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Rockwell Automation Publication 440R-UM013E-EN-P - March 2017

Preface

This manual is a reference guide for the family of Guardmaster® Safety Relays

(GSR). It describes the procedures that you use to install, wire, and

troubleshoot your relay. This manual also gives an overview of the operation of

safety relays.

Summary of Changes

This manual contains new and updated information as indicated in the

following table.

Who Should Use This

Manual?

Use this manual if your responsibilities include design, installation,

programming, or troubleshooting of control systems that use safety relays,

including catalog numbers:

• 440R-S13R2 (CI safety relay)
• 440R-D22R2 (DI safety relay)
• 440R-D22S2 (DIS safety relay)
• 440R-EM4R2 (EM safety relay)
• 440R-EM4R2D (EMD safety relay)
• 440R-S12R2 (SI safety relay)

You must have a basic understanding of electrical circuitry and familiarity with

safety-related control systems. If you do not have this knowledge, obtain the

proper training before using 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 of specific terms and abbreviations that are used in this

manual.

•

N.C. (Normally Closed) -

An electrical contact whose normal state is

in the closed position.

•

N.O. (Normally Open) -

An electrical contact whose normal state is in

the open position.

•

PLC -

A programmable logic controller or a programmable automation

controller.

•

Reaction Time -

The time between the true states of one input to the

ON state of the output.

Topic

Page

Updated Devices with OSSD Output section

Updated Safety Mats section

Added Troubleshooting chapter

Содержание Guardmaster

Страница 1: ...Guardmaster Safety Relays Catalog Numbers 440R S13R2 440R S12R2 440R D22R2 440R D22S2 440R EM4R2 440R EM4R2D User Manual OriginalInstructions...

Страница 2: ...nformation 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 T...

Страница 3: ...ay Cat No 440R EM4R2D 11 SI Safety Relay Cat No 440R S12R2 11 Chapter2 Installation Mounting Dimensions 13 DIN Rail Mounting and Removal 13 Removal 13 Spacing 14 Removable Terminals 14 Enclosure Consi...

Страница 4: ...n 41 Indicators During Diagnostics 42 Chapter6 Pulse Testing Functions Pulse Testing for Inputs 43 CI Safety Relay 43 DI DIS and SI Safety Relays 44 Pulse Testing for OSSD Outputs 44 Chapter7 EMD Safe...

Страница 5: ...e Power Supply 66 Check Safety Device Inputs Step 3 66 Check Voltage free Contacts 67 Examine Pulse Test Waveforms 70 Effect of OSSD Test Pulses 70 Detect Off Pulses 71 Capacitance Effect 71 Long Wire...

Страница 6: ...ntal 89 Safety Inputs IN IN1 and IN2 90 Reset Input 90 B1 Input 91 Safety Outputs 91 Auxiliary Output 92 Single Wire Safety 92 AppendixB Regulatory Approvals Agency Certifications 93 Compliance to Eur...

Страница 7: ...relay 440R S12R2 SI safety relay You must have a basic understanding of electrical circuitry and familiarity with safety related control systems If you do not have this knowledge obtain the proper tr...

Страница 8: ...d for short circuits to the DC power supply short circuits to the DC common and shorts circuits between the two signals Single Wire Safety SWS A unique safety rated signal that is sent over one wire t...

Страница 9: ...r removable terminal blocks two on top and two on bottom The terminal blocks are keyed to confirm that they are installed in their proper slots See Terminal Block Removal and Replacement on page 87 St...

Страница 10: ...Cat No 440R S13R2 The CI safety relay has one dual channel input with three electromechanical relay outputs The CI safety relay can be configured for automatic or monitored manual reset by adjusting t...

Страница 11: ...ace of the relay configure the functionality and duration of the delay and jog The main input to the EMD safety relay is the single wire safety input With the SWS signal the EMD safety relay is design...

Страница 12: ...12 Rockwell Automation Publication440R UM013E EN P March 2017 Chapter 1 Overview Notes...

Страница 13: ...mount onto 35 mm DIN rails 35x7 5x1 mm EN 50022 35x7 5 1 Hold the top at an angle Figure 3 2 Slide down until the housing catches the rail 3 Swing the bottom down and push until the latch clips onto t...

