Rockwell Automation 440R-D22R2 User Manual Download Page 1

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User Manual

Original Instructions

Guardmaster Safety Relays

Catalog Numbers 440R-S13R2, 440R-S12R2, 440R-D22R2,

440R-D22S2, 440R-EM4R2, 440R-EM4R2D

Summary of Contents for 440R-D22R2

Page 1: ...User Manual Original Instructions Guardmaster Safety Relays Catalog Numbers 440R S13R2 440R S12R2 440R D22R2 440R D22S2 440R EM4R2 440R EM4R2D...

Page 2: ...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...

Page 3: ...40R EM4R2 10 EMD Safety Relay Cat No 440R EM4R2D 10 SI Safety Relay Cat No 440R S12R2 11 Chapter 2 Installation Mounting Dimensions 13 DIN Rail Mounting and Removal 13 Removal 13 Spacing 14 Removable...

Page 4: ...apter 5 Status Indicators Indicators During Power up 35 Indicators During Normal Operation 35 Indicators During Diagnostics 36 Chapter 6 Pulse Testing Functions Pulse Testing for Inputs 37 CI Safety R...

Page 5: ...Status Indicator Step 1 54 Check the Power Supply Step 2 56 Check Voltage 56 Verify Grounding at the Power Supply 57 Check Safety Device Inputs Step 3 58 Check Voltage free Contacts 58 Examine Pulse...

Page 6: ...tal Specifications 77 Safety Inputs IN IN1 and IN2 Specifications 77 Reset Input Specifications 78 B1 Input Specifications 78 Safety Outputs Specifications 79 Auxiliary Output Specification 79 Single...

Page 7: ...sing this product 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 o...

Page 8: ...n and shorts circuits between the two signals Single Wire Safety SWS A unique safety rated signal that is sent over one wire to indicate a safety status The SWS can be used in safety systems that requ...

Page 9: ...tatus indicators provide status and diagnostics Under fault conditions the PWR Fault status indicator blinks in specific patterns to help diagnose the fault See Status Indicators on page 35 and View t...

Page 10: ...D22R2 The DI safety relay has two dual channel inputs and two electromechanical relay outputs In addition the DI safety relay has an SWS input and output The DI safety relay can be set for automatic...

Page 11: ...used with the jog function or to set the off delay as retriggerable See EMD Safety Relay Timing Functions on page 39 for detailed descriptions on the EMD safety relay timing functions SI Safety Relay...

Page 12: ...12 Rockwell Automation Publication 440R UM013F EN P July 2021 Chapter 1 Overview Notes...

Page 13: ...5 mm 1 38 in DIN rails 35x7 5x1 mm 1 38x0 3x0 04 in EN 50022 35x7 5 1 Hold the top at an angle see Figure 3 2 Slide down until the housing catches the rail 3 Swing the bottom down and push until the l...

Page 14: ...t 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...

Page 15: ...or outside the enclosure can 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 Addition...

Page 16: ...16 Rockwell Automation Publication 440R UM013F EN P July 2021 Chapter 2 Installation Notes...

Page 17: ...s 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 r...

Page 18: ...nd SI S21 Pulse Test Output for Channel 2 CI DI DIS and SI S12 Safety Input for IN1 Channel 1 CI DI DIS and SI S22 Safety Input for IN1 Channel 2 CI DI DIS and SI S32 Safety Input for IN2 Channel 1 DI...

Page 19: ...ith the MSR127 monitoring safety relay has A1 at the top and A2 at the bottom Figure 7 Power Supply Connections Safety Inputs GSR safety relays can be connected to the following devices Devices with m...

Page 20: ...ut Devices such as the GuardShield safety light curtains SafeZone laser scanners SensaGuard interlock switch TLS Z and 440G LZ guard locking switches and Bulletin 442G Multifunction Access Box MAB hav...

Page 21: ...ude SensaGuard interlocks and the TLS ZR and 440G LZ guard locking interlocks Devices with electromechanical EM outputs must be placed after the non cascadable device The EM safety relay devices can b...

Page 22: ...function from mechanical switches or OSSDs to safety mats GSR safety relays must go through the complete configuration process Figure 12 on page 23 shows the typical connections for safety mats You no...

Page 23: ...3 Safedge Operating Principle Figure 14 on page 24 shows the typical wire connections With the proper connection GSR safety relays detect the compression of the edge and turn off their outputs With no...

Page 24: ...n switch loads up to 1 5 A They can only tolerate a load capacitance up to 1 6 F Terminals 34 and 44 have a series diode and can switch loads up to 0 5 A They can tolerate a load capacitance up to 9 F...

