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Next Generation Guardmaster Safety Relay

1. 24V DC f o a p I _ D5 AL AZ spszszse z 1 a szsasese 37 a S12 S22 B2ss4 si2sz2aP IKL Al ASUSA Al AZ Al AZSUSZ Al A2 B1 B2 Al A2 SILSZ Al A2 PZ Om Omarart Ormrat Omarar Orrar O para O Parar O ma Om Om Osi Om Om Owe Ome One O ma O ua ou Oten p Orden f O rogem Oten h O aN O Loacm Oar Qar Oar Cowmcantig h OOF O geas 24V DC Com 116 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Notes Rockwell Automation Publication SAFETY WD001F EN P November 2015 117 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 fo
2. Green Black Red Blue 100S C43EJ04BC 100S C43EJO4BC 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 51 Next Generation Guardmaster Safety Relay GSR Global E stop and Zone Control Circuit Components e GuardShield light curtains e SensaGuard non contact interlock switch e Bulletin 440F MatGuard safety mats e Bulletin 800F E stops e DI safety relays e Bulletin 100S contactor Circuit Status The light curtains are unobstructed The safety gate is closed The E stops are reset and the safety mat is unoccupied The outputs of all three DI safety relays are off K1 K6 are ready to be energized Operating Principle The DI is chosen as the safety relay for its zoning capability The two E stops operate globally turning off relays 1 2 and 3 STARTING Press the reset button for relay 1 to energize its outputs Then press the reset button for relays 2 and 3 to energize their respective outputs STOPPING Obstructing the light curtain A or stepping on the safety mat turns off the outputs of relay 2 while leaving the outputs of relay 1 and relay 3 energized Obstructing the light curtain B or opening the safety gate with the SensaGuard interlock turns off the outputs to relay 3 while leaving the outputs of relay 1 and relay 2 energized Pressing either E stop shuts down all three relays Fault Detection Upon successful completion of internal checks on power up the DI relays chec
3. 24V DC Status Signals y Input Input Output SensaGuard 1756 IB16 1756 IV16 1756 OB16 cee T 440N Z21SS2HN 1769 IQ16 1769 IV16 PLC 1769 OB8 440N Z21 3 1746 IB16 1746 IV16 Processor 1746 OB4 1734 IB4 1734 IV4 1734 OB2 1793 IB6 1793 IV16 1793 OB4 i E Stop oi 800FM MT44 i 800F MX02S 889D P88RT M19 Ich l fe Q olori L1L2L3 f j Locic__ i U CE 8 3 Shorting Plugs DI 7 4 Device Patchcord 6 5 440R D22R2 889D F8ABDM 2 889D 81RU DM Homerun Patchcord tan 7 889M R1 9RMMU 2 Bulk Head i g alat eae use with bulkhead Receptacle Elen or 888M F19AE 1 Homerun Cordset 889M R19RM 2 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 39 Next Generation Guardmaster Safety Relay GSR Safety Valve Air Supply Release Circuit Components e GuardShield light curtain e Bulletin 800F E stops e DIsafety relay e Pneumatic safety valve Circuit Status The light curtain is clear and the E stop is released The DI safety relay outputs are off and the pneumatic valve is closed The DI safety relay Logic is set to 2 IN1 AND IN2 OR L12 with monitored manual reset Operating Principle STARTING Press the reset button to energize the output contacts of the safety relay The two solenoids in the valve energize and allow air to flow from the Air Supply to the Air Outlet STOPPING Pressing the E stop or blocking the light curtain de energizes the safety outputs o
4. Next Generation Guardmaster Safety Relay GSR Speed Status Only Circuit Components e Bulletin 872C proximity sensors e GLP safety relay Circuit Status The GLP safety relay has a Logic setting of 8 speed status only a Safe Limited Speed SLS1 setting of 0 0 5 Hz 10 1 seconds and a maximum SLS2 Time speed setting of 5 200 Hz TIP Start the GLP configuration from 9 to configure for speed status only Operating Principle The GLP safety relay is used to provide outputs that are a function of the speed the proximity sensors detect and the thresholds set by the SLS1 and SLS2 Time switches When the proximity sensors detect speed below the SLS1 setting all GLP outputs are OFF When the proximity sensors detect speed above the SLS1 setting and below the SLS2 Time setting the 51 and L61 outputs turn ON When the proximity sensors detect speed above the SLS2 setting the L11 X14 X24 and Y32 outputs turn ON The 51 and L61 outputs remain ON When the proximity sensors detect speed below the SLS2 setting the L11 X14 X24 and Y32 outputs turn OFF immediately The 51 and L61 outputs remain ON When the proximity sensors detect speed below the SLS1 0 5 Hz setting the GLP safety relay starts the SLS1 timer After 10 1 seconds the GLP safety relay turns off 51 and L61 Fault Detection Upon power up the GLP safety relay performs internal checks If the checks are completed safely the GLP safety relay reads
5. 66 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 31 Hazardous Location Hazardous Location U S Class ILI Div 1 2 European Zone 0 1 2 EExia IIB 440F Safedge Pressure Sensitive Sensing Edge e g 440F EAAAA01000 R1 R3 1K 1492 JD3RB102 R2 R4 10K 1492 JD3RB103 24V DC Non hazardous Location aaa a Nt L1L2L3 I lt 1 Galvanic Isolating Switching Amplifier 800F MX025 i PowerFlex R S T 937TH DISRS DC1 j a RI o 1 1 1 1 Settings S1 Il S2 3 DIN Rail Connections 937TH DISRS DC1 Status To PLC I 1 Settings 1 S1 Il 1 S2 i s3 1 S4 I DIN Rail Connections 1 I S1 Inverted Output S2 Output 2 Follows Output 1 I S3 Enable Line Fault Detection S4 Not Used 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 67 Next Generation Guardmaster Safety Relay GSR PowerFlex Drive Multiple Gate Access Circuit Components e Trojan 5 GD2 tongue interlock switch e MT GD2 latch release e DIS safety relay e PowerFlex 70 drive with DriveGuard Circuit Status One of the gates is open The safety outputs of the DIS safety relay are de energized The PowerFlex with DriveGuard is de energized and not enabled The motor is off The DIS safety relay has a Logic setting of 6 IN1 AND IN2 OR L12 with automa
6. The proximity sensors are rated for 400 Hz The K1 and K2 contactors are off The GLP safety outputs X14 and X24 the single wire safety output L11 and the auxiliary output Y32 are OFF The motor is off TIP Start the GLP logic configuration from 0 to configure X14 and X24 for use as safety outputs Operating Principle This is a cascaded safety system using the Guardmaster Safety Relay GSR single wire safety connection L11 to L12 Pressing the E stop initiates a safety stop command that turns off the contactors and the drive However by pressing the Gate Unlock Request button you can turn off the motor and get access to the safety gate while leaving K1 and K2 energized STARTING Press the Reset button on the SI to energize K1 and K2 and to enable the GLP through the single wire safety connection L11 to L12 Then press the Reset and Gate Lock Request button to lock the gate and turn the GLP safety outputs ON Press the Start button to turn the motor ON STOPPING A safety stop is initiated by either e Pressing the E stop which turns off K1 and K2 and initiates the Gate Unlock Request function in the GLP safety relay e Pressing the Gate Unlock Request which leaves K1 and K2 energized and initiates a Cat 1 stop to the PF70 drive When the GLP safety relay initiates a stop the Y32 output turns OFF and initiates a stop command to the drive When the proximity sensors detect speed below the safe limited speed for 5 05 sec
7. a1 xa xa 51 161 v321554 544 LOGIC SLS1 SLS2 TIME 0 0 1 1 1 9 2 2 2 8 3 3 3 GLP 7654 654 654 440R GL2S2P 0000 Brown Pwr Eo We oe Yellow OSSD Brow Blac Blac K DD im Proximity Sensors 872C D8NP18 E5 Gate Unlocked 440G TZS21UPRH 889D F8AC 2 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 79 Next Generation Guardmaster Safety Relay GSR Guard Locking Interlock with High Current Solenoid Circuit Components e Bulletin 440G MT solenoid guard locking switch e Bulletin 871TM proximity sensors e GLP and EM safety relays e PowerFlex 525 drive Circuit Status The gate is closed and locked The GLP safety relay has a Logic setting of 1 Category 1 Stop with Logic IN OFF a Safe Limited Speed SLS1 setting of 0 0 5Hz and a Maximum SLS2 speed setting of 0 unlimited The proximity sensors detect speed below 0 5Hz The single wire safety output L11 and the auxiliary output Y32 are OFF Terminals X14 amp X24 are configured for pulse testing TIP Start the GLP configuration from 9 to configure X14 and X24 for use as pulse testing TIP Since the 440G MT solenoid switch requires 540 mA an interposing relay CR1 must be used A diode must be connected across the solenoid of CR1 as shown in Figure 38 Operating Principle STARTING Press the Lock and Reset Request The Y32 output and SW
8. 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 63 Next Generation Guardmaster Safety Relay GSR Hazardous Location Circuit Components e Bulletin 440F MatGuard safety mats e Bulletin 800F E stops e Bulletin 937TH isolator e DIS safety relay e PowerFlex 525 drive Circuit Status The DIS safety relay logic is set to 2 IN1 AND IN2 OR L12 with monitored reset The safety mat is connected to input 1 of the DIS S12 and 22 through the galvanic isolator The E stop is connected to input 2 of the DIS safety relay S32 and 42 The gate is closed and the E stop is released The DIS safety outputs are off The PowerFlex 525 drive is powered but disabled The motor is off Operating Principle The galvanic isolator limits energy to the MatGuard which is considered a simple apparatus in the hazardous location The DIS safety relay checks the outputs of the galvanic isolator upon power up and each time the mat E stop is actuated STARTING Press the Reset button to turn the DIS safety outputs 14 24 34 44 and L11 ON This enables the PowerFlex 525 drive Press the Start button to turn the motor ON STOPPING Normal production stops are performed by pressing the Stop button Stepping on the safety mat or pressing the E stop initiates a safety stop the motor coasts to a stop Fault Detection The DIP switch setting of the galvanic isolator allows for open and short circuit detection of the safety mat
9. 3 seconds and a Time setting of 6 60 The delay is 1 8 seconds 60 of 3 seconds TIP Start the GLT configuration from 0 to generate test pulses at 11 S21 14 and 24 Operating Principle The GLT safety relay requires both the E stop to be released and the gate to be closed before the reset can take place Once the gate is opened or E stop is pressed it must remain in that state during the timing cycle or connect B2 to 24V DC to allow the GLT safety relay timer to retrigger STARTING Press the Reset button The GLT safety relay turns on Y32 14 24 51 and L61 The K1 and K2 contactors turn on their loads Press the Start button to turn on the motor STOPPING Opening the gate or pressing the E stop initiates a stop sequence GLT outputs Y32 14 and 24 turn off immediately The K1 and K2 contactors turn off and the PowerFlex 525 drive executes its stop function After 1 8 seconds the 51 and L61 outputs turn off and disable the PowerFlex 525 drive Fault Detection Upon power up the SI safety relay GLT safety relay and PowerFlex 525 drive perform internal checks The MC2 switch has redundant mechanical contacts that use the pulse testing of the SI to check for short circuit conditions The GLT safety relay uses pulse testing to check for short circuit conditions in the E stop circuits The 14 and 24 outputs of the GLT safety relay are pulse tested to check for short circuit conditions The reset circuit S44 of the GLT safe
10. Since the Bulletin 937TH isolator has a hardware fault tolerance of zero two are used to achieve single fault tolerance The isolator DIP switches must be set for Line Fault Detection I and inverted II output The Bulletin 1492 resistors are required to detect line faults These resistors must be located as close as possible to the safety mat Ratings The safety function that is initiated by the safety mat meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require up to Performance Level PLd per ISO 13849 1 2006 The safety function that is initiated by the E stop meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require up to Performance Level PLd per ISO 13849 1 2006 This circuit executes a Stop Category 0 See publication 937TH WD001_ EN P for more safeguarding examples with the galvanic isolator 64 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 30 Hazardous Location Hazardous Location US Class II IIl Div 1 2 European Zone 0 1 2 EExia IIB 440F M2030BYNN Parallel Plate Safety Mat R1 R3 1K 1492 JD3RB102 R2 R4 10K 1492 JD3RB103 24V DC E Stop Non hazardous Location 800FM MT44 lt gt L1 L2 L3 Galvanic Isolating Switching Amplifier 800F MX02
11. contacts of K1 and K2 close to hold the circuit energized across the Start button STOPPING Pull the Lifeline cable or press the E stop button on the Lifeline switch to de energize the outputs of the DI safety relay and turn off the motor To restart the motor make sure that the area is clear of hazards pull out the E stop button if pressed and rotate the reset knob to the Run position Then press the Start button to start the motor As an alternative the motor can be stopped by pressing the Stop push button It can then be restarted by pressing the Start push button Fault Detection Upon successful completion of internal checks on power up the DI safety relay checks its input circuits With both Lifeline switches reset the DI safety relay checks the output contactors through the K1 K2 34 circuit If the contactors are off the DI safety relay energizes its outputs and turns on the contactors which turn on the motor A short or open circuit fault in the Lifeline cable pull switches is detected by the DI safety relay If either the K1 or K2 faults in the energized state the other contactor stops the motor and the DI detects a fault on the next attempt to restart An internal fault in the DI safety relay is detected by itself Depending on the type of fault the result is de energization of the K1 and K2 contactors or prevention of restart 36 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster
12. operation of the safety gate or E stop device The safety system controls contactors K1 and K2 The machine control system and the safety system control contactor K2 This increases the probability of performance of the safety function because the K1 contacts are less likely to weld due to the diversity of expected wear out times 24 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety function that is initiated by the Trojan T15 and ELF GD2 safety gate interlocks and the Bulletin 800F E stop meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO13849 1 2006 This circuit executes a Stop Category 0 Figure 10 Interlock Switch Multiple Gate Access 24V DC Trojan T15 GD2 440K T11287 ELF GD2 440K E33046 E stop 800FM MT44MX02L Stop 800FM S v Input PLC Output O J 1756 IB16 Processor 1756 OW16l 1769 IQ16 1769 OW8 1746 IB16 1746 OW4 1734 1B4 1734 OW2 1793 IB6 1793 OW4 1005 09EJ14BC E4MX01 11 enh 12 Mig 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 25 Next Generation Guardmaster Safety Relay GSR SensaGuard Interlock Switches Circuit Components e SensaGuard non contact interlock switches e CI safety relay e Bullet
13. relay from turning on outputs 13 14 and 23 24 Ratings The safety function that is initiated by the series connection of the Bulletin 800F E stop buttons meets the safety performance requirements of SIL CL 2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO13849 1 2006 The Category 3 rating requires the redundant usage of K1 K10 to de energize the machine actuators and the contactors must be monitored by the safety system This circuit executes a Stop Category 0 12 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 4 Expansion Modules with Immediate and Delayed Outputs 24V DC Reset i 800FM F6MX10 O O K 6 K7 K8 Kk K10 k ke G QKA J J Ea bs Eun dE RANGE a TIME an 54 KA AAOR EM4R2D fn eee 700S DCP310Dz24 KA Ko with Rae TSI loo Fz ia KIOJA 100S 1005 C43EJ14BC CO9EJ14BC 24VC DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 13 Next Generation Guardmaster Safety Relay GSR Safety Motion Delayed Braking Circuit Components e Bulletin 800F E stops e SIand EMD safety relays e Kinetix GuardMotion with Resistor Braking Module RBM Circuit Status The E stop is reset The outputs of the safety relay are open and the motor is off The EMD Range switch is set to 1 1
14. the DI safety relay checks the K1 K2 K3 K4 and TLS1 monitoring circuit when the reset button is pressed If these checks are OK the output energizes The Reset Button is linked to the delayed Y32 output to supply 24V for reset only when delay time has lapsed If any of the DI safety relay contacts faults to the ON state the redundant outputs stop the motor The fault is detected by the Y32 K1 K2 K3 K4 and TLS1 monitoring circuit on the next attempt to restart If the Gate is not interlocked by the TLS1 solenoid or one of the 700S control relay faults to the ON state the DI safety relay will detect the fault in the Y32 K1 K2 K3 K4 and TLS1 monitoring circuit on the next attempt to reset An additional interlock Trojan T15 is added to the gate to prevent potential single point failures that are related to tongue style interlocks 48 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety function that is initiated by the gate interlocks and the E stop meets the safety performance requirements of SIL CL3 per IEC 62061 2005 and has a Category 4 structure that can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 This circuit executes Stop Category 0 Figure 22 Guard Locking with DI EMD Safety Relays 24V DC Reset 800FM F6MX10 m CR1 Gate 800FM MT44 Release E _ 800F x02S oO T TLS1 GD
15. 01 Me I DIS 54 E F 440R D22S2 H L1 L2 L3 L1 L2 L3 PowerFlex70 R S T with DriveGuard PowerFle 70x RJ S T with DriveGuard DeviceNet Gate Control Power Supply DeviceNet Gate Control Power Supply Control Circuit 1734 1B4 1734 PDN 1793 IB6 1794 ADN 24VC DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 71 Next Generation Guardmaster Safety Relay GSR Micro 400 Light Curtain Circuit Components e Micro 400 light curtain e MSR41 controller module e Bulletin 800F E stop e DIS safety relay e Bulletin 100S contactor Circuit Status The light curtain is clear and the E stop is released The MSR41 controller outputs are energized The safety outputs of the DIS safety relay are OFF The motor is off The DIS safety relay is ready for reset The DIS safety relay has a Logic setting of 2 IN1 AND IN2 OR L12 with monitored manual reset Operating Principle STARTING Press the reset button to turn the DIS safety outputs ON Press the Start button to turn the motor ON The Start Stop circuit operates only K2 as a planned maintenance feature K1 does not switch on motor current but it can switch off the motor current when a demand is placed on the safety system STOPPING Normal production stops are performed by pressing the Stop button A safety stop can be accomplished by obstructing the light curtain or by pressi
16. AND IN2 OR L12 with monitored reset The Trojan T15 switch is connected to input 1 of the DIS S12 and 22 through the galvanic isolator The E stop is connected to input 2 of the DIS safety relay S32 and 42 The gate is closed and the E stop is released The DIS safety outputs are off The PowerFlex 525 drive is powered but disabled The motor is off Operating Principle The galvanic isolator limits energy to the interlock switch which is considered a simple apparatus in the hazardous location The DIS safety relay checks the outputs of the galvanic isolator upon power up and each time the gate E stop is actuated STARTING Press the Reset button to turn the DIS safety outputs 14 24 34 44 and L11 ON This enables the PowerFlex 525 drive Press the Start button to turn the motor ON STOPPING Normal production stops are performed by pressing the Stop button Opening the gate or pressing the E stop initiates a safety stop the motor coasts to a stop Fault Detection The DIP switch setting of the galvanic isolator allows for open and short circuit detection of the Trojan switch circuits Since the Bulletin 937TH isolator has a hardware fault tolerance of zero two are used to achieve single fault tolerance The isolator DIP switches must be set for Line Fault Detection I and non inverted II output The Bulletin 1492 resistors are required to detect line faults These resistors must be located as close as possible to the interlock swi