Страница 14: ...tion in an industrial enclosure to reduce the effects of electrical interference and environmental exposure Pollution Degree 2 is an environment where normally only non conductive pollution occurs exc...

Страница 15: ...cation 1770 4 1 for additional installation requirements NEMA Standard 250 and IEC 60529 as applicable for explanations of the degrees of protection provided by different types of enclosure Prevent Ex...

Страница 16: ...16 Rockwell Automation Publication440R UM013E EN P March 2017 Chapter 2 Installation Notes...

Страница 17: ...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 ident...

Страница 18: ...WR Fault IN1 51 L61 Logic IN X14 X24 L11 L12 L11 Y32 S44 X14 X24 51 L61 S12 S22 S32 S42 A1 A2 S11 S12 PWR Fault IN1 IN2 Logic IN OUT L12 L11Y32 S34 13 14 23 24 LOGIC 0 1 2 3 4 5 6 7 8 DI 13 14 23 24 S...

Страница 19: ...IS 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 and DIS S34 Reset Input CI DI DIS and SI S42 Saf...

Страница 20: ...he top The CI safety relay which is backward compatible with the MSR127 monitoring safety relay has A1 at the top and A2 at the bottom Figure 7 Power Supply Connections Safety Inputs GSR relays can be...

Страница 21: ...e two sets of input terminals The DI and DIS safety relays can operate with only one device that is connected or with devices that are connected to both inputs Figure 9 Example Connections to 1 N C Me...

Страница 22: ...must always start the cascade Many cascadable devices Devices 3 6 or more can be included in the input circuit All devices must have the same voltage supply reference for instance 24V Com as the safe...

Страница 23: ...Guardmaster and similar safety mats can be connected to safety relays These mats use parallel metal plate technology Stepping on the mat shorts the top metal plate to the bottom metal plate With the p...

Страница 24: ...nd See publication 440F UM002 for further information on the Safedge edges IMPORTANT For fault detection purposes GSR relays must be configured for monitored manual reset when connected to Safedge saf...

Страница 25: ...etection purposes GSR relays must be configured for monitored manual reset when connected to Safedge safety edges IMPORTANT When using safety edges the DI and DIS safety relays must be set for AND log...

Страница 26: ...inals 34 and 44 are also pulse tested but these pulse tests are ignored as they are not used for short circuit detection These terminals are intended for devices with high capacitance For example use...

Страница 27: ...ure 17 shows an output with a suppression device 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...

Страница 28: ...ower reference 24V common In this example the safety function started by the CI or SI safety relay is expanded to the DI safety relay The safety functions monitored by the DI safety relay are expanded...

Страница 29: ...marizes the terminal connections of the auxiliary output Table 3 Auxiliary Outputs Reset and Monitor Input The CI DI DIS and SI safety relays have a reset monitoring input terminal S34 The expansion r...

Страница 30: ...monitored manual reset 4 Output devices are monitored along with a normally open push button The relay can be configured for automatic manual reset ormonitored manual reset 5 An EM or EMD expansion re...

Страница 31: ...ombined When a push button is used the reset occurs when the circuit is closed not when it is released Figure 21 Automatic Manual Reset Connections Monitored Reset Monitored reset requires a specific...

Страница 32: ...rated valves that do not have monitoring contacts The auxiliary output of the expansion relay must be the 24V DC source of the reset and monitoring input Figure 24 shows an example of the connections...

Страница 33: ...able operation is accomplished by connecting a jumper from terminal B1 to B2 Table 4 describes the off delay operation Table 4 Retriggerable Operation Jog Input When the EMD safety relay is configured...

Страница 34: ...34 Rockwell Automation Publication440R UM013E EN P March 2017 Chapter 3 Power Ground and Wire Notes...

Страница 35: ...o start the configuration mode and then turn to the position desired The status indicators on the front panel provide continuous feedback by flashing the switch positions Power cycling the device in a...

Страница 36: ...igures the relay for its reset and logic functionality Table 6 DI and DIS Logic Switch Example 1 Logic setting 1 or 5 If any of the inputs IN1 IN2 or L12 are ON then the safety relay refers to the res...

