Safety Wd001 en P Reles

Wiring Diagram
Next Generation Guardmaster Safety Relay (GSR)

Bulletin 440R
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 I/O 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, 700S-C 3 e 4 0
18 SI, DI, DIS 3 E-stops, Trojan T15, Safety Mat 100S, 700S-C 3 e 4 0
20 SI, MSR35H GuardShield, 800Z 100S-C 3 e 4 0
22 SI, DIS 3 SensaGuard with Integrated Latch, 2 E-stops PowerFlex 525 2 d 3 0
24 CI Trojan T15, Elf, E-stop, PLC on Ch2 100S-C 2 d 3 0
26 CI 3 SensaGuard 100S-C 3 e 4 0
28 CI 3 MC2 Magnetically Coded Sensors 100S-C 2 d 3 0
30 CI 3 Ferrogard GD2 Non-contact Sensors 100S-C 2 d 3 0
32 DI GuardShield 100S-C 3 e 4 0
34 DI 2 GuardShield 100S-C 3 e 4 0
36 DI 2 Lifeline 4 100S-C 3 e 4 0
38 DI 5 SensaGuard, 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
GLT, EM, SI,
44 EMD 440G-MT, MT-GD2, GripSwitch 100S-C 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 100S-C 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 100S-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
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
Safety
Relay SIL Cat. Stop
Page Modules Input Devices Output Devices CL PL No. Cat.
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
72 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 I/O 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 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 I/O 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
118 SI, EM E-stop, SI, EM 100S-D 3 e 4 0
120 GLP SensaGuard with Integrated Latch PowerFlex 70 2 d 3 SLS
Summary of Changes
This publication contains the following new and updated information:
Updated section: Guard Locking with DI/EMD Safety Relays on page 48.
2 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

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.
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 help 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 that is 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:
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.
The control guard must be the only access to the hazard area.
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-WD001I-EN-P - October 2016 3

Note 4
Safety monitoring relays 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.
For example, if 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 to 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, a GSR module) is used for fault detection, it is important to note the
following:
All safety-critical single faults, except for certain faults over the contact set at the E-stop, are detected at the next
opening of the guard.
All safety-critical single faults, except for certain faults over the contact set at the interlock switch, are detected at
the next operation of the E-stop.
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).

General Safety Information
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 for more information about our safety risk assessment services.
ATTENTION:
Perform a risk assessment to make sure that all tasks and hazard combinations are identified and addressed. The risk assessment requires 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 Description
GuardShield Micro 400 Safety Light Curtains User Manual, publication 445L-UM003_ 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/.

SI Safety Relay with E-stop to PowerFlex 525 Drive

Circuit Components
E-stop
Single input (SI) safety relay
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 non-operation of the motor
indicates the fault. The SI safety relay generates test pulses through the E-stop circuits to detect cross channel shorts and
shorts to power and ground. The drive detects some faults in the safe-off circuit of 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 E-stop initiates a safety function that 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.

Figure 1 - SI Safety Relay with E-stop to PowerFlex 525 Drive

+24V DC
Reset L1 L2 L3
PowerFlex R S T
525
11 +24V DC
1 Stop
S11 S21 S34 A1 13 23 2 Start

E-stop
800FM-MT44 0
RESET
800F-MX02S Gate control
AM power supply
SI
MM
440R-S12R2
Gate control
S22 S12 Y32 L11 A2 14 24 circuit
S1
S2
UV W
Status
To PLC
M
24V DC Com

SI Safety Relay with MAB Guard Locking to PowerFlex 525 Drive

Circuit Components
Multifunctional Access Box (MAB)
SI safety relay
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 action immediately opens
the safety outputs of 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 non-operation of the
motor indicates the fault. 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. The drive detects a fault in the
safe-circuit of 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
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.

Figure 2 - SI Safety Relay with MAB Guard Locking to PowerFlex 525 Drive
+24V DC
Reset L1 L2 L3
Unlock PowerFlex R S T
442G-MABH-R +
Request 525
442G-MABR-URM-C00
11 +24V DC
1 Stop
S11 S21 S34 A1 13 23 2 Start
MAB Fault RESET 0
Reset Gate control
AM power supply
SI
MM
Brown 440R-S12R2
Gate control
Violet S22 S12 Y32 L11 A2 14 24 circuit
889M-F19RM-5 Blue Grey/Pink
S1
Green/Black S2
UV W
Red/Blue Status
To PLC
M
24V DC Com

