required for Guard Locking)
Upstream
Downstream
Cordsets and Patchcords
On-Machine™
Power Supply
One DG
Safety Relay
Passive Tap for
GuardLink Enabled
Devices
Figure 1 - Typical GuardLink System
Taps Taps create nodes in the GuardLink circuit. A safety device is connected to
each tap. The following types of taps are available:
• GuardLink enabled taps that interface with devices having voltage-free
safety contacts
• GuardLink enabled taps that interface with devices that have OSSD
signals
• Passive taps that interface with devices that are GuardLink enabled
• Passive power taps that interface with devices that are GuardLink
enabled and add power to the link
GuardLink enabled taps are available in an 8-pin and 5-pin device connection
version. Passive style taps are only available in a 5-pin device connection
version.
The taps are intended to be mounted on the machine, near the location of the
device it monitors. The different types and versions can be connected in any
order and can be mixed.
12 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Chapter 1 Overview
DG Safety Relay The DG safety relay is the host of the GuardLink system. By using a sequence of
push buttons on the front face, the DG safety relay can be configured for many
types of safety applications. The DG safety relay can do the following:
• Monitor up to two GuardLink circuits, two safety devices or a
combination
• Use Single Wire Safety (SWS) input and output for expansion
• Execute Stop Categories 0 or 1 (immediate and delayed outputs)
• Monitor the status of output safety devices, like contactors
• Be configured for automatic or monitored manual reset
• Be configured to initiate a lock function for guard locking with a
GuardLink circuit
• Be configured to initiate an unlock function for guard locking with a
GuardLink circuit
Safety Device Inputs
The DG safety device inputs can be configured in one of the following
arrangements:
• One GuardLink circuit
•Two GuardLink circuits
• One GuardLink circuit and one safety device
•Two safety devices
• One safety device
The DG safety relay applies AND logic to all used inputs. Unused inputs are
ignored.
Single Wire Safety (SWS) Input
The DG safety relay then applies AND logic to the SWS input if configured for
use. The single wire safety input is ignored if not included in the
configuration.
Output Monitoring
The DG safety relay monitors the status of external safety output devices. After
all safety inputs are satisfied, the DG safety relay checks the monitoring input
terminal. If 24V is present, the DG safety relay proceeds to execute the reset
function.
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 13
Chapter 1 Overview
R
GuardLink circuit - one tap for each safety device
Safety device (E-stop, mechanical interlock, light curtain,
scanner, OSSD interlocks)
DG safety relay
EtherNet/IP
interface
Output
monitoring
Monitored
Manual
Reset
Reset
The DG safety relay reset function can be applied one of three ways:
• Automatic reset (no connection needed)
• Monitored manual reset by a momentary push button that is connected
to an input terminal
• With an Ethernet interface, the machine control system can initiate the
reset function.
The DG safety relay allows both an input terminal and the machine control
system to perform the monitored manual reset function. The reset signal must
transition from LO to HI and back to LO within a window of 0.25…3 seconds.
The reset occurs on the trailing edge. When using a programmable logic
controller (PLC) to generate the reset signal, use a narrower window
(0.26…2.99 s) for more reliable reset action.
ATTENTION: The reset function must not be used to start or restart the
machine.
In Figure 2
device input. The EtherNet/IP interface reports status information to the
machine control system. The DG safety relay monitors the status of the two
output contactors and uses monitored manual reset to energize the
contactors.
Figure 2 - One GuardLink Circuit and One Safety Device
, the DG safety relay has one GuardLink circuit and one safety
R
14 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Chapter 1 Overview
RR
DG safety relay
Two safety devices (E-stops, mechanical interlocks,
light curtains, scanners, OSSD interlocks)
Cordsets or
patchcords
Optional
EtherNet/IP
interface
Figure 3 shows an example of a DG safety relay operating as the equivalent of a
DI safety relay. In Figure 3
, the DG safety relay is configured to accept two
input devices, control and monitor two contactors with a manual reset input.