Страница 37: ...Example 1 The range setting is 3 starting with the Time set to 1 and the Time setting is 5 Then the off delay is 30s 50 15 seconds Example 2 The range setting is 6 starting with the Time set to 10 an...

Страница 38: ...y the settings by counting the blink rates of the status indicators Table 8 shows the indicator that flashes for the corresponding switch setting for each relay Figure 27 shows an example of the blink...

Страница 39: ...M 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 internal checks the relays are ready for operation I...

Страница 40: ...40 Rockwell Automation Publication440R UM013E EN P March 2017 Chapter 4 Configuration Notes...

Страница 41: ...uits 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 L1...

Страница 42: ...March 2017 Chapter 5 Status Indicators IndicatorsDuringDiagnostics See the following tables Table Page PWR Fault Status Indicator Is Solid Red 63 PWR Fault Status Indicator Is Flashing Red 64 PWR Fau...

Страница 43: ...he two input terminals Pulse Testing for Inputs Pulse testing for the inputs is 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 t...

Страница 44: ...pattern is shown in Figure 31 The pulse widths vary from 50 150 s The pulse pattern on terminal 14 is identical to terminal 34 and the pulse pattern on 24 is identical to 44 The pattern is repeated e...

Страница 45: ...mer starts when the logic link signal at terminal L12 turns off Once started the off delay timer runs for its full duration Figure 32 shows three cases of the timing sequences that can occur with this...

Страница 46: ...nk signal turns off A recoverable fault occurs The PWR Fault indicator is green and flashing red four times 13 The logic link turns back off The fault continues to exist 14 The off delay time has elap...

Страница 47: ...on until the logic link signal turns off If the logic link signal turns off during the timing cycle the safety outputs turn off immediately Figure 34 shows two cases of the timing sequences that can...

Страница 48: ...Then the jog can be restarted Figure 35 shows three cases of timing sequences During the on timer cycle the Logic IN indicator flashes at a 1 Hz rate During the off timer cycle the Logic IN indicator...

Страница 49: ...t terminal L12 is on The B1 signal turns on The jog on timer starts and the safety outputs turn on 13 The on timer elapses and the safety outputs turn off The off timer starts 14 During the off timer...

Страница 50: ...50 Rockwell Automation Publication440R UM013E EN P March 2017 Chapter 7 EMD Safety Relay Timing Functions Notes...

Страница 51: ...chapter show the internal 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...

Страница 52: ...er 8 Internal Circuit Block 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 Safet...

Страница 53: ...nitoring a device an E stop push button with mechanically operated contacts The CI safety relay is configured for monitored manual MM reset The output turns on if the E stop is released and the reset...

Страница 54: ...two devices having mechanical contacts and is set for monitored manual reset With the two devices closed the operator presses the reset button to energize contactors K1 and K2 The DI safety relay ver...

Страница 55: ...onitored manual reset Figure 45 With a SafetyMat and Device withOSSD Outputs Monitored Manual Reset AC Loads DIS Safety Relay Cat No 440R D22S2 Figure 46 shows the DIS safety relay with only one devic...

Страница 56: ...ty relay The single wire safety signal from terminal L11 to L12 instructs the EM safety relay to turn on and off The EM safety relay outputs mimic the DI safety relay outputs The DI safety relay monit...

Страница 57: ...e 49 EMD Off Delay Figure 50 shows the EMD safety relay that is configured for a 2 1 second on delay The single wire safety signal from terminals L11 to L12 instructs the EMD safety relay to turn on a...

Страница 58: ...seconds Figure 51 EMD Jog SI Safety Relay Cat No 440R S12R2 The SI safety relay monitors a gate interlock with mechanical contacts in Figure 52 The SI safety relay is configured for automatic reset Wh...

Страница 59: ...red to other devices over EtherNet IP with the catalog number 440R ENETR EtherNet IP module The CI safety relay does not have an optical link The catalog number 440R ENETR EtherNet IP module must be i...

Страница 60: ...00 Logix Designer Add on Profile AOP The catalog number 440R ENETR EtherNet IP module includes the Studio 5000 Logix Designer AOP for the DI DIS EM EMD and SI safety relays The AOP allows you to view...