SI Safety Relay to FLEX I/O

Circuit Components
Trojan T15 GD2 tongue interlock switch
Bulletin 800F push button
SI safety relay
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. During the manufacturing process, the FLEX output module switches the machine actuators. 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 the output module, before restarting.
STARTING: Press the Reset button to energize the output contacts 13/14 of the SI safety relay. This action 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, can lead to the loss of the safety function. When the SI safety relay and FLEX system are mounted
in the same cabinet with proper validation, this fault can be excluded. If not mounted in the same cabinet, a signal from
the output (A0) 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 not in agreement. If CR1 is not de-energized when the gate is closed, the
SI safety relay does not close its outputs.
Ratings
The Trojan T15-GD2 gate interlock initiates a safety function that 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 I/O

+24V DC
Start Stop
Reset 800FM- 800FM-
800FM-F6MX10 F3MX10 E4MX01
Brown 12 11
Black 700-HLT2Z24
700-TBR24
Limited to
6 Amps
S11 S21 A1 S34 13 23 34 16 0 0 16 34
11 21
RESET 0 35 17 CR1 1 1 17 35
AM
SI 36 18 2 2 18 36
MM
12 22 440R-S12R2
S12 S22 A2 L11 Y32 14 24 37 19 CR 3 3 19 37
Trojan T15 GD2
440K-T11390 White 38
. 20 4. 4. 20 38
.
. .
889D-F4AC-2 . . . .
. .
. . . .
Blue 50 32 CR .
14 .
14 32 50
51 33 Machine 15 15 33 51
Actuators
C B A A B C
1794-TB3 & 1794-OB16 1794-TB3 & 1794-I16
FLEX Output Module FLEX Input Module
24V DC Com

Expansion Modules with Immediate and Delayed Outputs

Circuit Components
Bulletin 800F E-stops
SI, Expansion Module (EM), Expansion Module Time Delayed (EMD) safety relays
Bulletin 100S contactor
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.
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 S34 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. K1K10
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 K1K6. Two seconds later, the safety outputs of the EMD safety relay turn off and de-energize K7K10.
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. The SI safety relay detects a cross fault on the E-stop circuit. With the E-stop signals
made, closing the Reset button places a voltage to the S34 terminal. The external devices (K1K10) are checked to
confirm that they are off. A fault in K1K10 causes their normally closed contacts to remain open, and this fault
prevents the SI safety relay from turning on outputs 13/14 and 23/24.
Ratings
The series connection of the Bulletin 800F E-stop buttons initiates a safety function that 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 K1K10
to de-energize the machine actuators, and the safety system must monitor the contactors. This circuit executes a Stop
Category 0.

Figure 4 - Expansion Modules with Immediate and Delayed Outputs

+24V DC Reset
800FM-F6MX10
K6 K7 K8 K9 K10
K1 K2 K3 K4 K5
S11 S21 S34 A1 13 23 X32 A1 13 23 33 43 B1 B2 X32 A1 17 27 37 47

RANGE 0 1 TIME 1
2
RESET 0 9 2 10 3
E-Stops 8 3 9 4
AM 7 6 54 8 5
7 6
800FM-MT44MX02L SI MM EM EMD
440R-S12R2 440R-EM4R2 440R-EM4R2D
S12 S22 Y32 L11 A2 14 24 L12 L11 A2 14 24 34 44 L12 L11 A2 18 28 38 48
700S-
100S- DCP310DZ24
K1 100S- K3 K5
C09EJ14BC K7 K9 with
C43EJ14BC
199-FSMZ-1
K2 K4 K6
K8 K10
24VC DC Com

Safety Motion - Delayed Braking

Circuit Components
SI and EMD safety relays
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-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 safety relay. This action energizes the
feedback relays in the Kinetix. The L11signal 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 controller then controls the motor.
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 off and 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 action 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, the SI safety relay checks the S34 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 S34 monitoring circuit detects the fault on the next attempt to
restart because K1 remains energized. If the drive faults to an ON state, the motor stops because K1 disconnects it. The
S34 monitoring circuit detects this fault on the next attempt to restart because the Kinetix feedback circuit remains off.
If K1 gets stuck or welded closed, the drive stops the motor and the S34 monitoring circuit of the SI safety relay detects
the fault on the next attempt to restart.
Ratings
The Bulletin 800F E-stop initiates a safety function that 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 1.