The 440R-ENETR interface reports the status to the machine control system.
The machine control system can also initiate a reset command.
Figure 3 - Two Safety Devices
GuardLink Principle of Operation
The GuardLink circuit is a continuous chain of safety devices that are
connected in series with only four wires. Two wires provide power and ground
to the taps and devices.
The third wire (GuardLink safety signal) performs the diagnostics on the taps
and the devices that are connected to each tap while in the safe state. It also
carries the dynamic safety signal while in an operational state.
The fourth wire (CLU) provides the lock/unlock commands to guard locking
devices on the circuit.
GuardLink State
The GuardLink chain can be in one of four states:
• Initialization
•Safe
•Operational
•Fault
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 15
Chapter 1 Overview
Initialization State
The initialization state starts when power is applied to the GuardLink circuit
and ends when the GuardLink circuit enters the safe state. If no errors exist,
the GuardLink circuit transitions to the safe state; the initialization state
cannot transition to the operational state.
During initialization, the DG safety relay establishes and verifies the validity of
the circuit by checking the following items:
• All devices set their node number
• Not more than 32 devices exist
• The firmware of the taps is compatible with the DG safety relay
firmware.
• The DG safety relay detects node type and position automatically. When
a 440R-ENETR interface is used, it acquires the node types and positions
from the DG safety relay. The 440R-ENETR interface validates the correct
type and position against the setup that is provided by the Studio 5000®
Add-On-Profile (AOP). If validation is not successful, the 440R-ENETR
interface reports an error.
• Validates a terminator is attached to the GuardLink circuit.
Safe State
The GuardLink safety signal commands the DG safety relay to a safe state,
which turns all safety outputs OFF. The GuardLink safety signal monitors the
circuit for changes of state from the taps.
The CLU signal is HI (if guard locking devices are not used) or sending a
dynamic unlock signal (if guard locking devices are used). The taps indicate
this state by a steady red Link indicator.
Operational State
The GuardLink operational state is described as the GuardLink safety signal
that generates a specific dynamic signal to the DG safety relay and the CLU
signal being LO. The state of the DG safety relay safety outputs can be OFF or
ON. The state depends on the configuration, other safety device inputs, the
feedback monitoring input, and the reset input.
Fault State
The DG safety relay and the taps have two fault states: recoverable and
nonrecoverable. When a fault occurs, the taps and DG safety relay are in a safe
state. Diagnostic information is provided by the indicators. The DG safety
relay also sends diagnostic information to the EtherNet/IP interface.
Recoverable faults can be cleared by cycling the faulted input devices.
Nonrecoverable faults require the power to the cycled and can also require
troubleshooting and correction of the fault. When an EtherNet/IP interface is
used, the machine control system can issue a fault reset (equivalent to a power
cycle).
16 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Chapter 1 Overview
GuardLink Transition from Safe State to Operational State
When the GuardLink signal is in the safe state, the DG safety relay holds the
CLU signal in the high or dynamic unlocking state. The DG safety relay puts all
taps in the safe state. For the GuardLink signal to return to the operational
state, the DG safety relay must know that all taps are ready to go to the
operational state. If the taps are ready to go, the CLU signal is set to LO.
Now that the CLU is set to LO, the last tap generates the safety signal. Each
successive upstream device verifies that the previous device is in a safe state,
confirms that its own device is in a safe state, and sends an inverted safe state
signal to the next device.
When the DG safety relay receives the safety signal, the GuardLink circuit is in
an operational state, and the DG safety relay continues with the evaluation of
the other inputs, output monitoring, and reset inputs.
GuardLink Transition from Operational State to Safe State
Once an input device has a demand on its safety function, the tap stops
sending the safety signal. When the DG safety relay no longer detects the
safety signal, the CLU signal is set to HI to make all taps enter the safe state.
GuardLink Fault Reset Command
Devices with OSSD outputs can sometimes go to a fault state that requires
power cycling. The Ethernet interface can be used to send a fault reset signal
from the machine control system to individual devices. This reset signal cycles
the power to the device connected to the specified tap.