Страница 61: ...roubleshoot your GSR relay you need the following tools Required Tools Medium sized Screwdriver For terminal screws to remove terminal blocks and to configure the switches on the front face of the rel...

Страница 62: ...ndicator is solid green Relay is functioning properly PWR Fault indicator solid green Flashing Go to Step 1 page 63 Go to Step 3 page 66 Go to Step 4 page 74 OUT indicator flashing green Output device...

Страница 63: ...ulted state See Table 12 on page 65 IMPORTANT For accurate diagnostics always start counting the flashing after the first pause The first cycle can be inaccurate PWR Fault status indicator Table 10 PW...

Страница 64: ...he wiring Remove the short circuit and cycle the power See additional information in Check Voltage free Contacts on page 67 CI DI DIS and SI A short circuit occurred and is no longer present or is pre...

Страница 65: ...per and the EMD functions properly Green with flashing red 3 times B1 B2 connection All B2 is connected to B1 after configuration The fault indication occurs when the EMD output is energized If the ou...

Страница 66: ...ted further Figure 59 24V Common to Protective Earth Connection IEC 60204 1 edition 5 1 Section 6 1 allows a SELV supply to be used when a PELV is not practicable due to physical or operational condit...

Страница 67: ...the device contacts open measure the voltage at the pulse testing outputs with a digital multimeter as shown in Figure 60 The voltage must be 18 19V on both pulse testing outputs of the CI safety rel...

Страница 68: ...the safety device do not operate consistently the safety device must be replaced Figure 61 Check the CI Safety Inputs with the Device Contacts Closed 3 If a significant difference in voltage levels ex...

Страница 69: ...close to the values measured at terminals S11 and S21 Figure 63 Typical Voltage Measurements of the DI DIS and SI Relays with Contacts Closed 3 If a significant difference in voltage levels exists see...

Страница 70: ...pulses are generated on terminals S11 and S21 The waveforms which are shown in Figure 64 and Figure 65 must always be present on their respective relays the test pulses cannot be turned off or adjuste...

Страница 71: ...ance Effect Capacitance leakage of the input wiring to ground causes a deformation of the leading edge of the pulses Figure 66 shows the deformation with 1 F on each signal to ground With this high ca...

Страница 72: ...aximum input resistance of 900 ohms Table 16 shows the resistance of wire sizes that are typically used to connect to safety devices For example if you used 200 m 656 2 ft of a 4 wire cable that conta...

Страница 73: ...Figure 68 Figure 68 GSR Relays Have Infinite Simultaneity Discrepancy Multiple channel Cycling GSR relay inputs are not satisfied if one channel turns ON and OFF multiple times followed by the closure...

Страница 74: ...safety SWS signal at terminal L12 The SWS output is terminal L11 Check the Logic IN status indicator SWS Connections L11 and L12 CI and SI safety relays only have SWS outputs terminal L11 they do not...

Страница 75: ...by a 500 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 multimet...

Страница 76: ...reset button is pressed measure the voltage at terminal S34 point 1 as shown in Figure 73 If 24V is not present when the reset button is pushed then check the other connections points 2 7 in the circu...

Страница 77: ...relay inputs are satisfied Applications with OSSD Outputs and Test Pulses If your application uses an OSSD output with test pulses as the source of my reset signal do the GSR relays execute the reset...

Страница 78: ...epeat the checking on the second channel 23 24 Figure 75 Measure the Terminal Voltage Step Description 1 The voltage at 13 must be the same as the supply voltage If not check for an open circuit broke...

Страница 79: ...properly and the GSR relay must be replaced Figure 76 Measure the Contact Resistance OSSD Output Issues If the OUT status indicator is solid green but the output device that is connected to terminal...

Страница 80: ...nts for one output channel terminal 34 Repeat the checking on the second channel terminal 44 The terminal connections from 34 and 44 to S1 and S2 can be reversed Step Description 1 The voltage at 14 m...

Страница 81: ...t pulse appears on all four terminals simultaneously Step Description 1 The voltage at 34 must be slightly less than the supply voltage If not then the DIS relay must be replaced 2 The voltage at S2 m...