17. Bulletin 800F push buttons e Bulletin 100S contactor Circuit Status The first gate is open The second and third gates are closed The CI safety relay 12 and 22 inputs are open due to the open gate and therefore the CI safety outputs are open The machine control PLC has a 24V auxiliary signal at terminal 10 from the first gate because the gate is open The second and third auxiliary signals are off as their gates are closed The PLC also has an auxiliary signal from the CI safety relay that indicates that the safety system is not ready The motor is off Operating Principle STARTING Closing the first gate satisfies the input of the CI safety relay The CI safety relay verifies that both K1 and K2 contactors are off and energizes its safety outputs Pressing the Start button starts the motor The Stop Start circuit is not part of the safety system and can be replaced by the machine control system for example a PLC STOPPING Press the Stop button to turn off the motor without affecting the status of the safety system Opening any of the gates causes the safety system to stop the motor Fault Detection Upon successful completion of internal checks on power up the CI safety relay checks for input signals If OK the CI safety relay checks the K1 K2 S34 monitoring circuit to determine whether both contactors are off If one of the contactors gets stuck on the other contactor de energizes the motor and the CI safety relay detects the
18. Fault Reset switch clears a fault within the MAB The SI performs pulse testing of the E stop button The SI generates a single wire safety output L11 to the GLT safety relay L12 to initiate a shutdown Outputs 14 and 24 of the GLT are pulse tested to check for short circuit conditions The reset circuit S44 of the GLT safety relay checks the status of the K1 and K2 contactors Ratings The safety function meets the performance requirements of SIL3 per IEC 62061 2005 has a Category 4 structure and can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 The safety function performs Stop Category 0 Figure 49 Guard Locking with Time Delay 24V DC Fault Reset 46 44 45 2 3 24 RST Closed amp Locked MAB z i an G 2 2 442G MABH L 442G MABR UT C03 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 103 Next Generation Guardmaster Safety Relay GSR Guard Locking with Time Delay and Stop Cat 1 Circuit Components e TLS ZR guard locking switch e GLT safety relay e PowerFlex 525 drive Circuit Status The gate is closed and locked The TLS ZR is a power to release guard locking switch The motor is off The GLT safety relay is ready for reset The GLT safety relay has a Logic setting of 3 Stop Cat 1 with Logic IN OR IN1 a Range setting of 4 10 seconds and a Time setting of 6 60 The delay is 6 seconds 60 of 10 seconds With no c
19. Next Generation Guardmaster Safety Relay GSR Fault Detection Upon power up the safety devices perform internal checks The GLP safety outputs are pulse tested to check for faults The GLP safety relay uses redundant proximity sensors that must be mounted on independent fixtures The PowerFlex 525 drive requires two safety signals to enable the drive The SI safety relay monitors K1 and K2 The GLP safety relay monitors K3 and K4 OVERSPEED If the proximity sensors detect a speed above the SLS2 200 Hz when the gate is locked or above 3 Hz when the gate is unlocked the auxiliary output Y32 the safety outputs X14 amp X24 and the single wire safety output L11 turn off Ratings The safety functions meet the safety performance requirements of SIL CL2 per IEC 62061 2005 and have a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO13849 1 2006 This circuit executes a Stop Category 0 for fault conditions Figure 41 Safe Limited Speed with Logic In Guard Locking and Proximity Sensors 440G LZS21SPRA L1 L2 L3 PowerFlex R S T 525 11 24V DC Reset amp Gate Lock Request 7 i Gate 9 am K1 gt r Unlock F Request LOGIC SLS1 SLS2 TIME RESET __ i 0 0 5 5 AM 9 MM 3 7 a a SI GLP 7654 65 65 440R S12R2 440R GL2S2P Status 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P
20. Note 2 In most of the following examples that show dual channel applications one interlock switch is shown switching both channels one contact set per channel If foreseeable damage for example at the actuator mounting point could allow the guard to be opened without operating the switch then two separate switches are required The electrical principle of the circuit remains the same Note 3 In most cases the circuits are shown with the guard door closed and ready for motor starting by operating the normal start control It must be possible to start the machine only by voluntary actuation of the control that is provided for the purpose see ISO 12100 2 4 11 8 For the purposes of these examples the use of a conventional contactor latching circuit has been assumed If not then a restart interlock is required to prevent an automatic or unintended starting of the motor when the guard is closed For example a Minotaur safety relay with a momentary action push button installed in the output to monitor the circuit can be used to achieve this protection If the guard is designated as a Control Guard see ISO 12100 2 5 3 2 5 these requirements do not apply However the use of control guards is allowed only under certain conditions including e A control guard can be used only where there is no possibility of an operator or part of their body staying in or reaching into the danger zone while the guard is closed e The control guard mus
21. November 2015 87 Next Generation Guardmaster Safety Relay GSR Stop Motion with Guard Locking and E stop Circuit Components e Bulletin 440G LZ guard locking switch e Bulletin 872C proximity sensors e GLP safety relay Circuit Status The gate is closed and locked The GLP safety relay outputs X14 and X24 are OFF The PowerFlex 525 drive is disabled and the motor is OFF The GLP safety relay is ready for reset The GLP safety relay has a Logic setting of 5 Stop Motion with 1 10 seconds Unlock Delay a Frequency Measuring Time SLS1 setting of 1 1 Hz 5 05 seconds and a SLS2 Time setting of 3 40 of the Delay TIP Start the GLP configuration from 0 when using Logic settings 5 The TLS ZR guard locking interlock can replace the 440G LZ guard locking switch using the same wiring connections Operating Principle When the proximity sensors detect speed below 1 Hz the SLS1 setting the GLP safety relay starts the timer set by SLS1 When the 5 05 seconds expire the GLP safety relay turns on Y32 X14 X24 and L11 which are not used in this example and starts the unlock timer The unlock timer is 4 seconds 40 of 10 seconds which is determined by the Logic switch setting and the SLS2 Time setting After 4 seconds the GLP safety relay unlocks the 440G LZ guard locking switch Fault Detection Upon power up the 440G LZ guard locking switch and GLP safety relay perform internal checks The 440G switch checks its OSSD
22. OSSD outputs turn off The CI also performs internal checks on power up It then checks for input signals If OK the CI checks the K1 K2 S34 monitoring circuit to determine whether both contactors are off If one of the contactors gets stuck on the other contactor will de energize the motor and the CI safety relay will detect the fault at the next attempt to start the motor The contactors have mechanically linked auxiliary contacts to help ensure fault detection of the contactors Ratings The safety performance of this circuit meets the requirements of SIL CL 3 per IEC 62061 2005 and has Category 4 structure and can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 The SensaGuard interlocks are designed to meet Category 4 when connected in series The CI is rated to Category 4 The design and connection of the contactors meets category 4 This circuit performs a Stop Category 0 26 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 11 SensaGuard Interlock Switches 24V DC bi Shown Open Start 800FM i oar F3MX10 Blue Green White Aux Stop 800FM E4MX01 18mm Cylindrical Plastic SensaGuard 440N Z21S26H ee Machine Control PLC Input Auxiliary 1756 IB16 Signals 1769 1Q16 to Machine 1746 IB16 1792 1B16 0 1734 1B4 11 1793 IB6 2 or similar 3 Control 24V DC
23. PLC or Drive ipo Jog Button 800FM MT64 800F X02S RANGE 04 wok K1 i Mirror 65 Contacts 800FM EMD K2 F2MX10 ot fen 440R EM4R2D re plete Tas 100S D1405ZJ33LC 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 45 Next Generation Guardmaster Safety Relay GSR DI EMD Safety Relays with Enabling Jog System Circuit Components e Bulletin 440G MT guard locking switch e Bulletin 440 GripSwitch enabling switch e DIand EMD safety relays e PowerFlex DriveGuard Circuit Status The Bulletin 440J enabling switch is held by two MT GD2 interlocks The DI safety outputs are closed The PowerFlex Enable and Safe off option are energized The EMD safety outputs are de energized The DI Logic is set to 5 IN1 OR IN2 OR L12 with automatic reset The EMD Range switch is set to 8 Jog 10 seconds and the Time is set to 2 20 therefore the Jog occurs for 2 seconds The motor is ready to run Operating Principle The EMD safety relay is chosen for its ability to perform timing functions In this case the EMD safety relay is configured to jog the PowerFlex drive with one pulse having a duration set between 0 5 10 seconds Adjustments to the pulse are made by potentiometers on the EMD safety relay While in the MT GD2 holder the Enabling switch is disabled and the drive can be controlled by the machine control system The machine control system disables the Jog switch STARTING As shown the PowerFlex drive is
24. a Stop Category 0 34 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 15 Two Light Curtains Point of Operation Control 24V DC Start 800FM H Receiver F3MX10 Transmitter Stop 800FM E4MX01 440L P4KLO960YD 1 889D F4AC 2 889D F8AC 2 Transmitter Receiver Aux Signal to PLC 440L P4KLO960YD 889D F4AC 2 889D F8AC 2 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 L1L2 L3 35 Next Generation Guardmaster Safety Relay GSR Lifeline Circuit Components e Lifeline cable pull switches e DIsafety relay e Bulletin 800F push buttons e Bulletin 100S contactor Circuit Status Both Lifeline cable pull switches are taut and reset their contacts are closed The DI Logic setting is 6 IN1 AND IN2 OR L12 with automatic reset The DI safety relay is energized as its inputs and monitoring circuits are satisfied The motor is off and ready to run Operating Principle Two cable pull switches are used to help protect an area from 10 70 m long Auxiliary lights provide indication as to which switch has been actuated to stop the motor The difference between the two switches is the conduit thread and shown for examples purposes STARTING Press the Start button to energize contactors K1 and K2 The motor starts and the two normally open
25. executes its stop function After 3 1 seconds the 51 and L61 outputs turn off and disable the PowerFlex 525 drive Fault Detection Upon power up the SI safety relay GLT safety relay and PowerFlex 525 drive perform internal checks The Ferrogard switch has redundant mechanical contacts that use the pulse testing of the SI to check for short circuit conditions The GLT safety relay uses pulse testing to check for short circuit conditions in the E stop circuits Outputs 14 and 24 of the GLT safety relay are pulse tested to check for short circuit conditions The reset circuit S44 of the GLT safety relay checks the status of the K1 and K2 contactors 114 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The PowerFlex 525 drive safety function meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The PowerFlex 525 drive safety function performs Stop Category 1 The safety function that is completed by the contactors meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The safety function performs Stop Category 0 Figure 55 Stop Cat 1 by Gate or E stop 24V DC Ferrogard FRS21 GD2 440N G02149 8
26. motor performs a coast to stop Fault Detection Upon power up the safety devices perform internal checks The OSSD outputs of the MSR42 module are pulse tested to check for crossfaults The OSSD outputs of the SensaGuard switch are pulse tested to check for crossfaults The single wire safety signal L11 to L12 tests for faults to power and ground when active The E stop signals are pulse tested to check for crossfaults The mechanically linked contacts of the Bulletin 100S contactor verify that the contactors are off after a demand is placed on the safety system 74 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety function meets the safety performance requirements of SIL CL3 per IEC 62061 2005 and has a Category 4 structure that can be used in systems that require Performance Levels up to PLe per ISO13849 1 2006 This circuit executes a Stop Category 0 Figure 35 Micro 400 Light Curtain 24V DC Mounted on Machine Micro 400 to Indicate 445L P4E0300FP Machine Position 445L AC8RJ5 2x Start Transmitter Receiver 800FM F E Stop F3MX10 SensaGuard 5 800FM MT44 440N Z21S26H 800F MX02S 889D F8AB 2 800FM E4MX01 F6MX10 MSR42 R45 440R P221AGS 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 75 Next Generation Guardmaster Safety Relay GSR Cat 1 Stop with Guard Locking Interlock and Proxim
27. operation The safety outputs of the SafeZone Mini generates test pulses to check for cross channel shorts and short circuit faults to power and ground The DI safety relay generates test pulses through the E stop circuit to check for cross channel shorts and short circuit faults to power and ground IMPORTANT Donot replace the DI safety relay with the DIS safety relay as the pulse checking on the outputs of the DIS safety relay causes an F059 fault on the Kinetix 350 drive safety inputs Ratings The safety functions initiated by the SafeZone Mini scanner and the E stop buttons can meet the safety performance requirements of SIL CL 2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Level up to PLd per IS013849 1 2006 This circuit executes a Stop Category 0 56 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 26 SafeZone Mini Laser Scanner E stop and DI Safety Relay with Kinetix 350 Drive 24V DC Input Input Output co 1756 IB16 1756 IV16 1756 OB16 White Warning Field 1769 IQ16 1769 IV16 pc 1769 088 SafeZone Mini 1746 IB16 1746 IV16 Processor 1746 OB4 442L SFZNMN 1734 IB4 1734 IV4 1734 OB2 442L ACABL210 Cable S 4 1793 IB6 1793 IV16 1793 OB4 a E aj o v Reset 1 a S11 S21 S22 S12 A1 13 23 S34 L1L2L3 H Locic_ 9 p 2 yA Kinetix 350 Drive 8 3 ea DI 76
28. outputs for faults The GLP safety relay uses redundant proximity sensors that must be mounted on independent fixtures Ratings The safety function meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO13849 1 2006 88 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 42 Stop Motion with Guard Locking and E stop 24V DC 440G LZS21SPRA Brown 51252251 ler S54 at saa van LOGIC SLS1 SLS2 TIME 0 0 1 1 1 9 2 2 2 8 3 3 3 GLP 7654 654 654 440R GL2S2P 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 89 Next Generation Guardmaster Safety Relay GSR Stop Motion to PLC Circuit Components e Bulletin 872C proximity sensors e GLP safety relay e CR30 configurable safety relay e Bulletin 1734 POINT Guard I O Circuit Status This example shows how to use the GLP safety relay for stop motion detection only The GLP has a logic setting of 5 delayed unlocking with automatic reset a safe limited speed SLS1 setting of 0 0 5 Hz and an SLS2 Time of 0 unlock delay of 10 The SLS2 Time setting is not relevant as the 51 L61 locking signals are not used in this application TIP Start the GLP logic configuration from 0 when using Logic setting 5 Operating Principle Whe
29. safety relay with the DIS safety relay as the pulse checking on the outputs of the DIS safety relay causes an F059 fault on the Kinetix 350 drive safety inputs Ratings The safety functions that are initiated by the SC300 safety sensor and the E stop buttons can meet the safety performance requirements of SIL CL 2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 This circuit executes a Stop Category 0 60 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 28 Safety Sensor E stop and DI Safety Relay with Kinetix 350 Drive Input Input Output 1756 IB16 1756 IV16 1756 OB16 1769 IQ16 1769 IV16 PLC 1769 OB8 1746 IB16 1746 IV16 Processor 1746 OB4 1734 IB4 1734 IV4 1734 OB2 1793 IB6 1793 IV16 1793 OB4 442L SAFCAM1 Cable 889D F8FB 5 LT L2 L3 Locic__ a 3 4 DI 765 E Stop Kinetix 350 Drive 800FM MT44 440R D22R2 800F MX025 1 424V DC 2 Com C 3 Status 4 Safety Input 1 Rockwell Automation Publication SAFETY WD001F EN P November 2015 61 Next Generation Guardmaster Safety Relay GSR Hazardous Location Circuit Components e Trojan T15 tongue interlock switch e Bulletin 800F E stops e Bulletin 937TH isolator e DIS safety relay e PowerFlex 525 drive Circuit Status The DIS safety relay logic is set to 2 IN1
30. second OFF Delay and the Time is set to 10 100 therefore the OFF Delay time is 1 second Operating Principle STARTING Press and release the reset button to energize the outputs of the SI This action energizes the feedback relays in the Kinetix The L1 Isignal from the SI safety relay to the EMD safety relay instructs the EMD safety relay to close its safety outputs which energizes the Bulletin 100S contactor in the resistor braking module The motor is now connected to the drive When the Kinetix drive is enabled an internal signal is sent back to its controller not shown to inform it that the drive is enabled The motor is then controlled by its controller STOPPING When the E stop is pressed the immediate outputs of the SI open and disable the drive The motor begins to execute a stop The L11 signal from the SI safety relay to the EMD safety relay turns offand the EMD safety relay begins its timing cycle After the time delay of the EMD safety relay expires the delayed outputs open and drop out the Bulletin 100S contactor in the RBM This disconnects the motor from the drive and engages the braking resistors which rapidly stop the motor Fault Detection Upon power up the Kinetix drive and SI and EMD safety relays perform internal checks The SI safety relay then looks for dual signals from the E stop The E stop has self monitoring contacts which open if the contact block falls off the control panel With the E stop signals made
31. stops e DIsafety relay e Kinetix 350 drive Circuit Status The Logic setting of the DI safety relay is set to 2 monitored manual reset with Input 1 AND Input 2 OR L12 The E stop is in the released position and is connected to Input 2 S32 and S42 of the DI safety relay The area that is scanned by the SafeZone Mini scanner is clear and the signals to Input 1 of the DI S12 and 22 are high The Warning Field signal is connected to a PLC which turns on an indicator and may also perform other logic The DI safety outputs 14 and 24 are OFF The Kinetix 350 Drive is powered but the safety inputs are off therefore the motor is OFF The Y32 Aux Signal is high which informs the PLC that the safety system is ready to run Operating Principle STARTING Press the Reset button to energize the safety outputs of the DI safety relay The Y32 status signal turns OFF The Kinetix 350 drive is enabled The PLC can now turn the motor ON not shown in Figure 26 STOPPING Entering the warning field of the SafeZone Mini scanner does not cause the safety system to turn off but the PLC turns on an indicator Entering the protective field of the SafeZone Mini scanner or pressing the E stop causes the DI safety relay to turn OFF which disables the Kinetix 350 drive The motor coasts to a stop Fault Detection Upon successful completion of internal checks on power up the SafeZone Mini scanner DI safety relay and Kinetix 350 drive are prepared for