OSSD Tap
The OSSD tap is designed to specifically interface with safety products that
generate OSSD outputs. The OSSD tap does not perform testing on the OSSD
signals as the input device must perform the test.
The OSSD tap is looking to see if the outputs of the connected device are
energized or de-energized. If the outputs are de-energized, then the tap goes
to a safe state, and the input indicator is red. If the outputs of the device are
energized, then the tap shows a solid or flashing green input indicator.
If the OSSD tap inputs are not the same state for three or more seconds, then
the tap enters a recoverable fault state. Both inputs must go to LO and then
back to HI to recover.
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 17
Chapter 1 Overview
EMSS Tap
The EMSS tap is designed to interface with two voltage-free contacts. The tap
applies 24V to one side of the contact on both channels and looks for the 24V on
the monitoring input. These contacts are pulse tested by the tap, see Pulse
Testing Functions on page 57 for pulse details.
The tap is looking to see if both contacts are closed or open. When the contacts
open, the tap goes to a safe state, and the input indicator is red. When the
contacts close, the tap goes to an operational state, which turns the input
indicator either solid or flashing green.
The EMSS tap has a 10 second simultaneity window. If one contact opens, the
second contact must open within 10 seconds. Similarly, if one contact closes,
the second contact must close within 10 seconds. If the simultaneity window
requirement is not met, the tap goes to a recoverable fault state. To recover,
both contacts must be cycled open and then closed again within 10 seconds.
Passive Tap
The passive tap is designed to interface with safety rated devices that have
built-in GuardLink technology. The passive tap simply passes the GuardLink
signals to and from the device. The passive tap does not operate with safety
devices that have OSSD or EMSS outputs.
Passive Power Tap
The passive power tap has two significant features:
• The passive power tap acts as a passive tap by passing the GuardLink
signals directly to devices with built-in GuardLink technology, and
• The passive power tap allows additional power to be introduced into the
GuardLink circuit to compensate for voltage drops resulting from long
cable lengths and numerous devices in the circuit.
18 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Chapter 1 Overview
Guard Locking with GuardLink Systems
Both Power to Release and Power to Lock guard locking devices can be
connected to GuardLink taps. Power to Release switches must be connected to
Power to Release taps, and Power to Lock switches must be connected to Power
to Lock taps (see Table 2
440R-ENETR interface must be used. The lock and unlock commands can only
be issued to the guard locking devices through the 440R-ENETR interface.
Table 2 - Guard Locking Taps
Locking Operation Switch Outputs Tap
Power to Release
Power to Lock
When a GuardLink circuit has both Power to Release and Power to Lock
devices, a lock command that is sent to all devices causes both PTR and PTL
devices to a locked state. An unlock command sent to all devices causes both
PTR and PTL devices to an unlocked state.
). When guard locking devices are connected, a
EMSS contacts 440S-MF8D
OSSD
EMSS contacts
OSSD 440S-SLF8D
440S-SF8D
440S-MLF8D
When an unlock request is issued, the DG safety relay turns off OUT X
(terminal X2) immediately and starts the off-delay timer. When the off-delay
timer expires, the DG safety relay issues an unlock command to the GuardLink
circuit and turns off its safety outputs (terminals 13/14 and 23/24).
When multiple guard locking devices are installed on a GuardLink system, the
DG safety relay inserts a short delay between commands to each successive
device to minimize the momentary inrush current to the solenoids. The device
closest to the DG safety relay receives the command first. The device furthest
away from the DG safety relay receives the command last.
The delay between commands is between 135…300 ms. When a few guard
locking devices are used, the delay is 135 ms. As more guard locking devices are
included in the circuit, the delay increases. When 32 guard locking devices are
used, the delay can be up to 300 ms between each device.
Figure 4 on page 20
shows an example timing diagram. The delay switch is set
to position 5 (1 second delay). The first guard unlocking command starts at
1000 ms. The second unlock signal occurs at 1135 ms. The third unlock signal
occurs at 1270 ms. If 32 guard locking devices are installed, the last one receives
the unlock command at 10,600 ms.