Page 25: ...occur when switching inductive load devices such as motor starters and solenoids the use of surge suppression to help protect and extend the operating life of the relays is required By adding a suppr...

Page 26: ...tion to an EM safety relay in parallel with a DIS safety relay The safety relays must have a common power reference 24V common In this example the safety function started by the CI or SI safety relay...

Page 27: ...safety relays have a reset monitoring input terminal S34 The expansion safety relays EM and EMD do not have a reset input The reset action can be configured for either automatic or manual reset When t...

Page 28: ...within a duration of 250 3000 ms as shown in Figure 22 on page 29 The reset occurs on the trailing edge If the reset signal is too short or too long the reset function is not executed and can be tried...

Page 29: ...ion relay must be the 24V DC source of the reset and monitoring input Figure 24 shows an example of the connections for a monitored reset with additional contactor monitoring This type of connection c...

Page 30: ...ation Jog Input When the EMD safety relay is configured for the Jog functions terminal B1 must be connected to 24V DC Table 4 Retriggerable Operation Configuration Jumper Action Retriggerable B1 B2 If...

Page 31: ...Power cycling the device in a timely manner completes the configuration mode and the device enters operation We recommend that the configuration is completed within 5 minutes The actual technical lim...

Page 32: ...ble 7 on page 33 show the setting options for the Range and Time switch With the Time switch set to 1 at the start of the configuration process the duration of the Range switch is the shorter range Wi...

Page 33: ...in the EEPROM is erased and the device is now prepared for a new configuration 3 Adjust the Logic Reset Time and Range switch settings as needed for your application 4 Verify the settings by counting...

Page 34: ...h settings are compared to the values in the EEPROM makes sure that the switches were not changed while power was off and the input and output circuits are checked Upon successful completion of the in...

Page 35: ...cuits at S32 and S42 are open B1 EMD ON Input circuit at B1 is closed OFF Input circuit at B1 is open LOGIC IN DI DIS EM EMD ON Logic IN signal Single Wire Safety at L12 is ON OFF Logic IN signal at L...

Page 36: ...July 2021 Chapter 5 Status Indicators Indicators During Diagnostics See the following tables Table Page PWR Fault Status Indicator Is Steady Red 55 PWR Fault Status Indicator Is Flashing Red 55 PWR F...

Page 37: ...generated on terminals S11 and S21 of the CI DI DIS and SI safety relays The EM and EMD safety relays do not use pulse testing CI Safety Relay The pulse testing that is associated with the CI safety...

Page 38: ...pulse pattern on terminal 14 is identical to terminal 34 and the pulse pattern on 24 is identical to 44 The pattern is repeated every 3 371 seconds Figure 31 OSSD Output Test Pulses on DIS Safety Rela...

Page 39: ...1 1 The logic link signal at terminal L12 turns on and the safety outputs turn on immediately that is within the specified reaction time 2 The logic link signal turns off and the off delay timer star...

Page 40: ...e Timing Diagram Case 1 1 The logic link signal at terminal L12 turns on and the safety outputs turn on immediately that is within the specified reaction time 2 The logic link signal turns off and the...

Page 41: ...ty outputs turn off Jog The jog function has two timers an on timer and an off timer The Range and Time switch settings set the on timer during configuration The on timer starts when both the B1 termi...

Page 42: ...urn off immediately and the off timer starts 11 The off timer elapses The logic link signal turns off to end Case 2 Case 3 12 The logic link signal at terminal L12 is on The B1 signal turns on The jog...

Page 43: ...al circuit block diagrams of each safety relay CI Safety Relay Cat No 440R S13R2 Figure 36 CI Safety Relay Circuit Diagram DI Safety Relay Cat No 440R D22R2 Figure 37 DI Safety Relay Circuit Diagram D...

Page 44: ...ck Diagrams EM Safety Relay Cat No 440R EM4R2 Figure 39 EM Safety Relay Circuit Diagram EMD Safety Relay Cat No 440R EM4R2D Figure 40 EMD Safety Relay Circuit Diagram SI Safety Relay Cat No 440R S12R2...

Page 45: ...d the reset push button is pressed and released between 0 25 3 seconds The CI safety relay monitors the status of the two output contactors K1 and K2 If either fails to close their N C contacts the CI...

Page 46: ...with OSSD outputs Make note of the specific wiring for the mat Also during configuration and for each power up the mat must be clear and the interlock closed The DI safety relay must be configured fo...

