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

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

INPUTPWR

INPUT

1607-XT

INPUT

INPUT INPUT INPUT INPUT

INPUTINPUT INPUT

INPUT

LNK2

LNK1

A2A1

LNK2

LNK1

IP: 192. 168. 1. ABC

33 34 43 44 A1 A2 S11 S12

PWR/Fault

Logic IN

OUT

L12 L11 X32 13 14 23 24

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

Cong/Set

Sel./Save

Reset

Time

OUT X

IN 2

PWR/Fault

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

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

14 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 1 Overview

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

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

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

INPUT

+24V DC

Ethernet

Host PC

Ethernet

24V DC Com

Reset

Stop

Start

Feedback

100S Contactors

Immediate Acting Loads

S32 14S42

13 23

S11 S12S21 S22

DG 440R-DG2R2T

OUT X SWS

PLCHMI

L2 L3

440R-ENETR

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

1606-XLP95E

2428V

DC ok

440S-SF5D

K1 K2

Status Status

Control

Schematic Logic

SMF Level

LOGIC Level

SOF Level

Chapter 1 Overview

IN 1

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

+ + - Vs=24V

Power Supply

Link Cable

Fuse

4 A

SLO-BLO™

Figure 6 - Tap Connections

Safety Device 2

Device Cable

Safety Device 3

Device Cable

Terminator

Link Cable

Safety Device 1

Device Cable

INPUT INPUT

VJ2V

Link Cable

INPUT

Table 4 - Key for Figure 6

Item Description

D1, D2, D3 Safety devices

, I2, I

, IT2, I

, ID2, I

, L2, L

, R2, R

T1, T2, T3 Taps

VJ1, VJ2, V

Current in the link cable (A)

Current required by a tap (A)

Current required by a safety device (A)

1D3

Length of link cable (m)

Resistance of wire (Ω)

Voltage at tap connector (V)

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.

= IT1 + ID1 + I2

The current in each segment of the GuardLink circuit is calculated in a similar fashion.

= IT2 +ID2 + I

I3 = IT3 + I

The total system current, I1, is therefore the sum of the device currents plus the sum of the tap currents.

= ∑ IT + ∑ I

, is the sum of the current required by the first tap

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

= 0.02095 * L

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:

= 2 * I1 * R

) is:

The tap has a small voltage from connector J1 to J2. The typical voltage at connector J2 (V

= VJ1 - (2 * 0.028V)

) drop through the tap from J1 to J2 is:

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.

= VJ1 - 0.4V (typical)

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

5wire Patchcord or

889D-F8NBDM-x

8wire Patchcord

10 m (32.8 ft) length, max

889D-F4NE-x 4-wire Cordset 30 m (98.4 ft) length, max

889D-F4NEDM-x 4wire Patchcord 5 m (16.4 ft) length, max

889D-418U-DM2 Ter min at or

Standard Safety

Device

Standard

Safety Device

Safety

Relay

White

Black Brown Blue

24V

Power

Supply

GuardLink Enabled

Safety Device

889D-M5NC-x

5wire Cordset or

889D-M8NB-x

8wire Cordset

10 m (32.8 ft) length, max

889D-F5NCDM-x

5wire Patchcord

10 m (32.8 ft) length, max

889D-F4NEDM-x 4wire 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

Installation

113.6 (4.47)

119.14 (4.69)

22.5

(0.88)

S12 S22 S32 S42 A1 A2 S11 S21

X1 X2 X3 X4 13 14 23 24

OUT IN 1

IN X Reset

Cong/Set

Sel./Save

Reset

Time

OUT X

IN 2

PWR/Fault

57 (2.24)

79.64 (3.14)

(0.67)

38.5 (1.51)

19.25 (0.76)

(0.55)

9 (0.35)

2X Ø5.4 (0.21) for M5 screws (Ø9.8 (0.38) max screw head)

M12 X 1 thread

The DG safety relay uses the same housing as GSR modules. The module dimensions are shown in Figure 10

Mounting Dimensions Figure 10 - DG Safety Relay Dimensions [mm (in.)]

, while Figure 11 shows the tap dimensions.

Chapter 3

Figure 11 - Tap Dimensions [mm (in.)]

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 31

Chapter 3 Installation

DIN Rail Latch

DIN Rail

DIN Rail Mounting and Removal

The DG safety relay easily mounts onto 35 mm (1.4 in.) DIN rails: 35 x 7.5 x 1 mm (1.4 x 0.3 x 0.04 in.) (EN 50022 - 35x7.5).

1. Hold the top at an angle (Figure 12

2. Slide down until the housing catches the rail.

3. Swing the bottom down and give a little push until the latch clips onto the rail.

Figure 12 - DIN Rail Mounting

Removal

To remove the DG safety relay, use a screwdriver to pry the DIN rail latch downwards until it is in the unlatched position. Then, swing the module up.

Spacing

The DG safety relay can be mounted next to other GSR safety relays. When the GSR Ethernet interface is used, the GSR module must be mounted within 10 mm (0.39 in.) of the module next to it to maintain effective communications.

Maintain 50 mm (2 in.) of space above, below, and in front of the relay for adequate ventilation.

32 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 3 Installation

1. Insert

2. Pry Up

Orange inserts match keys

Terminal Block Removal and Replacement

Terminal blocks can be removed and replaced following these instructions.

Terminal Block Removal

DG safety relays have removable terminal blocks. Use a screwdriver as a lever to remove the blocks. As shown in Figure 13 and pry up.

Figure 13 - DG Terminal Removal

, insert the screwdriver into the slot

Terminal Block Replacement

The terminal blocks are keyed to help prevent a block from being inserted into an incorrect location. The orange-colored insert provides the orientation of the key (Figure 14

Figure 14 - Orange-colored Keyway

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 33

Chapter 3 Installation

M5 Screws

40 mm (1.6 in.)

Quick Release Clip

Recessed Mounting Holes (x6)

6 x Ø5.4 (0.21) for M5 screws (Ø11 (0.43) max screw head)

Tap Installation The tap can be installed directly with two M5 screws. In Figure 15, the 38.5 mm

(1.5 in.) wide tap fits neatly on a standard 40 mm (1.6 in.) aluminum extrusion construction profile.

Figure 15 - Mounting Directly on 40 mm (1.6 in.) Profile

INPUT

Figure 16 shows an optional quick mounting bracket, catalog number

(a)

440S-GLTAPBRKx snaps into place and can be easily removed to install patchcords and cordsets.

Figure 16 - Quick-release Mounting Bracket

, is available to facilitate installation and removal. The tap

Figure 17 shows the dimensions of the quick-release mounting bracket.

Figure 17 - Mounting Bracket Dimensions

38.5

(1.51)

(0.79)

76.6 (3.01)

(0.98)

(a) Replace the x with 1 to order one bracket and replace with a 5 for a package of five brackets.

34 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

(0.87)

(0.43)

19.6

(0.77)

Chapter 3 Installation

20 mm Profile 30 mm Profile 45 mm Profile

In-line with Profile

Across Profile

Figure 18 shows some of the mounting options with the quick release bracket.

The bracket can be mounted on various sizes of profile and can mount in-line or across the profile.

Figure 18 - Mounting Options with Quick-release Bracket

Enclosure Considerations Consider the following when choosing your DG safety relay and tap enclosure.

DG Safety Relay

The DG safety relay is intended for use in a Pollution Degree 2 industrial environment, in overvoltage Category II applications (as defined in IEC 60664-1), at altitudes up to 2000 m (6562 ft) without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR 11. Without appropriate precautions, there can be difficulties with electromagnetic compatibility in residential and other environments due to conducted and radiated disturbances.

The DG safety relay is supplied as open-type equipment. It must be mounted within an enclosure that is suitably designed for those specific environmental conditions that are present and appropriately designed to help prevent personal injury that results from accessibility to live parts. The enclosure must have suitable flame-retardant properties to help prevent or minimize the spread of flame that complies with a flame spread rating of 5VA, V2, V1, V0 (or equivalent) if non-metallic. The interior of the enclosure must be accessible only by the use of a tool. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications.

Other helpful publications can be found in Additional Resources on page 9

Taps

Taps are intended to be mounted on the machine and are rated for Pollution Degree 3.

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 35

Chapter 3 Installation

Prevent Excessive Heat Consider the following to help prevent excessive heat for your DG safety relay

and tap.

DG Safety Relay

For most applications, normal convective cooling keeps the DG safety relay within the specified operating range. Verify that the specified temperature range is maintained. Proper spacing of components within an enclosure is usually sufficient for heat dissipation.

In some applications, other equipment inside or outside the enclosure produce a substantial amount of heat. In this case, place blower fans inside the enclosure to help with air circulation and to reduce hot spots near the controller.

Additional cooling provisions can be necessary when high ambient temperatures are encountered. Do not bring in unfiltered outside air. Place the controller in an enclosure to help protect it from a corrosive atmosphere. Harmful contaminants or dirt can cause improper operation or damage to components. In extreme cases, you may need to use air conditioning to help protect against heat buildup within the enclosure.

Taps

The taps have no spacing requirements.

36 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Wiring Requirements and Recommendation

Chapter 4

Power, Ground, and Wire

WA RN I NG : Before you install and wire any device, disconnect power to the

system.

WA RN I NG : Calculate the maximum possible current in each power and common wire. Observe all electrical codes that dictate the maximum current allowable for each wire size. Current above the maximum rating can cause wiring to overheat, which can cause damage.

• Allow for at least 50 mm (2 in.) between I/O wire ducts or terminal strips and the relay.

• Route incoming power to the relay by a path separate from the device wiring. Where paths must cross, their intersection must be perpendicular.

• Do not run signal or communications wiring and power wiring in the same conduit. Route wires with different signal characteristics by separate paths.

• Separate wiring by signal type. Bundle wiring with similar electrical characteristics together.

• Separate input wiring from output wiring.

• Label wiring to all devices in the system. Use tape, shrink-tubing, or other more dependable means to label wire. Use colored insulation as well to identify wiring by signal characteristics. For example, use blue for DC wiring and red for AC wiring.

DG Safety Relay Wire Size

Each terminal can accommodate copper wire with size from 0.2…2.5 mm (24…14 AWG). Use copper that can withstand 60/75 °C (140/167 °F).

Terminal Torque

Torque terminals to 0.4 N•m (4 lb•in).

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 37

Chapter 4 Power, Ground, and Wire

}X2 }X1

}X3 }X4

X3 X4

S12 S22 S32 S42 A1 A2 S11 S21

X1 X2 X3 X4 13 14 23 24

OUT IN 1

IN X Reset

Cong/Set

Sel./Save

Reset

Time

OUT X

IN 2

PWR/Fault

Terminal Assignment and Function

The relays have four terminals: two on the top and two on the bottom. As shown in Figure 19 further back. The X1 and X3 terminals apply to the terminals closest to the front.

Figure 19 - DG Terminal Identification

, the X2 and X4 terminal markings apply to the terminals

Some of the terminals can be configured for multiple functions. Table 8 lists the functions available for each terminal.

Table 8 - Terminal Assignments and Functions

Terminal Function

A1 +24V Supply (+10%, -15%) A2 0V Common

S11 Pulse Test Output S21 Pulse Test Output S12 GuardLink® Safety or Safety N.C.

S22 GuardLink CLU or Safety N.C. S32 GuardLink Safety or Safety N.C. S42 GuardLink CLU or Safety N.C.

X1 SWS In or OSSD In X2 SWS Out or OSSD Out X3 Standard Input (Feedback) X4 Standard Input (Reset)

14 23 24

Redundant Positive-Guided Relay Output 1

Redundant Positive Guided Relay Output 2

38 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 4 Power, Ground, and Wire

GuardLink Enabled and Passive

J1 Link In J1 Link In

J4 Power In

J2 Link Out

J3 Device

Passive Power

J2 Link Out

J3 Device

J1 Link In (Male) J2 Link Out (Female)

2: GuardLink Safety 2: GuardLink Safety

1: +24V DC 1: +24V DC

4: GuardLink CLU 4: GuardLink CLU

3: 0V DC 3: 0V DC

2: +24V DC

1: Aux

7: 0V

6: Safety OSSD B

3: Lock/Unlock Command 8: Safety OSSD A+

4: Safety OSSD B+

5: Safety OSSD A

Tap Pin Assignment and Function

The taps have three or four M12 quick disconnect connectors (Figure 20). The system is designed to use premanufactured patchcords to facilitate installation, modification, and troubleshooting. The link connectors are 4-pin. The device connectors are either 5-pin or 8-pin.

Figure 20 - Tap Connection Identification

INPUT

INPUTPWR

The link connections carry the power and command signals. Figure 21 shows the functions of each pin. When using Allen-Bradley® Guardmaster® patchcords and safety devices, you do not need to be concerned about the pin assignments, the system is connect and go.

