GUARDMASTER 440R-S35003

440R-SG001_Cover 7/19/2011 2:33 PM Page 2 Bul. 440R — Guardmaster® Safety Relays (DI, DIS, SI, CI, EM, and EMD) Selection Guide 440R-SG001B 7/20/2011 8:26 AM Page 2 Bulletin 440R ® Next Generation Guardmaster Safety Relays DI, DIS, SI, CI, EM & EMD Specifications Safety Ratings IEC 60204-1, EN ISO 13849-1, EN ISO 12100, IEC Standards 61508 Suitable up to PLe and CAT4 per EN ISO 13849- 1:2006, SIL CL3 per IEC 61508:2010 / Safety Classification IEC62061:2006 depending on architecture and application characteristics CE Marked for all applicable directives, cULus and Certifications TÜV Description Functional Safety Data See below ® The new generation of Guardmaster Safety Relays addresses the Power Supply broad scope of applications in the intricate safety world with a Input Power Entry 24V DC (-15…+10%) range of devices. Designed to meet new functional safety DI/SI: 2.5 W standards, such as EN ISO 13849-1 and EN 62061, the new family Power Consumption DIS: 2 W offers key functions to simplify installation and system complexity. CI/EM/EMD: 3.5 W A broad range of safety devices such as safety interlock switches, Inputs emergency stop devices, pressure sensitive safety mats, and OSSD DI/DIS: 2 dual N.C., 2 dual OSSD, or safety mats and devices such as safety light curtains are all compatible with the 1 single-wire safety input Safety Inputs same relay without any additional configuration. SI/CI: 1 dual N.C., 1 dual OSSD, or safety mats EM/EMD: 1 single-wire safety input The functionality of two standard safety relays can be achieved in Input Simultaneity Infinite one Dual Input (DI) device, allowing connection of two dual-channel input devices into one safety relay. Input Resistance, Max. 900 Ω A TÜV-approved single rotary switch sets the required function of Reset Configured automatic/manual or monitored manual the safety relay and eliminates the typical redundant switch setting Reset Pulse Duration 250 ms…3 s process. Selectable functions include simple logic, reset, timing, and Power ON Delay Time 5.5 s diagnostics. DI/DIS/SI/CI: 100 ms Recovery Time The single-wire safety connection simplifies cascading and EM/EMD: 150 ms expanding safety functions by linking relays with a single-wire DI: 35 ms (40 ms with mat input) connection. A dynamic signal from device to device provides a Response Time (Safety DIS: 25 ms (30 ms with mat input) linkage in accordance with SIL 3, PLe, allowing easy addition of Outputs) SI/CI: 35 ms (45 ms with mat input) EM/EMD: 35 ms extra I/O, which can be configured with simple logic combinations. Flexible AND/OR logic can be configured simply in a single relay or DI/DIS: 25 ms (30 ms with mat input) Response Time (Single-Wire SI/CI: 25 ms (35 ms with mat input) through a combination of relays via single-wire connection. Safety Outputs) EM/EMD: 25 ms Expansion modules are available with four immediate or time- Outputs delayed outputs. The time delay module can be configured for on DI/SI: 2 N.O. delay, off delay, or jog. CI: 3 N.O. Safety Contacts DIS: 2 PNP Features EM: 4 N.O. EMD: 4 N.O. delayed � Suitable for applications up to PLe, SIL 3 Per ISO13849-1 DI: AgNi + 0.2μ Au � Stop Category 0 Contact Material SI/CI/EM/EMD: AgNi � One or two dual-channel inputs DI/DIS/SI/EM/EMD: 1 PNP; 50 mA max Auxiliary Contacts � Two or three safety contacts CI: 1 N.C. � One auxiliary contact Thermal CurrentI 1 x 6 A lth � Cross-fault monitoring Rated Impulse withstand 2500V Voltage � Rotary switch configures auto/manual or monitored manual reset Switching Current @ Voltage, � Same rotary