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 19
Chapter 1 Overview
1270 1405 1540 10,600113510000
1
2
3
4
5
32
Unlock Commands to
Guard Locking Devices
Time [ms]
Unlock Request
OUT X (X2)
OUT (13/14, 23/24)
Figure 4 - Unlock Command Timing Diagram
Guard Locking Application Example
Figure 5 on page 21 shows a typical guard locking application example. The DG
safety relay has four taps on the GuardLink circuit:
• First tap — SensaGuard™ integrated-latch interlock switch
• Second tap — 440G-LZ guard locking interlock switch
• Third tap — TLS –ZR guard locking switch
• Fourth tap — SensaGuard flat pack interlock switch
The TIME switch on the DG safety relay is set to position 9, which provides a
5 second delay to allow the motor to coast to a full stop.
The SensaGuard switches allow immediate access to the machine. Additional
risk reduction measures must be provided to help prevent access to the
hazards during the timing period.
Because guard locking is used, a 440R-ENETR interface must be included in
the application. An HMI and PLC initiate the unlock and lock control
commands. The PLC sends the command to the 440R-ENETR interface. Over
the optical bus, the 440R-ENETR interface instructs the DG safety relay to
generate the unlock and lock commands through the GuardLink circuit. The
DG and EM safety relays report status information over the optical bus back to
the PLC through the 440R-ENETR interface.
20 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Figure 5 - Guard Locking Application Example Schematic and Logic
A1
L12
X32
L11 34
13 23 33 43
4414 24A2
EM
440R-EM4R2
0
.
2
.
4
.
6
.
8
.
1
0
.
1
2
.
1
4
.
9
INPUT
+24V DC
Ethernet
Host PC
Ethernet
24V DC Com
Reset
Stop
Start
Feedback
100S
Contactors
Immediate
Acting
Loads
A1
S32 14S42
13 23
24
S11 S12S21 S22
X2
X3
X4
X1
A2
DG
440R-DG2R2T
OUT X
SWS
PLCHMI
L1
L2 L3
M
K1
K2
+
440R-ENETR
A
B
C
TIME
440N-Z21SS3PH
SensaGuard
Interlock
898D-418U-DM2
Terminator
440N-Z21SS2JN9
SensaGuard
Interlock
INPUT INPUT
440G-LZS21SPRH
Guard Locking
Safety Switch
INPUT
440S-SF8D 440S-SF8D
440S-SF8D
440G-TZS21UPRH
Guard Locking
Safety Switch
L
++
N
1606-XLP95E
2428V
DC ok
K2
K1
440S-SF5D
K1 K2
Status Status
Control
Schematic Logic
SMF Level
LOGIC Level
SOF Level
Chapter 1 Overview
IN 1
RR
FBFB
OUT X OUT 14/24
Table 3 - Guard Locking Application Example Configuration
Indicator Function Configuration ID: 0x6A
OUT Safety Functions IN1
IN 1 Input Type GuardLink
IN 2 Input Type Not used
OUT X Output Type SWS
IN X Input Mode SWS Disabled
Reset Reset Type Monitored Manual
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 21
FB Reset Assignment SOF
• Circuit Status
The gates that the SensaGuard interlock switches monitor are closed.
The guard locking switches are closed and locked. The DG and EM safety
relays are OFF and ready for reset.
•Starting
Press the Reset button to energize the DG and EM safety relays. Their
output contacts close. Press the Start button to start the motor via
contactors K1 and K2 and energize the two immediate acting loads.
controlled system to start or restart the hazards after the safety system
is reset.
•Stopping
Press the Stop button to turn off the motor and immediate acting loads.
The immediate acting loads and contactors K1 and K2 de-energize
immediately, and the motor coasts to a stop. This action does not unlock
the guard locking switches.