Figure 21 - J1 and J2 Link Connections on All Taps

Pin Function

1 +24V Supply (+10%, -15%) 2 GuardLink Safety Signal 3 0V DC, the reference for the 24V supply 4 GuardLink Control Lock Unlock (CLU) Signal

Figure 22...Figure 25 show the functions that are assigned to the 8-pin and

5-pin quick-disconnect connections for safety devices. These figures include tables with the wire colors of the recommended cordset that can be used where a patchcord cannot.

Figure 22 - J3 8-Pin OSSD (Female) Connector on 440S-SF8D and 440S-SLF8D Taps

Pin Function Cordset Wire Color

1 The auxiliary status output signal is not used by the tap White 2 +24V Supply (+10%, -15%) Brown 3 The Lock/Unlock command to the device Green 4 Safety OSSD channel B+ (24V DC, no pulse test) Yellow 5 Safety OSSD channel A Gray 6 Safety OSSD channel B Pink 7 0V DC, the reference for the 24V supply Blue 8 Safety OSSD channel A+ (24V DC, no pulse test) Red

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 39

Chapter 4 Power, Ground, and Wire

2: Lock/Unlock Command

1: Aux Contact

7: 0V

6: Safety Contact B

3: Aux Contact 8: Safety Contact A

4: Safety Contact B

5: Safety Contact A

2: Safety OSSD A

1: +24V DC

4: Safety OSSD B

5: Aux

3: 0V

2: Safety Contact A

4: Safety Contact B

1: Safety Contact A

5: Safety Contact B

3: N/C

Figure 23 - J3 8-Pin EMSS (Female) Connector on 440SD-MF8D and 440S-MLF8D Taps

Pin Function Cordset Wire Color

1 Auxiliary (non-safety) contact White 2 Lock/Unlock command Brown 3 Auxiliary (non-safety) contact Green 4 24V output for safety contact channel B Yellow 5 Safety contact channel A Gray 6 Safety contact channel B Pink 7 0V DC, the reference for the Lock/Unlock command Blue 8 24V output for safety contact channel A Red

Figure 24 - J3 5-pin OSSD (Female) Connector on 440S-SF5D Tap

Pin Function Cordset Wire Color

1 The +24V power supply to the device Brown 2 Safety OSSD channel A White 3 0V DC, the reference for the power supply Blue 4 Safety OSSD channel B Black 5 The auxiliary status signal is not used by the tap Gray

Figure 25 - J3 5-pin EMSS (Female) Connector on 440S-MF5D Tap

Pin Function Cordset Wire Color

1 24V output for safety contact channel A Brown 2 Safety contact channel A White 3 0V DC (the reference for the power supply) Blue 4 Safety contact channel B Black 5 24V output for safety contact channel B Gray

40 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 4 Power, Ground, and Wire

2: GuardLink Safety In

4: GuardLink Safety Out

1: 24V DC

5: GuardLink CLU

3: 0V DC (GND)

2: N/C

1: +24V DC

4: N/C

Use 898D-418U-DM or

871A-TS5-DM for 5-pin OSSD taps

Use 871A-TS5-DM for 5-pin

EMSS taps

Use 898D-81RU-DM or 871A-TS8-DM1 for

8-pin OSSD and EMSS taps

1 2 3 4 5 6 7 8

1 2 3 4 5

Use 898D-41KU-DM2 or 871A-TS5-DM for

5-pin Passive taps

Figure 26 - J3 5-pin GuardLink Enabled (Female) Connector on 440S-PF5D and 440S-PF5D4 Taps

Pin Function Cordset Wire Color

1 +24V DC Brown 2 GuardLink Safety In White 3 0V DC (the reference for the 24V supply) Blue 4 GuardLink Safety Out Black 5 GuardLink CLU Gray

Figure 27 - J4 4-pin Power In (Male) Connector on 440S-PF5D4 Tap

Pin Function Cordset Wire Color

1 +24V DC Brown 2 No Connection White 3 0V DC (the reference for the 24V supply) Blue 4 No Connection Black

Bulletin 871A field-attachable quick-disconnect connectors can be used as shorting plugs during installation, troubleshooting, and for long distances. When the distance between taps exceeds 30 m (98.4 ft), a tap must be inserted into the GuardLink system at least every 30 m (98.4 ft). A shorting plug must then be added to the J3 connector. Figure 28

shows the wiring connections that

are required to create a shorting plug.

IMPORTANT

For 5-pin OSSD taps, a shorting plug (Cat. No. 898D-418U-DM) can be used in place of the terminal chamber (Cat. No. 871A-TS5-DM).

For 8pin taps, a shorting plug (Cat. No. 898D-81RU-DM) can be used in place of the terminal chamber (Cat. No. 871A-TS8-DM1).

For passive taps, a shorting plug (Cat. No. 898D-41KU-DM2) can be used in place of the terminal chamber (Cat. No. 871A-TS5-DM).

Figure 28 - Shorting Plug Schematics

1 2 3 4 5

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 41

Chapter 4 Power, Ground, and Wire

Connect +24V DC to Terminal A1

Connect 24V Common to Terminal A2

Power Supply Connection Many Bulletin 1606 power supplies are protected extra low voltage (PELV),

safety extra low voltage (SELV), and Class 2-compliant.

DG Safety Relay

To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with a PELV or, under certain conditions, a SELV per IEC 60204-1 must power the DG safety relay.

For the USA, a PELV supply is required, per NFPA 79.

Figure 29

shows the power supply connections for the DG safety relay. Connect terminal A1 to +24V DC. Terminal A2 must be connected to the common of a 24V supply.

Figure 29 - DG Power Supply Connections

S12 S22 S32 S42 A1 A2 S11 S21

PWR/Fault OUT IN 1

IN 2

OUT X IN X Reset

Cong/Set

Reset

Sel./Save

Time

X1 X2 X3 X4 13 14 23 24

Taps

To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with a PELV or, in certain circumstances, a SELV per IEC 60204-1 must power the tap. For IEC applications, an in-line, slow-blow 4 A fuse is recommended if the power supply can provide more than 4 A.

For the USA, a Class 2 power supply must be used. The Class 2 supply limits the current to 4 A, so an in-line fuse is not needed.

IMPORTANT

In the USA, use of a 4 A fuse or circuit breaker in place of a Class 2 power supply is not acceptable.

42 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 4 Power, Ground, and Wire

4 A

1606-XLE240EN

24-

28V

DC ok

1606-XLP95E

2428V

DC ok

PELV for IEC Compliance Class 2 for USA Compliance

GuardLink First Tap GuardLink First Tap

Pin 1: +24V DC Pin 1: +24V DC

Pin 3: 0V DC Pin 3: 0V DC

S12 S22 S32 S42 A1 A2 S11 S21

X1 X2 X3 X4 13 14 23 24

OUT IN 1

IN X Reset

Cong/Set

Sel./Save

Reset

Time

OUT X

IN 2

PWR/Fault

INPUT

1606-XLP95E

2428V

DC ok

INPUTPWR

1607-XT100D1A

24V 3.8A

When using the passive power tap, ground only the primary power supply to protective earth.

889N-F3AFC-6F 889D-F4AENM-2

100…240V AC

On-Machine Power Supply

Figure 30 shows the power connections to the power tap. Power is connected

only to the first tap.

Figure 30 - Tap Power Connections

Multiple Power Supplies

When a passive power tap is included in the GuardLink circuit, only the primary power supply must be connected to protective earth. The passive power tap must not be connected to protective earth to avoid ground loops.

Figure 31

shows an example with a 1606-XLP95E primary power supply and a 1607-XT100D1A On-Machine™ power supply for the passive power tap. The 1606-XLP95E power supply has a protective earth connection, while the 1607XT100D1A does not.

IMPORTANT

Figure 31 - Multiple Power Supplies

To avoid potential exposure to harmful voltage (greater than 50V), do not use more than seven passive power taps on a GuardLink circuit.

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 43

Chapter 4 Power, Ground, and Wire

Device 1

S12

S22

+24V DC

24V Com

Device 2

S32

S42

Input 2Input 1

DG Safety Relay

DG Safety Relay Input Wiring

This section describes DG safety relay input wiring.

GuardLink Connections

Up to two GuardLink circuits can be connected to the DG safety relay. The GuardLink safety signal must be connected to either S12 or S32 and the GuardLink CLU signal must be connected to either S22 or S42. Figure 32 the connections for the GuardLink circuits; the wire colors apply when the recommended cordsets are used.

Figure 32 - GuardLink Connections

+24V DC

Blue

INPUT

Brown

S22 CLU

Black

S32

Safety

DG Safety Relay

White

S12

Safety

Blue

White

Input 2Input 1

Brown

Black

S42 CLU

INPUT

shows

24V Com

Devices with OSSD Outputs

Devices with OSSD outputs perform their own short circuit detection. The DG can be configured to accept up to two devices with OSSD signals. Connections of the OSSD outputs are shown in Figure 33

Figure 33 - Wiring to Devices with OSSD Outputs

44 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 4 Power, Ground, and Wire

Dual Channel Single Channel

Voltage-free Contacts

Devices with voltage-free contacts must use the pulse testing outputs to detect short-circuit faults between the following:

• Channels

• Channels and power

• Channels and ground

Figure 34

shows the recommended wiring for dual-channel and singlechannel, voltage-free contacts. Voltage-free contacts can be connected to either Input 1, Input 2, or both inputs.

Figure 34 - Wiring to Voltage-free Contacts

Device 1 Device 2

S11

S21

Pulse

Testing

Outputs

S22

S12

DG Safety Relay DG Safety Relay

S32

S42

Input 2Input 1

S11

S21

Pulse

Testing

Outputs

S12

S22

S32

S42

Input 2Input 1

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 45

Chapter 4 Power, Ground, and Wire

24V DC Com (the relays must have a common reference)

24V

10 1.7 2.2 4 ms

Ter min al s X1 and X2

Single Wire Safety The DG safety relay has the Single Wire Safety (SWS) capability to expand the

safety function (both input and output).

SWS Connections

The SWS feature allows a safety relay to expand the safety function to additional safety relays using one wire, provided all safety relays have the same voltage supply reference.

The SWS signal is unidirectional. The signal flows from L11 to L12.

There can be many variations and combinations of series and parallel connections of the SWS. Each L11 terminal can be connected to up to ten L12 terminals.

IMPORTANT

Figure 35

shows an example wiring diagram with an SWS signal. The SWS can

Do not connect two or more L11 terminals together.

be connected between the DG safety relay and other relays in the GSR family (the CI, DI, DIS, EM, EMD, and SI relays). Relay 1 has a series connection to Relay 2. Relay 2 has a parallel connection to Relays 3 and 4. Relay 4 has a series connection to Relay 5. The safety relays must have a common power reference (24V common). In this example, the safety function started by Relay 1 turns off all other relays if AND logic is applied to L12 on all relays.

IMPORTANT

The DG safety relay terminals are marked X2 and X1; which is equivalent to terminal L12 and L11 on other GSR relays.

Figure 35 - SWS Connection Example

+24V DC +24V DC

GSR Relay 1

L12

L11

SWS

GSR Relay 2

X1 X2

+24V DC

GSR Relay 3

X1 X2

SWS SWS

+24V DC

GSR Relay 4

EM L12 L11

+24V DC

GSR Relay 5

EMD

L12 L11

Figure 36 shows the characteristics of SWS signal when it is active. It starts

with a 1 ms pulse, followed 700 µs later by a 500 µs wide pulse. This waveform is repeated every 4 ms. The tolerance of all edges is ±10%.

When inactive, the SWS signal is 0V.

Figure 36 - SWS Waveform

46 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 4 Power, Ground, and Wire

V supply

V common

Safety

Relay

Output

Other

Devices

Safety Output Wiring The DG safety relay has two voltage-free, safety-related outputs (terminals

13/14 and 23/24).

13/14 and 23/24 Safety Outputs

The 13/14 and 23/24 safety outputs have redundant (two) positive-guided relays that are internally connected between each terminal. An example of the wiring connections is shown in Figure 37 and current ratings of these relays. To maintain safety integrity, the safety relay contacts must be the last device that is connected to the actuator (K1 and K2 in this example). All other devices must be connected between the power supply and the safety relay contacts.

If the voltage supply of the outputs exceeds the voltage supply of the relay, then low-voltage wiring must be separated from the high-voltage wiring.

Figure 37 - Output Connections of the DG Safety Relay

. See Specifications on page 65 for the voltage

13 23

14 24

K2K1

Surge Protection

Due to potentially high-current surges that occur when switching inductive load devices, such as motor starters and solenoids, the use of some type of surge suppression to help protect and extend the operating life of the relays is recommended. By adding a suppression device directly across the coil of an inductive device, you prolong the life of the outputs. You also reduce the effects of voltage transients and electrical noise from radiating into adjacent systems.

Figure 38 on page 48

is a safety-related circuit, the surge protection must not be connected across (in parallel with) the safety relay outputs.We recommend that you locate the suppression device as close as possible to the load device.