switch configures AND/OR logic of input to device DI/SI/CI/EM/EMD: 10 mA/10V Min. � Removable terminals Fuses, Output 6 A slow blow or 10 A quick blow � Can be used with interlocks, light curtains, safety mats, E-stops, Mechanical Life DI/SI/CI/EM/EMD: 10,000,000 operations and SensaGuard™ switches Utilization Category � Single-wire safety output connects to single-wire safety input DI: 3 A/250V AC relays while maintaining SIL 3, PLe Inductive: AC-15 SI/CI: 1.5 A/250V AC � Timed ON delay, OFF delay and Jog outputs on EMD EM/EMD: 1.5 A/250V AC DI: 4 A/24V DC (0.1 Hz) Inductive: DC-13 SI/CI: 2 A/24V DC (0.1 Hz) Functional Safety Data � EM/EMD: 2 A/24V DC Note: Subject to change. For up-to-date information, visit DIS: 14, 24: 1.5 A each http://www.ab.com/safety/ Output Rating 34, 44: 0.5 A each PFH Environmental and Physical Characteristics MTTFd D -9 Enclosure Type Rating/ DI 355 yr 4.35 x 10 IP40 (NEMA 1)/IP20 Terminal Protection -9 DIS 484 yr 4.39 x 10 Operating Temperature [C (F)] -5…+55 ° (23…131 °) -9 SI 262 yr 3.98 x 10 Vibration 10…55 Hz, 0.35 mm -9 CI 164 yr 4.26 x 10 Shock 10 g, 16 ms 100 shocks -9 EM 190 yr 1.81 x 10 Mounting 35 mm DIN Rail -9 EMD 165 yr 4.4 x 10 DI: 180 (0.40) DIS: 150 (0.33) �Usable for ISO 13849-1: 2006 and IEC 62061. Data is based on the SI: 150 (0.33) Weight [g (lb)] following assumptions: CI: 225 (0.5) - Mission time/proof test interval of 20 yr EM: 225 (0.50) EMD: 220 (0.49) - Functional test at least once within six-month period -The PFH given is the sum of the PFH of the electronic aspects and the D D Terminals Removable (Screw) PFH resulting from the B10d values of the two output relays based on 1 D 2 Conductor Size, Max. 0.2…4 mm (24…12 AWG) operation/hour, 365 days a year, 24 hours a day (8760 operations/year) at AC15 1 A 230V AC or at DC13 1.5 A 24V DC. Visit our website: www.ab.com/catalogs 2 Publication 440R-SG001B-EN-P 440R-SG001B 7/20/2011 8:26 AM Page 3 Bulletin 440R ® Next Generation Guardmaster Safety Relays DI, DIS, SI, CI, EM & EMD Product Selection Safety Relays Relay Type No. of Inputs Inputs Safety Outputs Auxiliary Outputs Power Supply Cat. No. Dual Input (DI) 2 N.O. 440R-D22R2 2 dual-channel 1 S.S. 1 N.C., 2 N.C., Dual Input Solid-State Output (DIS) 2 S.S. 440R-D22S2 OSSD, Safety 24V Single Input (SI) 2 N.O. 1 S.S. 440R-S12R2 Mat 1 dual-channel Compatible Input (CI) 3 N.O. 1 N.C. 440R-S13R2 Expansion Module Relays Delayed Safety Safety Auxiliary Relay Type No. of Inputs Outputs Outputs Time Delay Outputs Power Supply Cat. No. Expansion Module (EM) 4 N.O. — — 440R-EM4R2 1 single-wire 1 S.S. 24V Expansion Module Time 100 ms…300 s safety — 4 N.O. 440R-EM4R2D Delayed (EMD) off delay LED Indicators Accessories Indicator on Description Cat. No. Housing Function LED Color(s) Bag of four, 4-pin screw terminals 440R-ATP4 PWR/FAULT Status and diagnostics Green/Red IN1 Status of safety output IN1 Green IN2 Status of safety output IN2 Green LOGIC IN Status of single wire safety input Green OUT Status of safety output Green Status and diagnostics Green B1� �B1 on EMD only. Approximate Dimensions Dimensions are shown in mm. Dimensions are not intended to be used for installation purposes. S12 S22 S32 S42 S12 S22 S32 S42 S12 S22 13 23 33 41 33 34 43 44 37 38 47 48 A1 A2 S11 S21 A1 A2 S11 S21 A1 A2 S11 S21 A1 S11 S12 L11 A1 A2 A1 A2 B1 B2 PWR/Fault PWR/Fault PWR/Fault PWR/Fault PWR/Fault PWR/Fault IN 1 IN 1 IN IN B 1 IN 2 IN 2 LOGIC IN LOGIC IN LOGIC IN LOGIC IN OUT OUT OUT OUT OUT OUT 0 0 0 RESET RESET 0 0 1 1 33 34 43 44 RANGE 1 AM AM LOGIC 2 LOGIC 2 2 9 3 8 3 8 3 8 MM MM 4 7 4 4 