32. that can be connected in parallel is dependent on e The load the safe off option plus the enable of each drive e Appropriate derating to prevent early wear out of the DIS safety relay solid state outputs e The application requirements for example zoning e The risk assessment for example some drives require separate safety systems Operating Principle STARTING Upon closing the gate the Trojan 5 GD2 switch closes the safety inputs of the DIS safety relay S32 and 42 and opens the signal to the PLC The safety outputs of the DIS safety relay close and enable both PowerFlex drives The auxiliary signal of the DIS safety relay opens The PLC compares the gate and safety relay aux signals When both signals are open the PLC knows that the safety system is ready The PLC can now start and control the drives over the DeviceNet network The PLC must verify that the drives are not started upon the closing of the gate a separate intentional action must initiate the motor movement not shown Figure 33 STOPPING The PLC performs normal stopping If the gate is opened the input signals to the DIS safety relay open The DIS safety relay opens its safety outputs that disable all drives that are connected to them via the Safe Off option The drives perform an immediate coast to stop 70 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Fault Detection Upon power up
33. the DIS safety relay performs internal checks The DIS safety relay then looks for dual signals from the Trojan5 GD2 switch If only one signal is present or a crossfault exists the DIS safety relay assumes that a fault is present and does not energize its safety outputs With the gate closed the DIS safety relay checks the 34 monitoring circuit If the Safe Off options are de energized the DIS safety relay assumes that the drives are off and are ready to be enabled The DIS safety relay energizes its safety outputs If the monitoring circuit remains open the DIS safety relay assumes that a fault is present and not allow its safety outputs to energize Single point failures that are related to the tongue interlock are excluded if actuator speed alignment and mechanical stops meet installation instruction requirements and a periodic proof test confirms proper operation Ratings The safety function that is initiated by the Trojan 5 GD2 gate interlock meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 This circuit executes a Stop Category 0 aen fva m2 34 ea 14 24 alk Input DeviceNet E 1756 IB16 Processor 1756 DNB 1769 IQ16 1769 SDN C T 1746 IB16 1747 SDN Figure 33 Multiple PowerFlex Drives 24V DC Gate shown C open E Trojan5 GD2 i Cc A 511521 512 522 52 542 534 Ar
34. the output module before restarting STARTING Press the reset button to energize the output contacts 13 14 of the SI safety relay This connects the 24V supply to terminal C34 of catalog number 1974 OB16 FLEX output module and also sends a signal to the A3 terminal of the catalog number 1794 IB16 input module The logic system is informed that the gate is closed and the machine is ready to run Press the Start button to start the machine process STOPPING Press the Stop button to stop the machine Then open the gate to access the machine While the gate is open the machine actuators cannot operate because power is removed from the output module If the gate is inadvertently opened while the machine is running power is removed from output module and the machine actuators are de energized Fault Detection Upon successful completion of internal checks on power up the SI checks the input circuits With the gates closed the SI safety relay checks the dual circuits and then waits for the reset signal A single fault a short from 24V to terminal 14 of the SI safety relay may lead to the loss of the safety function With the SI safety relay and FLEX system mounted in the same cabinet and with proper validation this fault may be excluded If not mounted in the same cabinet a signal from the output AO should be fed back into the input module A2 The logic can perform a comparison of input A2 and A3 and turn off the machine if these signals are no
35. the speed of the redundant proximity sensors and turns ON the appropriate outputs The 51 L61 X14 X24 and L11 outputs are safety rated outputs that check for short circuit conditions Ratings The safety function meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO13849 1 2006 92 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Figure 44 Speed Status Only Next Generation Guardmaster Safety Relay GSR Speed Exceeds SLS1 OSSD Outputs 24V DC x24 Y32 LOGIC SLS1 SLS2 TIME o 0 1 1 1 8 3 3 3 7 54 6 4 6 4 a2 AP Pr2 P22 512 S22 544 554 6 E a a rae MYD Proximity Sensors TI 872C D8NP18 D4 i 989D F4Ac 2 5 a 24V DC Com Speed Exceeds SLS2 Single Wire Safety Output OSSD Outputs Auxiliary Output Rockwell Automation Publication SAFETY WD001F EN P November 2015 93 Next Generation Guardmaster Safety Relay GSR Guard Locking with Time Delay Circuit Components e TLS3 GD2 guard locking switch e Guard Locking with Time delay GLT safety relay e PowerFlex 525 Circuit Status The gate is closed and locked The TLS3 GD2 is a power to release guard locking interlock The motor is off The GLT safety relay is ready for reset The GLT safety relay has a Logic setting of 1 Stop Cat 0 with Logic In OFF a Range setting of 4 10 seconds and a Tim
36. 0 for fault conditions Figure 40 Safe Limited Speed with Guard Locking Interlock and Proximity Sensors 24V DC Input EtherNet IP 1756 IB16 1756 ENBT 1769 1016 Gate Reset amp o Q PLC Unlock p Gate Lock 1746 1B16 Processor nena 1734 IB4 equest 1793 1B6 mm L1 L2 L3 Kinetix 300 LOGIC SLS1 SLS2 TIME 30 Clear Faults o 0 T L L 29 Enable 7 3 26 Gnd GLP 7654 654 657 1 24V DC 440R GL2S2P an 3 Status 4 Safety Input 1 Brown Red TLS ZR 5 SafetyCommon 440G TZS21UPRH 6 Safety Input 2 ease rene Gate D Proximity Sensors LY Unlocked MML 871TM N40NP30 D4 D J 889D F4AC 2 JANI w 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 85 Next Generation Guardmaster Safety Relay GSR Safe Limited Speed with Logic In Guard Locking and Proximity Sensors Circuit Components e Bulletin 440G LZ guard locking switch e Bulletin 871TM proximity sensors e Bulletin 800F E stop e SI GLP and EM safety relays e PowerFlex 525 drive Circuit Status The E stop is released The safety gate is closed and locked The SI and GLP are ready for reset The GLP safety relay has a logic setting of 4 Safe Limited Speed with Logic IN a safe limited speed SLS1 setting of 3 3 Hz 1 75 seconds and a maximum speed setting SLS2 Time of 5 200 Hz The proximity sensors are rated for 400 Hz The K1 K4 contact
37. 00Z touch buttons causes the outputs of the MSR35H safety relay to turn off which drops out K1 and K2 and stops the motor Obstructing the light curtain de energizes the safety outputs of the SI safety relay which in turn drops out K1 and K2 and turns off the motor Clearing the light curtain does not restart the motor even if the operator has their hands on the palm buttons The reset button must be pressed after the light curtain is cleared Fault Detection Upon power up the Bulletin 800Z GuardShield light curtain MSR35H safety relay and SI safety relay perform internal checks After passing internal checks the MSR35H safety relay waits for a change of state of its inputs Faults opens and shorts at the inputs are detected by the MSR35H and prevent the outputs from being energized The GuardShield light curtain also performs checks on its Output Signal Switching Device OSSD output signals for crossfaults shorts and opens The SI looks for dual signals at its inputs It then checks the status of the contactors If one contactor fails in the actuated state the other contactor stops the motor The SI detects if one of the contactors are stuck in the energized position and prevents restart 20 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety function that is provided by the GuardShield light curtain meets the safety performance requirements of SIL CL
38. 015 77 Next Generation Guardmaster Safety Relay GSR Stop Motion with Guard Locking by PLC Circuit Components e TLS ZR guard locking switch e Bulletin 872C proximity sensors e Guard locking proximity GLP safety relay e Bulletin 1734 POINT Guard I O Circuit Status This example shows how to use the GLP safety relay to measure the speed of the machine and allow a safety PLC to control the locking function of the guard locking interlock The gate is closed and locked The GLP safety relay is ready for reset The GLP safety relay has a Logic setting of 1 Category 1 Stop with Logic IN OFF a safe limited speed SLS1 setting of 0 0 5 Hz 10 1 seconds and a maximum speed setting SLS2 Time of 2 20 Hz The safety outputs X14 amp X24 the single wire safety output L11 and the auxiliary output Y32 are OFF TIP Start the GLP logic configuration from 0 to configure X14 and X24 for use as safety outputs Operating Principle STARTING Press the Lock and Reset Request button The PLC locks the safety gate if not already locked and sends the reset signal to terminal 44 of the GLP safety relay The safety outputs at X14 and X24 of the GLP safety relay turn ON The safety PLC uses the X14 and X24 signals to allow the execution of a safety function STOPPING Press the Unlock Request button The safety PLC executes a stop function and sends an unlock signal to terminal 54 of the GLP safety relay When the proximity sens
39. 01F EN P November 2015 53 Next Generation Guardmaster Safety Relay GSR E stops for a PowerFlex 755 Drive Circuit Components e Bulletin 440F MatGuard safety mats e DIsafety relay e PowerFlex 755 drive Circuit Status Both safety mats are clear The safety outputs of the DI safety relay are energized The PowerFlex 755 drive is powered and its safety circuit is enabled The motor is off The DI safety relay has a Logic setting of 6 IN1 AND IN2 OR L12 with automatic reset IMPORTANT The safety mat wiring must be crossed as compared to an E stop button 11 connects to 22 amp S42 and 21 connects to 12 amp 32 and safety mat applications require Logic settings with IN1 AND IN2 Operating Principle STARTING Press the start button or other equivalent machine control system not shown to start the motor Although the DI safety relay is set for automatic reset stepping off the safety mats does not cause the motor to start rotating STOPPING The Stop switch or other equivalent machine control system not shown stops normal production Stepping on either safety mat initiates a safety stop The DI safety relay removes power to the Start Stop circuit and the Gate Control Circuit The motor executes a safe torque off function and the motor coasts to a stop Fault Detection Upon power up the PowerFlex drive and DI safety relay perform internal checks The DI safety relay then looks for dual signals from the safety ma
40. 0S CF 3 e 4 0 50 DI EMD MAB E stop 100S C 2 d 3 0 52 DI DI DI 2 E stops 2 GuardShield Safe 4 Mat SensaGuard 1005 C 2 3 d e 3 4 0 54 DI 2 Safety Mats Powerflex 755 2 d 3 0 56 DI SafeZone Mini E stop Kinetix 350 2 d 3 0 LISTEN NS Rockwell Allen Bradley Rockwell Software Automation Next Generation Guardmaster Safety Relay GSR Safety Relay SIL Cat Stop Page Modules Input Devices Output Devices CL PL No Cat 58 DI SafeZone Multizone E stop Kinetix 350 2 d 3 0 60 DI SC300 Safety Sensor E stop Kinetix 350 2 d 3 0 62 DIS Galvanic Isolator 937TH Trojan T15 E stop PowerFlex 525 2 d 3 0 64 DIS Galvanic Isolator 937TH MatGuard E stop PowerFlex 525 2 c d 1 3 0 66 DIS Galvanic Isolator 937TH Safedge E stop PowerFlex 525 2 c d 1 3 0 68 DIS Trojan 5 MT GD2 PowerFlex 70 2 d 3 0 70 DIS Trojan 5 2 PowerFlex 70 2 d 3 0 rps DIS MSR41 Micro 400 GuardShield E stop 100S C 3 e 4 0 74 DIS MSR42 Micro 400 GuardShield SensaGuard E stop 100S C 3 e 4 0 76 GLP 872C TLS3 GD2 GLP Logic 1 PowerFlex 70 2 d 3 1 78 GLP 872C TLS ZR GLP Logic 1 1734 POINT Guard 1 0 2 d 3 1 80 GLP EM 871TM 440G MT 700 HPS GLP Logic 1 PowerFlex 525 2 d 3 1 82 GLP SI 871TM 440G LZ E stop GLP Logic 2 PowerFlex 70 2 d 3 1 84 GLP 871TM TLS ZR GLP Logic 3 Kinetix 300 2 d 3 SLS 86 GLP SI EM 871TM 440G LZ E stop GLP Logic 4 PowerFlex
41. 2 440G T27171 O Remove internal jumper from Powerto 12to 41 Release H or ial L1 12 63 EMD 440R EM4R2D 700 HPS2Z24 700S CFB440EJC Trojan T15 GD2 440K T11397 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 49 Next Generation Guardmaster Safety Relay GSR Guard Locking with DI EMD Safety Relays Circuit Components e MAB e Bulletin 800F E stop e Dland EMD safety relays e Bulletin 100S contactor Circuit Status The E stop is reset The safety gate is closed and locked The outputs of the safety relays are open and the motors are off The rotary switches of the EMD safety relay have the delay time set to 18 seconds Range 3 30 seconds OFF Delay Time 6 60 of range The EMD will open its contacts 18 seconds after the signal from the DI L11 output turns off The EMD safety relay retriggerable input B2 is not needed because the DI safety relay cannot turn on its outputs until after the EMD safety relay timer expires Operating Principle STARTING Press the Reset button to energize the outputs of the DI safety relay The outputs of the DI safety relay energize the K1 and K2 contactors and motor M1 starts Simultaneously the DI safety relay sends a signal via L11 to the EMD safety relay The outputs of the EMD safety relay energize the K3 and K4 contactors and motor M2 starts STOPPING When the E stop is pressed the outputs of the DI safety relay open an
42. 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 This application executes a Stop Category 0 Figure 27 Multizone Laser Scanner E stop and DI Safety Relay with Kinetix 350 Drive 24V DC Select Zone A White Red amp White Orange Select Zone B White Yellow amp White Green SS Wa SSS S Input Input Output rning Field White Brown 1756 IB16 1756 IV16 1756 OB16 E E PLC 1769 OB8 1746 OB4 1734 IB4 1734 IV4 1734 OB2 1793 IB6 1793 IV16 1793 OB4 L1L2 L3 LOGIC _ 404 2 as 3 Kinetix 350 Drive 6 5 E Stop 440R D22R2 1 24V DC 800FM MT44 32 S42 L11 L12 Y 2 Com 800F MX02S E 3 Status 4 Safety Input 1 H 5 Safety Common SafeZone Multizone 442L SFZNMZ Cable amp Mem Module 442L CSFZNMZ 10 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 59 Next Generation Guardmaster Safety Relay GSR Safety Sensor E stop and DI Safety Relay with Kinetix 350 Drive Circuit Components e SC300 hand detection safety sensor e Bulletin 800F E stops e DIsafety relay e Kinetix 350 drive Circuit Status The Logic setting of the DI safety relay is set to 2 monitored manual reset with Input 1 AND Input 2 OR L12 The E stop is in the released position and is connected to Input 2 S32 and 42 of the DI safety relay The area that is scanned by the SC300 safety sensor is clear a
43. 3 per IEC 62061 2005 and has a Category 4 structure that can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 This circuit executes a Stop Category 0 The safety function of the two hand control meets Type IIIC of ISO 13851 Figure 8 GuardShield Light Curtain and Bulletin 800Z Zero Force Touch Buttons 24V DC Transmitter Receiver Brown GuardShield Reset 440L P4J0640YD 800FM F6MX10 889D F4AC 2 889D F8AC 2 EJ 800Z GL3Q5 889N F5AE 6F Two Hand Control 800Z GL3Q5 s2 889N F5AE 6F To PLC 100S C09EJ14BC 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 21 Next Generation Guardmaster Safety Relay GSR SI DIS Safety Relays SensaGuard Interlock E stops and PowerFlex 525 Drive with Contactor Circuit Components e SensaGuard integrated latch interlocks e Bulletin 800F E stop e SIand DI safety relays e Bulletin 100S contactor e PowerFlex 525 drive Circuit Status The DIS safety relay logic is set to 4 IN1 AND IN2 AND L12 with monitored reset The SI is set for automatic reset The SensaGuard integrated latch interlocks are connected in series to the SI The two E stops are connected to inputs 1 S12 and S22 and 2 32 and 42 of the DIS The three gates monitored by the SensaGuard integrated latch interlocks are closed and safety outputs of the SI L11 13 14 and 23 24 are ON Both E stops are released The DIS safety outputs 14 24 34 and 44 a
44. 5 C7 H Reset 24V DC Col PowerFlex R 525 1 Stop 937TH DISRS DC1 2 Start 4Gnd o Settings S1 Il S2 Gate control circuit DIN Rail Connections 937TH DISRS DC1 Settings S1 Il S2 S3 S4 ar DIN Rail Connections S1 Inverted Output S2 Output 2 Follows Output 1 S3 Enable Line Fault Detection S4 Not Used Rockwell Automation Publication SAFETY WD001F EN P November 2015 WA 65 Next Generation Guardmaster Safety Relay GSR Hazardous Location Circuit Components e Safedge pressure sensitive sensing edge e Bulletin 440F MatGuard safety mats e Bulletin 800F E stops e Bulletin 937TH isolator e DIS safety relay e PowerFlex 525 drive Circuit Status The DIS safety relay logic is set to 2 IN1 AND IN2 OR L12 with monitored reset The sensing edge is connected to input 1 of the DIS S12 and 22 through the galvanic isolator The E stop is connected to input 2 of the DIS safety relay S32 and 42 The gate is closed and the E stop is released The DIS safety outputs are off The PowerFlex 525 drive is powered but disabled The motor is off Operating Principle The galvanic isolator limits energy to the sensing edge which is considered a simple apparatus in the hazardous location The DIS safety relay checks the outputs of the galvanic isolator upon power up and each time the safety edge E stop is actuated STARTIN
45. 5 aia stop E 800FM MT44 440R D22R2 1 24V DC 800F MX02S 32 S42 L11 L12 A2 14 24 Y32 2Com 3 Status 4 Safety Input 1 5 Safety Common 6 Safety Input 2 Warning Field M 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 57 Next Generation Guardmaster Safety Relay GSR Multizone Laser Scanner E stop and DI Safety Relay with Kinetix 350 Drive Circuit Components e SafeZone Multizone safety laser scanner e Bulletin 800F E stops e DIsafety relay e Kinetix 350 drive Circuit Status The Logic setting of the DI safety relay is set to 2 monitored manual reset with Input 1 AND Input 2 OR L12 The E stop is in the released position and is connected to Input 2 S32 and S42 of the DI safety relay The area that is scanned by the SafeZone Multizone is clear and the signals to Input 1 of the DIS safety relay S12 and 22 are high The Warning Field signal is connected to a PLC which turns on an indicator and may also perform other logic The DI safety outputs 14 and 24 are OFF The Kinetix 350 drive is powered but the safety inputs are off therefore the motor is OFF The Y32 Aux Signal is high which informs the PLC that the safety system is ready to run Operating Principle The PLC sends a pair of signals a N C anda N O to the SafeZone Multizone scanner to switch the active zones between Zones A and B The OSSD outputs respond to either zone STARTING Press the Reset button to energize the s
46. 5 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO13849 1 2006 This circuit executes a Stop Category 0 68 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 32 PowerFlex Drive Multiple Gate Access 24V DC Guard Shown Open 440K T11341 Trojan 5 GD2 O 51520 512 529 532 52 524 AT DIS 440R D22S2 FN 440K MT55080 MT GD2 Latch Release 24V DC Co PowerFlex 70 with DriveGuard 1 Stop 2 Start 7 DC Comm 8 Dig Comm Control Circuit Remove Jumper Rockwell Automation Publication SAFETY WD001F EN P November 2015 69 Next Generation Guardmaster Safety Relay GSR Multiple PowerFlex Drives Circuit Components e Trojan 5 GD2 tongue interlock switch e DIS safety relay e PowerFlex 70 drive with DriveGuard Circuit Status The safety gate is open The DIS safety outputs 14 24 34 and 44 are off The Enable and Safe Off Option on both PowerFlex drives are off Auxiliary signals from the Trojan 5 GD2 switch 33 34 and the DIS safety relay Y32 inform the PLC that the safety system is OFF The motors of both drives are off The Logic setting of the DIS safety relay is set to 5 IN1 OR IN2 OR L12 with automatic reset This circuit is intended to show that multiple drives can be connected in parallel The number of drives