For outputs that use 24V DC, we recommend 1N4001 (50V reverse voltage) to 1N4007 (1000V reverse voltage) diodes for surge suppression for OSSD safety outputs. The diode must be connected as close as possible to load coil.

shows an output with a suppression device. This example

For outputs that use 120V AC or 240V AC, we recommend metal oxide varistors.

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 47

Chapter 4 Power, Ground, and Wire

K2K1

Metal oxide varistors

for V AC supply

Diodes

for V DC supply

V common V common

Figure 38 - Surge Protection Examples

Table 9 lists the recommended surge suppressors for some commonly used

safety control relays and contactors.

Table 9 - Surge Suppressor Recommendations

Safety Control Relay or Contactor Coil Voltage Suppressor

100S-C09QJxxxBC

100S-C09EJxxxBC 700S-CFBxxxQJBC 700S-CFBxxxEJBC

700S-DCPxxxDZ24

700S-DCPxxxZ24

700S-PxxxA1 120V AC 700S-PxxxA2 240V AC

(1) The QJ coil drops out faster than the EJ coil and is preferred when response time is important. The “B” bifurcated auxiliary

contacts are recommended, as the safety monitoring current is typically on the order of a few milliamps.

(1)

24V DC Electronic Coil —

24V DC

199-FSMZ-1

199-FSMA10 199-FSMA11

48 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 5

Configuration

The DG safety relay has two push buttons on the front faceplate. These buttons are labeled Config/Set and Sel./Save.

These push buttons allow you to do the following:

• Configure the DG safety relay to perform a safety function

• Confirm the existing safety functions

• Reset the DG safety relay

• Report the fault code

The DG safety relay has two modes of operation: run and configuration. The functions that the push buttons perform depend on the operating mode and length of time the push button is pressed.

• Short: The button is pressed less than 1 second.

• Long: The button is pressed for longer than 3 seconds, but shorter than 10 seconds.

Config/Set Push Button Run Mode

Button Press Function

Short

Long

IMPORTANT

The indicators show the configuration of the DG safety relay.

• Press once to see the configuration (see Table 10 on page 51

• Press a second time to see the time delay setting (see Table 11 on page 52

• Press a third time to see the status of the wiring terminals again (see Table 13 on page 55 After about 20 seconds of inactivity, the indicators revert to the wiring terminal status.

The DG safety relay enters Configuration mode. The 13/14, 23/24, and X2 outputs turn OFF, if they are ON. After 60 seconds of inactivity, the indicators revert to the wiring terminal status. Changes to the configuration are not saved.

After changes to the hardware configuration of the DG safety relay or the GuardLink® circuit, power must be cycled to the DG safety relay, the GuardLink circuit, and the EtherNet/IP™ interface.

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 49

Chapter 5 Configuration

Configuration Mode

When you are in the configuration mode, the duration that the Config/Set button is depressed determines what the DG safety relay reveals.

Button Press Function

Short

Long

Sel./Save Push Button Run Mode

Button Press Function

Short

Long Nothing happens.

You can cycle through the configuration and can switch between the function of the blinking indicator. See Table 10

Abort the changes; you leave the configuration mode without saving the changes. The PWR/Fault indicator flashes green at a 1 Hz rate. Upon release, the indicators revert to the wiring terminal status.

The status indicators display the following:

• Alternating flashing green indicators if optical buses are active.

• Alternating flashing red indicators if optical buses are inactive.

for indicator descriptions.

Configuration Mode

Button Press Function

Short You can jump from one configuration step to the next.

Long The new configuration is saved.

Reset If you press both buttons simultaneously for longer than 3 seconds, the DG

safety relay performs a power cycle. The same can be accomplished if you remove and reapply power to terminal A1.

50 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 5 Configuration

Configuration Steps Before starting to configure the DG safety relay, review the configuration

Table 10 - Configuration

functions in Table 10 on page 51

page 69

help you select the correct configuration.

. The configuration examples in Appendix B on

Status

Indicator

OUT Number of Safety Functions

IN 1 Input Type IN1

IN 2 Input Type IN2

OUT X Output Type Activate SWS Output on X2 Activate OSSD Output on X2 —

IN X Input Mode

Reset Reset Type Manual Monitored Reset Automatic Reset —

FB Reset Assignment Reset on the Output function

(1) Only available if Manual Monitored Reset is selected.

Function Indicator Color and Setting Indicator Color and Setting Indicator Color and Setting

Activate two Safety Functions (IN1 and IN2)

Activate GuardLink Input function on IN1

Activate GuardLink Input function on IN2

Activate SWS or OSSD Input on X1, depends on the previous step (SWS Input if OUT X is SWS Out, OSSD In out if OUT X is OSSD.)

Activate one Safety Function (only IN1)

Activate OSSD or EMSS Input function on IN1

Disable Input on X1 —

Reset only on IN 1

(1)

1. Long press the Config/Set button.

The PWR/Fault indicator turns green and all other indicators flash red quickly, which indicates that the DG safety relay is in Configuration mode. Shortly after release of the Config/Set button:

• The PWR/Fault status indicator flashes green at 1 Hz.

• The OUT status indicator flashes the current configuration (red or

green) at 1 Hz.

• The remaining status indicators are steady red, steady green, or off.

2. Short press the Config/Set button to change the function of the OUT status indicator.

—

If only one Safety Function (IN1) is selected, the IN2 is disabled

Not used if Automatic Reset is selected

IMPORTANT

If you press the Config/Set button in these steps again, the status indicator switches back and forth between red and green.

Short press the Sel./Save button to accept and go to the next step.

3. Short press the Config/Set button to change the function on the IN 1 status indicator.

Short press the Sel./Save button to accept and go to the next step.

IMPORTANT

If the IN 2 indicator is off, the function is not available in this configuration. The configuration proceeds to the OUT X indicator - go to

step 5.

4. Short press the Config/Set button to change the function on the IN 2 status indicator, if available.

Short press the Sel./Save button to accept and go to the next step.

5. Short press the Config/Set button to change the function on the OUT X status indicator.

Short press the Sel./Save button to accept and go to the next step.

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 51

Chapter 5 Configuration

6. Short press the Config/Set button to change the function on the IN X status indicator.

Short press the Sel./Save button to accept and go to the next step.

7. Short press the Config/Set button to change the function on the Reset status indicator.

Short press the Sel./Save button to accept and go to the next step.

8. Short press the Config/Set button to change the function on the FB status indicator.

Short press the Sel./Save button to accept and go to the next step.

9. All indicators flash the new configuration. Use this step to confirm your configuration.

Short press the Sel./Save button to accept and go to the next step.

10. Now, you can verify and adjust the time delay. If the rotary switch is at position 0, all indicators (except the PWR/Fault) are off. If the rotary switch is in a position other than 0, then the bottom three indicators flash. The number of times the indicators flash is equal to the Time switch position.

11. Rotate the rotary switch to the desired off-delay setting (see Table 11 on

page 52).

12. When the configuration is finished, long press the Sel./Save button to save the new configuration.

The status indicators flash their configuration while the button is held down. When the button is released, the PWR/Fault status indicator flashes green twice, turns steady red for about 5 seconds, and then turns steady green again. Now, the other status indicators reflect the status of the wiring terminals (see Table 13 on page 55

IMPORTANT To abort the configuration without saving your settings:

• Long press the Config/Set button, then short press the Config/Set button. Then, you must either press and hold both the Config/Set and Sel./Save buttons for 3 seconds to perform a reset or cycle power to the DG safety relay.

• Wait longer than 60 seconds without any additional changes.

Delay Setting The delay is set by the 16 position switch as described in Table 11. The DG

inputs must be opened during the delay. If the inputs close before the expiration of the delay time, the delayed output remains ON and any locked guards remain locked. If the inputs are reopened, the timer restarts from zero.

Table 11 - Delay Switch Settings

Position Delay Position Delay

0 Immediate 8 3 s 1 100 ms 9 5 s 2 200 ms 10 8 s 3 300 ms 11 10 s 4 500 ms 12 15 s 51 s 1320 s

61.5 s 1425 s 72 s 1530 s

52 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 5 Configuration

Table 12 shows how the status indicators confirm the delay setting. The bottom

three indicators flash at 1 Hz. The flashing pauses for 4 seconds and then repeats. The number of flashes is equal to the delay switch setting.

Table 12 - Indicators Confirm Delay Setting

Indicator Color Status

PWR/Fault Configuration mode

OUT —

IN 1 —

IN 2 —

OUT X —

IN X

The number of flashes

indicates the delay switch

Reset

setting. For example:

0 = no flashing 5 = five flashes

Verification You can verify the configuration of the DG safety relay in three ways:

• The buttons on the front of the DG safety relay

• The 440R-ENETR interface webpage

• The Add-on Profile (AOP) in the Studio 5000® environment

Buttons on the Front of DG Safety Relay

While in the Run mode, short presses of the Config/Set button can verify the configuration.

IMPORTANT

1. Short press the Config/Set push button.

The indicators show the configuration. Compare the colors of each indicator to your desired colors.

2. Short press the Config/Set push button again.

The indicators show the Time switch setting. If the indicators are off, then the TIME is set to zero. For a setting other than zero, the bottom three indicators flash green. The number of flashes is equal to the switch setting. The flashing pauses for 4 seconds and then repeats.

The PWR/Fault indicator remains green through these steps.

3. Short press the Config/Set push button one last time to return to the running status indication.

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 53

Chapter 5 Configuration

AOP in the Studio 5000 Environment

Each configuration is assigned a unique identification. The ID appears as a decimal value in the Config field in the Controller Tags. See publication

440R-UM009

value. This value can then be compared in the future to detect changes.

for details. After the initial configuration, record the Config

54 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Status Indicators

Chapter 6

DG Safety Relay Status Indicators

Table 13 describes the status of the DG safety relay status indicators during

normal operation.

Table 13 - DG Indicators during Normal Operation

Indicator State Description

OFF No power

Steady red DG safety relay is in self-test state or idle state

PWR/Fault

OUT

IN 1

IN 2

OUT X

IN X

Reset

Steady green Normal operation (Run mode)

Flashing green 1 Hz Configuration mode - proceed with configuration

Flashing red 1 Hz Fault Mode - See Appendix D

Green Output circuits at 13/14 and 23/24 are closed

Red Output circuits at 13/14 and 23/24 are open

Green Input circuits at S12 and S22 are closed

Red Input circuits at S12 and S22 are open

Flashing red 1 Hz

Green Input circuits at S32 and S42 are closed

Red Input circuits at S32 and S42 are open

Flashing red 1 Hz

OFF Input circuit is disabled

Green OSSD output/SWS output at X2 is ON

Red OSSD output/SWS output at X2 is OFF

Flashing red 1X Wiring short from terminal X2 to 24V or to 0V when X2 is configured as SWS.

Alternate flashing

green/red

Green Input circuit at X1 closed

Red Input circuit at X1 open OFF Input circuit is disabled

Green Reset button at X4 pushed

Flashing green 1 Hz Reset at X4 required

Flashing red 1 Hz Reset at X4 held ON. Try resetting again.

Green Feedback circuit at X3 closed

OFF Feedback circuit at X3 open

Input signal missing, incorrect configuration, fault on a tap, or short circuit of input S12 or S22 to power or ground.

Input signal missing, incorrect configuration, or short circuit from S11 or S21 to 24V or to 0V. If short circuit, remove short circuit and cycle the input device to clear fault.

Wiring short from terminal X2 to 0V when X2 is configured as OSSD.

on page 95 to determine the fault.

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 55

Chapter 6 Status Indicators

Link indicator

Input indicator DC Power indicator No indicator

Passive Power TapGuardLink Enabled Tap Passive Tap

1234567

Tripped

Device

DG Safety

Relay

Possible

Tripped Device

Possible

Tripped Device

Tap Status Indicators Figure 39 shows the location of the tap indicators. The GuardLink® enabled tap

has a device input indicator. The power passive tap has an indicator to indicate power. Both passive taps do not have an indicator for the input device nor Link indicators. For the passive taps, you must observe the indicator on the device to determine its status. Table 14 indicator.

Figure 39 - Tap Indicators

provides a description of the status for each

INPUT

Table 14 - Tap Indi cators

Indicator State Description

The input device is in the operational state with no demand on its safety function (for example, the OSSD inputs are ON or safety contacts are closed). The tap is also in the operational state.

The input device is in the operational state (no demand on its safety) and the tap is in the safe state. One or more upstream taps are in a safe state. The CLU signal is high, so all taps are in the safe state.

OSSD inputs are OFF or safety contacts are open. The input device is in the safe state (for example, OSSD inputs are OFF or safety contacts are open), and there are no faults with the tap.

The input device has not performed as expected; for example, both inputs did not change simultaneously. Try cycling the input device again. Cycle power to GuardLink circuit if necessary.

Fault at tap or input device. Correct fault and cycle power to the GuardLink system.

