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.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

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

Table of Contents

	Preface
	Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 7
	Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . .	7
	Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	9
	Chapter 1
Overview	What Is a GuardLink System? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11
	Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
	DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	Safety Device Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	Single Wire Safety (SWS) Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	Output Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	14
	GuardLink Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
	GuardLink State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
	GuardLink Transition from Safe State to Operational State . . . . . .	17
	GuardLink Transition from Operational State to Safe State . . . . . .	17
	GuardLink Fault Reset Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
	OSSD Tap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
	EMSS Tap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
	Passive Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
	Passive Power Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
	Guard Locking with GuardLink Systems . . . . . . . . . . . . . . . . . . . . . . .	19
	Guard Locking Application Example. . . . . . . . . . . . . . . . . . . . . . . . . . .	20
	Chapter 2
GuardLink System Design	Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
	System Current Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	24
	Voltage Drop Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	25
	Tap Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	28
	Terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
	Tap Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
	Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29

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

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	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

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	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	Determine a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
Codes	Clear a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
	Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99

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

Preface

Who Should Use This

Manual

Download Firmware, AOP,

EDS, and Other Files

Summary of Changes

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

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.

	Topic	Page
	Updated Catalog Number List.	Front - User
		Manual
	Updated Guard Locking with GuardLink Systems section.	19
	Updated Figure 7.	28
	Updated figure headings for Figure 21…Figure 27.	39…41
	Updated Table 19…Table 24	66…68

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

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•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

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

Symbol Description

Green indicator flashes with certain frequency Red indicator is OFF

Green indicator is ON

Red indicator is ON

Green indicator flashes with certain frequency Red indicator flashes with certain frequency

•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

Additional Resources

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

	Resource	Description
	NEMA Standard 250 and IEC 60529	Provides explanations of the degrees of protection that is
		provided by different types of enclosure.
	Guardmaster EtherNet/IP Network Interface User	A detailed description of module functionality, configuration,
		installation procedure, and information on how to use the
	Manual, publication 440R-UM009	Guardmaster® EtherNet/IP™ Network Interface (catalog
		number 440R-ENETR).
	Industrial Automation Glossary, publication AG-7.1	A glossary of industrial automation terms and abbreviations.
	Industrial Automation Wiring and Grounding	Provides general guidelines for installing a Rockwell
	Guidelines, publication 1770-4.1	Automation industrial system.
	Product Certifications website,	Provides declarations of conformity, certificates, and other
	rok.auto/certifications.	certification details.

You can view or download publications at rok.auto/literature.

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

9

Notes:

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

What Is a GuardLink

System?

Chapter 1

Overview

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 shows the basic components of a typical application. The 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.

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

Figure 1 - Typical GuardLink System

Each DG safety relay can accommodate up to two GuardLink circuits, each containing up to 32 devices.

Upstream					Downstream

One DG

Safety Relay

A1 A2			<![if ! IE]> <![endif]>IP:	S12 S22 S32 S42				33	34	43	44	Standard Safety Devices
LNK1								A1 A2 S11 S12
MS			<![if ! IE]> <![endif]>.192	A1 A2		S11 S21
					PWR/Fault				PWR/Fault
LNK1			<![if ! IE]> <![endif]>168
					OUT
LNK2			<![if ! IE]> <![endif]>.1 .
NS			<![if ! IE]> <![endif]>ABC		IN 1
					IN 2				Logic IN
					OUT X				OUT
9	0	1	A		IN X
8		2						33 34 43 44
7		43			Reset
6	5				FB
	0
9		1	B			Config/Set
7		3
8		2
6	5	4		DG		Reset
						Sel./Save						Cordsets and Patchcords
9	0	1	C		. 0.2. Time			13 14 23 24
78	5	2
					.01.
					.14 .			EM
6		4			1	4
						8.
		3			2	6
				X1	X2	X3	X4	L12 L11 X32
								13	14	23	24
				13	14	23	24
LNK2

1607-XT

Single Wire Safety for Expansion

On-Machine™

Power Supply

R

Output Monitoring

One Optional Ethernet Module (Required for Guard Locking)