47. 5 seconds 50 of 30 seconds TIP Start the GLT configuration from 0 to generate test pulses at 11 21 14 and 24 Operating Principle STARTING With the E stop released press the Reset button The GLT safety relay turns on outputs Y32 L11 51 L61 14 and 24 Contactors K1 and K2 turn ON The EM safety relay turns on via the L11 L12 connection and turns on contactors K3 and K4 The PowerFlex 525 drive is enabled Press the Start button to start the motor STOPPING Normal stops and starts of the motor are performed using the Start Stop buttons Emergency stops are initiated by pressing the E stop button The Y32 14 24 and L11 outputs turn OFF immediately The EM safety relay turns off contactors K3 and K4 and PowerFlex 525 drive performs its pre programmed deceleration function After 15 seconds the GLT safety relay turns OFF 51 and L61 to disable the PowerFlex 525 drive Fault Detection Upon power up the GLT safety relay EM safety relay and PowerFlex 525 drive perform internal checks The GLT safety relay uses test pulses through the E stop circuitry to test for short circuit faults The SWS signal from L11 of the GLT safety relay to L12 of the EM safety relay detects short circuit conditions The K1 K4 contactors are monitored by the GLT safety relay reset circuit if one is stuck in the energized position the GLT does not restart The PowerFlex 525 drive has redundant safety inputs and is safety rated 108 Rockwell Auto
48. 525 2 3 d e 3 4 SLS 88 GLP 872C 440G LZ GLP Logic 5 Stop Motion Unlock Delay 2 d 3 90 GLP 872C GLP Logic 5 Stop Motion Only 1734 POINT Guard 1 0 2 d 3 92 GLP 872C GLP Logic 8 Status Only 2 d 3 94 GLT TLS3 GD2 GLT Logic 1 PowerFlex 525 2 d 3 0 96 GLT 440G LZ GLT Logic 1 PowerFlex 525 2 d 3 0 98 GLT Multiple 440G LZ or TLS ZR GLT Logic 1 PowerFlex 525 2 d 3 0 100 GLT Multifunction Access Box MAB GLT Logic 1 PowerFlex 525 2 d 3 0 102 GLT SI MAB with three buttons GLT Logic 2 100S 3 e 4 0 104 GLT TLS ZR or 440G LZ GLT Logic 3 PowerFlex 525 2 d 3 1 106 GLT SI E stop TLS ZR or 440G LZ GLT Logic 4 PowerFlex 525 2 d 3 1 108 GLT EM E stop GLT Logic 5 PowerFlex 525 100S 700S C 2 3 d e 3 4 1 0 110 GLT SI MC2 E stop GLT Logic 6 PowerFlex 525 100S 2 d 3 1 112 GLT EM E stop GLT Logic 7 PowerFlex 525 100S 700S C 2 3 d e 3 4 1 0 114 GLT SI Ferrogard GD2 E stop GLT Logic 8 PowerFlex 525 100S 3 e 4 1 116 ENETR DI EM DIS EMD GLT GLT 2 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Notes for Example Wiring Diagrams Note 1 In the wiring diagrams that are shown in this publication the type of Allen Bradley Guardmaster device is shown as an example to illustrate the circuit principle For special applications the choice of device type is based on the suitability of its characteristics for its intended use
49. 8 Digital In Com 512 523 51 ar s54 saa yaa 17 LOGIC SLS1 SLS2 TIME 0 RESET 1 0 0 AM 9 2 2 MM 3 BE ME SI GLP 7654 6 6 440R S12R2 440R GL2S2P L12 ts1 a2 ap P12 P22 MD ME Proximity Sensors 871TM N10NP12 D4 889D F4AC 2 Unlocked 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 83 Next Generation Guardmaster Safety Relay GSR Safe Limited Speed with Guard Locking Interlock and Proximity Sensors Circuit Components e TLSZR GD2 guard locking switch e Bulletin 871TM proximity sensors e GLP safety relays e Kinetix 300 drive Circuit Status The gate is closed and locked The motor is off The GLP safety relay is ready for reset The GLP safety relay has a Logic setting of 3 Safe Limited Speed with Logic IN OFF a Safe Limited Speed SLS1 setting of 9 10 Hz 0 6 seconds and a maximum SLS2 Time speed setting of 0 no checking for max frequency The safety outputs X14 amp X24 the single wire safety output L11 and the auxiliary output Y32 are OFF TIP Start the GLP logic configuration from 0 to configure X14 and X24 for use as safety outputs Operating Principle STARTING Press the Reset and Gate Lock Request button to turn the GLP safety outputs and enable the Kinetix 300 drive Press the Start button to turn the motor ON STOPPING Normal production stops are performed by pressing the Stop button Access through the saf
50. 89D F8AB 10 L1 L2 L3 R PowerFlex 525 1 Stop 2 Start 2 3 8 7654 RESET a a GLT 440R S12R2 440R GL2S2T 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 115 Next Generation Guardmaster Safety Relay GSR EtherNet IP to Logix Controllers Circuit Components e Bulletin 440R ENETR EtherNet IP network interface e DI EM DIS EMD GLT and GLP safety relays Circuit Status The schematic only shows the Ethernet power and SWS connections The safeguarding connections are not shown Operating Principle The ENETR network interface must reside in the left most position The GSR relay modules can be located in any order and must be firmware revision 2 or later The ENETR network interface has two Ethernet connections one on top and one on bottom that can be used in linear star or Device Level Ring topologies The ENETR network interface only reports status information for up to six relays using an Add On Profile in the Logix Controller The information can be used for ON OFF status and troubleshooting TIP The Cl and SI safety relays do not function with the ENETR network interface Figure 56 EtherNet IP to Logix Controllers
51. Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 27 Next Generation Guardmaster Safety Relay GSR Magnetically Coded Sensor Circuit Components e MC2 magnetically coded non contact interlock switch e CI safety relay e Bulletin 800F push buttons e Bulletin 100S contactor Circuit Status The first gate is open The second and third gates are closed The CI safety relay 12 and 22 inputs are open due to the open gate and therefore the CI safety outputs are open The machine control PLC has a 24V auxiliary signal at terminal 10 from the first gate because the gate is open The second and third auxiliary signals are off as their gates are closed The PLC also has an auxiliary signal from the CI safety relay that indicates that the safety system is not ready The motor is off Operating Principle STARTING Closing the first gate satisfies the input of the CI safety relay The CI safety relay verifies that both K1 and K2 contactors are off and energizes its safety outputs Pressing the Start button starts the motor The Stop Start circuit is not part of the safety system and can be replaced by the machine control system for example a PLC STOPPING Press the Stop button to turn off the motor without affecting the status of the safety system Opening any of the gates causes the safety system to stop the motor Fault Detection Upon successful completion of internal checks on power up the CI safety relay check
52. Components e E stop e Single input SI safety relay e PowerFlex 525 drive Circuit Status The SI safety relay logic is set to MM monitored manual reset The E stop is released The SI safety outputs 13 14 and 23 24 are off The PowerFlex 525 drive is powered but disabled The motor is off Operating Principle STARTING Press the Reset button to turn on the SI safety outputs The drive in enabled and power is applied to the Start and Stop buttons Press the Start button to start the motor STOPPING Press the Stop button to stop the motor for production stops Press the E stop to initiate a safety stop The motor coasts to a stop Fault Detection Upon successful completion of internal checks by the SI safety relay and PowerFlex 525 drive the drive awaits the closure of the safety outputs If the SI safety relay fails the drive does not energize the motor and the fault is detected by non operation of the motor The SI safety relay generates test pulses through the E stop circuits to detect cross channel shorts and shorts to power and ground Some faults in the safe off circuit of the drive are detected by the drive and the drive executes a Safe Torque Off stop The safety system does not detect a short circuit from S1 to 2 Ratings The safety function that is initiated by the E stop meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Per
53. F E stop e MSR42 controller module e DIS and DI safety relays e Bulletin 100S contactor Circuit Status The light curtain is clear the SensaGuard switch is closed and the E stop is released The MSR42 module and DIS safety outputs are energized The safety outputs of the DI safety relay are OFF The motor is off The DI safety relay is ready for reset The DIS safety relay has a Logic setting of 6 IN1 AND IN2 OR L12 with automatic reset When the machine is in a specified position as detected by the SensaGuard switch the light curtain is bypassed When the machine moves away from the specified position the SensaGuard switch turns OFF and the Micro 400 light curtain becomes active The DI safety relay has a logic setting of 3 IN1 OR IN2 AND L12 with monitored manual reset this makes the E stop effective and the SensaGuard switch or Micro 400 light curtain at all times Operating Principle STARTING Press the reset button to turn the DI safety outputs ON Press the Start button to turn the motor ON The Start Stop circuit operates only K2 as a planned maintenance feature K1 does not switch on motor current but it can switch off the motor current when a demand is placed on the safety system STOPPING Normal production stops are performed by pressing the Stop button A safety stop can be accomplished by obstructing the light curtain when the machine position is not detected by the SensaGuard switch or pressing the E stop The
54. G Press the Reset button to turn the DIS safety outputs 14 24 34 44 and L11 ON This enables the PowerFlex 525 drive Press the Start button to turn the motor ON STOPPING Normal production stops are performed by pressing the Stop button Stepping on the sensing edge or pressing the E stop initiates a safety stop the motor coasts to a stop Fault Detection The DIP switch setting of the galvanic isolator allows for open and short circuit detection of the safety edge Since the Bulletin 937TH isolator has a hardware fault tolerance of zero two are used to achieve single fault tolerance The isolator DIP switches must be set for Line Fault Detection I and inverted II output The 1492 resistors are required to detect line faults These resistors must be located as close as possible to the safety edge Ratings The safety function that is initiated by the sensing edge meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require up to Performance Level PLd per ISO 13849 1 2006 The safety function that is initiated by the E stop meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require up to Performance Level PLd per ISO 13849 1 2006 This circuit executes a Stop Category 0 See publication 937TH WD001_ EN P for more safeguarding examples with the galvanic isolator
55. Guard Integrated Latch and PowerFlex 525 Drive 24V DC L1 L2 L3 R PowerFlex 525 SensaGuard Integrated Latch 440N Z21SS3PA E Stop 800FM MT44 800F MX02S 11 24V DC 1 Stop LOGIC 04 2 Start Bey 3 s7 4 D 6 5 l 440R D22R2 saa s32 11 L12 A2 14 24 v32 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 43 Next Generation Guardmaster Safety Relay GSR Interlock Switch with Enabling Device Guard Locking with Time Delay Circuit Components e Bulletin 440 GripSwitch enabling switch e MT GD2 latch release e Bulletin 440G MT guard locking switch e Bulletin 800F E stops e Dland EMD safety relays e Bulletin 100S contactor Circuit Status The Bulletin 440 GripSwitch is held by two MT GD2 tongue interlocks by its mounting plate accessories The safety gate is closed and the 440G MT guard locking interlock is locked The DI and EMD safety outputs are open Contactors K1 and K2 are de energized The EMD Range switch is set to 8 Jog 10 seconds and the Time is set to 2 20 therefore the Jog occurs for 2 seconds The motor is off and the application ready to run Operating Principle The GripSwitch enabling device is used to access the hazardous area while the motor is running The access is of the full body type With the safety gate unlocked the operator walks into the hazardous area with the GripSwitch Before accessing
56. R IN1 with Auto Reset a Range setting of 9 30 min and a Time setting of 10 100 The delay is 30 minutes 100 of 30 min TIP Start the GLT configuration from 0 to generate test pulses at 11 S21 14 and 24 Operating Principle The GLT safety relay has a connection to B2 the retriggerable input If the E stop is pressed it can be released before the completion of the time delay without causing a recoverable fault in the GLT safety relay When the E stop is released the immediate outputs turn back ON and the timer is reset STARTING With the E stop released the GLT safety relay turns on its Y32 L11 51 L61 14 and 24 outputs Contactors K1 and K2 turn ON The EM relay turns on via the L11 L12 connection and turns on contactors K3 and K4 The PowerFlex 525 drive is enabled Press the Start button to start the motor STOPPING Normal stops and starts of the motor are performed using the Start Stop buttons Emergency stops are initiated by pressing the E stop button Outputs Y32 14 24 and L11 turns OFF immediately The EM relay turns off contactors K3 and K4 and PowerFlex 525 drive performs its pre programmed deceleration function After 30 minutes the GLT safety relay turns OFF 51 and L61 to disable the PowerFlex 525 drive Fault Detection Upon power up the GLT safety relay EM relay and PowerFlex 525 drive perform internal checks The GLT safety relay uses test pulses through the E stop circuitry to test for short circu
57. S safety relays e Bulletin 100S contactor e Bulletin 700S safety control relay Circuit Status The E stops are reset The safety gate is closed The safety mat is unoccupied The outputs of all three safety relays are off K1 K6 are ready to be energized The SI is set for monitored manual reset The DI has logic set to 4 IN1 AND IN2 AND L12 with monitored manual reset because the safety gate provides full body access The DIS has logic set to 8 INIAND IN2 AND L12 with automatic reset as operators cannot get between the safety mat and the hazard Safety mat applications require Logic setting with IN AND IN2 Operating Principle The SI safety relay provides a global E stop function The DI and DIS safety relays are cascaded from the SI safety relay STARTING Press the reset button for the SI safety relay to energize its outputs Then press the Start button energize K1 and K2 and send the L11 link signal to the DI safety relay This enables the DI safety relay Press the reset button to energize the DI safety relay This sends a L11 link signal to the DIS safety relay The outputs of the DIS safety relay energize automatically Press the respective Start buttons to energize the contactors K3 K4 K5 and K6 STOPPING Pressing the E stop of the SI safety relay shuts down all three relays Opening the interlocked gate or pressing the E stop of the DI safety relay turns off the outputs of both the DI and DIS safety relays while the SI safe
58. S output at L11 turn ON and the EM safety relay is energized The EM safety relay energizes S1 and S2 which enable the PowerFlex 525 drive Press the Start button to start the motor STOPPING Normal production stops are performed by pressing the Stop button To gain access through the safety gate press the Gate Unlock Request button The Y32 output turns OFF and the PowerFlex 525 drive decelerates When the proximity sensors detect speed below 0 5 Hz for 10 1 seconds the GLP safety relay energizes terminals 51 and L61 which unlocks the 440G MT switch OVERSPEED Overspeed is not checked because SLS2 is set to 0 Fault Detection Upon power up the safety devices perform internal checks The 440G MT switch has dual channel contacts and is tested for short circuits by pulse testing from the GLP safety relay The GLP safety relay uses redundant proximity sensors that must be mounted on independent fixtures If the Gate Lock Request is pressed while the gate is open the GLP PWR Fault indicator flashes red three times Close the gate press the Gate Unlock Request and then press the Gate Lock Request to clear the fault If the speed exceeds 0 5 Hz while the gate is unlocked the GLP PWR Fault indicator flashes red seven times Reduce the speed and cycle the power to the GLP safety relay to clear the fault 80 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The saf
59. S2T bop ti iig uts vag a2 51 oer 4 24 Gate Unlocked 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 97 Next Generation Guardmaster Safety Relay GSR Guard Locking with Time Delay Circuit Components e Bulletin 440G LZ guard locking switches e GLT safety relay e PowerFlex 525 Circuit Status The safety gates are closed and locked The 440G LZ is power to release guard locking switch The motor is off The GLT safety relay is ready for reset The GLT safety relay has a Logic setting of 1 Stop Cat 0 with Logic In OFF a Range setting of 4 10 seconds and a Time setting of 7 70 The delay is 7 seconds 70 of 10 seconds TIP Start the GLT configuration from 0 to generate test pulses as 11 21 14 and 24 11 and 21 are not used with the 440G LZ The solenoid locking signals require low current 5 mA and can be wired in parallel The TLS ZR guard locking switches can replace the 440G LZ switches using the same wiring Operating Principle STARTING Press the Door Lock and Reset Request After verifying that the gates are closed and locked the GLT safety relay turns on outputs 14 and 24 The PowerFlex 525 drive is enabled Press the Start button to start the motor STOPPING Normal production stops and starts are performed using the Start Stop buttons When access through the safety gates is needed press the Door Unlock Request button Outputs 14 and 24 turn OFF immed
60. Safety Relay GSR Ratings The safety function that is initiated by the Lifeline cable pull switches meets the safety performance requirements of SIL CL3 per IEC 62061 2005 and has Category 4 structure that can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 The circuit executes a Stop Category 0 Figure 16 Lifeline 24V DC LifeLine ser L13042 LifeLine 440E L1 i DI 440R D22R2 32 01 2 3 4 D Aux Signal To PLC 100S C09EJ413BC 440A A17173 SZ 800E N157R 855D T10SC20B24Y4 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 37 Next Generation Guardmaster Safety Relay GSR Safety Distribution Block and DI Safety Relay with Kinetix 350 Drive Circuit Components e SensaGuard non contact interlock switch e Safety Distribution Block e Bulletin 800F E stops e DI safety relay e Kinetix 350 drive Circuit Status The Logic setting of the DI safety relay is set to 2 monitored manual reset with Input 1 AND Input 2 OR L12 The E stop is released and connected to Input 1 S12 and 22 The SensaGuard switches are closed and are connected in series through the Distribution Block to Input 2 32 and 42 The PLC monitors the status of each SensaGuard The DI safety outputs 14 and 24 are OFF The Kinetix 350 Drive is powered but the safety inputs are off therefore the motor is OFF The Y32 Aux Signal and three status si
61. SensaGuard integrated latch interlocks and the E stop meets the safety performance requirements of SIL CL3 per IEC 62061 2005 and a Category 4 structure that can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 The circuit executes a Stop Category 0 Figure 9 SI DIS Safety Relays SensaGuard Interlock E stops and PowerFlex 525 Drive with Contactor 24V DC 3 SensaGuard S Integrated E stops Latches BOEM VraS 800F MX02 A40N Z21SS3PA A a l s Grey Red L1L2L3 rise gt PowerFlex R S T 525 1 Stop Blue Tin 7 2 Start 4Gnd Gate control power supply Status To PLC 100S CO9EJ14BC 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 23 Next Generation Guardmaster Safety Relay GSR Interlock Switch Multiple Gate Access Circuit Components e Trojan T15 and Elf GD2 tongue interlock switch e Bulletin 800F E stop e Compatible Input CI safety relay e Bulletin 100S contactor Circuit Status The circuit is shown with the safety gates closed and E stop released The CI safety relay is de energized The motor is off The monitoring circuit is connected to 34 for automatic reset of the CI safety relay Operating Principle This circuit shows how to connect the second channel of the interlock switches through a standard programmable l