No communication to DG safety relay. Input is configured for OSSD/EMSS; recheck the configuration. Input is in faulted state. Correct fault and/or cycle power to the DG safety relay and GuardLink circuit.

Input

Link

Power

Steady green

Flashing green at 1 Hz

Steady red

Flashing red at 1 Hz

Steady green The tap is transmitting the safety signal.

Steady red GuardLink safety signal is OFF. Or terminator is missing.

Flashing red at 1 Hz

Off

Steady green Power applied

Off No power applied

INPUTPWR

INPUT

Figure 40 shows an example with seven taps; five GuardLink enabled taps and

two passive taps. The link indicators are steady red, which indicates a safe (OFF) state. The flashing green indicators show that the devices are operational. The steady red input indicator at tap 3 shows that the device has tripped. To determine if the devices connected to the passive taps (5 and 7) are tripped, you must examine the indicators on the device.

Figure 40 - Tripped Device with Steady Red Status Indicators

56 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 7

24V

S21

S11

24V

0.6 15 15.6

0.3

15.3

Time [ms]

Pulse Testing Functions

Your DG safety relay uses pulse testing of inputs with voltage free contacts to detect short circuit conditions. The test pulses are used to detect three short circuit conditions:

• Between the input terminals and +24V

• Between the input terminals and 24V common

• Between the two input terminals.

Pulse testing for the inputs must be used with devices like E-stop push buttons, tongue operated interlock switches, and limit switches that have voltage-free contacts.

The pulse-testing cannot be turned on or off and cannot be changed. Therefore, the purpose of this chapter is informational, but it can be used during troubleshooting of a DG safety circuit.

Pulse Testing for Inputs Pulse tests for the inputs are generated on terminals S11 and S21 of the DG

safety relay.

Figure 41

The pulse widths are either 300 µs or 600 µs wide, and the pulses are repeated every 15 ms.

Figure 41 - Pulse Test Sequence for DG Safety Relay

shows the pulse testing that is associated with the DG safety relay.

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 57

Chapter 7 Pulse Testing Functions

1 ms

21 ms

8 ms

EMSS Tap Pulse Tests The EMSS GuardLink-enabled tap generates pulse tests to detect short circuit

conditions. The waveforms are shown in Figure 42 Channel 2 pulse occurs 8 ms after Channel 1. The pulses are repeated every 21 ms. When either of the input channels goes to an open state, the pulses are turned off.

Figure 42 - EMSS Test Pulses

. The pulses are 1 ms wide.

58 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 8

Opto Bus 2

Opto Bus 3

Opto-link Communications

Optical Bus The GSR family of relays uses an optical bus to communicate status

information to the 440R-ENETR Guardmaster® Ethernet/IP™ network interface

• Bus 2 allows communication to pass from the 440R-ENETR interface to

• Bus 3 is used exclusively by the DG safety relay for GuardLink®

(a)

. DG safety relays have two optical buses:

the DI, DIS, EM, EMD. GLP, GLT, and SI safety relays (the CI safety relay does not have an optical bus).

communications.

The optical bus ports are on each side of the housing, as shown in Figure 43

Figure 43 - Optical Bus Ports

(a) See publication 440R-UM009 for detailed 440R-ENETR interface information.

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 59

Chapter 8 Opto-link Communications

The 440RENETR interface can monitor up to six relays of any combination. The DG safety relays must be closest to the 440RENETR interface.

5 mm (0.2 in.) max spacing between relays

Arrangement with 440RENETR Interface

Each 440R-ENETR interface can communicate with up to six GSR relays, in any combination. All DG safety relays must be located closest to the 440R-ENETR interface, as shown in Figure 44

Figure 44 - 440RENETR Interface Arrangement

A1 A2

LINK1

ENETR

LINK2

MS LNK1 LNK2

S12 S22 S32 S42 A1 A2 S11 S21

IP: 192. 168. 1. ABC

X1 X2 X3 X4 13 14 23 24

PWR/Fault OUT IN 1

IN 2

OUT X IN X Reset

Cong/Set

Sel./Save

9 8 7

Reset

Time

2 3

S12 S22 S32 S42 A1 A2 S11 S21

PWR/Fault OUT IN 1

IN 2

OUT X IN X Reset

Cong/Set

Reset

Sel./Save

Time

X1 X2 X3 X4 13 14 23 24

S12 S22 S32 S42 A1 A2 S11 S12

PWR/Fault

IN1

IN2

Logic IN

OUT

LOGIC

13 14 23 24

L12 L11 Y32 S34 13 14 23 24

2 3

S12 S22 S32 S42 A1 A2 S11 S12

PWR/Fault

IN1

IN2

Logic IN

OUT

LOGIC

34 44 14 24

DIS

L12 L11 Y32 S34 34 44 14 24

2 3

33 34 43 44 A1 A2 S11 S12

PWR/Fault

Logic IN

OUT

33 34 43 44

13 14 23 24

L12 L11 X32 13 14 23 24

37 38 47 48 A1 A2 B1 B2

PWR/Fault

Logic IN

OUT

RANGE

TIME

EMD

L12 L11 X32 17 18 27 28

2 3

3 4

The DG safety relay requires a 440R-ENETR interface when controlling guard locking interlock switches on a GuardLink circuit. An Ethernet interface is also useful, but not required, when monitoring guarding interlocks and E-stop devices. Status and fault codes can be transferred from the DG safety relay to the machine controller and control signals can be sent from the machine controller to the DG safety relay.

The status signals form the DG safety relay to the machine controller include:

• Status of the DG safety relay terminals

• Status of the taps on the GuardLink circuits

• Fault codes of the DG safety relay or the taps.

The control signals from the machine controller to the DG safety relay include:

• Reset command to turn on the DG safety relay outputs if the inputs are satisfied.

• Lock and unlock commands to lock or unlock the guard locking interlocks.

• Fault reset to cycle power to the DG relay to clear certain faults.

Tap fault reset to cycle power to the device connected to the tap to clear certain faults.

See publication 440R-UM009

for details.

60 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 9

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

INPUT

+24V DC

Ethernet

Host PC

Ethernet

24V DC Com

Reset

Stop

Start

Feedback

100S-C09 Contactors

700S-CFB Relays (AC-15)

S32 14S42

13 23

S11 S12S21 S22

DG 440R-DG2R2T

OUT X SWS

PLCHMI

L2 L3

K1 K2

440R-ENETR

TIME

440N-Z21SS3PH

SensaGuard™

Interlock

898D-418U-DM2 Terminator

450L-B4FN0900YD 450L-APT-PW-5 (Tx) 450L-APR-ON-5 (Rx)

Light Curtain

INPUT INPUT

440G-LZS21SPRH

Guard Locking

Safety Switch

INPUT

440S-SF8D 440S-SF8D

440S-MF5D

800F-1YMD51

(800FP-LMP44)

E-Stop Push Button

1606-XLP95E

2428V

DC ok

440S-SF5D

K1 K2

Status Status

Control

K3 K4

440G-LZ

1485P-RDR5 Tee

Safety Function Calculations

GuardLink System The GuardLink® system typically consists of multiple taps and input devices.

When calculating the Performance Level or the safety integrity level, the safety function must only consider the input device, the associated tap, the DG and EM safety relays, and the output devices driven by the safety relays. Figure 45 shows an example safety system to help demonstrate the process of determining the Performance Level.

Figure 45 - Example Circuit for Safety System Calculation

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 61

Chapter 9 Safety Function Calculations

Input Logic Output

440R-EM4R2

Subsystem 1 Subsystem 2 Subsystem 3 Subsystem 4 Subsystem 5

440R-DG2R2T

100S-C09 Contacto r Channel 1

100S-C09 Contacto r Channel 2

Tap 2

440S-SF8D

440G-LZS21SPRH

Guard Locking Switch

Channel 1

440G-LZS21SPRH

Guard Locking Switch

Channel 2

440R-EM4R2

Subsystem 1 Subsystem 2 Subsystem 3 Subsystem 4 Subsystem 5

440R-DG2R2T

100S-C09 Contacto r Channel 1

100S-C09 Contacto r Channel 2

Tap 3

440S-MF5D

800FP-LMP44

E-Stop

Channel 1

440G-TZS21UPRH

Guard Locking Switch

Channel 2

Subsystem 1 Subsystem 2 Subsystem 3 Subsystem 4

440R-DG2R2T

440N-Z21SS3PH

SensaGuard

Channel 1

440N-Z21SS3PH

SensaGuard

Channel 2

700S-CFB

Relay

Channel 1

700S-CFB

Relay

Channel 2

Tap 1

440S-SF8D

Subsystem 1 Subsystem 2 Subsystem 3 Subsystem 4

440R-DG2R2T

700S-CFB

Relay

Channel 1

700S-CFB

Relay

Channel 2

Tap 2

440S-SF8D

440G-LZS21SPRH

Guard Locking Switch

Channel 1

440G-LZS21SPRH

Guard Locking Switch

Channel 2

Subsystem 1 Subsystem 2 Subsystem 3 Subsystem 4

440R-DG2R2T

700S-CFB

Relay

Channel 1

700S-CFB

Relay

Channel 2

Tap 3

440S-MF5D

800FP-LMP44

E-Stop

Channel 1

800FP-LMP44

E-Stop

Channel 2

440R-EM4R2

Subsystem 1 Subsystem 2 Subsystem 3 Subsystem 4 Subsystem 5

440R-DG2R2T

440N-Z21SS3PH

SensaGuard

Channel 1

440N-Z21SS3PH

SensaGuard

Channel 2

100S-C09 Contacto r Channel 1

100S-C09 Contacto r Channel 2

Tap 1

440S-SF8D

Subsystem 1 Subsystem 2 Subsystem 3 Subsystem 4

440R-DG2R2T

450L-B4FN0600YD

Light Curtain

Channel 1

450L-B4FN0600YD

Light Curtain

Channel 2

700S-CFB

Relay

Channel 1

700S-CFB

Relay

Channel 2

Tap 4

440S-SF5D

440R-EM4R2

Subsystem 1 Subsystem 2 Subsystem 3 Subsystem 4 Subsystem 5

440R-DG2R2T

450L-B4FN0900YD

Light Curtain

Channel 1

450L-B4FN0900YD

Light Curtain

Channel 2

100S-C09 Contacto r Channel 1

100S-C09 Contacto r Channel 2

Tap 4

440S-SF5D

This system has eight safety functions; two functions for each input device. One function is for the DG outputs, and the second is for the expansion module outputs. The safety Function Block Diagrams are shown in Figure 46

Figure 46 - Safety Function Block Diagrams

62 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Chapter 9 Safety Function Calculations

SISTEMA SISTEMA is a free program that is used to determine the safety function values

per ISO 13849. Many devices are preloaded into a Rockwell Automation library. The DG relay and taps were loaded into a local library, based on the safety data in Appendix C the Rockwell Automation library.

on page 93. These devices will be available in a future update of

Figure 47

functions, you can simply copy and paste these functions back into the project and then change the input device.

To achieve a PLe rating and a 20-year mission time, the system is limited to 65,000 operations each year. The limiting component is the 100S contactors, which are driving the motor load. The E-stop has a limitation of 12,000 operations per year.

Figure 47 - SISTEMA Project - First Two Safety Functions

shows the first two safety functions. To generate the remaining

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 63

Chapter 9 Safety Function Calculations

Figure 48 shows a summary of the project. Each safety function has a required

Performance Level of “e”, and each safety function has achieved that level.