GuardLink

Enabled

Devices

Passive Tap for GuardLink Enabled

Passive Power Tap Devices for Extra Power

One Terminator for each GuardLink Circuit

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

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, the DG safety relay has one GuardLink circuit and one safety 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

GuardLink circuit - one tap for each safety device

Safety device (E-stop, mechanical interlock, light curtain, scanner, OSSD interlocks)

EtherNet/IP						DG safety relay
interface
						R		Monitored
								Manual
								Reset
Output
monitoring

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

GuardLink Principle of

Operation

Chapter 1

Overview

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

Two safety devices (E-stops, mechanical interlocks, light curtains, scanners, OSSD interlocks)

Cordsets or patchcords

DG safety relay

R

Optional

EtherNet/IP interface

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). When guard locking devices are connected, a 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	EMSS contacts	440S-MF8D
		OSSD	440S-SF8D
	Power to Lock	EMSS contacts	440S-MLF8D
		OSSD	440S-SLF8D

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 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

Figure 4 - Unlock Command Timing Diagram

<![if ! IE]> <![endif]>Unlock Commands to

<![if ! IE]> <![endif]>Guard Locking Devices

32

5

4

3

2

1

OUT (13/14, 23/24)

OUT X (X2)

Unlock Request

0

1000

1135

1270

1405

1540

10,600

Time [ms]

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

Chapter 1

Overview

Figure 5 - Guard Locking Application Example Schematic and Logic

Schematic

Logic

440N-Z21SS3PH		440G-LZS21SPRH
SensaGuard		Guard Locking
Interlock		Safety Switch

440G-TZS21UPRH				440N-Z21SS2JN9	SMF Level	IN 1
Guard Locking				SensaGuard
Safety Switch				Interlock

				LOGIC Level
				SOF Level	R	R
440S-SF8D	440S-SF8D	440S-SF8D	440S-SF5D	898D-418U-DM2	FB	FB
				Terminator
+24V DC					OUT X	OUT 14/24

K1

Start

K2

Host PC

Reset

Stop

Ethernet

+

+

+

S11

S21

S12

S22

A1

13

23

X4

A1

X32

13

23

33

43

L1

L2

L3

DC ok

A

TIME

Control

24-

HMI

PLC

B

0

Status

.

.2

Status

4 .

28V

.1

4

K1

2 .

1

6

.

8.

C

DG

01.

EM

1606-XLP95E

9

440R-ENETR

440R-DG2R2T

440R-EM4R2

K2

N

L

S32

S42

X1

X2

A2

14

24

X3

A2

L12

L11

14

24

34

44

Ethernet

Feedback

OUT X

Immediate

100S

M

SWS

K1

K2

Acting

Contactors

Loads

24V DC Com

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
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.

•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 controlled system to start or restart the hazards after the safety system is reset.

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

21

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 identifies three tap connections: T1, T2, and T3. The voltage and safety signals are sourced to connection J1. J2 is connected to downstream taps. J3 of each tap is connected to a safety device.

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

23

Chapter 2 GuardLink System Design

Figure 6 - Tap Connections

					D1	Safety Device 1		D2	Safety Device 2
											Safety Device 3
											D3
					Device Cable			Device Cable			Device Cable
	R1				J3	R2		J3	R3		J3
					INPUT			INPUT			INPUT
Fuse	I1				I2				I3
	Link Cable		J1			Link Cable	J1	J2	Link Cable	J1	J2
4 A				T1	J2
SLO-BLO™	L1					L2		T2	L3	T3	Terminator
	+ + - -	VJ1			VJ2 VJ3
	Vs=24V
	Power
	Supply
					Table 4 - Key for Figure 6
					Item	Description
					D1, D2, D3	Safety devices
					I1, I2, I3	Current in the link cable (A)
					IT1, IT2, IT3	Current required by a tap (A)
					ID1, ID2, I1D3	Current required by a safety device (A)
					L1, L2, L3	Length of link cable (m)
					R1, R2, R3	Resistance of wire (Ω)
					T1, T2, T3	Taps
					VJ1, VJ2, VJ3	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, I1, is the sum of the current required by the first tap 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.