62. Stop 800FM MT44 4 800F MX02S Aux to PLC RESET __ 9 O SI MM 440R S12R2 E Stop 800FM MT44 800F MX02S E Stop 800FM MT44 Stop Ese 800F MX02S 700S CFB440EJC C43EJ14BC CO9EJ14BC 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 19 Next Generation Guardmaster Safety Relay GSR GuardShield Light Curtain and Bulletin 800Z Zero Force Touch Buttons Circuit Components e GuardShield light curtain e Bulletin 800Z Zero Force Touch Buttons e SlIand MSR35H safety relay e Bulletin 100S contactor Circuit Status The hands of the operator are not on the two Bulletin 800Z Zero Force Touch Buttons The outputs of the MSR35H are off The light curtain is configured with the factory default settings Guard only mode and is unobstructed The outputs of the SI safety relay are off The motor is offand ready to run The light curtain is helps protect one portion of the machine An operator using two hand control accesses another portion of the machine and has full view of their area Operating Principle STARTING Press the Reset button to energize the output of the SI safety relay The operator places both hands on the Bulletin 800Z Zero Force Touch Buttons simultaneously within 0 5 seconds The outputs of the MSR35H terminals 14 and 24 energize the Bulletin100S contactors which start the motor STOPPING Removing one or both hands from the Bulletin 8
63. The EMD Range setting is 2 10 second OFF Delay and the Time setting is 2 20 therefore the time delay is 2 seconds The reset and monitoring circuit are connected to 34 for monitored manual reset Operating Principle Additional outputs are added to the SI safety relay CI DI or DIS by the EM safety relay immediate outputs and the EMD safety relay delayed outputs A single wire safety rated signal from terminal L11 of the SI communicates the output status to L12 of the EM and EMD safety relays STARTING Press and release the reset button to energize the outputs of the SI EM and EMD safety relays K1 K10 safety contactors or safety control relays energize to control the hazardous portion of the machine STOPPING When an E stop is pressed the safety outputs of the SI and EM safety relays turn off immediately and de energize K1 K6 Two seconds later the safety outputs of the EMD safety relay turn off and de energize K7 K10 Fault Detection Upon power up the SI EM and EMD safety relays perform internal checks Then the SI safety relay looks for dual signals from the E stop circuit A crossfault on the E stop circuit is detected by the SI safety relay With the E stop signals made closing the reset button places a voltage to the 34 terminal The external devices K1 K10 are checked to confirm that they are off A fault in K1 K10 causes their normally closed contacts to remain open and this fault prevents the SI safety
64. Wiring Diagram AB wy Allen Bradley Guard Imaster Next Generation Guardmaster Safety Relay GSR Bulletin Number 440R Table 1 Quick Reference Safety Relay SIL Cat Stop Page Modules Input Devices Output Devices CL PL No Cat 6 SI E stop PowerFlex 525 2 d 3 0 8 SI MAB PowerFlex 525 2 d 3 0 10 SI Trojan T15 1794 FLEX 1 0 2 d 3 0 12 SI EM EMD 4 E stops 100S C 700S DCP 2 d 3 0 14 SI EMD E stop Kinetix 6000 Guardmotion with RBM 3 e 4 1 16 SI EMD GuardShield Safe 4 100S 7005 C 3 e 4 0 18 SI DI DIS 3 E stops Trojan T15 Safety Mat 100S 7005 C 3 e 4 0 20 SI MSR35H GuardShield 800Z 100S C 3 e 4 0 22 SI DIS 3 SensaGuards with Integrated Latch 2 E stops PowerFlex 525 3 e 4 0 24 dl Trojan T15 Elf E stop PLC on Ch2 100S C 2 d 3 0 26 Cl 3 SensaGuards 1005 C 3 e 4 0 28 Cl 3 MC2 Magnetically Coded Sensors 1005 C 2 d 3 0 30 Cl 3 Ferrogard GD2 Non contact Sensors 1005 C 2 d 3 0 32 DI GuardShield 1005 C 3 e 4 0 34 DI 2 GuardShields 1005 C 3 e 4 0 36 DI 2 Lifeline 4 100S C 3 e 4 0 38 DI 5 SensaGuards Distribution Block E stop Kinetix K350 2 d 3 0 40 DI GuardShield E stop Pneumatic Safety Valve 3 e 4 0 42 DI SensaGuard with Integrated Latch E stop PowerFlex 525 2 d 3 0 44 DI EMD 440G MT MT GD2 GripSwitch 100S D 2 d 3 0 46 DI EMD MT GD2 GripSwitch Jog PowerFlex 70 2 d 3 0 48 DI EMD TLS1 GD2 Trojan T15 E stop 70
65. afety outputs of the DI safety relay The Y32 status signal turns OFF The Kinetix 350 drive is enabled The PLC can now turn the motor ON not shown in Figure 27 STOPPING Entering the warning field of the SafeZone Multizone scanner does not cause the safety system to turn off but the PLC turns on an indicator Entering the protective field of the SafeZone Multizone scanner or pressing the E stop causes the DI safety relay to turn OFF which disables the Kinetix 350 drive The motor coasts to a stop Fault Detection Upon successful completion of internal checks on power up the SafeZone Multizone scanner DIS safety relay and Kinetix 350 drive are prepared for operation The safety outputs of the SafeZone Multizone scanner generates test pulses to check for cross channel shorts and short circuit faults to power and ground The DI safety relay generates test pulses through the E stop circuit to check for cross channel shorts and short circuit faults to power and ground IMPORTANT Donot replace the DI safety relay with the DIS safety relay as the pulse checking on the outputs of the DIS safety relay causes an F059 fault on the Kinetix 350 drive safety inputs 58 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety functions initiated by the SafeZone Multizone scanner and the E stop buttons can meet the safety performance requirements of SIL CL 2 per IEC 62061
66. aults in the DI safety relay result in non operation of the motor Internal faults of the DI safety relay result in non operation of the jog function 46 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety function that is initiated by the GripSwitch meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The circuit executes a Stop Category 0 Figure 21 DI EMD Safety Relays with Enabling Jog System 24V DC GripSwitch 440J N21TNPM NP Jog Button LIL2L3 Machine Controlled Jog Enable PowerFlex 70 RIS w DriveGuard 9 24V DC 7 DC Comm 8 Dig Comm ma 2S X32 an Gate Control 3 1 ae sT SN AN TT 18 28 38 48 440K MT55050 440K MT55026 440J A04N To PLC Input for Jog Enable 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 47 Next Generation Guardmaster Safety Relay GSR Guard Locking with DI EMD Safety Relays Circuit Components e Bulletin 800F E stop e TLS1 GD2 guard locking switch e Trojan T15 GD2 tongue interlock switch e DIand EMD safety relays e Bulletin 700S safety control relay Circuit Status The E stop is reset and the safety gate is closed and locked The output
67. d 4 5 are OSSD outputs The E stop is released the SI outputs including L11 are closed The MAB is configured with three buttons e A latching dual channel E stop e A momentary Unlock e A momentary Lock and Reset button The two momentary buttons are also status indicators that show if the gate is locked and or closed Operating Principle STARTING With the E stop button released press the Lock and Reset button on the MAB The GLT safety relay turns OFF terminal 51 After verifying that the gate is closed and locked the GLT safety relay turns on its 14 and 24 outputs The K1 and K2 contactors turn on their loads STOPPING When normal access through the safety gate is needed press the Unlock button Outputs 14 and 24 turn OFF immediately and the load coasts to a stop After 6 seconds the GLT safety relay applies power to terminal 51 to unlock the gate When an emergency situation exists press the E stop button on the MAB The SI immediately sends a stop signal to the GLT safety relay through the L11 L12 connection The GLT safety relay immediately turns K1 and K2 OFF and the load coasts to a stop After a 6 second delay the MAB is unlocked 102 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Fault Detection Upon power up the MAB SI safety relay and GLT safety relay perform internal checks The MAB has redundant OSSD outputs to check for short circuits The
68. d motor M1 coasts to stop After the time delay of the EMD safety relay expires motor M2 coasts to a stop and the Y32 output energizes The gate can be unlocked by closing the Unlock selector switch Fault Detection Upon power up the MAB DI relay and EMD relay perform internal checks The DI safety relay then looks for signals from the E stop and the MAB With the E stop signals made the DI relay checks the K1 K2 K3 K4 monitoring circuit when the reset button is pressed If these checks are OK the output energizes The MAB has pulse tested outputs to detect wiring faults The MAB Fault Reset clears faults within the MAB Ratings The safety function that is initiated by the gate interlocks and the E stop meets the safety performance requirements of SIL CL3 per IEC 62061 2005 and has a Category 4 structure that can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 This circuit executes Stop Category 0 50 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 23 Guard Locking with DI EMD Safety Relays 24V DC L1 EZL i 442G MABH R pe ff AVENE 442G MABR URM C00 RANGE a TIME 8 ae 54 a DI 785 A ology FAR EM4R2D E stop 800FM MT44 800F MX02 Reset 800FM F6MX1 0 LOGIC L1 L2 L3 ath MAB Fault Reset p Grey Pink Violet Unlock 800FM SM220X
69. e setting of 7 70 The delay is 7 seconds 70 of 10 seconds TIP Start the GLT configuration from 0 to generate test pulses as 11 21 14 and 24 Operating Principle STARTING Press the Door Lock and Reset Request After verifying that the gate is closed and locked the GLT safety relay turns on output 14 and 24 The PowerFlex 525 drive is enabled Press the Start button to start the motor STOPPING Normal production stops and starts are performed using the Start Stop buttons When access through the safety gate is needed press the Door Unlock Request button Outputs 14 and 24 turn OFF immediately and the motor coasts to a stop After 7 seconds the GLT safety relay applies power to terminals 51 and L61 to unlock the gate Fault Detection Upon power up the TLS3 GD2 interlock switch GLT safety relay and PowerFlex 525 drive perform internal checks The GLT safety relay generates test pulses on terminals 11 and S21 to check for short circuits on the guard locking switch The TLS3 GD2 solenoid is powered through redundant wiring The 14 and 24 outputs of the GLT safety relay are pulse tested to check for short circuit conditions The PowerFlex 525 drive has dual safety inputs and is safety rated Ratings The safety function meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The safety function perfo
70. ed in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The safety function performs Stop Category 0 100 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 48 Guard Locking with Delayed Unlock 24V DC L1 L2 L3 PowerFlex R 525 Door Lock and Reset Request 11 24V DC 1 Stop 2 Start Sin H 512 522 B2 Ssa SH AT LOGIC oO RANGE b TIME UA UB 4 6 44 4 5 MAB 9 2 2 3 Gate Control 8 3 3 4 power supply Multifunction 7654 65 6 Access Box GLT 440R GL2S2T 24V DC Com Gate Gate Closed Locked Rockwell Automation Publication SAFETY WD001F EN P November 2015 101 Next Generation Guardmaster Safety Relay GSR Guard Locking with Time Delay Circuit Components e MAB e Sland GLT safety relays e Bulletin 100S contactor Circuit Status The gate is closed and locked The MAB is a power to release guard locking interlock The K1 and K2 contactors are off The GLT safety relay is ready for reset The GLT safety relay has a Logic setting of 2 Stop Cat 0 with Logic In AND IN1 a Range setting of 3 10 seconds and a Time setting of 6 60 The delay is 6 seconds 60 of 10 seconds TIP Start the GLT configuration from 0 to generate test pulses as 11 21 14 and 24 The MAB does not use 11 and 21 because terminals 4 4 an
71. er source and the motor coasts to a stop Clearing the obstruction in either light curtain does not cause the motor to energize the Start button must be pressed The motor can also be turned off by pressing the Stop button Fault Detection Upon successful completion of internal checks on power up the GuardShield light curtains energize their outputs with no objects present If a crossfault is detected the GuardShield light curtain goes to a lockout state with its outputs OFF After successful completion of internal checks the DI safety relay checks the signals from the light curtains If OK the DI safety relay then checks the status of the K1 and K2 contactors If either K1 or K2 fails in the actuated state the other contactor disconnects the motor The DI safety relay detects the faulted contactor and does not allow the motor to restart until the fault is corrected The safety system controls contactor K1 The machine control system and the safety system control contactor K2 This increases the probability of performance of the safety function because K1 and K2 are less likely to weld simultaneously due to the diversity of expected wear out times Ratings The safety function that is initiated by the GuardShield light curtains meets the safety performance requirements of SIL CL 3 per IEC 62061 2005 and has a Category 4 structure that can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 This circuit executes
72. ety function meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The safety function performs a Stop Category 1 Figure 38 Guard Locking Interlock with High Current Solenoid 24V DC Lock and Reset Request L1 L2 L3 R PowerFlex 525 x32 ar 13 23 33 43 LOGIC SLS1 SLS2 TIME 1 Stop o 0 onli 1 1 1 a Ge ME oo 2 Start GLP 7654 65 65 4 Digital Com 440R GL2S2P 440G MT47037 Power to Unlock MOD DY Proximity Sensors 871TM N40NP30 D4 889D F4AC 2 A 700 HPSXZ 24 relay 700 HN123 base 700 ADL1R diode 700 HN119 retainer 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 81 Next Generation Guardmaster Safety Relay GSR Stop Category 1 with Logic IN Guard Locking and Proximity Sensors Circuit Components e Bulletin 440G LZ guard locking switch e Bulletin 871TM proximity sensors e Bulletin 800F E stops e Sland GLP safety relays e PowerFlex 70 drive Circuit Status The E stop is released The safety gate is closed and locked The SI and GLP safety relay are ready for reset The GLP safety relay has a Logic setting of 2 Stop Category 1 with Logic IN a safe limited speed SLS1 setting of 1 1 Hz 5 05 seconds and a maximum speed setting SLS2 Time of 5 200 Hz
73. ety gate is initiated by pressing the Gate Unlock Request button The Y32 output of the GLP safety relay turns ON and commands the Kinetix drive to bring the motor to a safe limited speed less than 10 Hz When the proximity sensors detect speed below 10 Hz for 0 6 seconds the gate unlocks The operator can enter the machine cell as the motor continues to run at the safe slow speed After leaving the cell and closing the gate press the Reset and Gate Lock Request button to lock the gate and return the machine to production speeds Fault Detection Upon power up the safety devices perform internal checks The TLSZR switch has OSSD outputs and checks for crossfaults The GLP safety outputs are pulse tested to check for faults The GLP safety relay uses redundant proximity sensors that must be mounted on independent fixtures The Kinetix 300 drive requires two safety signals to enable the drive OVERSPEED If the gate is unlocked and the motor speed increases beyond the safe limited speed the GLP safety relay turns its safety outputs OFF and the motor coasts to a stop 84 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety function meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO13849 1 2006 This circuit executes Stop Category
74. f the DI safety relay which in turn drops out the solenoids of the safety valve The valve closes the Air Supply and releases the air pressure to the Air Exhaust Releasing the E stop button or clearing the light curtain does not cause the valve to turn back on Fault Detection Upon successful completion of internal checks on power up the DI safety relay checks the E stop and light curtain status If an open or short circuit is detected the DI safety relay does not energize its outputs If both input circuits are closed the DI safety relay checks the status of the safety valve If one or both solenoids of the safety valve are energized the Status contact is open and the DI safety relay does not energize its outputs If both solenoids are de energized the Status contact is closed and the DI safety relay Reset button energizes the DI safety outputs and opens the safety valve The safety valve performs its own internal checks If one of the valves remains actuated gets stuck or moves too slowly the Air Outlet flow is redirected to the exhaust To clear the fault condition both valves must be de energized and the valve reset button pressed Ratings This safety function that is initiated by the Bulletin 800F E stop and the GuardShield light curtain meets the safety performance requirements of SIL CL 3 per IEC 62061 2005 and has a Category 4 structure that can be used in systems that require Performance Levels up to PLe per ISO13849 1 2006 Thi
75. fault at the next attempt to start the motor The contactors have mechanically linked auxiliary contacts to help with fault detection of the contactors Ratings This safety performance of this circuit meets the requirements of SIL CL 2 per IEC 62061 2005 and has Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 This circuit performs a Stop Category 0 30 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 13 Stainless Steel Ferrogard GD2 Noncontact Interlock Switch 24V DC Stainless Steel Ferrogard Shown Open FRS21 GD2 Bigzr2222i52 StsrrrrrrrrT 440N G02149 O i E y CK I FS 889D F8AB 10 PLC Input 1756 1B16 Signal c AM 1769 IQ16 to Machi 1746 1B16 Sie 20 Enz 1792 IB16 10 Control 1734 IB4 11 System Oooo ss rE ME a or similar 3 Com 100S C43EJ14BC L Machine Control J Auxiliary 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 31 Next Generation Guardmaster Safety Relay GSR Light Curtain Point of Operation Control Circuit Components e GuardShield light curtain e DIsafety relay e Bulletin 800F push buttons e Bulletin 100S contactor Circuit Status The light curtain is clear and the motor is ready to run The DI safety relay is set for Logic 5 L12 or IN1 or IN2 with Automatic Reset Operatin
76. figuration from 0 to generate test pulses as 11 21 14 and 24 11 and 21 are not used with the TLS ZR The GLT requires both 12 22 and L12 to be ON to enable the PowerFlex 525 drive Operating Principle STARTING With the E stop released press the Door Lock and Reset Request button After verifying that the gate is closed and locked the GLT safety relay turns on its Y32 14 and 24 outputs The PowerFlex 525 drive is enabled Press the Start button to start the motor STOPPING Normal production stops and starts are performed using the Start Stop buttons When access through the safety gate is needed you have two options e Press the Door Unlock Request button e Press the E stop button The Y32 output turns OFF immediately and the PowerFlex 525 drive performs its pre programmed deceleration function After 6 seconds the GLT turns OFF 14 and 24 to disable the PowerFlex 525 drive and applies power to terminal 51 to unlock the gate Fault Detection Upon power up the TLS ZR switch SI safety relay GLT safety relay and PowerFlex 525 drive perform internal checks The SI safety relay uses pulse testing to check for short circuit conditions in the E stop circuits The L11 output of the SI safety relay is Single Wire Safety SWS capable of checking for short circuit conditions The TLS ZR switch has OSSD outputs to check for short circuits The 14 and 24 outputs of the GLT safety relay are pulse tested to check for short circuit c
77. formance Levels up to PLd per ISO 13849 1 2006 The circuit executes a Safe Torque Off stop 6 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 1 SI Safety Relay with E stop to PowerFlex 525 Drive 24V DC _jReset L1 L2L3 PowerFlex S T 525 11 24V DC 1 Stop A E stop gt e 2 Start 800FM MT44 RESET 800F MX02S ico SI oe 0 440R S12R2 Status JN To PLC m 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 7 Next Generation Guardmaster Safety Relay GSR SI Safety Relay with MAB Guard Locking to PowerFlex 525 Drive Circuit Components e Multifunctional Access Box MAB e SI safety relay e PowerFlex 525 drive Circuit Status The SI safety relay logic is set to MM monitored manual reset The MAB is closed and locked The SI safety outputs 13 14 and 23 24 are off The PowerFlex 525 drive is powered but disabled The motor is off Operating Principle STARTING Press the Reset button to turn on the SI safety outputs The drive is enabled and power is applied to the Start and Stop buttons Press the Start button to start the motor STOPPING Press the Stop button to stop the motor for production stops Press the E stop to initiate a safety stop the motor coasts to a stop GATE ACCESS Rotate the Unlock Request button to apply power to unlock the gate This immediately opens the safety outputs of