Figure 48 - Project Summary

64 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Specifications

Appendix A

DG Safety Relay

Table 15 - General Specifications — DG Safety Relay

Attribute 440R-DG2R2T

Dimensions, H x W x D 119.14 x 22.5 x 113.6 mm (6.49 x 0.88 x 4.47 in.) Shipping weight, approx. 225 g (0.5 lb) Wire size 0.2…2.5 mm ² (24…14 AWG) Wiring category Copper that withstands 75 °C (167 °F) Insulation stripping length 7 mm (0.28 in.) Terminal screw torque 0.4 N•m (4 lb•in) Power supply voltage range 24V DC PELV/SELV, UL Class 1 Div. 2., 0.85…1.1 x rated voltage Power consumption 3.5 W Power on delay 5.5 s Case material Polyamide PA 6.6 Terminal p rote ctio n IP20 Enclosure protection IP40 (NEMA 1) Mounting 35 mm (1.4 in.) DIN rail in enclosure that is rated to a minimum of IP54

Table 16 - Environmental Specifications — DG Safety Relay

Attribute 440R-DG2R2T

Temperature, operating -5…+55 °C (23…131 °F) Relative humidity 90% Vibration 10…55 Hz, 0.35 mm Shock 10 g, 16 ms Pollution level 2 Installation group Overvoltage Category III, VDE 0110-1 Impulse withstand voltage 2500V

Table 17 - Pulse Test Output Specifications — DG Safety Relay

Attribute 440R-DG2R2T

Wiring terminals S11/S21 Continuous output current, max 100 mA Surge output current, max 0.7 A Surge output current duration, max 5 ms Residual voltage drop from P/S, max 0.6V

Load capacitance, max [nF/mA load]

Off state leakage current, max < 0.1 mA Short circuit detection Yes Short circuit protection Yes Galvanic isolation: I/O from logic No Pulse test duration ≤700 µs Pulse test period 5 ms

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 65

200/20 100/10 22/0

Appendix A Specifications

Table 18 - Input Devices with Voltage-free Contacts Specifications — DG Safety Relay

Attribute 440R-DG2R2T

Wiring terminals S12/S22 and S32/S42 ON voltage, max 26.4V ON voltage, min 11V OFF voltage, max 5V OFF current, max 2 mA ON current, min at 20V DC 10 mA Galvanic isolation: I/O from logic No Off pulse that is accepted for OSSD setting

without declaring the input as OFF Off pulse period, min 15 ms Input capacitance 220 nF

Min = 0 µs Max = 700 µs

Table 19 - SWS Specifications — DG Safety Relay

Attribute 440R-DG2R2T

Wiring terminal

Continuous output current, max 50 mA ON state voltage drop (P/S to +), max 0.2V Surge output current, max 700 mA Surge output current duration, max 5 ms Load capacitance, max 1 µF Off state leakage current, max < 0.1 mA Short circuit detection Yes Short circuit protection Yes Galvanic isolation: I/O from logic No Fan-out

(max number of connections to L11) Cable length between L11 and L12 30 m (98.4 ft) Off state leakage current, max < 0.1 mA

Output - X2 Input - X1

Table 20 - Safety Output Specifications — DG Safety Relay

Attribute 440R-DG2R2T

Wiring terminals 13/14, 23/24 Types 2 N.O. Thermic current I

Fuses output (external) 6 A slow blow or 10 A quick blow Switched current, min 10 mA Switched voltage, min 10V Mechanical life 10,000,000 cycles

Rating

Contact material AgNi + 0.2 µ Au Reaction times

Automatic reset <100 ms Monitored manual reset <500 ms

Response time

13/14 and 23/24 safety outputs 35 ms SWS output 30 ms

Recovery time 100 ms

1 x 6 A

UL:C300 AC-15:1.5 A / 250V AC DC13: 2 A / 24V DC (0.1 Hz)

66 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Tap

Appendix A Specifications

Table 21 - General Specifications — Tap

Attribute

Dimensions, L x W x H 79.64 x 38.5 x 17 mm (3.14 x 1.51 x 0.67 in.) Shipping weight, approx. 27.2 g (0.96 oz) Case material Red RAL 3020 unfilled ABS MG47C plastic Mounting screw torque 2.25 N•m (20 lb•in) Mounting Any orientation

440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D, 440S-PF5D, 440S-PF5D4, 440S-MLF8D, 440S-SLF8D

Table 22 - Electrical Specifications — GuardLink® Enabled Tap

Attribute 440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D, 440S-MLF8D, 440S-SLF8D

Voltage requirements 24V DC +10%, -15% Supply over voltage protection, max 60V DC Reverse polarity protection Yes Short circuit protection

OSSD supply and lock signal 700 mA

GuardLink signals 500 mA ON voltage, max 26.4V ON voltage, min 11V OFF voltage, max 5V OFF current, max 2 mA ON current, min at 20V DC 10 mA Galvanic isolation: I/O from logic No Off pulse that is accepted for OSSD setting

without declaring the input as OFF Off pulse period, min 15 ms Input capacitance 220 nF Current consumption

EMSS input ON 40 mA

EMSS input OFF 25 mA

OSSD input ON 29 mA

OSSD input OFF 25 mA Voltage that is supplied to OSSD device connected to the J3 connector

Pin1 of 5-pin OSSD J1 supply voltage -1.2V @ 500 mA, max load, 0.4V at 50 mA load

Pin 2 of 8-pin OSSD J1 supply voltage -1.2V @ 500 mA, max load, 0.4V at 50 mA load Response time

EMSS tap

OSSD tap CLU timing between successive lock/unlock 135…300 ms

Min = 0 µs Max = 700 µs

5 ms plus 35 µs for each upstream tap

Table 23 - Passive Tap Specifications

Attribute 440S-PF5D

Voltage requirements at J1 24V DC +10%, -15% Current consumption, max 0 mA Galvanic isolation: I/O from logic No Voltage supplied to device connected to J3 J1 supply voltage Response time 0 µs plus 30 µs for each upstream tap CLU timing between successive lock/unlock 135…300 ms

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 67

Appendix A Specifications

Table 24 - Passive Power Tap Specifications

Attribute 440S-PF5D4

Voltage requirements at J4 24V DC +10%, -15% Supply over voltage protection, max 60V DC Reverse polarity protection Yes Short-circuit protection Yes Current consumption, max 15 mA Galvanic isolation: I/O from logic No Voltage supplied to device connected to J3 J4 supply voltage Response time 1 µs plus 30 µs for each upstream tap CLU timing between successive lock/unlock 135…300 ms

Table 25 - Environmental Specifications — Taps and Terminator

Attribute

Tem pera tur e

Operating -25…+70 °C (-13…+158 °F)

Storage -40…+85 °C (-40…+185 °F) Relative humidity 35…85%, not exceed 50%RH at 70 °C (158 °F) Vibration per IEC 60068-2-6 10…55 Hz, 1 mm Shock per IEC 60068-2-27 30 g, 11 ms, half-sine Pollution level per IEC 60947-5-2 3 Enclosure protection IP65, IP67 washdown according to EN 60529, UL Type 1 PR61413 Flammability UL94, DIN 752000/FMV 55302 Protection against electric shock Class III per EN 61140 Emissions CISPR 11

Tap: 440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D, 440S-PF5D, 440S-PF5D4, 440S-MLF8D, 440S-SLF8D Ter min ator : 89 8D-418 U-DM 2

68 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix B

Configuration Examples

This appendix contains examples of configurations. Each example contains the following:

•Schematic

This diagram shows the major connections. The input devices are not shown because of multiple configuration options.

• Logic diagram

This diagram shows the safety monitoring function (SMF), the logic level, and the safety output function (SOF).

• Configuration table

This table shows potential examples of configuration for the corresponding schematic and logic diagram. Each configuration also shows the color of the status indicators during configuration. If in Run mode, a short press of the Config/Set button also shows these indicators.

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 69

Appendix B Configuration Examples

Schematic Logic

OUT X OUT 14/24

IN X IN 1 IN 2

OUT X OUT 14/24

IN X IN 1 IN 2

+24V DC

24V DC Com

Input 1

Reset

Feedback

S32 14S42

13 23

S11 S12S21 S22

DG 440R-DG2R2T

L12 L11A2

GSR CI/SI/DI/DIS

SWS

IN X

OUT X

Test Out

Input 2

K4K3

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

TIME

K1 K2

SMF Level

LOGIC Level

SOF Level

Configuration 1 In Configuration 1, both safety inputs, Input 1 and Input 2, are in use. They can

either be configured for GuardLink® or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN X (terminal X1) is configured for SWS In; this input is ANDed with IN 1 and IN 2.

The output OUT X (terminal X2) is configured for SWS Out and can drive any other SWS compatible device. In this example, the SWS out is driving an EM safety relay. OUT X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.

The relay configuration is considered a middle SWS as it requires an SWS input and provides an SWS output.

The Reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all inputs of the safety function are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.

Figure 49 - Two Safety Inputs, Middle SWS, and Monitored Manual Reset Assigned to Safety Outputs

Table 26 - Configuration 1 — Hex (Dec)

Indicator Function Configuration ID: 0x7F (127) Configuration ID: 0x7B (123) Configuration ID: 0x7D (125) Configuration ID: 0x79 (121)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

OUT X Output Type SWS SWS SWS SWS

IN X Input Mode SWS Enabled SWS Enabled SWS Enabled SWS Enabled

Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual

FB Reset Assignment SOF SOF SOF SOF

70 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix B Configuration Examples

Schematic Logic

IN 1

IN 2

IN X

OUT 14/24

OUT X

+24V DC

24V DC Com

Input 1

Reset

Feedback

S32 14S42

13 23

S11 S12S21 S22

DG 440R-DG2R2T

L12 L11A2

SWS

IN X

OUT X

Test Out

Input 2

K4K3

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

TIME

K1 K2

GSR CI/SI/DI/DIS

SMF Level

LOGIC Level

SOF Level

Configuration 2 In Configuration 2, both safety inputs, Input 1 and Input 2, are in use. They can

either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN X (terminal X1) is configured for SWS In. This input is ANDed with IN 1 and IN 2.

The relay configuration is considered a middle SWS as it requires an SWS input and provides an SWS output.

The Reset mode is configured for manual monitored reset that is assigned to Input 1. After a demand of the safety function by Input 1, the outputs are enabled when all safety inputs are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.

After a demand of the safety function by Input 2 or IN X, the outputs are enabled when the IN 2 and IN X safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.

Figure 50 - Two Safety Inputs, Middle SWS, Monitored Manual Reset Assigned to Input 1, Automatic Reset Assigned to Input 2

Table 27 - Configuration 2 — Hex (Dec)

Indicator Function Configuration ID: 0x3F (63) Configuration ID: 0x3B (59) Configuration ID: 0x3D (61) Configuration ID: 0x39 (57)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 71

OUT X Output Type SWS SWS SWS SWS

IN X Input Mode SWS Enabled SWS Enabled SWS Enabled SWS Enabled

Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual

FB Reset Assignment SMF IN1 SMF IN1 SMF IN1 SMF IN1

Appendix B Configuration Examples

Schematic Logic

IN X

IN 1

IN 2

OUT X

OUT 14/24

GSR CI/SI/DI/DIS

+24V DC

24V DC Com

Input 1

Feedback

S32 14S42

13 23

S11 S12S21 S22

X2 X3

DG 440R-DG2R2T

L12 L11A2

SWS

IN X

OUT X

Test Out

Input 2

K4K3

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

TIME

K1 K2

SMF Level

LOGIC Level

SOF Level

Configuration 3 In Configuration 3, both safety inputs, Input 1 and Input 2, are in use. They can

either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN X (terminal X1) is configured for SWS In. This input is ANDed with IN 1 and IN 2.

The relay configuration is considered a middle SWS as it requires an SWS input and provides an SWS output.

The Reset mode is configured for automatic and assigned to the safety outputs. After a demand of the safety function by any input, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.

Figure 51 - Two Safety Inputs, Middle SWS, Automatic Reset Assigned to Safety Outputs

Table 28 - Configuration 3 — Hex (Dec)

Indicator Function Configuration ID: 0x1F (31) Configuration ID: 0x1B (27) Configuration ID: 0x1D (29) Configuration ID: 0x19 (25)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

OUT X Output Type SWS SWS SWS SWS

IN X Input Mode SWS Enabled SWS Enabled SWS Enabled SWS Enabled

Reset Reset Type Automatic Automatic Automatic Automatic

FB Reset Assignment Not used Not used Not used Not used

72 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix B Configuration Examples

Schematic Logic

GSR CI/SI/DI/DIS

+24V DC

24V DC Com

Input 1

Feedback

S32 14S42

13 23

S11 S12S21 S22

DG 440R-DG2R2T

L12 L11A2

SWS

IN X

OUT X

Test Out

K4K3

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

TIME

K1 K2

Reset

SMF Level

LOGIC Level

SOF Level

Configuration 4 In Configuration 4, only safety Input 1 is in use. It can either be configured for

GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN X (terminal X1) is configured for SWS In. This input is ANDed with IN 1.

The relay configuration is considered a middle SWS as it requires an SWS input and provides an SWS output.

Figure 52 - One Safety Input, Middle SWS, Monitored Manual Reset Assigned to Safety Outputs

Table 29 - Configuration 4 — Hex (Dec)

Indicator Function Configuration ID: 0x7A (122) Configuration ID: 0x78 (120)

OUT Safety Functions IN1 IN1

IN 1 Input Type GuardLink OSSD/EMSS

IN 2 Input Type Not used Not used

OUT X Output Type SWS SWS

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 73

IN X Input Mode SWS Enabled SWS Enabled

Reset Reset Type Monitored Manual Monitored Manual

FB Reset Assignment SOF SOF

IN X

OUT X

IN 1

OUT 14/24

Appendix B Configuration Examples

Schematic Logic

IN X

IN 1

OUT 14/24

OUT X

GSR CI/SI/DI/DIS

+24V DC

24V DC Com

Input 1

Feedback

S32 14S42

13 23

S11 S12S21 S22

DG 440R-DG2R2T

L12 L11A2

SWS

IN X

OUT X

Test Out

K4K3

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

TIME

K1 K2

SMF Level

LOGIC Level

SOF Level

Configuration 5 In Configuration 5, only safety Input 1 is in use. It can either be configured for

GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN X (terminal X1) is configured for SWS In. This input is ANDed with IN 1.