I1 = IT1 + ID1 + I2

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

I2 = IT2 +ID2 + I3

I3 = IT3 + ID3

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

I1 = ∑ IT + ∑ ID

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 (R1) is:

R1 = 0.02095 * L1

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 (VJ1) is:

VJ1 = 2 * I1 * R1

The tap has a small voltage from connector J1 to J2. The typical voltage at connector J2 (VJ2) drop through the tap from J1 to J2 is:

VJ2 = VJ1 - (2 * 0.028V)

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.

VJ3 = 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

	Tap	Cable Length	Safety Device	Tap + Device	Total Current	J1 Voltage	J3 Voltage
		[m (ft)]		Current (mA)	(mA)	(V)	Typical (V)
	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	20.32	19.92
	7	15 (49.2)	TLSZR-GD2 PLe	135	647	19.88	19.48
	8	15 (49.2)	TLSZR-GD2 PLe	135	512	19.53	19.13
	9	15 (49.2)	Lite Lock 440G-LZ	135	377	19.27	18.87
	10	15 (49.2)	SensaGuard Ser A	81	242	19.10	18.70
	11	15 (49.2)	SensaGuard Ser A	81	161	18.99	18.59
	12	15 (49.2)	Mechanical Switch	40	80	18.94	18.54
	13	15 (49.2)	Mechanical Switch	40	40	18.91	18.51
	14	0 (0)	—	0	0	—	—
	15	0 (0)	—	0	0	—	—

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

	Tap	Cable Length	Safety Device	Tap + Device	Total Current	J1 Voltage	J3 Voltage
		[m (ft)]		Current (mA)	(mA)	(V)	Typical (V)
	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	—	—

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

27

Chapter 2 GuardLink System Design

Tap Cabling

White Black Brown

Blue

+ + - -

DG 24V Safety Power Relay Supply

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 mm2) 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 mm2) 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)

Standard Safety		GuardLink Enabled
	Device	Safety Device
889D-F5NCDM-x			889D-M5NC-x	Standard
5­wire Patchcord or			5­wire Cordset or
889D-F8NBDM-x		889D-F5NCDM-x	889D-M8NB-x	Safety Device
8­wire Patchcord	5­wire Patchcord		8­wire Cordset
10 m (32.8 ft) length, max	10 m (32.8 ft) length, max		10 m (32.8 ft) length, max
INPUT	INPUT		INPUT
GuardLink Enabled Tap	Passive Tap		GuardLink Enabled Tap	889D-418U-DM2
	889D-F4NEDM-x
889D-F4NE-x			889D-F4NEDM-x	Terminator
	4­wire Patchcord
			4­wire Patchcord
4-wire Cordset	25 m (82 ft) length, max
			5 m (16.4 ft) length, max
30 m (98.4 ft) length, max

30 m (98.4 ft) length, max between GuardLink enabled taps

(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.

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

Terminator

Tap Replacement

Response Time

Chapter 2 GuardLink System Design

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

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.

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 shows an example GuardLink safety circuit with six taps. In this example, a SensaGuard™ rectangular flat pack interlock, which is connected to Tap 4, opens.

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

29

Chapter 2 GuardLink System Design

Figure 9 - Response Time Example Calculation

SensaGuard

Opens

Tap 1

Tap 2

Tap 3

Tap 4

Tap 5

Tap 6

Upstream

Downstream

DG Safety Relay

Single Wire Safety Out

100S-C09EJ

Safety

Contactors

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	Response Time [ms]
		DG Output 13/14, 23/24	DG Output SWS (X2)
	SensaGuard (1)	54.0	54.0
	Tap 4	5.0	5.0
	Tap 3	0.035	0.035
	Tap 2	0.035	0.035
	Tap 1	0.035	0.035
	DG Safety Relay	60.0	55.0
	100S Contactor (2)	50.0	0.0
	Total	169.105	114.105

(1)See publication 440N-IN018.

(2)See publication 100-TD013.

IMPORTANT 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 time of additional components that are connected to the SWS signal) must be considered.

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