78. g Principle STARTING Press the Start button to energize contactors K2 The motor starts with the two normally open contacts of K1 and K2 holding the circuit energized STOPPING Obstructing the light curtain de energizes the safety outputs of the DI safety relay which in turn drops out K1 and K2 The contactors disconnect the motor from its power source and the motor coasts to a stop Clearing the obstruction in the light curtain does not cause the motor to start Fault Detection Upon successful completion of internal checks on power up the GuardShield light curtain energizes its outputs with no objects present The successful completion of internal checks the DI safety relay checks the signals from the light curtain If OK the DI safety relay then checks the status of the K1 and K2 contactors If either K1 or K2 fails in the actuated state the other contactor disconnects the motor The DI safety relay detects the faulted contactor and does not allow the motor to restart until the fault is corrected The safety system controls contactor K1 The machine control system and the safety system control contactor K2 Ratings The safety function that is initiated by the GuardShield light curtain meets the safety performance requirements of SIL CL 3 per IEC 62061 2005 and has a Category 4 structure that can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 This circuit executes a Stop Category 0 32 Rockwell Automat
79. gnals are OFF and inform the PLC that the safety system is ready to run The PLC turns ON an output that enables the Reset of the safety system Operating Principle STARTING Press the Reset button to energize the safety outputs of the DI safety relay The Y32 and three status signals turn OFF The Kinetix 350 drive is enabled The PLC can now turn the motor ON not shown in Figure 17 STOPPING Opening any gate or pressing any E stop de energizes the safety outputs of the DI safety relay which in turn cause the output of the Kinetix drive to turn OFF The motor will coast to a stop Fault Detection Upon successful completion of internal checks on power up the DI safety relay Kinetix 350 drive and SensaGuard interlock switch components are prepared for operation The SensaGuard interlocks generate test pulses to check for short circuit faults to power and ground The DI safety relay generates test pulses through the E stop circuit to check for short circuit faults to power and ground Ratings The safety functions initiated by the SensaGuard interlocks and the E stop buttons can meet the safety performance requirements of SIL CL 2 per IEC 62061 2005 and Performance Level PLd per ISO13849 1 2008 This circuit executes a Stop Category 0 38 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 17 Safety Distribution Block and DI Safety Relay with Kinetix 350 Drive
80. iately and the motor coasts to a stop After 7 seconds the GLT safety relay applies power to terminals 51 and L61 to unlock the gates Fault Detection Upon power up the 440G LZ switches GLT safety relay and PowerFlex 525 drive perform internal checks The 440G LZ switches have OSSD outputs to check for short circuits The 14 and 24 outputs of the GLT are pulse tested to check for short circuit conditions The PowerFlex 525 drive has redundant safety inputs and is safety rated Ratings The safety function meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The safety function performs Stop Category 0 98 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 47 Guard Locking with Time Delay 24V DC Door L1L2L3 Unlock H Request Door Lock PowerFlex R and Reset 525 Request Brown 11 24V DC 1 Stop 2 Start 9 2 Gate control 8 3 power supply 7654 GL 440R GL2S2T 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 99 Next Generation Guardmaster Safety Relay GSR Guard Locking with Delayed Unlock Circuit Components e MAB e GLT safety relay e PowerFlex 525 Circuit Status The gate is closed and locked The MAB is a power to release guard locking interlock The
81. in 800F push buttons e Bulletin 100S contactor Circuit Status The first and third gates are closed The second gate is open The CI safety relay 12 and S22 inputs are open due to the open gate and therefore the CI safety outputs are open The machine control PLC has a 24V auxiliary signal at terminal I1 from the second gate because the gate is open The first and third auxiliary signals are off as their gates are closed The PLC also has an auxiliary signal from the CI safety relay that indicates that the safety system is not ready The motor is off Operating Principle STARTING Closing the second gate satisfies the input of the CI safety relay The CI safety relay verifies that both K1 and K2 contactors are off and energizes its safety outputs Pressing the Start button starts the motor The Stop Start circuit is not part of the safety system and can be replaced by the machine control system for example a PLC STOPPING Press the Stop button to turn off the motor without affecting the status of the safety system Opening any of the gates causes the safety system to stop the motor Fault Detection Upon successful completion of internal checks on power up the SensaGuard interlock switches check for 24V at pins 4 and 8 If the actuator is within range the SensaGuard interlock switch activates its OSSD outputs The OSSD outputs perform continuous checking for short circuits to 24V ground and crossfaults Upon detection of a fault the
82. ion Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 14 Light Curtain Point of Operation Control 24V DC Start 800FM H F3MX10 Transmitter Receiver Restart not used EDM not used Brown Stop 800FM H E4MX01 White Aux Signal to PLC L1L2 L3 440L P4KL0960YD 1 889D F4AC 2 889D F8AC 2 532 saa enr a me 14 Aux Signal to PLC 100S C43EJ14BC 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 33 Next Generation Guardmaster Safety Relay GSR Two Light Curtains Point of Operation Control Circuit Components e GuardShield light curtains e DIsafety relay e Bulletin 800F push buttons e Bulletin 100S contactor Circuit Status The light curtains are configured with factory default settings guard only mode The light curtains are unobstructed The outputs of the safety relay are closed and the motor is ready to run The DI relay is set for Logic 6 IN1 AND IN2 OR L12 with Automatic Reset Operating Principle STARTING Press the Start button to energize contactor K2 The motor starts with the two normally open contacts of K1 and K2 holding the circuit energized STOPPING Obstructing either light curtain de energizes the safety outputs of the DI safety relay which in turn drops out K1 and K2 The contactors disconnect the motor from its pow
83. ion meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The safety function performs Stop Category 1 104 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 50 Guard Locking with Time Delay and Stop Cat 1 24V DC L1 L2 L3 Door Unlock H 440G Request TSZ21UPRH R PowerFlex 525 Door Lock and Reset Request 11 24V DC 1 Stop 2 Start Gate control power supply Brown Red Yellow Grey Pink 889D F8AC u 2 ps Gate amp Unlocked 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 105 Next Generation Guardmaster Safety Relay GSR Guard Locking with Time Delay and Stop Cat 1 Circuit Components e TLS ZR guard locking switch e Sland GLT safety relays e PowerFlex 525 drive Circuit Status The E stop is released Output L11 of the SI safety relay is active The gate is closed and locked The TLS ZR is a power to release guard locking switch The motor is off The GLT safety relay is ready for reset The GLT safety relay has a Logic setting of 4 Stop Cat 1 with Logic IN AND IN1 a Range setting of 4 10 seconds and a Time setting of 6 60 The delay is 6 seconds 60 of 10 seconds TIP Start the GLT con
84. it faults The SWS signal from L11 of the GLT safety relay to L12 of the EM relay detects short circuit conditions The reset circuit S44 of the GLT safety relay checks the status of the K1 K4 contactors If one is stuck in the energized position the GLT safety relay does not restart The PowerFlex 525 drive has redundant safety inputs and is safety rated 112 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The PowerFlex 525 drive safety function meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The PowerFlex 525 drive safety function performs Stop Category 1 If the contactors are used as redundant pairs their safety function meets the performance requirements of SIL3 per IEC 62061 2005 has a Category 4 structure and can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 The K1 K4 contactors perform Stop Category 0 Figure 54 E stop with Auto Reset and Stop Cat 0 and 1 24V DC L1 L2 L3 PowerFlex R 525 1 Stop 2 Start 4 Digital Com 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 113 Next Generation Guardmaster Safety Relay GSR Stop Cat 1 by Gate or E stop Circuit Components e Ferrogard GD2 non contact interlock switch e Sland GLT safety
85. ity Sensors Circuit Components e TLS3 GD2 guard locking switch e Bulletin 872C proximity sensors e Guard locking proximity GLP safety relay e PowerFlex 70 drive Circuit Status The gate is closed and locked The motor is off The GLP safety relay is ready for reset The GLP safety relay has a Logic setting of 1 Category 1 Stop with Logic IN OFF a safe limited speed SLS1 setting of 0 0 5 Hz 10 1 seconds and a maximum speed setting SLS2 Time of 2 20 Hz The safety outputs S11 amp 21 the single wire safety output L11 and the auxiliary output Y32 are OFF TIP Start the GLP logic configuration from 0 to configure X14 and X24 for use as safety outputs Operating Principle STARTING Press the Reset button to lock the gate and turn the GLP safety outputs ON Press the Start button to turn the motor ON STOPPING Normal production stops are performed by pressing the Stop button Access through the safety gate is initiated by pressing the Gate Unlock Request button The Y32 output of the GLP safety relay turns OFF and initiates a stop command to the drive When the proximity sensors detect speed below the safe limited speed for 10 1 seconds the gate unlocks and the safety outputs turn OFF The PowerFlex drive goes to a safe off state Fault Detection Upon power up the safety devices perform internal checks The TLS3 interlock switch has dual channel signals but does not check for crossfaults The GLP safety out
86. k their input circuits Shorts from the inputs to power ground or other inputs are detected immediately and prevent energization or de energize the respective outputs If one of the Bulletin 100S or Bulletin 700S output devices K1 K6 is stuck in an actuated state the respective DI safety relay prevents startup because the 34 feedback loop remains open Ratings The safety functions initiated by the input devices except the safety mat meet the safety performance requirements of SIL CL3 per IEC 62061 2005 and have Category 4 structures that can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 The safety function that is initiated by the safety mat meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 This circuit executes a Stop Category 0 52 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 24 Global E stop and Zone Control 24V DC MatGuard Safety Mat amp Trim 440F M2030BYNN 440F T2030 SensaGuard 440N Z21S26H E Stop 800FM MT44 800F MX02L E stop 800FM MT44 800F MX02L 100S C09 GuardShield Safe4 GuardShield Safe 4 7 EJ14BC Light Curtain Light Curtain 445L P4L1920YD 445L P4L0240YD 24V DC Com Rockwell Automation Publication SAFETY WD0
87. lock Request 7 y 889M F19RM 5 24V DC Com su sajssa ai 13 23 Reset SI AM Brown 440R S12R2 Violet Blue Grey Pink Green Black Red Blue Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR L1L2L3 PowerFlex R S T 525 11 24V DC 1 Stop 2 Start Next Generation Guardmaster Safety Relay GSR SI Safety Relay to Flex 1 0 Circuit Components e Trojan T15 GD2 tongue interlock switch e Bulletin 800F push button e SI safety relay e FLEX I O module Circuit Status The safety gate is closed The outputs of the SI safety relay are open and the machine actuators are off Control Relay CR1 is de energized and the 11 12 contact is closed Operating Principle The SI safety relay is chosen for this application because its thermal non switching current carrying capacity is 6 A in one circuit The FLEX output module performs the normal switching of the machine actuators during the manufacturing process The safety system enables the machine functions by providing power to the FLEX output module One of the FLEX outputs must drive an electromechanical device CR1 whose normally closed contact is in the monitoring loop of the safety relay The machine logic must energize this output while the machine is running as it is used by the SI safety relay to confirm that power is removed from
88. mation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The PowerFlex 525 drive safety function meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The PowerFlex 525 drive safety function performs Stop Category 1 If the contactors are used as redundant pairs their safety function meets the performance requirements of SIL3 per IEC 62061 2005 has a Category 4 structure and can be used in systems that require Performance Levels up to PLe per ISO 13849 1 2006 The K1 K4 contactors perform Stop Category 0 Figure 52 E stop with Monitored Reset and Stop Cat 0 and 1 24V DC L1L2L3 PowerFlex R 525 1 Stop o 2 Start 4 Digital Com 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 109 Next Generation Guardmaster Safety Relay GSR Guard Locking with Time Delay Circuit Components e MC2 magnetically coded non contact interlock switch e Sland GLT safety relays e Bulletin 100S contactor e PowerFlex 525 drive Circuit Status The safety gate is closed and the SI safety relay outputs are ON The E stop is released and the GLT safety relay outputs are OFF The GLT safety relay is ready for reset The GLT safety relay has a Logic setting of 6 Stop with Logic IN AND IN1 and Monitored Reset a Range setting of 2
89. motor is off The GLT is ready for reset The GLT has a Logic setting of 1 Stop Cat 0 with Logic In OFF a Range setting of 4 10 seconds and a Time setting of 7 70 The delay is 7 seconds 70 of 10 seconds TIP Start the GLT configuration from 0 to generate test pulses as 11 21 14 and 24 11 and S21 are not used with the MAB Operating Principle STARTING Press the Door Lock and Reset Request After verifying that the gate is closed and locked the GLT safety relay turns on its 14 and 24 outputs The PowerFlex 525 drive is enabled Press the Start button to start the motor STOPPING Normal production stops and starts are performed using the Start Stop buttons When access through the safety gate is needed press the Door Unlock Request button The 14 and 24 outputs turn OFF immediately and the motor coasts to a stop After 7 seconds the GLT safety relay applies power to terminals 51 and L61 to unlock the gate Fault Detection Upon power up the MAB GLT safety relay and PowerFlex 525 drive perform internal checks The MAB has OSSD outputs to check for short circuits The Fault Reset switch clears a fault within the MAB Outputs 14 and 24 of the GLT safety relay are pulse tested to check for short circuit conditions The PowerFlex 525 drive has redundant safety inputs and is safety rated Ratings The safety function meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be us
90. n the proximity sensors detect speed above 0 5 Hz the X14 X24 outputs turn OFF When the proximity sensors detect speed below 0 5 Hz the X14 and X24 outputs turn ON The X14 and X24 outputs can be connected to other safety rated devices like POINT Guard IO and the CR30 safety relay Fault Detection Upon power up the GLP safety relay POINT Guard I O and CR30 safety relay perform internal checks The GLP safety relay uses dual channel OSSD outputs that check for fault conditions The POINT Guard I O blocks are safety rated and must be controlled by a GuardLogix safety PLC Ratings The safety function meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO13849 1 2006 90 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 43 Stop Motion to PLC 24V DC EtherNet IP to Guardlogix Controller 1734 AENTR 1734 IB8S 1734 OB8S Va at peraja 51 61 52554 saa LOGIC SLS1 SLS2 TIME 0 0 1 1 1 9 2 2 2 8 3 3 3 76 54 6 4 6 4 0000 00009 0000 0000 O00 0000 00 01 02 03 04 05 06 07 08 09 10 11 CR30 440C CR30 22BBB Ai 2 12 13 14 15 16 17 18 19 20 21 D 0 DD Proximity Sensors 872C D8NP18 E5 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 91
91. nd the signals to Input 1 of the DI safety relay S12 and 22 are high The Warning Field signal is connected to a PLC which turns on an indicator and may also perform other logic The DI safety outputs 14 and 24 are OFF The Kinetix 350 drive is powered but the safety inputs are off therefore the motor is OFF The Y32 Aux Signal is high which informs the PLC that the safety system is ready to run Operating Principle STARTING Press the Reset button to energize the safety outputs of the DI safety relay The Y32 status signal turns OFF The Kinetix 350 drive is enabled The PLC can now turn the motor ON this circuitry is not shown STOPPING Entering the warning field of the SC300 safety sensor does not cause the safety system to turn off but the PLC turns on an indicator Entering the protective field of the SC300 safety sensor or pressing the E stop causes the DI safety relay to turn OFF which disables the Kinetix 350 drive The motor coasts to a stop Fault Detection Upon successful completion of internal checks on power up the SC300 safety sensor DI safety relay and Kinetix 350 drive are prepared for operation The safety outputs of the SC300 safety sensor generates test pulses to check for cross channel shorts and short circuit faults to power and ground The DI safety relay generates test pulses through the E stop circuit to check for cross channel shorts and short circuit faults to power and ground IMPORTANT Donot replace the DI
92. ng the E stop The motor performs a coast to stop Fault Detection Upon power up the safety devices perform internal checks The OSSD outputs of the MSR41 controller are pulse tested to check for crossfaults The E stop signals are pulse tested to check for crossfaults The mechanically linked contacts of the Bulletin 100S contactor verify that the contactors are off after a demand is placed on the safety system Ratings The safety function meets the safety performance requirements of SIL CL3 per IEC 62061 2005 and has a Category 4 structure that can be used in systems that require Performance Levels up to PLe per IS013849 1 2006 This circuit executes a Stop Category 0 72 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 34 Micro 400 Light Curtain 24V DC Micro 400 BOOFM MT44 j 445L P4C0300FP 800F MX025 445L AC8RJ5 2x Transmitter Receiver _ of Reset 800FM F6MX10 Status to PLC Tar wz ov TT DIS 440R D2252 s3442 aa 34 44 14 Joa JET Lockout Status to PLC Safety Output Status to PLC 100S C43EJ14BC 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 73 Next Generation Guardmaster Safety Relay GSR Micro 400 Light Curtain Circuit Components e Micro 400 light curtain e SensaGuard non contact interlock switch e Bulletin 800
93. o use one monitoring device per switch Most of the examples in this publication show an interlock switch and an emergency stop switch combined in the circuit When a monitoring safety relay for example GSR Guardmaster safety relay is used for fault detection it is important to note the following e All safety critical single faults except for certain faults over the contact sets at the E stop are detected at the next opening of the guard e All safety critical single faults except for certain faults over the contact sets at the interlock switch are detected at the next operation of the E stop e Because the E stop device is operated infrequently we recommend that you check its function with the guard closed regularly at the start of your shift or daily to enable the safety monitoring relay to detect single faults If the guard is rarely opened the interlock switch must be checked in a similar manner Note 5 This symbol indicates that the associated component or device features direct opening positive opening operation In the even t of a fault welded contacts are forced open by the motion of the safety guard or E Stop device This symbol denotes mechanically linked contacts if one contact welds closed all other dependent auxiliary contacts remain in position that is they cannot change state 4 Rockwell Automation Publication SAFETY WD001F EN P November 2015 General Safety Information Next Generation Guardmaste