The relay configuration is considered a middle SWS as it requires an SWS input and provides an SWS output.

The Reset mode is configured for automatic/manual and assigned to the safety outputs. After a demand of the safety function by any input, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.

Figure 53 - One Safety Input, Middle SWS, Automatic Reset Assigned to Safety Outputs

Table 30 - Configuration 5 — Hex (Dec)

Indicator Function Configuration ID: 0x1A (26) Configuration ID: 0x18 (24)

OUT Safety Functions IN1 IN1

IN 1 Input Type GuardLink OSSD/EMSS

IN 2 Input Type Not used Not used

OUT X Output Type SWS SWS

74 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

IN X Input Mode SWS Enabled SWS Enabled

Reset Reset Type Automatic Automatic

FB Reset Assignment Not used Not used

Appendix B Configuration Examples

Schematic Logic

IN 1 IN 2

OUT X

OUT 14/24

+24V DC

24V DC Com

Input 1

Reset

Feedback

S32 14S42

13 23

S11 S12S21 S22

DG 440R-DG2R2T

SWS

OUT X

Test Out

Input 2

K4K3

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

TIME

K1 K2

SMF Level

LOGIC Level

SOF Level

Configuration 6 In Configuration 6, both safety inputs, Input 1 and Input 2, are in use. They can

either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN 1 (terminal X1) is disabled; there is no connection to terminal X1.

The output OUT X (terminal X2) is configured for SWS Out. SWS Out can drive any other SWS compatible device. In this example, the SWS out is driving an EM safety relay. OUT X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.

The relay configuration is considered a first SWS as it does not require SWS input and provides an SWS output.

The Reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all safety inputs are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.

Figure 54 - Two Safety Inputs, First SWS Device, Manual Monitored Reset Assigned to Safety Outputs

Table 31 - Configuration 6 — Hex (Dec)

Indicator Function Configuration ID: 0x6F (111) Configuration ID: 0x6B (107) Configuration ID: 0x6D (109) Configuration ID: 0x69 (105)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

OUT X Output Type SWS SWS SWS SWS

IN X Input Mode Disabled Disabled Disabled Disabled

Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual

FB Reset Assignment SOF SOF SOF SOF

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 75

Appendix B Configuration Examples

Schematic Logic

IN 1

IN 2

OUT 14/24OUT X

+24V DC

24V DC Com

Input 1

Reset

Feedback

S32 14S42

13 23

S11 S12S21 S22

DG 440R-DG2R2T

SWS

OUT X

Test Out

Input 2

K4K3

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

TIME

K1 K2

SMF Level

LOGIC Level

SOF Level

Configuration 7 In Configuration 7, both safety inputs, Input 1 and Input 2, are in use. They can

either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN 1 (terminal X1) is disabled; there is no connection to terminal X1.

The output Out X (terminal X2) is configured for SWS Out. SWS Out can drive any other SWS compatible device. In this example, the SWS out is driving an EM safety relay. Output Out X is switched off immediately when demanded by the safety functions. The relay outputs 14/24 can be configured for a time delay to switch off after the delay time.

The Reset mode is configured for manual monitored reset and is assigned to Input 1. After a demand of the safety function by Input 1, the outputs are enabled when all safety inputs are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.

After a demand of the safety function by Input 2, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.

Figure 55 - Two Safety Inputs, First SWS Device, Monitored Manual Reset Assigned to Input 1, Automatic Reset Assigned to Input 2

Table 32 - Configuration 7 — Hex (Dec)

Indicator Function Configuration ID: 0x2F (47) Configuration ID: 0x2B (43) Configuration ID: 0x2D (45) Configuration ID: 0x29 (41)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

OUT X Output Type SWS SWS SWS SWS

IN X Input Mode Disabled Disabled Disabled Disabled

Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual

FB Reset Assignment SMF IN1 SMF IN1 SMF IN1 SMF IN1

76 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix B Configuration Examples

Schematic Logic

+24V DC

24V DC Com

Input 1

Feedback

S32 14S42

13 23

S11 S12S21 S22

DG 440R-DG2R2T

SWS

OUT X

Test Out

Input 2

K4K3

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

TIME

K1 K2

SMF Level

LOGIC Level

SOF Level

Configuration 8 In Configuration 8, both safety inputs, Input 1 and Input 2, are in use. They can

either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN 1 (terminal X1) is disabled; there is no connection to terminal X1.

The relay configuration is considered a first SWS as it does not require SWS input and provides an SWS output.

The Reset mode is configured for automatic manual and assigned to the safety outputs. After a demand of the safety function by any input, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.

Figure 56 - First SWS Device, Two Safety Inputs, Automatic Restart Assigned to Safety Outputs

Table 33 - Configuration 8 — Hex (Dec)

Indicator Function Configuration ID: 0x0F (15) Configuration ID: 0x0B (11) Configuration ID: 0x0D (13) Configuration ID: 0x09 (9)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

OUT X Output Type SWS SWS SWS SWS

IN X Input Mode SWS Enabled SWS Enabled SWS Enabled SWS Enabled

Reset Reset Type Automatic Automatic Automatic Automatic

FB Reset Assignment Not used Not used Not used Not used

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 77

IN 1 IN 2

OUT X OUT 14/24

Appendix B Configuration Examples

Schematic Logic

+24V DC

24V DC Com

Input 1

Reset

Feedback

S32 14S42

13 23

S11 S12S21 S22

DG 440R-DG2R2T

SWS

OUT X

Test Out

K4K3

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

TIME

K1 K2

SMF Level

LOGIC Level

SOF Level

Configuration 9 In Configuration 9, only safety Input 1 is in use. It can either be configured for

GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN 1 (terminal X1) is disabled; there is no connection to terminal X1.

The relay configuration is considered a first SWS as it does not require SWS input and provides an SWS output.

Figure 57 - One Safety Input, First SWS, Monitored Manual Reset Assigned to Safety Outputs

Table 34 - Configuration 9 — Hex (Dec)

Indicator Function Configuration ID: 0x6A (106) Configuration ID: 0x68 (104)

OUT Safety Functions IN1 IN1

IN 1 Input Type GuardLink OSSD/EMSS

IN 2 Input Type Not used Not used

OUT X Output Type SWS SWS

78 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

IN X Input Mode SWS Disabled SWS Disabled

Reset Reset Type Monitored Manual Monitored Manual

FB Reset Assignment SOF SOF

IN 1

OUT X OUT 14/24

Appendix B Configuration Examples

Schematic Logic

+24V DC

24V DC Com

Input 1

Feedback

S32 14S42

13 23

S11 S12S21 S22

DG 440R-DG2R2T

SWS

OUT X

Test Out

K4K3

L12

X32

L11 34

13 23 33 43

4414 24A2

EM 440R-EM4R2

K1 K2

TIME

SMF Level

LOGIC Level

SOF Level

Configuration 10 In Configuration 10, only safety Input 1 is in use. It can either be configured for

GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN 1 (terminal X1) is disabled; there is no connection to terminal X1.

The relay configuration is considered a first SWS as it does not require SWS input and provides an SWS output.

Figure 58 - First SWS Device, One Safety Input, Automatic Reset Assigned to Safety Outputs

Table 35 - Configuration 10 — Hex (Dec)

Indicator Function Configuration ID: 0x0A (10) Configuration ID: 0x08 (8)

OUT Safety Functions IN1 IN1

IN 1 Input Type GuardLink OSSD/EMSS

IN 2 Input Type Not used Not used

OUT X Output Type SWS SWS

IN X Input Mode SWS Disabled SWS Disabled

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 79

Reset Reset Type Automatic Automatic

FB Reset Assignment Not used Not used

OUT X

IN 1

FBFB

OUT 14/24

Appendix B Configuration Examples

Schematic Logic

IN X

IN 1

IN 2

OUT 14/24OUT X

Input 2

Input 1

Reset

S32 14S42

13 23

S11 S12S21 S22

X1 A2

DG 440R-DG2R2T

OSSD

IN X OUT X

Test Out

+24V DC

24V DC Com

Gate control

power supply

Gate control

circuit

S1 S2

Stop

L1 L2 L3

PowerFlex

Start Com

RTS

UWV

Com

+24+24

Machine

Control System

Out

TIME

SMF Level

LOGIC Level

SOF Level

Configuration 11 In Configuration 11, both safety inputs, Input 1 and Input 2, are in use. They

can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The output type for OUT X (terminal X2) is configured for OSSD, and input IN X (terminal X1) is enabled. In this mode, IN X accepts a 24V DC input signal and output OUT X can be used as an immediate switching safety output to initiate a stop function of a drive. The 2-channel safety output 14/24 can drive the safety circuit for a Safe Torque Off with a delay time to perform a Stop Category 1 function.

Figure 59 - Two Safety Inputs, No SWS, Monitored Manual Assigned to Safety Outputs

Table 36 - Configuration 11 — Hex (Dec)

Indicator Function Configuration ID: 0x77 (119) Configuration ID: 0x73 (115) Configuration ID: 0x75 (117) Configuration ID: 0x71 (113)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

OUT X Output Type OSSD OSSD OSSD OSSD

IN X Input Mode OSSD Enabled OSSD Enabled OSSD Enabled OSSD Enabled

Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual

FB Reset Assignment SOF SOF SOF SOF

80 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix B Configuration Examples

Schematic Logic

IN X IN 1 IN 2

OUT X

OUT 14/24

OSSD

IN X OUT X

Reset

Input 2

Input 1

S32 14S42

13 23

S11 S12S21 S22

X1 A2

DG 440R-DG2R2T

Test Out

+24V DC

24V DC Com

Com

+24+24

Machine

Control System

Out

Gate control

power supply

Gate control

circuit

S1 S2

Stop

L1 L2 L3

PowerFlex

Start Com

RTS

UWV

TIME

SMF Level

LOGIC Level

SOF Level

Configuration 12 In Configuration 12, both safety inputs, Input 1 and Input 2, are in use. They

can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

After a demand of the safety function by Input 2, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.

Figure 60 - Two Safety Inputs, No SWS, Monitored Manual Reset Assigned to Input 1, Automatic Reset Assigned to Input 2 and IN X

Table 37 - Configuration 12 — Hex (Dec)

Indicator Function Configuration ID: 0x37 (55) Configuration ID: 0x33 (51) Configuration ID: 0x35 (53) Configuration ID: 0x31 (49)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

OUT X Output Type OSSD OSSD OSSD OSSD

IN X Input Mode OSSD Enabled OSSD Enabled OSSD Enabled OSSD Enabled

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 81

Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual

FB Reset Assignment SMF IN1 SMF IN1 SMF IN1 SMF IN1

Appendix B Configuration Examples

Schematic Logic

IN X IN 1 IN 2

OUT X

OUT 14/24

Input 2

Input 1

S32 14S42

13 23

S11 S12S21 S22

X1 A2

DG 440R-DG2R2T

OSSD

IN X

OUT X

Test Out

+24V DC

24V DC Com

Gate control

power supply

Gate control

circuit

S1 S2

Stop

L1 L2 L3

PowerFlex

Start Com

RTS

UWV

Com

+24+24

Machine

Control System

Out

TIME

SMF Level

LOGIC Level

SOF Level

Configuration 13 In Configuration 13, both safety inputs, Input 1 and Input 2, are in use. They

can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

Figure 61 - No SWS, Two Safety Inputs, Automatic Restart Assigned to Safety Outputs

Table 38 - Configuration 13 — Hex (Dec)

Indicator Function Configuration ID: 0x17 (23) Configuration ID: 0x13 (19) Configuration ID: 0x15 (21) Configuration ID: 0x11 (17)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

OUT X Output Type OSSD OSSD OSSD OSSD

IN X Input Mode OSSD Enabled OSSD Enabled OSSD Enabled OSSD Enabled

Reset Reset Type Automatic Automatic Automatic Automatic

FB Reset Assignment Not used Not used Not used Not used

82 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix B Configuration Examples

Schematic Logic

+24V DC

24V DC Com

Input 1

S32 14S42

13 23

S11 S12S21 S22

X3X1 A2

DG 440R-DG2R2T

OSSD

Test Out

IN X OUT X

Gate control

power supply

Gate control

circuit

S1 S2

Stop

L1 L2 L3

PowerFlex

Start Com

RTS

UWV

Reset

Com

+24+24

Machine

Control System

Out

TIME

SMF Level

LOGIC Level

SOF Level

Configuration 14 In Configuration 14, only safety Input 1 is in use. It can either be configured for

GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

Figure 62 - No SWS, One Safety Input, Monitored Manual Reset Assigned to Safety Outputs

IN X IN 1

Table 39 - Configuration 14 — Hex (Dec)

Indicator Function Configuration ID: 0x72 (114) Configuration ID: 0x70 (112)

OUT Safety Functions IN1 IN1

IN 1 Input Type GuardLink OSSD/EMSS

IN 2 Input Type Not used Not used

OUT X Output Type OSSD OSSD

IN X Input Mode OSSD Enabled OSSD Enabled

Reset Reset Type Monitored Manual Monitored Manual

FB Reset Assignment SOF SOF

OUT X

OUT 14/24

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 83

Appendix B Configuration Examples

Schematic Logic

IN X OUT X

+24V DC

24V DC Com

Input 1

S32 14S42

13 23

S11 S12S21 S22

X2 X3

X1 A2

DG 440R-DG2R2T

OSSD

Test Out

Com

+24+24

Machine

Control System

Out

Gate control

power supply

Gate control

circuit

S1 S2

Stop

L1 L2 L3

PowerFlex

Start Com

RTS

UWV

TIME

SMF Level

LOGIC Level

SOF Level

Configuration 15 In Configuration 15, only safety Input 1 is in use. It can either be configured for

GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The Reset mode is configured for automatic and assigned to the safety outputs. After a demand of the safety function by any input, the outputs are enabled when the Input 1 safety input is ACTIVE and the feedback signal is present. A reset operation is not required.