IMPORTANT The Start/Stop circuit can be replaced by an equivalent machine
Chapter 1 Overview
• SensaGuard Switches
Opening either SensaGuard interlock turns off the DG and EM safety
relays. The EM safety relay turns off K1 and K2 immediately, and the
motor coasts to a stop. With the Time switch on the DG safety relay set to
9, the 13/14 and 23/24 outputs on the DG safety relay turn off after
5 seconds. This action does not unlock the guard locking switches.
• Unlock the Guard Locking Switches
Use the HMI to unlock the guard locking switches. The EM safety relay
turns off K1 and K2 immediately, and the motor coasts to a stop. After
5 seconds, both the 13/14 and 23/24 outputs of the DG safety relay turn off
the immediate acting loads and the guard locking switches are unlocked.
IMPORTANT The outputs of the DG safety relay (13/14 and 23/24) turn off and the
unlock command occurs after the time delay expires. The immediate
acting loads must remove the hazards that they control quickly before
you can open the gate and reach the hazard.
•Restart
Close the safety gates. If the gates were unlocked, use the HMI to initiate
a lock command. Both gates are locked and the GuardLink circuit is
satisfied. Press the Reset button. Press the Start button to energize the
immediate acting loads and turn on the motor.
22 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Chapter 2
GuardLink System Design
Design Considerations The design of a GuardLink® circuit requires knowledge of the power
requirements of the input devices and the length of the link cables. A voltage
drop occurs across each tap. The cumulative voltage drop determines the
number of taps that can be included in the circuit.
The GuardLink system makes it easy to monitor multiple devices over long
distances when multiple access points to the hazardous area are required.
The DG safety relay monitors the GuardLink system. The GuardLink system
can provide diagnostic information on each access point back to the machine
control system.
The GuardLink system must be designed considering these factors:
• Voltage available at each node
• Current flowing through each node
• Cable lengths
•Wire size
• Power requirements for each tap
• Safety device power requirements
The GuardLink system is designed to operate on a 24V DC system. The
maximum continuous current on the link circuit must not exceed 4 A; the taps
and link cables are rated for 4 A continuous.
Figure 6 on page 24
and safety signals are sourced to connection J1. J2 is connected to downstream
taps. J3 of each tap is connected to a safety device.
identifies three tap connections: T1, T2, and T3. The voltage
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 23
Chapter 2 GuardLink System Design
R
1
I
+ + - Vs=24V
Power
Supply
1
Link Cable
L
1
Fuse
4 A
SLO-BLO™
Figure 6 - Tap Connections
Safety Device 2
Device Cable
J3
J2
D2
Safety Device 3
D3
Device Cable
J3
J2
T3
Terminator
I
3
Link Cable
L
R
3
3
J1
Safety Device 1
D1
Device Cable
J3
INPUT INPUT
J1
V
J1
J2
T1
VJ2V
J3
I
2
Link Cable
L
2
R
2
INPUT
J1
T2
Table 4 - Key for Figure 6
Item Description
D1, D2, D3 Safety devices
, I2, I
I
1
I
, IT2, I
T1
I
, ID2, I
D1
L
, L2, L
1
R
, R2, R
1
T1, T2, T3 Taps
VJ1, VJ2, V
Current in the link cable (A)
3
Current required by a tap (A)
T3
Current required by a safety device (A)
1D3
Length of link cable (m)
3
Resistance of wire (Ω)
3
Voltage at tap connector (V)
J3
System Current Calculation The GuardLink circuit current must be calculated to determine whether a
significant voltage drop occurs to a safety device.
The total system current, I
plus the current required by the device that is connected to the first tap plus
the current required by the downstream circuit. The total system current must
not exceed 4 A, continuous.
I
= IT1 + ID1 + I2
1
The current in each segment of the GuardLink circuit is calculated in a similar
fashion.
I
= IT2 +ID2 + I
2
I3 = IT3 + I
D3
The total system current, I1, is therefore the sum of the device currents plus the
sum of the tap currents.