94. ocked the GLT turns on its 14 and 24 outputs The PowerFlex 525 drive is enabled Press the Start button to start the motor STOPPING Normal production stops and starts are performed using the Start Stop buttons When access through the safety gate is needed press the Door Unlock Request button The 14 and 24 outputs turn OFF immediately and the motor coasts to a stop After 7 seconds the GLT safety relay applies power to terminals 51 and L61 to unlock the gate Fault Detection Upon power up the 440G LZ guard locking switch GLT safety relay and PowerFlex 525 drive perform internal checks The 440G LZ switch has OSSD outputs to check for short circuits Outputs 14 and 24 of the GLT safety relay are pulse tested to check for short circuit conditions The PowerFlex 525 drive has redundant safety inputs and is safety rated Ratings The safety function meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The safety function performs Stop Category 0 96 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 46 Guard Locking with Time Delay 24V DC 440G LZS21SPRA L1 L2 L3 S PowerFlex R S Door Lock 525 sa and Reset 11 24V DC Request 1 Stop 2 Start 9 2 2 3 8 3 g 7654 6 a GL a 440R GL2
95. ogic controller PLC to get status information without auxiliary contacts in the interlock switch The PLC program must monitor the safety relay and prevent the PLC from turning the output ON if the safety relay is not OFF STARTING Channel 1 input S11 S12 of the CI safety relay is satisfied Using isolated relay contacts in its output module the PLC closes the second safety channel 21 22 of the CI safety relay The safety outputs of the CI safety relay close Press the Start button to start the motor STOPPING Opening any one of the safety gates or pressing the E stop causes the motor to turn off Closing the gate or releasing the E stop does not cause the motor to start due to the start stop interlocking circuit To restart the motor close the safety gate or release the E stop Then press the Start button Fault Detection If the PLC fails with its output closed the safety relay detects the difference between the safety gate and the PLC and stops the motor A single fault open or short across one of the interlocks is detected by the safety relay and the motor is turned off The motor remains off until the fault is corrected or power is cycled Ifeither contactor K1 or K2 sticks ON the motor stops on command due to the other contactor but the CI safety relay cannot be reset revealing the fault A single fault that is detected on the CI safety relay input circuits will result in the lockout of the system to a safe state OFF at the next
96. onditions The PowerFlex525 has redundant safety inputs and is safety rated 106 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety function meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The safety function performs Stop Category 1 Figure 51 Guard Locking with Time Delay and Stop Cat 1 24V DC Door Lock L1L2L3 Door and Reset 440G Pian Request PowerFlex R TSZ21UPRH i 525 LXXX XX 11 24V DC dy su s21 s34 a1 13 23 1 Stop 2 Start Gate control power supply 440R S12R2 889D F8AC Gate Unlocked 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 107 Next Generation Guardmaster Safety Relay GSR E stop with Monitored Reset and Stop Cat 0 and 1 Circuit Components e Bulletin 800F E stop e GLT safety relay e PowerFlex 525 drive Circuit Status The E stop is released Outputs 14 24 51 L61 L11 and Y32 of the GLT safety relay are OFF The PowerFlex 525 drive is disabled and the motor is off The GLT safety relay is ready for reset The GLT safety relay has a Logic setting of 5 E stop Cat 1 with Logic IN OR IN1 a Range setting of 5 30 seconds and a Time setting of 5 50 The delay is 1
97. onds the gate unlocks and the safety outputs turn OFF The PowerFlex drive goes to a safe off state 82 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Fault Detection Upon power up the safety devices perform internal checks The 440G LZ switch and GLP safety relay have dual channel pulse tested outputs that check for faults The GLP safety relay uses redundant proximity sensors that must be mounted on independent fixtures The PowerFlex 70 drive requires two safety signals to enable the drive OVERSPEED If the proximity sensors detect a speed above the maximum speed 200 Hz the auxiliary output Y32 the safety outputs X14 amp X24 and the single wire safety output L11 turn off The PWR Fault indicator flashes at a 3X rate When the speed drops below the max speed limit press the Reset button to clear the fault and energize the safety outputs Ratings The safety function meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per IS013849 1 2006 This circuit executes a Stop Category 1 Figure 39 Stop Cat 1 with Logic IN Guard Locking and Proximity Sensors 24 VDC I 440G LZS21SPRA Reset L1L2L3 i Reset amp Gate Lock Request PowerFlex 70 with DriveGuard 2 Start 1 Stop 7 DC Comm
98. onnection to the Logic IN terminal L12 the GLT only uses the 12 and 22 inputs to initiate its safety function TIP Start the GLT configuration from 0 to generate test pulses as 11 21 14 and 24 11 and 21 are not used with the TLS ZR The TLS ZR guard locking switch can be replaced with the 440G LZ guard locking switch using the same wiring Operating Principle STARTING Press the Door Lock and Reset Request button After verifying that the gate is closed and locked the GLT safety relay turns on its Y32 14 and 24 outputs The PowerFlex 525 drive is enabled Press the Start button to start the motor STOPPING Normal production stops and starts are performed using the Start Stop buttons When access through the safety gate is needed press the Door Unlock Request button The Y32 output turns OFF immediately and the PowerFlex 525 drive performs its pre programmed deceleration function After 6 seconds the GLT safety relay turns OFF terminals 14 and 24 to disable the PowerFlex 525 drive and applies power to terminal 51 to unlock the gate Fault Detection Upon power up the TLS ZR guard locking switch GLT safety relay and PowerFlex 525 drive perform internal checks The TLS ZR switch has OSSD outputs to check for short circuits The 14 and 24 outputs of the GLT safety relay are pulse tested to check for short circuit conditions The PowerFlex 525 drive has redundant safety inputs and is safety rated Ratings The safety funct
99. ors are off The GLP safety outputs X14 and X24 the single wire safety output L11 and the auxiliary output Y32 are OFF The motor is off TIP Start the GLP logic configuration from 0 to configure X14 and X24 for use as safety outputs Operating Principle This is a cascaded safety system using the GSR single wire safety connections from L11 to L12 The E stop turns off K1 and K2 and also instructs the GLP safety relay to issue a safe limited speed command to the Preset Freq input of the PowerFlex 525 drive The safe limited speed command can also be initiated by pressing the Gate Unlock Request this leaves K1 and K2 energized STARTING Press the Reset button on the SI safety relay to energize K1 and K2 and to enable the GLP safety relay through the single wire safety connection L11 to L12 Then press the Reset and Gate Lock Request button to lock the gate and turn the GLP safety outputs ON Press the Start button to turn the motor ON STOPPING Safe limited speed is initiated by either e Pressing the E stop which turns off K1 and K2 and initiates the Gate Unlock Request function in the GLP safety relay e Pressing the Gate Unlock Request which leaves K1 and K2 energized and initiates a safe limited speed command to the PowerFlex 525 drive When the proximity sensors detect speed below the safe limited speed of 3 Hz for 1 75 seconds the gate unlocks 86 Rockwell Automation Publication SAFETY WD001F EN P November 2015
100. ors detect speed below the SLS1 setting for 10 1 seconds the safety outputs X14 and X24 turn OFF The safety PLC uses the X14 and X24 signals to prevent the restart of the hazard Fault Detection Upon power up the safety devices perform internal checks The GLP and TLS ZR devices have dual channel OSSD outputs that check for fault conditions The GLP safety outputs are pulse tested to check for faults The GLP safety relay uses redundant proximity sensors that must be mounted on independent fixtures The POINT Guard I O blocks are safety rated and must be controlled by a GuardLogix safety PLC OVERSPEED If the proximity sensors detect a speed above the maximum speed 20 Hz the safety outputs at terminals X14 amp X24 turn off The PWR Fault indicator flashes at a 3X rate When the speed drops below the max speed limit press the Reset button to clear the fault and re energize the safety outputs 78 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety function meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO13849 1 2006 This circuit executes a Stop Category 1 Figure 37 Stop Motion with Guard Locking by PLC 24V DC Ethernet I P Unlocked to Guardlogix Request 1734 AENTR _1734 IB8S 1734 OB8S
101. puts are pulse tested to check for faults The GLP safety relay uses redundant proximity sensors that must be mounted on independent fixtures The PowerFlex 70 requires two safety signals to enable the drive OVERSPEED If the proximity sensors detect a speed above the maximum speed 20 Hz the auxiliary output Y32 the safety outputs X14 amp X24 and the single wire safety output L11 turn off The PWR Fault indicator flashes at a 3X rate When the speed drops below the max speed limit press the Reset button to clear the fault and energize the safety outputs 76 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety function meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO13849 1 2006 This circuit executes a Stop Category 1 Figure 36 Cat 1 Stop with Guard Locking Interlock and Proximity Sensors 24V DC L1 L2 L3 Gate Reset amp Unlock Gate Lock 9 Request PowerFlex 70 with DriveGuard 2 Start 1 Stop LOGIC SLS1 SLS2 TIME 0 oO 5 1 1 9 2 2 8 3 3 3 7 DC Comm 7654 654 654 8 Digital In Com 440R GL2S2P TLS3 GD2 440G T27183 K DD 0 DD Proximity Sensors 872C D8NP18 E5 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2
102. r Safety Relay GSR IMPORTANT The examples in this section are for advanced users and assumes that you are trained and experienced in safety system requirements Contact Rockwell Automation to find out more about our safety risk assessment services ATTENTION rN Perform a risk assessment to make sure that all tasks and hazard combinations are identified and addressed The risk assessment may require additional circuitry to reduce the risk to a tolerable level Safety distance calculations are an important consideration in safety circuits but is not part of the scope of this document Additional Resources These documents contain additional information concerning related products from Rockwell Automation Resource GuardShield Micro 400 Safety Light Curtains User Manual publication 445L UM003 Description Provides an explanation of safety distance calculations Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Provides general guidelines for installing a Rockwell Automation industrial system Product Certifications website http www ab com Provides declarations of conformity certificates and other certification details You can view or download publications at http www rockwellautomation com literature Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR SI Safety Relay with E stop to PowerFlex 525 Drive Circuit
103. r 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 Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page Allen Bradley DriveGuard Ferrogard FLEX GuardLogix Guardmaster GuardMotion GuardShield Kinetix Lifeline LISTEN THINK SOLVE MatGuard Minotaur Panel View POINT Guard I O PowerFlex Rockwell Software Rockwell Automation Safedge SafeZone SensaGuard Trojan and Zero Force Touch Buttons are
104. re off and await a reset signal The PowerFlex 525 drive is powered but disabled Contactor K1 is de energized The motor is off Operating Principle STARTING Press the Reset button to turn on the DIS safety outputs K1 is energized which enables the drive and also applies power to the Start and Stop buttons Press the Start buttons to start the motor STOPPING Press the Stop button to stop the motor for production stops Press either E stop or open any safety gate to initiate a safety stop the motor coasts to a stop Fault Detection Upon successful completion of internal checks by the SI DIS SensaGuard and PowerFlex 525 drive the drive awaits the closure of the safety outputs If the DIS fails the drive does not energize the motor and the fault is detected by non operation of the motor The DIS generates test pulses through the E stop circuits to detect cross channel shorts and shorts to power and ground The SensaGuard interlocks generate test pulses on their outputs to detect cross channel shorts and shorts to power and ground A fault in the safe circuit of the drive is detected by the drive and issues a safety stop The DIS monitors the mechanically linked contacts of K1 to verify that the contactor is de energized before resetting the safety system 22 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety functions that are initiated by the
105. ready to run Press the Start button JOGGING Close the 3 position GripSwitch to close the outputs of the DI safety relay and enable the drive Remove the enabling switch from the MT GD2 holder The machine control system is notified that the GripSwitch has been removed and enables the jog switch Press the Jog button on the GripSwitch to initiate the operation of the EMD safety relay The EMD safety relay closes its safety outputs for the set duration The Jog button must be held closed during the jog time STOPPING The jog function stops after the set time expires To restart momentarily release the jog button and then reclose it to repeat the jog Releasing or squeezing the 3 position GripSwitch opens the outputs of the DI safety relay and the PowerFlex drive executes a coast to stop Fault Detection Upon successful completion of internal checks by the DI and EMD safety relays and the PowerFlex drive the drive awaits the closure of the EMD safety outputs If the DI safety relay fails the drive does not energize the motor and the fault is detected by non operation of the motor The DI safety relay uses dual channel to detect faults to power ground and cross channel faults on the Enabling switch or the MT GD2 A short across the jog switch is detected and a subsequent jog attempt is prevented by the EMD safety relay A fault in the Safe Off option of the drive is detected by the DI safety relay on the next attempt to restart the drive Internal f
106. relay checks the reset circuit Upon release of the reset button the DI safety relay checks the status of the contactors Due to the size of the Bulletin 100S D contactors mirrored contacts on either side of the unit are used to reflect the status of the armature safely If all mirrored contacts are closed then the DI energizes its outputs If one contactor welds in the closed state the second contactor shuts off the motor and the fault is detected by the DI safety relay upon the next attempt to start the motor Single channel faults on the input devices GripSwitch interlocks and stop switch are detected by the DI safety relay either on or before a demand is placed on the safety system depending on the nature of the fault Ratings The safety function that is initiated by the MT GD2 guard locking interlock and the GripSwitch button meets the safety performance requirements of SIL CL 2 per IEC62061 2005 and has Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 This circuit performs a Stop Category 0 Figure 20 Interlock Switch with Enabling Device Guard Locking with Time Delay 24V DC Guardlocking Interlock GripSwitch K1 440G MT47045 440J N21TNPM NP Start Primary MT GD2 440J A04N MT GD2 1 800FM F3MX10 uu Latch Release 440T MT55076 K2 Safeguard W N Q H Stop 800FM E4MX01 Reset 800FM F6MX10 Dp O Jog Signal to a gt GripSwitch
107. relays e Bulletin 100S contactor e PowerFlex 525 drive Circuit Status The safety gate is closed The SI safety relay set to automatic reset turns ON output L11 The E stop is released and the GLT safety relay outputs are ON The GLT safety relay has a Logic setting of 8 Stop with Logic IN AND IN1 and Automatic Reset a Range setting of 3 3 seconds and a Time setting of 7 70 The delay is 2 1 seconds 70 of 3 seconds TIP Start the GLT configuration from 0 to generate test pulses as 11 21 14 and 24 Operating Principle The GLT safety relay requires both the E stop to be released and the safety gate to be closed to energize its outputs The GLT safety relay has a connection to B2 the retriggerable input If the E stop is pressed it can be released before the completion of the time delay without causing a recoverable fault in the GLT safety relay When the E stop is released the immediate outputs turn back ON and the timer is reset STARTING With the E stop released the GLT safety relay turns on outputs Y32 L11 51 L61 14 and 24 Contactors K1 and K2 turn ON The PowerFlex 525 drive is enabled Press the Start button to start the motor STOPPING Normal stops and starts of the motor are performed with the Start Stop buttons Opening the gate or pressing the E stop initiates a stop sequence GLT safety relay outputs Y32 14 and 24 turn off immediately The K1 and K2 contactors turn off and the PowerFlex 525 drive
108. rms Stop Category 0 94 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 45 Guard Locking with Time Delay 24V DC 5 L1 L2 L3 oor o H PowerFlex R q l Door Lock 2 Safety H ee 11 24V DC Gate eques r 1 Stop H 2 Start LOGIC 0 RANGE o TIME 1 LL 1 1 2 2 ate control 9 2 Gat trol BE as nfs T te z4 power supply GL 440R GL2S2T he 7 eS Unlocked 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 95 Next Generation Guardmaster Safety Relay GSR Guard Locking with Time Delay Circuit Components e Bulletin 440G LZ guard locking switch e GLT safety relay e PowerFlex 525 Circuit Status The gate is closed and locked The 440G LZ is a power to release guard locking switch The motor is off The GLT safety relay is ready for reset The GLT safety relay has a Logic setting of 1 Stop Cat 0 with Logic In OFF a Range setting of 4 10 seconds and a Time setting of 7 70 The delay is 7 seconds 70 of 10 seconds TIP Start the GLT configuration from 0 to generate test pulses as 11 21 14 and 24 11 and 21 are not used with the 440G LZ The TLS ZR guard locking switch can replace the 440G LZ guard locking switch using the same wiring connections Operating Principle STARTING Press the Door Lock and Reset Request After verifying that the gate is closed and l
109. s circuit performs a Stop Category 0 40 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 18 Safety Valve Air Supply Release 24V DC E Stop amp gt 800FM MT44 800F MxX02S DM2 CrossFlow SERPAR Safety Rated Valve Air Supply Reset F6MX10 800FM F6MX10 TT Air Exhaust Ch1 Sn l S A OE Air Outlet to other pneumatic valves Locic_ 3 DI eee 440R D22R2 Aux Signal to PLC Transmitter Receiver 440L P4K0960YD i 889D F4AC 2 889D F8AC 2 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 41 Next Generation Guardmaster Safety Relay GSR DI Safety Relay with SensaGuard Integrated Latch and PowerFlex 525 Drive Circuit Components e SensaGuard integrated latch e Bulletin 800F E stops e DIsafety relay e PowerFlex 525 drive Circuit Status The DI safety relay logic is set to 2 IN1 AND IN2 OR L12 with monitored reset The SensaGuard Light Latch interlock is connected to input 1 of the DI S12 and 22 The E stop is connected to input 2 of the DI S32 and 42 The gate monitored by the SensaGuard Light Latch is closed and the E stop is released The DI safety outputs are off The PowerFlex 525 drive is powered but disabled The motor is off Operating Principle STARTING Pres