Figure 63 - No SWS, One Safety Function, Automatic Reset Assigned to Safety Outputs

IN X

IN 1

Table 40 - Configuration 15 — Hex (Dec)

Indicator Function Configuration ID: 0x12 (18) Configuration ID: 0x10 (16)

OUT Safety Functions IN1 IN1

IN 1 Input Type GuardLink OSSD/EMSS

IN 2 Input Type Not used Not used

OUT X Output Type OSSD OSSD

IN X Input Mode OSSD Enabled OSSD Enabled

Reset Reset Type Automatic Automatic

FB Reset Assignment Not used Not used

OUT X

OUT 14/24

84 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix B Configuration Examples

Schematic Logic

OUT X

Input 2

Input 1

Feedback

S32 14S42

13 23

S11 S12S21 S22

X1 A2

DG 440R-DG2R2T

OSSD

Test Out

L2 L3

Machine Control

System

+24V DC

24V DC Com

Reset

Com

+24+24

Machine

Control System

K2K1

TIME

SMF Level

LOGIC Level

SOF Level

Configuration 16 In Configuration 16, both safety inputs, Input 1 and Input 2, are in use. They

can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN X (terminal X1) is disabled. The output type for OUT X (terminal X2) is configured for OSSD and can be used as a status output or to drive another control device.

The reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all safety inputs are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.

Figure 64 - No SWS, Two Safety Inputs, Manual Monitored Reset Assigned to Safety Outputs

IN 1

IN 2

Table 41 - Configuration 16 — Hex (Dec)

Indicator Function Configuration ID: 0x67 (103) Configuration ID: 0x63 (99) Configuration ID: 0x65 (101) Configuration ID: 0x61 (97)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

OUT X Output Type OSSD OSSD OSSD OSSD

IN X Input Mode OSSD Disabled OSSD Disabled OSSD Disabled OSSD Disabled

Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual

FB Reset Assignment SOF SOF SOF SOF

OUT X

OUT 14/24

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 85

Appendix B Configuration Examples

Schematic Logic

IN 1 IN 2

OUT X

OUT 14/24

OUT X

Input 2

Input 1

S32 14S42

13 23

S11 S12S21 S22

X1 A2

DG 440R-DG2R2T

OSSD

Test Out

L2 L3

Machine Control

System

+24V DC

24V DC Com

Reset

Com

+24+24

Machine

Control System

TIME

SMF Level

LOGIC Level

SOF Level

Configuration 17 In Configuration 17, both safety inputs, Input 1 and Input 2, are in use. They

can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN X (terminal X1) is disabled. The output type for OUT X (terminal X2) is configured for OSSD and can be used as a status output or to drive another control device.

After a demand of the safety function by Input 2, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.

Figure 65 - No SWS, Two Safety Inputs, Monitored Manual Reset Assigned to Input 1, Automatic Reset Assigned to Input 2

Table 42 - Configuration 17 — Hex (Dec)

Indicator Function Configuration ID: 0x27 (39) Configuration ID: 0x23 (35) Configuration ID: 0x25 (37) Configuration ID: 0x21 (33)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

OUT X Output Type OSSD OSSD OSSD OSSD

IN X Input Mode OSSD Disabled OSSD Disabled OSSD Disabled OSSD Disabled

Reset Reset Type Monitored Manual Monitored Manual Monitored Manual Monitored Manual

FB Reset Assignment SMF IN1 SMF IN1 SMF IN1 SMF IN1

86 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix B Configuration Examples

Schematic Logic

IN 1

IN 2

OUT X OUT 14/24

OUT X

Input 2

Input 1

Feedback

S32 14S42

13 23

S11 S12S21 S22

X3X1 A2

DG 440R-DG2R2T

OSSD

Test Out

L2 L3

Machine Control

System

+24V DC

24V DC Com

Com

+24+24

Machine

Control System

TIME

SMF Level

LOGIC Level

SOF Level

Configuration 18 In Configuration 18, both safety inputs, Input 1 and Input 2, are in use. They

can either be configured for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN X (terminal X1) is disabled. The output type for OUT X (terminal X2) is configured for OSSD and can be used as a status output or to drive another control device.

The reset mode is configured for automatic and assigned to the safety outputs. After a demand of the safety function by any input, the outputs are enabled when all safety inputs are ACTIVE and the feedback signal is present. A reset operation is not required.

Figure 66 - No SWS, Two Safety Inputs, Automatic Reset Assigned to Safety Outputs

Table 43 - Configuration 18 — Hex (Dec)

Indicator Function Configuration ID: 0x07 (7) Configuration ID: 0x03 (3) Configuration ID: 0x05 (5) Configuration ID: 0x01 (1)

OUT Safety Functions IN1 and IN2 IN1 and IN2 IN1 and IN2 IN1 and IN2

IN 1 Input Type GuardLink GuardLink OSSD/EMSS OSSD/EMSS

IN 2 Input Type GuardLink OSSD/EMSS GuardLink OSSD/EMSS

OUT X Output Type OSSD OSSD OSSD OSSD

IN X Input Mode OSSD Disabled OSSD Disabled OSSD Disabled OSSD Disabled

Reset Reset Type Automatic Automatic Automatic Automatic

FB Reset Assignment Not used Not used Not used Not used

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 87

Appendix B Configuration Examples

Schematic Logic

OUT X

Input 1

Feedback

S32 14S42

13 23

S11 S12S21 S22

X3X1 A2

DG 440R-DG2R2T

OSSD

Test Out

L2 L3

Machine Control

System

+24V DC

24V DC Com

Reset

Com

+24+24

Machine

Control System

TIME

SMF Level

LOGIC Level

SOF Level

Configuration 19 In Configuration 19, only safety Input 1 is in use. It can either be configured for

GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN X (terminal X1) is disabled. The output type for OUT X (terminal X2) is configured for OSSD and can be used as a status output or to drive another control device.

The reset mode is configured for manual monitored reset and is assigned to the safety outputs. The outputs are enabled when all inputs of the safety function are ACTIVE, the feedback signal is present, and a valid reset operation has been performed.

Figure 67 - First SWS Device, One Safety Input, Monitored Manual Reset Assigned to Safety Outputs

IN 1

Table 44 - Configuration 19 — Hex (Dec)

Indicator Function Configuration ID: 0x62 (98) Configuration ID: 0x60 (96)

OUT Safety Functions IN1 IN1

IN 1 Input Type GuardLink OSSD/EMSS

IN 2 Input Type Not used Not used

OUT X Output Type OSSD OSSD

IN X Input Mode OSSD Disabled OSSD Disabled

Reset Reset Type Monitored Manual Monitored Manual

FB Reset Assignment SOF SOF

OUT X

OUT 14/24

88 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix B Configuration Examples

Schematic Logic

OUT X

OUT 14/24

IN 1

OUT X

Input 1

S32 14S42

13 23

S11 S12S21 S22

X1 A2

DG 440R-DG2R2T

OSSD

Test Out

L2 L3

Machine Control

System

+24V DC

24V DC Com

Com

+24+24

Machine

Control System

TIME

SMF Level

LOGIC Level

SOF Level

Configuration 20 In Configuration 20, only safety Input 1 is in use. It can either be configured

for GuardLink or OSSD with autodetect of EMSS devices. Input devices are not shown in the drawing.

The input IN X (terminal X1) is disabled. The output type for OUT X (terminal X2) is configured for OSSD and can be used as a status output or to drive another control device.

Figure 68 - No SWS, One Safety Input, Automatic Reset Assigned to Safety Outputs

Table 45 - Configuration 20 — Hex (Dec)

Indicator Function Configuration ID: 0x02 (2) Configuration ID: 0x00 (0)

OUT Safety Functions IN1 IN1

IN 1 Input Type GuardLink OSSD/EMSS

IN 2 Input Type Not used Not used

OUT X Output Type OSSD OSSD

IN X Input Mode OSSD Disabled OSSD Disabled

Reset Reset Type Automatic Automatic

FB Reset Assignment Not used Not used

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 89

Appendix B Configuration Examples

Notes:

90 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix C

Regulatory Approvals

Agency Certifications • UL Listed Industrial Control Equipment, certified for US and Canada.

• CE Marked for all applicable directives

• RCM marked for all applicable acts

• CCC Mark

•S-Mark

• KC marked for Korea

Compliance to European Union Directives

This product has the CE Marking and is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives.

• Electromagnetic compatibility EMC Directive 2014/30/EU

• Low Voltage Directive 2014/35/EU

• Machinery Directive 2006/42/EC

Machine Safety Directive

This product is designed and tested to meet the European Council Directive 2006/42/EC on machinery and the following standards.

• IEC/EN 61508 - Functional safety of electrical/electronic/programmable electronic safety-related systems

• IEC/EN 62061 - Safety of machinery - Functional safety of safety-related electrical, electronic, and programmable electronic control systems

• EN ISO 13849-1 - Safety of machinery — Safety-related parts of control systems — Part 1: General principles for design

This product is intended for use in an industrial environment.

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 91

Appendix C Regulatory Approvals

DG Safety Relay Ratings SIL Rating

The DG safety relay meets the requirements of SIL in accordance with IEC/EN 61508 and SIL CL 3 in accordance with IEC/EN 62061.

Table 46 - SIL Ratings

Attribute 440R-DG2R2T

Safety integrity level 3 Safety integrity level claim limit [SILCL] 3

[1/h]

PFH

Mode of operation High-demand mode Safety-related subsystems Type B (use of programmable / complex components)

Hardware fault tolerance

Proof test interval, max [a] 20 Safe failure fraction [%] 98.9 Diagnostic coverage [%] 97.12

Performance Level/Category

-8

1.92 x 10

HFT = 1 (dual channel system) HFT = 0 (single channel system)

The Performance Level of the safety function is dependent on the structure of all devices that comprise the safety function.

The DG safety relay can be used in safety systems meeting up to Category 4 and Performance Level PLe in accordance with ISO 13849-1.

Table 47 - DG Performance Level Ratings

Attribute 440R-DG2R2T

Category Up to 4 Performance Level Up to e

[a]

MTTF

[%]

avg

SFF [%] 99.06 CCF 80

92.2

97.31

92 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Tap Ratings SIL Rating

The tap modules can be used in systems that require up to SIL 3 in accordance with IEC/EN 61508 and SIL CL 3 in accordance with EN 62061. A comprehensive analysis of the components that comprise the safety system function determines the actual performance rating. The passive taps simply pass the GuardLink® signals to the safety device, therefore the passive taps do not have a SIL rating.

Table 48 - GuardLink Enabled Tap SIL Ratings

Appendix C Regulatory Approvals

Attribute

Safety integrity level 3 Safety integrity level claim limit [SILCL] 3

[1/h]

PFH

Mode of operation High-demand mode Proof test interval, max [a] 20 Safe failure fraction [%] 98.68

440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D, 440S-MLF8D, 440S-SLF8D

-10

2.65 x 10

Table 49 - GuardLink Enabled Tap Lock Command SIL Ratings

Attribute

Safety integrity level 2 Safety integrity level claim limit [SILCL] 2

[1/h]

PFH

Mode of operation High-demand mode Proof test interval, max [a] 20 Safe failure fraction [%] 98.16

440S-SF8D, 440S-SF5D, 440S-MF5D, 440S-MF8D, 440S-MLF8D, 440S-SLF8D

-9

1.5 x 10

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 93

Appendix C Regulatory Approvals

Performance Level/Category

The Performance Level of the safety function is dependent on the structure of all devices that comprise the safety function. The GuardLink taps can be used in safety systems meeting up to Category 4 and Performance Level PLe in accordance with ISO 13849-1. The passive taps simply pass the GuardLink signals to the safety device, therefore the passive taps do not have a Category or Performance Level rating.