Page 47: ...nd K2 are off by monitoring the mechanically linked normally closed contacts in the S34 circuit When the DIS safety relay is off the auxiliary signal at terminal Y32 turns on and reports the status to...

Page 48: ...l from terminals L11 to L12 instructs the EMD safety relay to turn on and off When the E stop is pressed the CI safety relay turns off immediately and the EMD safety relay turns off 5 seconds later Th...

Page 49: ...imum of a 100 second jog The single wire safety signal from terminals L11 to L12 enables the EMD safety relay When enabled the jog switch can be pressed and held closed to turn on the EMD safety relay...

Page 50: ...y relay outputs turn on if contactors K1 and K2 are already off The Start button can then be pressed to turn on contactors K1 and K2 Figure 52 SI Safety Relay Example A1 L11 X32 B1 B2 L12 18 38 48 28...

Page 51: ...erNet IP module must be in the leftmost position see Figure 53 See publication 440R UM009 for further details on the EtherNet IP module The safety relays must be Series A 200 or later Figure 53 Arrang...

Page 52: ...Designer AOP for the DI DIS EM EMD and SI safety relays The AOP allows you to view the status of the relays including open and closed inputs outputs ON and OFF waiting for reset and fault information...

Page 53: ...Required Tools Medium sized Screwdriver For terminal screws to remove terminal blocks and to configure the switches on the front face of the relays Digital Multimeter To measure signal levels and con...

Page 54: ...cator Start OUT indicator is steady green Relay is functioning properly PWR Fault indicator steady green Flashing Go to Step 1 page 54 Go to Step 3 page 58 Go to Step 4 page 64 OUT indicator flashing...

Page 55: ...on mode All The relay is shipped from the factory with no configuration The configuration process was not completed successfully Continue with the configuration process Rotate the switches to the desi...

Page 56: ...ycle power again If the new setting agrees with the EEPROM the PWR Fault indicator is steady green the GSR safety relay functions properly 2 DIS safety relays only Table 11 PWR Fault Status Indicator...

Page 57: ...n between machine ground and the 24V common temporarily Then wait to see if the fault does not occur wait time varies If the fault occurs then the grounding scheme must be investigated further Figure...

Page 58: ...h a digital multimeter as shown in Figure 60 The voltage must be 18 19V on both pulse testing outputs of the CI safety relay Figure 60 Typical Voltage Measurements of the CI Safety Relay 2 Check the v...

Page 59: ...stance Effect on page 62 To find where the voltage drop is occurring you have to trace the wiring of the circuit that is not achieving at least 11V as measured by an oscilloscope Check DI DIS and SI S...

Page 60: ...62 Examine Pulse Test Waveforms If you have an oscilloscope you can examine the pulse tests The test pulses are used to check for short circuit conditions the test pulses are not used to turn the inp...

Page 61: ...ribed in Table 15 Test pulses on OSSD outputs are less than 1 ms therefore the GSR safety relay ignores the test pulses Capacitance Effect Capacitance leakage of the input wiring to ground causes a de...

Page 62: ...e Effect on Input Signal GSR safety relays have a maximum input resistance of 900 ohms Table 16 on page 63 shows the resistance of wire sizes that are typically used to connect to safety devices For e...

Page 63: ...cling GSR safety relay inputs are not satisfied if one channel turns ON and OFF multiple times followed by the closure of the second channel see Figure 69 The input status indicator remains red This c...

Page 64: ...e causes the output to turn off The IN1 or IN2 indicator is off and the output is off even with automatic reset Repeated cycles of the input at less than 20 ms cause the output to be off or on but a t...

Page 65: ...s pulse This waveform is repeated every 4 ms When inactive the SWS is 0V Figure 72 SWS Waveform When the signal is active use a digital multimeter to measure the voltage The digital multimeter shows 8...

Page 66: ...erminal S34 point 1 as shown in Figure 74 If 24V is not present when the reset button is pushed then check the other connections points 2 7 in the circuit If 24V is present at terminal S34 then you mu...

Page 67: ...ulses up to 6 ms in duration Figure 75 shows a reset signal that is 2500 ms long During this time a 6 ms test pulse occurs This test pulse is ignored A test pulse of 7 ms causes the GSR safety relay t...

Page 68: ...replaced Step Description 1 The voltage at 13 must be the same as the supply voltage If not check for an open circuit broken wire blown fuse or tripped circuit breaker 2 The voltage at 14 must be the...

Page 69: ...he safety circuit is open check the connections to the PowerFlex drive See Check the PowerFlex Drive Connections on page 70 Check the OSSD Connections Confirm that voltage is present at the relay term...