I
= ∑ IT + ∑ I
1
D
, is the sum of the current required by the first tap
1
3
24 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Chapter 2 GuardLink System Design
Voltage Drop Consideration With the potential of using up to 32 taps and long cable lengths between taps,
the voltage available to the safety devices at connector J3 must be calculated.
The voltage available to the safety device has two components:
• The voltage drop due to the wire resistance of the cables
• The voltage drop within the tap
The resistance of the recommended 18 AWG cordsets and patchcords is
(0.02095 ohms/m (0.00664 ohms/ft). The wire resistance of the cordset from
the power supply to tap 1 (R
R
= 0.02095 * L
1
1
The wire resistance must be considered for both the power and ground;
therefore the voltage drop is multiplied by two. The voltage at connector J1 of
tap T1 (V
) is:
J1
V
= 2 * I1 * R
J1
1
) is:
1
The tap has a small voltage from connector J1 to J2. The typical voltage at
connector J2 (V
V
= VJ1 - (2 * 0.028V)
J2
) drop through the tap from J1 to J2 is:
J2
The voltage available at connector J3 is dependent on the device that is
connected to J3. The typical voltage drop from J1 to J3 is 0.4V when the device
uses 50 mA.
V
= VJ1 - 0.4V (typical)
J3
IMPORTANT
The voltage drop from J1 to J3 can be as high as 1.2V with a maximum
load of 500 mA at the highest rated ambient temperature.
The TLS-ZR guard locking switch voltage drop is 0.29V when locked and
0.31V when unlocked.
The taps consume 25 mA when OFF. The EMSS taps consume an additional
15 mA (7.5 mA per channel) when the contacts are closed. The OSSD taps
consume an additional 6 mA (3 mA per channel), when the outputs are ON.
A spreadsheet can be used to calculate the voltage available to the safety device.
Table 5 on page 26
shows the voltage available to the safety device of a number
of different devices. Assuming that the power supply voltage is set to 24V, and
the cable is the recommended 18 AWG, the voltage available to the safety
devices is shown in the right-hand column.
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 25
Chapter 2 GuardLink System Design
When guard locking devices are used in the circuit, the taps and wiring
components are subjected to momentary surges in current. With the
sequential operation of the lock/unlock command, the momentary surges
should not adversely affect the performance of the GuardLink circuit.
The operating voltage specification of the tap is 20.4…26.4V. In the example
that is shown in Table 5
, the voltage at J1 of tap 6 has fallen below the lowest
supply voltage specification of 20.4V DC. This system is not feasible, and
remedial action must be taken (see Table 6
).
IMPORTANT
Table 5 assumes the following:
•Supply voltage = 24V
• Link cable wire gauge = 18 AWG
• Link wire resistance = 0.02095 ohms/m
Table 5 - Voltage Calculation at 24V Supply
Cable Length
Tap
[m (ft)]
1 15 (49.2) SensaGuard™ Ser A 81 1105 23.24 22.84
2 15 (49.2) SensaGuard Ser A 81 1024 22.54 22.14
3 15 (49.2) Lite Lock 440G-LZ 135 943 21.90 21.50
4 15 (49.2) 800F E-stop 40 808 21.34 20.94
5 15 (49.2) Lifeline™ 4 40 768 20.82 20.42
6 15 (49.2) LifeLine 5 81 728
7 15 (49.2) TLSZR-GD2 PLe 135 647
8 15 (49.2) TLSZR-GD2 PLe 135 512
9 15 (49.2) Lite Lock 440G-LZ 135 377 19.27 18.87
10 15 (49.2) SensaGuard Ser A 81 242
11 15 (49.2) SensaGuard Ser A 81 161
12 15 (49.2) Mechanical Switch 40 80 18.94 18.54
13 15 (49.2) Mechanical Switch 40 40
14 0 (0) — 0 0 — —
15 0 (0) — 0 0 — —
Safety Device
Tap + Device
Current (mA)
Total Current
(mA)
J1 Voltage
(V)
20.32 19.92
19.88 19.48
19.53 19.13
19.10 18.70
18.99 18.59
18.91 18.51
Typical (V)
J3 Voltage
26 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
Chapter 2 GuardLink System Design
The example in Table 5, can be corrected in one of two ways:
• The supply voltage can be increased from 24V to 26V as shown in Table 6
Now, all 13 taps meet the minimum voltage specification of 20.4V at
connector J1.