Table 50 - GuardLink Enabled Tap Performance Level Ratings

Attribute Taps

Category Up to 4 Performance Level Up to e MTTFd [a] 1943.07 DCavg [%] 97.65 SFF [%] 99.00 CCF 80

Table 51 - GuardLink Enabled Tap Lock Command Performance Level Ratings

Attribute Taps

Category Up to 2 Performance Level Up to d MTTFd [a] 2159.99 DCavg [%] 92.78 SFF [%] 98.24 CCF 80

EMC Directive

This product is designed and tested to meet the European Council Directive 2014/30/EU on Electromagnetic Compatibility (EMC) and the following standards:

• EN 55011: Industrial, scientific, and medical equipment - Radio frequency disturbance characteristics - Limits and methods of measurement CISPR 11:2009 (Modified)

• EN 61000-6-2: Generic Standards - Immunity for Industrial Environments

• EN 61000-6-7: Electromagnetic compatibility (EMC) Generic standards. Immunity requirements for equipment that is intended to perform functions in a safety-related system (functional safety) in industrial locations.

• EN 61326-3-1: Electrical equipment for measurement, control, and laboratory use - EMC requirements - Part 3-1: Immunity requirements for safety-related systems and for equipment that is intended to perform safety-related functions (functional safety) - General industrial applications

This product is intended for use in an industrial environment.

Declaration of Conformity For the latest Declaration of Conformity (DoC), see the following:

• For taps, see publication 440S-CT002

• For DG safety relays, see publication 440R-CT004

94 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix D

DG Safety Relay Indicator Fault Codes

Determine a Fault The DG safety relay performs an extensive range of internal tests to verify the

performance of the safety function. When the PWR/Fault indicator is flashing red at 1 Hz, the indicators on the front of the DG safety relay can provide information on the fault.

Use the following procedure to determine the fault.

1. Press the Config/Set button.

2. Read the flashing red indicators for the Faulted Module.

3. Press the Config/Set button again.

4. Read the flashing green indicators for the Fault number. If there are no flashing green indicators; the Fault ID value is 0.

5. Add the values as shown in the example in Table 52 on page 96

6. Use the total of the values to look up the Module and Fault IDs in Table 53

on page 96.

Clear a Fault Use the following recommended actions to clear a fault.

1. Where a terminal is specified, check the wiring and, if possible, measure the voltage to confirm the status at the specified terminal.

2. Where the Time Delay switch has been changed in Module 21, return the switch to its original position and cycle power.

3. Where the Time Delay switch has been changed in Module 22, simply return the switch to its original position.

4. Cycle power to the relay to clear the fault.

5. If the fault is not cleared, reconfigure the relay.

6. If the fault persists, replace the relay.

An example fault is shown in Table 52 on page 96 demonstrated by turning the Delay switch to a new position after the relay has been successfully configured. In this example, the rotary switch is not in position 3. Return the switch to position 3, and the fault is cleared.

. This fault can easily be

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 95

Appendix D DG Safety Relay Indicator Fault Codes

Table 52 - Example Fault after Configuration

Indicator

PWR/Fault 128 128

OUT 64 64

IN1 32 32

IN2 16 16

OUT X 8 8

IN X 4 4

Reset 2 2

FB 1 1

Total Value 22 3

Color Red Value Color Green Value

Module Fault ID

Table 53 - Indicator Fault Codes

Module Module Description Fault ID Fault Description

1…5 Internal Fault All Various faults

1 Status host configuration is invalid 2 Default case configuration procedure 3 Load type one configuration failed 4 Device not configured 5 Load configuration table failed

6 Configuration Procedure

7…14 Internal Fault All Various faults

15 Plausibility Tests

6 Existing configuration does not match EEPROM data 7 Load existing configuration failed 8 Save configuration PB And CRC In EEPROM failed 9 CRC check of copied data failed

10 CRC check of copied data failed, invalid amount of data

Compare received data CRC with co-safety processor

1 Terminal S11 should be HI 2 Terminal S21 should be HI 3 Terminal S12 should be HI 4 Terminal S22 should be HI 5 Terminal S32 should be HI 6 Terminal S42 should be HI 7 Terminal X1 should be HI 8 Terminal X2 should be HI 11 Terminal S11 should be LO

12 Terminal S21 should be LO 13 Terminal S12 should be LO

failed

96 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Appendix D DG Safety Relay Indicator Fault Codes

Table 53 - Indicator Fault Codes

Module Module Description Fault ID Fault Description

14 Terminal S22 should be LO 15 Terminal S32 should be LO 16 Terminal S42 should be LO 17 Terminal X1 should be LO

15 Plausibility Tests

16 Internal Fault ALL Various faults

17 Read Inputs

18…19 Internal Fault All Various Faults

20 Start Up Tests

18 Terminal X2 should be LO 21 Feedback internal relay coil should be HI 22 Feedback internal relay coil should be LO 23 Terminal X4 should be HI 24 Terminal X4 should be LO 31 MT should be HI

1Default Case 2 Terminal S22. The CLU signal has an invalid pattern 3 Terminal S42. The CLU signal has an invalid pattern 4 Terminal X1 SWS signal has an invalid pattern 5 Terminal X2 SWS signal has an invalid pattern 6 Default Case Call of Input Interpretation 7 Default Case Read Input Once 8 Default Case Mon DC Once

1 Internal main transistor is ON when it should be OFF 2 Internal main transistor is OFF when it should be ON 3 Internal main transistor is ON when it should be OFF 4 Terminal S11stuck at HI 5 Terminal S21stuck at HI 6 Terminal S12stuck at HI 7 Terminal S32stuck at HI 11 Terminal S11 internal test switch N.C.

12 Terminal S21 internal test switch N.C. 13 Terminal S12 internal test switch N.C. 14 Terminal S22 internal test switch N.C. 15 Terminal S32 internal test switch N.C. 16 Terminal S42 internal test switch N.C. 17 Terminal X1 internal test switch N.C. 18 Terminal X2 internal test switch N.C. 21 Terminal S11 should be LO 22 Terminal S21 should be LO 23 Terminal S12 should be LO 24 Terminal S22 should be LO 25 Terminal S32 should be LO 26 Terminal S42 should be LO 27 Terminal X1 should be LO 28 Terminal X2 should be LO 30 — 31 32

Internal feedback relay is energized

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 97

Appendix D DG Safety Relay Indicator Fault Codes

Table 53 - Indicator Fault Codes

Module Module Description Fault ID Fault Description

0 Saved position is 0

1 Saved position is 1 2 Saved position is 2 3 Saved position is 3 4 Saved position is 4 5 Saved position is 5 6 Saved position is 6

23…46 Internal Fault All Various faults

Invalid Rotary Position

During Power-up

Invalid Rotary Position

During Run

7 Saved position is 7 8 Saved position is 8 9 Saved position is 9

10 Saved position is 10

11 Saved position is 11

12 Saved position is 12 13 Saved position is 13 14 Saved position is 14 15 Saved position is 15 20 Default case

0 Saved position is 0

1 Saved position is 1 2 Saved position is 2 3 Saved position is 3 4 Saved position is 4 5 Saved position is 5 6 Saved position is 6 7 Saved position is 7 8 Saved position is 8 9 Saved position is 9

10 Saved position is 10

11 Saved position is 11

12 Saved position is 12 13 Saved position is 13 14 Saved position is 14 15 Saved position is 15 20 Rotary switch pin has short circuit

98 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Index

Numerics

13/14

safety output

23/24

safety output

440R-ENETR (Ethernet) interface

arrangement

agency certification 91 AOP

verification

arrangement

440R-ENETR (Ethernet) interface

bus

optical

cabling

tap

calculation

safety function

GuardLink system 61 SISTEMA

system current

certification

agency

clear

fault

CLU signal command

communication

compliance

config/set

configuration

conformity

connection

fault reset

opto-link

European Union directives

configuration mode push button 49 run mode

example mode

config/set sel./save

steps 51

declaration of

power supply

DG safety relay multiple tap

single wire safety 46 SWS

consideration

enclosure voltage drop

contact

voltage-free

control, lock, and unlock signal 7

declaration of conformity 94 definition delay setting determine

DG safety relay

dimension

DIN rail

directive

fault

enclosure consideration excessive heat 36 output monitoring overview performance level/category 92 power supply connection reset safety device input 13 SIL rating single wire safety input status indicators 55 terminal assignment terminal function terminal torque wire size 37

mounting

mountingDIN rail

spacing

compliance to European Union machine safety 91

removal

electrical mechanical safety switch 7 EMC directive

tap

EMSS 7

tap

EMSS SmartTap

pulse test

enclosure

consideration

European Union directives

compliance

example

configuration fault

excessive heat

prevent

DG safety relay 35 tap

Rockwell Automation Publication 440R-UM015F-EN-P - December 2020 99

Index

fault

clear

determine example

fault code

indicator

fault reset command function

pulse testing safety

ground 37 guard locking

GuardLink system

GuardLink

connectionsinput wiring fault reset command 17 guard locking principle of operation state 15 system

typical what is 11

system design transition (operational state - safe state) transition (safe state - operational state) 17

heat

prevent excessive

HI 8

indicator

fault code status

input

pulse testing single wire safety SWS 13

input wiring

DG safety relay GuardLink connections OSSD output device 44 voltage-free contact

installation

tap

8, 55

DG safety relay tap 56

LO 8 lock command

timing diagram

machine safety directive 91 mode

configuration

config/set sel./save

run

config/set

monitoring

mounting

multiple

sel./save

output

dimension DIN rail

power supply connection

N.C. 8 N.O.

N/C

normally closed normally open

operation

operational state

optical bus opto-link

OSSD 8

OSSD output device

output

output signal

output wiring

overview

GuardLink, principle

GuardLink

communication

tap

input wiring

monitoring

switching device

safety

DG safety relay tap

performance level/category

DG safety relay tap

pin assignment

tap

pin function

tap

power

power supply

connection

DG safety relay multiple tap

100 Rockwell Automation Publication 440R-UM015F-EN-P - December 2020

Rockwell Automation Guardmaster DG Safety Relay User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Preface

Who Should Use This Manual

Download Firmware, AOP, EDS, and Other Files

Summary of Changes

Definitions

Additional Resources

Overview

What Is a GuardLink System?

Taps Taps create nodes in the GuardLink circuit. A safety device is connected to

DG Safety Relay The DG safety relay is the host of the GuardLink system. By using a sequence of

Safety Device Inputs

Single Wire Safety (SWS) Input

Output Monitoring

Reset

GuardLink Principle of Operation

GuardLink State

GuardLink Transition from Safe State to Operational State

GuardLink Transition from Operational State to Safe State

GuardLink Fault Reset Command

OSSD Tap

EMSS Tap

Passive Tap

Passive Power Tap

Guard Locking with GuardLink Systems

Guard Locking Application Example

GuardLink System Design

Design Considerations The design of a GuardLink® circuit requires knowledge of the power

System Current Calculation The GuardLink circuit current must be calculated to determine whether a

Voltage Drop Consideration With the potential of using up to 32 taps and long cable lengths between taps,

Tap Cabling The GuardLink system was designed with the intent to minimize wiring by

Ter mi nat or The terminator (Figure 8), must be installed on the J2 connector of the last tap

Tap Replacement A GuardLink tap can be replaced with the same type of tap while the link is

Response Time The GuardLink circuit has a fast response time. When a safety device opens,

Installation

Mounting Dimensions Figure 10 - DG Safety Relay Dimensions [mm (in.)]

DIN Rail Mounting and Removal

Removal

Spacing

Terminal Block Removal and Replacement

Terminal Block Removal

Terminal Block Replacement

Tap Installation The tap can be installed directly with two M5 screws. In Figure 15, the 38.5 mm

Enclosure Considerations Consider the following when choosing your DG safety relay and tap enclosure.

DG Safety Relay

Taps

Prevent Excessive Heat Consider the following to help prevent excessive heat for your DG safety relay

DG Safety Relay

Taps

Wiring Requirements and Recommendation

Power, Ground, and Wire

DG Safety Relay Wire Size

Terminal Torque

Terminal Assignment and Function

Tap Pin Assignment and Function

Power Supply Connection Many Bulletin 1606 power supplies are protected extra low voltage (PELV),

DG Safety Relay

Taps

Multiple Power Supplies

DG Safety Relay Input Wiring

GuardLink Connections

Devices with OSSD Outputs

Voltage-free Contacts

Single Wire Safety The DG safety relay has the Single Wire Safety (SWS) capability to expand the

SWS Connections

Safety Output Wiring The DG safety relay has two voltage-free, safety-related outputs (terminals

13/14 and 23/24 Safety Outputs

Surge Protection

Configuration

Config/Set Push Button Run Mode

Configuration Mode

Sel./Save Push Button Run Mode

Configuration Mode

Reset If you press both buttons simultaneously for longer than 3 seconds, the DG

Configuration Steps Before starting to configure the DG safety relay, review the configuration

Delay Setting The delay is set by the 16 position switch as described in Table 11. The DG