Page 70: ...slightly less than the supply voltage and must be the same voltage as measured at terminal 14 If not check for an open circuit broken wire between terminal 14 and A1 3 The voltage at A2 must be zero...

Page 71: ...lse appears on all four terminals simultaneously The main transistor pulses are about 110 s wide Each channel is tested individually as shown in Figure 82 The individual pulses are about 50 s wide The...

Page 72: ...es not turn ON See Check the X32 Output on page 74 The safety outputs are OFF The Y32 output must be ON This is true for both faulted and running states See Check the Y32 Output on page 73 For more in...

Page 73: ...s not turn ON or when the safety outputs are OFF the Y32 output must be ON This is true for both faulted and running states Use a digital multimeter to measure the voltage at Y32 point 1 in Figure 85...

Page 74: ...elay must be replaced Figure 86 Measure X32 Voltage EMD Expansion Safety Relay B1 B2 Inputs Step 7 Figure 87 on page 75 shows the waveform from B1 to B2 This waveform is the same as the single wire sa...

Page 75: ...Terminal Block Removal GSR safety relays have removable terminal blocks Use a screwdriver as a lever to remove the blocks As shown in Figure 88 insert the screwdriver into the slot and pry up Figure 8...

Page 76: ...The series firmware revision number and manufacturing date code are identified on the safety relay label as shown in Figure 90 Figure 90 Product Label Series and Revision Identification Old Product L...

Page 77: ...rminal Protection IP20 Enclosure Protection IP40 NEMA 1 Mounting 35 mm 1 38 in DIN rail in enclosure that is rated to a minimum of IP54 Attribute 440R S13R2 CI 440R D22R2 DI 440R D22S2 DIS 440R EM4R2...

Page 78: ...440R S13R2 CI 440R D22R2 DI 440R D22S2 DIS 440R EM4R2 EM 440R EM4R2D EMD 440R S12R2 SI Attribute 440R S13R2 CI 440R D22R2 DI 440R D22S2 DIS 440R EM4R2 EM 440R EM4R2D EMD 440R S12R2 SI Wiring Terminal...

Page 79: ...L C300 AC 15 1 5 A 250V AC DC13 2 A 24V DC 0 1 Hz 14 24 1 5 A each 34 44 0 5 A each UL B300 AC 15 1 5 A 250V AC DC13 2 A 24V DC 0 1 Hz UL C300 AC 15 1 5 A 250V AC DC13 2 A 24V DC 0 1 Hz Capacitance 14...

Page 80: ...I Wiring Terminal Output L11 Input L12 Continuous Output Current Max mA 50 ON State Voltage Drop P S to Max V 0 2 Surge Output Current Max mA 700 Surge Output Current Duration Max ms 5 Load Capacitanc...

Page 81: ...Rockwell Automation Publication 440R UM013F EN P July 2021 81 Appendix A Specifications Notes...

Page 82: ...82 Rockwell Automation Publication 440R UM013F EN P July 2021 Appendix A Specifications...

Page 83: ...nment 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 electric...

Page 84: ...s can be used in safety systems that meet up to Category 4 and Performance Level PLe in accordance with ISO 13849 1 Table 19 SIL Rating 440R S13R2 CI 440R D22R2 DI 440R D22S2 DIS 440R EM4R2 EM 440R EM...

Page 85: ...et 51 compliance European Union EU directives 83 configuration 31 process 33 connect power supply 19 considerations enclosure 14 contact resistance 72 voltage free 58 cycling multiple channel 63 D dat...

Page 86: ...44 50 H hardware features 9 heat prevent excessive 15 I indicator PWR fault 54 flashing red 55 green with flashing red 56 solid red 55 indicators diagnostics 36 normal operation 35 powerup 35 status...

Page 87: ...input 37 CI safety relay 37 DI DIS and SI safety relay 37 OSSD outputs 38 PWR fault status indicator 54 flashing red 55 green with flashing red 56 solid red 55 R rating SIL 84 recommendation wiring 1...

Page 88: ...eshooting 53 Studio 5000 Logix Designer add on profile AOP 52 suppressors surge 25 surge suppressors 25 switch adjustment 31 DI safety relay 32 DIS safety relays 32 EMD safety relay 32 multi position...

Page 89: ...Rockwell Automation Publication 440R UM013F EN P July 2021 89 Guardmaster Safety Relays User Manual...

Page 90: ...Local Technical Support Phone Numbers Locate the telephone number for your country rok auto phonesupport Literature Library Find installation instructions manuals brochures and technical data publica...

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