7 7 6 5 6 5 13 23 33 41 6 5 119.4 119.4 119.4 119.4 119.4 119.4 1 2 TIME A1 10 3 4 9 13 14 23 24 5 13 14 23 24 13 14 23 24 8 14 24 34 42 7 6 DI DIS 34 44 14 24 SI CI EM EMD L12 L11 Y32 S34 L12 L11 Y32 S34 L11 Y32 S34 S21 S22 S34 A2 L12 L11 Y32 L12 L11 X32 13 14 23 24 34 44 14 24 34 14 23 24 14 24 34 42 13 14 23 24 17 18 27 28 22.5 22.5 22.5 22.5 22.5 22.5 Dual Input Dual Input Single Input Single Input Expansion Expansion Relay Output Solid-State Relay Output Legacy Module Module Delayed (DI) Output (SI) Compatible (EM) (EMD) (DIS) (CI) Safety Relay Model: GuardMaster Cat No.: 440R-D22S2 Series: A Supply: 24VDC Lot No.: 006 0 Output: 2 SS 24VDC 1 SS 24VDC 1042 105.7 10885630102211 Made in Germany Rockwell Automation Germany Westring 222 42329 Wuppertal XXXXX 113.6 Side View (All Versions) Visit our website: www.ab.com/catalogs 3 Publication 440R-SG001B-EN-P 440R-SG001B 7/20/2011 8:26 AM Page 4 Bulletin 440R ® Next Generation Guardmaster Safety Relays DI, DIS, SI, CI, EM & EMD Block Diagrams Dual Input Relay (DI) Dual Input Solid State Output Relay (DIS) Safety Outputs (N.O.): 13-14, 23-24 Safety Outputs (PNP N.O.): 14 & 24 (1.5 A each max), 34 & 44 (0.5 A each max, for high capacitive loads) A1 A2 S11 S21 S12 S22 S32 S42 IN1 IN2 A1 A2 S11 S21 S12 S22 S32 S42 IN1 IN2 PWR mon. AND/OR PWR mon. PWR IN1 K1 AND/OR PWR IN2 AND/OR IN1 LOGIC IN Logic K2 IN2 AND/OR OUT LOGIC IN Logic OUT L12 L11 Y32 S34 13 14 23 24 L12 L11 Y32 S34 34 44 14 24 Single Input Relay (SI) Single Input Relay Compatible Layout (CI) Safety Outputs (N.O.): 13-14, 23-24 Safety Outputs (N.O.): 13-14, 23-24, 33-34 A1 A2 S11 S21 S12 S22 A1 S11 S12 L11 13 23 33 41 IN1 IN1 PWR mon. PWR mon. K1 PWR PWR IN IN K1 K2 Reset Reset K2 OUT OUT L11 Y32 S34 13 14 23 24 S21 S22 S34 A2 14 24 34 42 Expansion Module Relay (EM) Expansion Module Delayed Output Relay (EMD) Safety Outputs (N.O.): 13-14, 23-24, 33-34, 43-44 Delayed Safety Outputs (N.O.): 17-18, 27-28, 37-38,47-48 A1 A2 B1 B2 A1 A2 37 38 47 48 33 34 43 44 PWR mon. PWR mon. on delay K1 K1 PWR off delay PWR Logic B1 jogging K2 Range Time K2 LOGIC IN LOGIC IN OUT OUT X32 L12 L11 17 18 27 28 L12 L11 X32 13 14 23 24 Common Terminals Auxiliary/Feedback Output Behavior Terminals Relay Description DI, DIS, SI CI EM, EMD A1, A2 All Power Unit Status Y32 41-42 X32 S12, S22 DI, DIS, SI, CI IN1: Safety input 1 Active & healthy Off Open Off S32, S42 DI, DIS IN2: Safety input 2 Inactive & healthy 24V DC Closed 24V DC S11, S21 DI, DIS, SI, CI Test outputs for safety inputs Fault 24V DC Closed Off S34 DI, DIS, SI, CI Monitoring feedback loop for reset Y32 DI, DIS, SI Auxiliary PNP semiconductor output 41-42 CI Auxiliary N.C. relay output X32 EM, EMD Feedback PNP semiconductor output L12 DI, DIS, EM, EMD Single wire safety input L11 All Single wire safety output B1, B2 EMD Configuration for retriggering/jogging Note: Output terminals described by image. Visit our website: www.ab.com/catalogs 4 Publication 440R-SG001B-EN-P Jogging On 440R-SG001B 7/20/2011 8:26 AM Page 5 Bulletin 440R ® Next Generation Guardmaster Safety Relays DI, DIS, SI, CI, EM & EMD Configuration Setting the Logic Function/Reset Mode — DI, DIS, SI, and CI 1. Start configuration/overwrite: with power off, turn rotary switch to position 0 and unit is powered up. After power-up test, PWR LED will flash red. 2. Set configuration: turn rotary switch to desired position. IN1 LED blinks new setting. Note: Position is not stored until PWR LED is solid green. 3. Lock in configuration by cycling unit power. 