• Where voltage drops below 20.4V DC on the link, a passive power tap
(440S-PF5D4) can be added to bring voltage on the link back to within
necessary specification.
.
IMPORTANT
Table 6 assumes the following:
•Supply voltage = 26V
• Link cable wire gauge = 18 AWG
• Link wire resistance = 0.02095 ohms/m
Table 6 - Voltage Calculation at 26V Supply
Cable Length
Tap
[m (ft)]
1 15 (49.2) SensaGuard Ser A 81 1105 25.24 25.84
2 15 (49.2) SensaGuard Ser A 81 1024 24.54 24.14
3 15 (49.2) Lite Lock 440G-LZ 135 943 23.90 23.50
4 15 (49.2) 800F E-stop 40 808 23.34 23.94
5 15 (49.2) LifeLine 4 40 768 22.82 22.42
6 15 (49.2) LifeLine 5 81 728 22.32 21.92
7 15 (49.2) TLSZR-GD2 PLe 135 647 21.88 21.48
8 15 (49.2) TLSZR-GD2 PLe 135 512 21.53 21.13
9 15 (49.2) Lite Lock 440G-LZ 135 377 21.27 20.87
10 15 (49.2) SensaGuard Ser A 81 242 21.10 20.70
11 15 (49.2) SensaGuard Ser A 81 161 20.99 20.59
12 15 (49.2) Mechanical Switch 40 80 20.90 20.54
13 15 (49.2) Mechanical Switch 40 40 20.91 20.51
14 0 (0) — 0 0 — —
15 0 (0) — 0 0 — —
Safety Device
Tap + Device
Current (mA)
Total Current
(mA)
J1 Voltage
(V)
J3 Voltage
Typical (V)
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 27
Chapter 2 GuardLink System Design
889D-F5NCDM-x
5wire Patchcord or
889D-F8NBDM-x
8wire Patchcord
10 m (32.8 ft) length, max
889D-F4NE-x
4-wire Cordset
30 m (98.4 ft) length, max
889D-F4NEDM-x
4wire Patchcord
5 m (16.4 ft) length, max
889D-418U-DM2
Ter min at or
Standard Safety
Device
Standard
Safety Device
DG
Safety
Relay
White
Black Brown Blue
24V
Power
Supply
GuardLink Enabled
Safety Device
889D-M5NC-x
5wire Cordset or
889D-M8NB-x
8wire Cordset
10 m (32.8 ft) length, max
889D-F5NCDM-x
5wire Patchcord
10 m (32.8 ft) length, max
889D-F4NEDM-x
4wire Patchcord
25 m (82 ft) length, max
30 m (98.4 ft) length, max
between GuardLink enabled taps
GuardLink Enabled Tap Passive Tap GuardLink Enabled Tap
Tap Cabling The GuardLink system was designed with the intent to minimize wiring by
using quick-disconnect patchcords, while also allowing some manual wiring to
terminals, when pinout incompatibilities exist.
Figure 7
shows the recommended cable options for the various stages of a
GuardLink system (to show the cable options only two taps are required, a full
system has 32 taps). These cables are red-colored, PVC, unshielded, with epoxycoated hardware. Although any color jacket can be used, the red color is
preferred to indicate a safety circuit.
Visit ab.rockwellautomation.com/Connection-Devices/DC-Micro-Cordsets-
and-Patchcords for other options, like right-angle connectors, stainless steel
couplings, and shielded cables.