Страница 82: ...s are about 110 s wide Each channel is tested individually as shown in Figure 81 The individual pulses are about 50 s wide These pulse widths are provided for informational purposes the pulses cannot...

Страница 83: ...e Y32 output must be ON This is true for both faulted and running states See Check the Y32 Outputon page 84 TIP For more information on auxiliary outputs see Auxiliary Output on page 29 Step Descripti...

Страница 84: ...Figure 83 Measure Contact Resistance of Aux Output Terminals ChecktheY32Output When OUT status indicator is OFF terminal Y32 does not turn ON Or when the safety outputs are OFF the Y32 output must be...

Страница 85: ...of X32 point 1 as the source for the monitoring circuit The voltage must be around 23V DC If it is 23V then follow the circuit and check the voltage at each of the remaining points 2 6 If X32 measures...

Страница 86: ...the same as the single wire safety waveform The waveform is present only when the output of the EMD expansion relay is ON With a digital multimeter the voltage measures 8 9V DC If the B1 status indic...

Страница 87: ...minal blocks Use a screwdriver as a lever to remove the blocks As shown in Figure 87 insert the screwdriver into the slot and pry up Figure 87 Terminal Block Removal Terminal Block Replacement The ter...

Страница 88: ...l The series firmware revision number and manufacturing date code are identified on the safety relay label as shown in Figure 89 Figure 89 Product Label Series and Revision Identification Old Product...

Страница 89: ...pper that withstands 75 C 167 F Terminal Screw Torque N m lb in 0 4 4 Power Supply Voltage Range 24V DC PELV SELV 0 85 1 1 x rated voltage Power On Delay s 5 5 Power Consumption W 3 5 2 5 2 3 5 3 5 2...

Страница 90: ...on Yes Yes Test Out Pulse Duration ms 2 5 1 5 3 1 5 3 Period ms 14 13 6 13 6 Off Pulse Accepted for OSSD Setting Without Declaring the Input as OFF Max ms 3 1 2 2 2 2 Recovery Time Min ms 30 30 Revers...

Страница 91: ...N O delayed 2 N O Thermic CurrentIth 1 x 6 A 1 x 6 A Fuses output external 6 A slow blow or 10 A quick blow 6 A slow blow or 10 A quick blow Switched Current Min mA 10 10 Switched Voltage Min V 10 10...

Страница 92: ...Type 1 N C 1 PNP 50 mA max Attribute 440R S13R2 CI 440R D22R2 DI 440R D22S2 DIS 440R EM4R2 EM 440R EM4R2D EMD 440R S12R2 SI Wiring Terminal Output L11 Input L12 Continuous Output Current Max mA 50 ON...

Страница 93: ...atibility EMC and the following standards EN 61000 6 4 Generic Standards Emission Standard for Industrial Environments EN 61000 6 2 Generic Standards Immunity for Industrial Environments This product...

Страница 94: ...the proof test interval PTI is assumed Components failure rates are according to SN29500 SIL Rating Safety relays meet the requirements in Table 27 in accordance with IEC EN 61508 and IEC 62061 Table...

Страница 95: ...ication Ethernet 59 compliance European Union EU directives 93 configuration 35 process 38 connect power supply 20 considerations enclosure 14 contact resistance 84 voltage free 67 cycling multiple ch...

Страница 96: ...51 53 DI 10 36 51 54 DIS 10 36 51 55 EM 11 52 56 EMD 11 37 45 52 57 SI 11 52 58 H hardware features 9 heat prevent excessive 15 I indicator PWR fault 63 flashing red 64 green with flashing red 65 sol...

Страница 97: ...ormance level 94 power 17 power supply check 65 connect 20 ground 66 powerup indicators 41 prevent excessive heat 15 process configuration 38 product label current 88 old 88 pulse testing functions 43...

Страница 98: ...63 flashing red 64 green with flashing red 65 solid red 63 status indicators 9 41 diagnostics 42 normal operation 41 powerup 41 steps troubleshooting 62 Studio 5000 Logix Designer add on profile AOP 6...

Страница 99: ......

Страница 100: ...se the code to route your call directly to a technical support engineer http www rockwellautomation com global support direct dial page Literature Library Installation Instructions Manuals Brochures a...

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