4. Configuration must be confirmed before operation. A white space on face of device is provided to record unit setting. Enable program mode Set operation mode Cycle power to store Setting the Time Delay — EMD 1. Start configuration/overwrite: with power off , turn rotary switch RANGE to position 0 and power unit up. After power-up test, PWR LED will flash red. 2. Set configuration: turn rotary switch to desired position, both RANGE and TIME. LED B1 indicates position of RANGE and Logic IN of TIME. Note: Position is set when “PWR“ LED is solid green. 3. Lock in configuration by cycling unit power. 4. Configuration must be confirmed before operation. A white space on face of device is provided to record unit setting. Note: When in off-delay mode, terminals B1 and B2 are used to modify the settings of retriggering. The terminals are not used in on-delay mode. Terminal B1 is used for the pulse source when the relay is in single pulse jogging mode. OFF-DELAY (RANGE 1, 2, 3, 4): Time delay starts when single-wire safety input L12 changes from HIGH to LOW. Delayed safety outputs remain active until the set time has lapsed. The unit is safe against time extension. Restart the unit by cycling the safety input L12, LOW to HIGH. RETRIGGERABLE (JUMPER B1-B2): In off-delay mode, the device can be set to retriggerable setting. In retrigger mode, if the safety input is triggered and cleared within the duration of the time delay then the timing request is ignored and the safety output contacts will remain closed. Retrigger setting can only be done in off-delay mode and can be set by running a jumper wire from terminal B1 to B2 (corresponds with MSR178 and MSR132ED delayed outputs). NON-RETRIGGERABLE (NO JUMPER): In off-delay mode, if retriggerable setting is not configured (terminals B1 and B2 are left vacant) the full time delay will lapse and the safety output contacts will open before the relay can be reset (corresponds with MSR178 and MSR132ED delayed outputs). ON-DELAY (RANGE 5, 6, 7): Time delay starts when the single-wire safety input changes from LOW to HIGH. Safety outputs are activated after time has lapsed and L12 is still HIGH. SINGLE-PULSE JOGGING: The safety outputs are activated when both, the single-wire safety input L12 and B1 are HIGH. It remains active until the set time has lapsed. When one of the inputs changes to LOW, the safety outputs are deactivated immediately. B1 acts as an automatic/manual start to trigger the Jog function while L12 monitors the safety device through a base unit. If there is any malfunction, the JOG switch should be replaced. x10% of max. Off-Delay On-Delay 1: 10% 6: 60% 1: 0.1…1 s 5: 0.3…3 s 2: 20% 7: 70% 2: 0.3…3 s 6: 3…30 s 3: 30% 8: 80% 3: 3…30 s 7: 30…300 s 4: 40% 9: 90% 4: 30…300 s 5: 50% 10: 100% Jogging Time 8: 0.3…3 s Range 9: 3…30 s 0: Configuration Mode Logic The logic between the two safety inputs IN1 (S12, S22) and IN2 (S32, S42) and the single-wire safety input (L12) can be configured to the four options shown below, in either manual monitored or automatic/manual reset configurations (yielding eight settings total). L12 will only recognize a valid test pattern from the L11 output of a Guardmaster device. Any other signal to that port will be detected as a fault. (A high signal is considered to be true in this logic. So if an input is to be ignored or muted, OR logic should be used). Note: In case only one safety input is used the second one can be left open if it is configured for OR. An AND conjunction requires this input to be wired to S11 and S21. In case L12 is not in use, this input needs to be configured for OR. Manual Monitored