110. s for input signals If OK the CI safety relay checks the K1 K2 S34 monitoring circuit to determine whether both contactors are off If one of the contactors gets stuck on the other contactor de energizes the motor and the CI safety relay detects the fault at the next attempt to start the motor The contactors have mechanically linked auxiliary contacts to verify fault detection of the contactors Ratings This safety performance of this circuit meets the requirements of SIL CL 2 per IEC 62061 2005 and has Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 This circuit performs a Stop Category 0 28 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 12 Magnetically Coded Sensor 24V DC Shown Open Start 800FM F3MX10 K2 Stop 800FM E4MX01 MC2 Sensor 440N Z21W1PH Cordset 889D F8AB 2 Machine Control PLC Input 1756 IB16 Auxiliary Signals 1769 6 to Machine 1746 1B16 Control 1792 1B16 0 1734 1B4 l1 1793 IB6 2 or similar 3 System 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 29 Next Generation Guardmaster Safety Relay GSR Stainless Steel Ferrogard GD2 Non contact Interlock Switch Circuit Components e Ferrogard GD2 non contact interlock switch e CI safety relay e
111. s of the safety relays are open and the motors are off The rotary switches of the EMD safety relay have the delay time set to 18 seconds Range 3 30 seconds OFF Delay Time 6 60 of range The EMD safety relay will open its contacts 18 seconds after the signal from the DI L11 output turns off Operating Principle STARTING Press the Reset button to energize the outputs of the DI safety relay The outputs of the DI safety relay energize the K1 and K2 control relays and motor M1 starts Simultaneously the DI safety relay sends a signal via L11 to the EMD safety relay The outputs of the EMD safety relay energize the K3 and K4 control relays and motor M2 starts STOPPING When the E stop is pressed the outputs of the DI safety relay open and motor M1 coasts to stop After the time delay of the EMD safety relay expires motor M2 coasts to a stop and the Y32 output energizes The gate can be unlocked by pressing the Gate Release button Press the Gate Release button to power the solenoid and open the Gate Closing the Gate or resetting the E stop does not re energize the Bulletin 700S control relays Fault Detection Upon power up the DI and EMD safety relays perform internal checks The DI safety relay then looks for signals from the E stop and the TLS1 GD2 guard locking switch and Trojan T15 tongue interlock switch The E stop has a self monitoring contact which opens if the contact block falls off the control panel With the E stop signals made
112. s the Reset button to turn on the DI safety outputs The drive is enabled and power is applied to the Start and Stop buttons Press the Start buttons to start the motor STOPPING Press the Stop button to stop the motor for production stops Press the E stop or open the safety gate to initiate a safety stop the motor coasts to a stop Fault Detection Upon successful completion of internal checks by the DI safety relay SensaGuard latch and PowerFlex 525 drive the drive awaits the closure of the safety outputs If the DI safety relay fails the drive does not energize the motor and the fault is detected by non operation of the motor The DI safety relay generates test pulses through the E stop circuits to detect cross channel shorts and shorts to power and ground The SensaGuard latch generates test pulses on its outputs to detect cross channel shorts and shorts to power and ground A fault in the safe circuit of the drive is detected by the drive and the drive issues a safety stop Ratings The safety functions initiated by the SensaGuard latch and the E stop meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The circuit executes a Stop Category 0 42 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 19 DI Safety Relay with Sensa
113. t be the only access to the hazard area e The interlocking system must have the highest possible reliability It is often advisable to use a solenoid locking switch such as the Guardmaster 440G LZ or TLS ZR guard locking switches Rockwell Automation Publication SAFETY WD001F EN P November 2015 3 Next Generation Guardmaster Safety Relay GSR Note 4 Safety monitoring relay units are used in dual channel circuits with infrequent operation or with multiple switching devices connected This note applies to all monitoring devices that compare the signal at the change of state of dual channels Certain faults are only detected at a change of state of the input switching device interlock switch or E stop switch If there are long periods for example months as opposed to days between switching actions it is possible for multiple faults to accumulate which could lead to a dangerous situation Therefore a regular check must be performed on the system to detect single faults before an accumulation occurs This check can be manual or initiated by part of the control system If for example three interlock switches are connected to the monitoring unit certain faults are detected only at the switch on the first opened guard and the switch on the last closed guard This is because any switching between the first opening last closing does not change the state of the monitoring unit input circuits Therefore in some applications it is necessary t
114. t in agreement If CR is not de energized when the gate is closed the SI safety relay does not close its outputs 10 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety function that is initiated by the Trojan T15 GD2 gate interlock meets the safety performance requirements of SIL CL 2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO13849 1 2006 This circuit executes a Stop Category 0 Figure 3 SI Safety Relay to FLEX 1 0 24V DC Start 800FM F F3MX10 Reset 800FM F6MX10 in Sed E4MX01 1 O 1700 HLT2Z24 1700 TBR24 Limited to sI r 440R S12R2 S Trojan T15 GD2 440K T11390 889D F4AC 2 33 Machine 15 15 33 51 Onm o peed ued a 1794 TB3 amp 1794 116 FLEX Output Module FLEX Input Module 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 11 Next Generation Guardmaster Safety Relay GSR Expansion Modules with Immediate and Delayed Outputs Circuit Components e Bulletin 800F E stops e SI Expansion Module EM Expansion Module Time Delayed EMD safety relays e Bulletin 100S contactor e Bulletin 700S safety control relay Circuit Status The E stops are reset The safety outputs of the SI EM and EMD safety relays are de energized All contactors are off
115. tch Ratings The safety function that is initiated by the Trojan T15 switch meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require up to Performance Level PLd per ISO13849 1 2006 The safety function that is initiated by the E stop meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require up to Performance Level PLd per ISO 13849 1 2006 This circuit executes a Stop Category 0 See publication 937TH WD001_ EN P for more safeguarding examples with the galvanic isolator 62 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 29 Hazardous Location 24V DC Hazardous Location Non hazardous Location E Stop L1 L2 L3 ita Galvanic Isolating Switching Amplifier ee om H Reset ass II III Div 1 2 937TH DISRS DC1 PowerFlex R S T European Zone 0 1 2 EExia IIB 5 E at Settings 4Gnd S1 R1 R3 1K ohm S2 1492 JD3RB102 3 7 R2 R4 10K ohm 1492 JD3RB103 Gate control circuit gt DIN Rail Connections 937TH DISRS DC1 Status eS To PLC m I I I 1 i DIN Rail Connections i S1 Normal Output Trojan T15 i S2 Output 2 Follows Output 1 440K T11395 4 S3 Enable Line Fault Detection I I S4 Not Used
116. tected by the light curtain With the light curtain signals made closing the reset button places a voltage to the 34 terminal The external devices K1 K6 are checked to confirm that they are off A fault in K1 K6 causes their normally closed contacts to remain open and this fault is detected by the SI safety relay Ratings The safety function that is initiated by the light curtain meets the safety performance requirements of SIL CL 3 per IEC 62061 2005 and has a Category 4 structure that can be used in systems that require Performance Levels up to PLe per 1SO13849 1 2006 The Category 4 rating requires the redundant usage of K1 K6 to de energize the machine actuators and the contactors must be monitored by the safety system This circuit executes a Stop Category 0 16 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 6 Light Curtain with Immediate and Delayed Outputs 24V DC Reset 800FM F6MX10 Transmitter Receiver POC Type 4 Safe 4 a list a 445L P4S1200YD Cordset 2 x 889D F5AC 2 7005S 24VC DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 17 Next Generation Guardmaster Safety Relay GSR Global E stop Cascaded Safety Functions Circuit Components e Bulletin 800F E stops e Trojan T15 tongue interlock switch e Bulletin 440F MatGuard safety mat e SI Dual Input DI Dual Input Solid state Output DI
117. the MAB which in turn causes the safety outputs of the SI to turn OFF Then the PowerFlex 525 drive safety inputs turn OFF and the motor coasts to a stop The stopping time of the machine must be less than the time from when the operator presses the Unlock Request to when the operator can reach the hazard Fault Detection Upon successful completion of internal checks by the MAB SI safety relay and PowerFlex 525 drive the drive awaits the closure of the safety outputs If the SI safety relay faults the drive does not energize the motor and the fault is detected by non operation of the motor The MAB generates test pulses through its output signals to detect cross channel shorts and shorts to power and ground The MAB Fault Reset switch clears faults within the MAB A fault in the safe circuit of the drive is detected by the drive and the drive executes a Safe Torque Off stop The safety system does not detect a short circuit from S1 to S2 Ratings The safety function that is initiated by the E stop meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The circuit executes a Safe Torque Off stop 8 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Figure 2 SI Safety Relay with MAB Guard Locking to PowerFlex 525 Drive 24V DC 442G MABH R 442G MABR URM C00 o 4Reset Un
118. the SI safety relay checks the 34 monitoring circuit when the reset button is pressed If these checks are OK the output energizes If the delayed outputs of the EMD safety relay fault to the ON state the SI safety relay does not start the motor The fault is detected by the 34 monitoring circuit on the next attempt to restart because K1 will remain energized If the drive faults to an ON state the motor stops because it is disconnected by K1 This fault is detected by the 34 monitoring circuit on the next attempt to restart because the Kinetix feedback circuit will remain off If K1 gets stuck or welded closed the motor will stop by the drive and the fault is detected by the 34 monitoring circuit of the SI safety relay on the next attempt to restart 14 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety function that is initiated by the Bulletin 800F E stop meets the safety performance requirements of SIL CL3 per IEC 62061 2005 and has a Category 4 structure that can be used in systems that require Performance Levels up to PLe per 1SO13849 1 2006 This circuit executes a Stop Category 1 Figure 5 Safety Motion Delayed Braking 24 VDC A Estop L1L2L3 800FM MT44 800F MX02S Reset 800FM F6MX10 Kinetix 6000 with GuardMotion 2099 BMxx s RANGE lt TIME 65 ae EMD 440R EM4R2D 24V DC Com Rockwell A
119. the hazard area the motor must be stopped After entering the hazard area the motor can be restarted with the GripSwitch One MT GD2 interlock is used to bypass the gate interlock safety circuit The other MT GD2 is used to reset the safety system and prevent the starting of the motor from outside the cell when the GripSwitch is used STOPPING Press the Safety Stop The immediate outputs of the DI safety relay open and the motor initiates a coast to stop After the time expires on the EMD safety relay the delayed outputs change state The EMD safety relay outputs close and the safety gate can be unlocked Press the lock release button to power the solenoid of the 440G MT interlock momentarily and open the gate STARTING Remove the enabling switch from the MT GD2 holders Squeeze the GripSwitch trigger to the middle position The DI safety relay resets and closes its safety outputs and the motor is ready to run Press the jog button on the GripSwitch to turn on the motor momentarily STOPPING DURING ENABLING Release the jog switch to stop the motor Releasing or applying further pressure to the trigger switch on the GripSwitch stops the motor 44 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Fault Detection Upon successful completion of internal checks on power up DI safety relay checks the E stop gate and GripSwitch circuit If the circuits are closed the DI safety
120. tic reset Operating Principle STARTING When the last gate closes the safety outputs of the DIS safety relay close and apply power to the Drive Enable circuit Safe Off option and Start Stop buttons Pressing the Start and Stop buttons turns the motor on and off Parameters set within the PowerFlex drive control the motor STOPPING Opening any of the guard doors causes the DIS safety outputs to de energize This removes power to the PowerFlex Enable Safe Off Start and Stop circuits The motor performs a coast to stop Fault Detection Upon power up the PowerFlex drive and DIS safety relay perform internal checks The DIS safety relay then looks for dual signals from the gate interlocks With the gates closed the DIS safety relay checks the wiring of the drive Safe Off option If closed then the DIS safety relay energizes its outputs and the motor can be started A single open circuit fault at the gate interlocks is detected immediately and the motor will coast to a stop A crossfault channel 1 to channel 2 at the gate interlocks is detected immediately The DIS safety relay is rated for Category 4 and does not lose the safety function due to an accumulation of faults The PowerFlex 70 DriveGuard is rated at Category 3 as it performs the safety function in the presence of a single internal fault Ratings The safety function that is initiated by the gate interlocks meets the safety performance requirements of SIL CL2 per IEC 62061 200
121. trademarks of Rockwell Automation Inc CrossFlow is a trademark of Delphix Corp SERPAR isa trademark of Ross Operating Valve Company DM2 is a trademark of DM2 International Inc DeviceNet and EtherNet IP are trademarks of the ODVA Trademarks not belonging to Rockwell Automation are property of their respective companies Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication SAFETY WD001F EN P November 2015 Supersedes Publication SAFETY WD001E EN P October 2013 Copyright 2015 Rockwell Automation Inc All rights reserved Printed in the U S A
122. ts A crossfault channel 1 to channel 2 is equivalent to stepping on the safety mat The DI safety relay is rated for Category 4 and does not lose the safety function due to an accumulation of faults The PowerFlex 755 drive is rated at Category 3 as it performs the safety function in the presence of a single internal fault Ratings The safety function that is initiated by the safety mats meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per 1SO13849 1 2006 This circuit executes a safe torque off Stop Category 0 54 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Figure 25 E stops for a PowerFlex 755 Drive 24V DC MatGuard Safety Mat amp Trim 440F M2030BYNN 440F T2030 L1 12 13 PowerFlex 755 Series Stop Status Start Start Stop Common 24V DC Com Locic__ 3 BO 3 DI a a 440R D22R2 53215221111112 A2 14 241732 Gate Control Circuit MatGuard Safety Mat amp Trim 440F M2030BYNN 440F T2030 Rockwell Automation Publication SAFETY WD001F EN P November 2015 55 Next Generation Guardmaster Safety Relay GSR SafeZone Mini Laser Scanner E stop and DI Safety Relay with Kinetix 350 Drive Circuit Components e SafeZone Mini safety laser scanner e Bulletin 800F E
123. ty relay checks the status of the K1 and K2 contactors 110 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The PowerFlex 525 drive safety function meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The PowerFlex 525 drive safety function performs Stop Category 1 The safety function that is completed by the contactors meets the performance requirements of SIL2 per IEC 62061 2005 has a Category 3 structure and can be used in systems that require Performance Levels up to PLd per ISO 13849 1 2006 The safety function performs Stop Category 0 Figure 53 Guard Locking with Time Delay 24V DC MC2 Sensor L1L2L3 440N Z21W1PH Cordset PowerFlex R 889D F8AB 2 55 1 Stop 2 Start RESET _ z0 E 440R S12R2 24V DC Com Rockwell Automation Publication SAFETY WD001F EN P November 2015 111 Next Generation Guardmaster Safety Relay GSR E stop with Auto Reset and Stop Cat 0 and 1 Circuit Components e TLS ZR guard locking switch e GLT safety relay e PowerFlex 525 drive Circuit Status The E stop is released Outputs 14 24 51 L61 L11 and Y32 of the GLT safety relay are ON The PowerFlex 525 drive is enabled and the motor is off The GLT safety relay has a Logic setting of 7 E stop Cat 1 with Logic IN O
124. ty relay is unaffected Pressing the E stop or stepping on the safety mat of the DIS safety relay turns off the outputs of the DIS safety relay only Fault Detection Upon successful completion of internal checks on power up the SI DI and DIS safety relays check their input circuits Shorts from the inputs to power ground or other inputs are detected immediately and prevents energization or de energizes the respective outputs If one of the contactors K1 K6 is stuck in an actuated state the respective control prevents startup because the 34 feedback loop remains open 18 Rockwell Automation Publication SAFETY WD001F EN P November 2015 Next Generation Guardmaster Safety Relay GSR Ratings The safety functions initiated by the E stop devices and the two Trojan interlocks meet the safety performance requirements of SIL CL3 per IEC 62061 2005 and have Category 4 structures that can be used in systems that require Performance Levels up to PLe per 1S013849 1 2006 The safety function that is initiated by the safety mat meets the safety performance requirements of SIL CL2 per IEC 62061 2005 and has a Category 3 structure that can be used in systems that require Performance Levels up to PLd per IS013849 1 2006 This circuit executes a Stop Category 0 Figure 7 Global E stop Cascaded Safety Functions 24V DC Trojan T15 GD2 440K T11287 MatGuard Safety Mat amp Trim 440F M2030BYNN 440F T2030 K5 K6 E
125. utomation Publication SAFETY WD001F EN P November 2015 15 Next Generation Guardmaster Safety Relay GSR Light Curtain with Immediate and Delayed Outputs Circuit Components e Safe 4 light curtain e SIand EMD safety relays e Bulletin 100S contactor e Bulletin 700S safety control relay Circuit Status The light curtain is clear The safety outputs of the SI and EMD are de energized All contactors are off The EMD Range setting is 2 10 second OFF Delay and the Time setting is 2 20 therefore the time delay is 2 seconds The reset and monitoring circuit are connected to 34 for monitored manual reset Operating Principle Additional outputs are added to the SI safety relay by the EMD Expansion Module with Delayed outputs A single wire safety rated signal from terminal L11 of the SI communicates the output status to L12 of the EMD relay STARTING Press and release the reset button to energize the outputs of the SI and EMD K1 K6 safety contactors or safety control relays energize to control the hazardous portion of the machine STOPPING When the light curtain is interrupted the safety outputs of the SI turn off immediately and de energize K1 K2 Two seconds later the safety outputs of the EMD turn off and de energize K3 K6 Fault Detection Upon power up the SI and EMD safety relays perform internal checks The SI safety relay then looks for dual signals from the light curtain A crossfault on the light curtain is de

Next Generation Guardmaster Safety Relay

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