To maintain the safety integrity of the GuardLink signal, the wiring distance
between GuardLink enabled taps is limited to 30 m (98.4 ft) and requires
18 AWG (0.82 mm) wire. If the distance between devices is greater than
30 m (98.4 ft), then a GuardLink enabled tap must be inserted at least every
30 m (98.4 ft). A field-attachable quick-disconnect can be wired as a shorting
plug for the device connection. The wiring distance between taps and the
safety device is limited to 10 m (32.8 ft), and requires at least 24 AWG (0.2 mm)
wire size.
IMPORTANT
The max distance between GuardLink enabled taps is 30 m (98.4 ft).
A passive tap with a shorting plug in the device input port does not
count as a GuardLink enabled tap.
To maintain integrity of the GuardLink safety signal, a GuardLink
enabled tap must be replicated at least every 30 m (98.4 ft).
+ + - -
Figure 7 - Recommended Cable Options
(a)
INPUT INPUT
INPUT
28 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
(a) Replace the x with 0M3 (0.3 m [0.984 ft]), 0M6 (0.6 m [1.968 ft]), 1 (1 m [3.28 ft]), 2 (2 m
[6.56 ft]), 5 (5 m [16.4 ft]), 10 (10 m [32.8 ft]), 15 (15 m [9.2 ft]), 20 (20 m [65.6 ft]), or 30 (30 m
[98.4 ft]) for standard cable lengths.
Chapter 2 GuardLink System Design
Ter mi nat or The terminator (Figure 8), must be installed on the J2 connector of the last tap
to complete the link connection. The terminator contains internal electrical
components specifically for a GuardLink system; other terminators cannot be
used as substitutes.
To help troubleshoot a GuardLink system, reduce the number of taps in the
GuardLink circuit by relocating the terminator. After relocation, cycle power to the
DG safety relay to allow the DG safety relay to relearn how many taps are
connected. If the 440R-ENETR interface is used, then it must also be power cycled,
and its AOP must be updated.
Figure 8 - Terminator — Catalog Number 898D-418U-DM2
Tap Replacement A GuardLink tap can be replaced with the same type of tap while the link is
powered. When the connections are remade; the GuardLink circuit recovers
automatically.
When a GuardLink tap is replaced with another type of tap, removed from the
circuit, or added to the circuit; cycle power to the DG safety relay to allow the
DG safety relay to relearn how many and what types of taps are connected. If
the 440R-ENETR interface is used, then it must also be power cycled, and its
AOP must be updated.
Response Time The GuardLink circuit has a fast response time. When a safety device opens,
the tap responds within 5 ms. The GuardLink safety signal then travels
upstream to the DG safety relay, which takes an additional 35 µs through each
upstream tap.
Figure 9 on page 30
In this example, a SensaGuard™ rectangular flat pack interlock, which is
connected to Tap 4, opens.
shows an example GuardLink safety circuit with six taps.
Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 29
Chapter 2 GuardLink System Design
Tap 1 Tap 2 Tap 3 Tap 4 Tap 5 Tap 6
Upstream Downstream
SensaGuard
Opens
DG Safety Relay
Single Wire Safety Out
100S-C09EJ
Safety
Contactors
Figure 9 - Response Time Example Calculation
The safety system response time for the system that is shown in Figure 9 is
listed in Table 7
. The time from when the SensaGuard interlock opens to the
time when the 100S contactors drop out is 169.105 ms. The time from when the
SensaGuard interlock opens to the time when the SWS signal turns OFF is
114.105 ms.
Table 7 - Example Response Time Calculation
Component
SensaGuard
DG Safety Relay 60.0 55.0
100S Contactor
(1) See publication 440N-IN018.
(2) See publication 100-TD013.
IMPORTANT
(1)
Tap 4 5.0 5.0
Tap 3 0.035 0.035
Tap 2 0.035 0.035
Tap 1 0.035 0.035
(2)
Total 169.105 114.105
Figure 9 and Table 7 show only a portion of a complete safety system.
Additional time (for example, for motor stopping time and the response
DG Output 13/14, 23/24 DG Output SWS (X2)
Response Time [ms]
54.0 54.0
50.0 0.0
time of additional components that are connected to the SWS signal)
must be considered.
30 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020
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