Reset Automatic / Manual Reset IN1 = S12, S22 IN1 IN2 = S32, S42 1 (IN1 OR IN2) OR L12 5 (IN1 OR IN2) OR L12 AND/ 2 (IN1 AND IN2) OR L12 6 (IN1 AND IN2) OR L12 OR IN2 3 (IN1 OR IN2) AND L12 7 (IN1 OR IN2) AND L12 AND/ OR 4 (IN1 AND IN2) AND L12 8 (IN1 AND IN2) AND L12 L12 Visit our website: www.ab.com/catalogs 5 Publication 440R-SG001B-EN-P Off 440R-SG001B 7/20/2011 8:26 AM Page 6 Bulletin 440R ® Next Generation Guardmaster Safety Relays DI, DIS, SI, CI, EM & EMD Typical Wiring Diagram Light Curtain and Dual Channel E-stop, Manual Monitored Reset Here the logic is set to 2, which will AND IN1 and IN2. The single wire safety input is set to OR with the standard safety inputs so the relay ignores the fact that no input is coming to L12. This logic can be applied to the DI and DIS. 24V DC E-Stop OSSD Reset A2 S11 S21 S12 S22 S32 S42 A1 +- PULSE IN1 IN2 Power 24V DC L1 L2 L3 0 Logic 1 In1 DI K1 2 In2 3 K2 Out 8 4 5 Logic 7 6 L11 Y32 S34 13 14 23 24 L12 PLC M K1 K2 GND Single Channel E-stop, Automatic Reset, Monitoring Here the logic is set to 5, which will OR all inputs. The device will source its outputs if any input is high. Here S12 and S22 are jumpered to allow a single-channel source for the one input used. 24V DC E-Stop A1 A2 S11 S21 S12 S22 S32 S42 +- IN2 PULSE IN1 Power 24V DC L1 L2 L3 0 Logic In1 1 DIS K1 2 In2 3 Out K2 4 8 Logic 5 7 6 PULSED L12 L11 Y32 S34 33 34 14 24 PLC M K1 K2 GND Visit our website: www.ab.com/catalogs 6 Publication 440R-SG001B-EN-P 24V DC E-Stop E-Stop Reset L1 L2 L3 Test Out K1 K2 K3 K4 M K1 K2 K3 K3 GND 440R-SG001B 7/20/2011 8:27 AM Page 7 Bulletin 440R ® Next Generation Guardmaster Safety Relays DI, DIS, SI, CI, EM & EMD E-stop, Safety Mat, Light Curtain and Interlock Switch, Monitored Manual Reset Here the DI to the left will AND the IN1 and IN2 inputs. The single-wire safety input is ignored. The DI on the right will AND IN1, IN2 and the single-wire safety input (L12). For the safety mat input, S11 is wired to S22 and S21 is wired to S12 (opposite of N.C. safety switch wiring) so the relay recognizes that a mat is wired to the input rather than a N.C. safety switch with a cross fault. If the E-stop or the OSSD devices are tripped, all outputs on both relays will turn off. If the mat or interlock switch are tripped, only the outputs to K3 and K4 will turn off. 24V DC Reset E-Stop OSSD K1 Safety Interlock Mat K2 A1 A2 S11 S21 S12 S22 S32 S42 K3 A1 A2 S11 S21 S12 S22 S32 S42 +- IN2 +- PULSE IN1 PULSE IN1 IN2 Power Power 24V DC 24V DC 0 Logic 0 Logic In1 1 In1 1 K4 DI DI 2 2 In2 In2 3 3 Out Out 8 4 4 8 5 5 Logic 7 Logic 6 7 6 L12 L11 Y32 S34 13 14 23 24 L12 L11 Y32 S34 13 14 23 24 K1 K2 K3 K4 PLC GND Two Dual-Channel E-stops to DI Connected to EM via Single-Wire Safety Connection, Manual Monitored Reset Here the DIS will AND IN1 and IN2 while ignoring the single-wire safety input. The single-wire safety output is driving the input of the expansion module (EM) while not using any of the safety outputs of the base device. A1 A2 S11 S21 S12 S22 S32 S42 A1 A2 33 34 43 44 +- +- IN1 IN2 Power Power 24V DC 24V DC A1 0 In1 1 DIS EM LOGIC In2 2 3 Out 8 Logic IN 4 7 6 5 Logic Out 1 L12 L11 Y32 S34 33 44 14 24 L11 X32 13 14 23 24 L12 PLC Visit our website: www.ab.com/catalogs 7 Publication 440R-SG001B-EN-P 440R-SG001_Cover 7/20/2011 10:43 AM Page 1 Trademark List Guardmaster and SensaGuard are trademarks of Rockwell Automation, Inc. Publication 440R-SG001B-EN-P – July 2011 Copyright ©2011 Rockwell Automation, Inc. All Rights Reserved. Printed in USA. Supersedes Publication 440R-SG001A-EN-P – March 2011