Figure 5 - Safety Motion - Delayed Braking

+24 VDC
E-Stop L1 L2 L3
800FM-MT44 Reset
800F-MX02S 800FM-F6MX10 Kinetix 6000 Gate
with GuardMotion Control
2099-BMxx-s Power
Supply
EN1+ R2
S11 S21 S34 A1 13 23 B1 B2 X32 A1 17 27 37 47 R1
RANGE 0 1 TIME 1 EN1-
2
RESET 0 9 2 10 3 Gate
3 9 4 EN2- Safety
8
5
Control
AM 7 6 54 8
7 6 Monitor
SI R2 Circuit
MM EMD
440R-S12R2 440R-EM4R2D EN2+
S12 S22 Y32 L11 A2 14 24 L12 L11 A2 18 28 38 48 FBK1 R1
R1
FBK1
To PLC
FBK2 Gate
R2 Control
FBK2 Enable
Resistor Braking Module U V W

COIL A1
CONSTAT41
K1
CONSTAT42
COIL A2
100S-C
T1 Contactor U V W
M
24V DC Com

Light Curtain with Immediate and Delayed Outputs

Circuit Components
Safe 4 light curtain
SI and EMD safety relays
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 S34 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. K1K6 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
K1K2. Two seconds later, the safety outputs of the EMD turn off and de-energize K3K6.
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. The light curtain detects a cross fault on the light curtain. With the light curtain signals made,
closing the Reset button places a voltage to the S34 terminal. The external devices (K1K6) are checked to confirm that
they are off. A fault in K1K6 causes their normally closed contacts to remain open, and the SI safety relay detects this
fault.
Ratings
The light curtain initiates a safety function that 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. The Category 4 rating requires the redundant usage of K1K6 to de-energize the machine actuators,
and the safety system must monitor the contactors. This circuit executes a Stop Category 0.

Figure 6 - Light Curtain with Immediate and Delayed Outputs

+24V DC
Reset
800FM-F6MX10
Transmitter Receiver K1 K2 K3 K4 K5 K6
Brown Brown
1 1
2
4
Black A1 13 B1 B2 X32 A1 17 27 37 47
4 S11 S21 S34 23
White RANGE 0 1 TIME 1
2 2
RESET 0 9 2 10 3
8 3 9 4
Blue Blue AM 7 6 54 8
7 6
5
3 3 SI MM EMD
Grey Grey 440R-S12R2
5 5 440R-EM4R2D
S12 S22 Y32 L11 A2 14 24 L12 L11 A2 18 28 38 48
POC Type 4 Safe 4
445L-P4S1200YD
Cordset: 2 x 889D-F5AC-2
K1 100S- K3 K5 700S-
C43EJ14BC CFB440EJC
K2 K4 K6
24VC DC Com

Global E-stop, Cascaded Safety Functions

Circuit Components
Trojan T15 tongue interlock switch
Bulletin 440F MatGuard safety mat
SI, Dual Input (DI), Dual Input Solid-state Output (DIS) safety relays
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.
K1K6 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 4
[(IN1AND IN2) AND L12] with monitored manual reset. Safety mat applications require Logic setting with IN1
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 to
energize K1 and K2 and send the L11 link signal to the DI safety relay that enables the DI safety relay. Press the Reset
button to energize the DI safety relay and send a L11 link signal to the DIS safety relay. Press the Reset button to energize
the outputs of the DIS safety relay. Press the respective Start buttons to energize the contactors K3, K4, K5, and K6.
STOPPING: Press the E-stop of the SI safety relay to shut down all three relays. Open the interlocked gate or press the
E-stop of the DI safety relay to turn off the outputs of both the DI and DIS safety relays, while the SI safety relay is
unaffected. Press the E-stop or step on the safety mat of the DIS safety relay to turn 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 (K1K6) is stuck in an actuated state, the respective control
prevents startup because the S34 feedback loop remains open. For fault detection purposes, all GSR modules that are
used in safety mat applications must be configured for monitored manual reset.
Ratings
The E-stop devices and the two Trojan interlocks initiate safety functions that 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 ISO13849-1:2006.
The safety mat initiates a safety function that 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

Figure 7 - Global E-stop, Cascaded Safety Functions

+24V DC
Trojan T15-GD2 MatGuard
440K-T11287 Safety Mat & Trim
K1 K3 440F-M2030BYNN K5
Start
Start 440F-T2030
K2 K4 K6
Stop
11 12 11 12 Reset
E-Stop 800FM-
800FM-MT44 Reset Stop
800F-MX02S 21 22 21 22 Reset F6MX10
800FM- 800FM- Aux. to PLC
F6MX10 F6MX10
S11 S12 A1 S34 13 23 S11 S12 S21 S22 A1 13 23 S34 S11 S21 S12 S22 A1 A2 Y32 S34
0 0
RESET 0 LOGIC
1
LOGIC
1
2 2
8 3 8 3
AM 7 4 7 4
SI MM DI 6 5 DIS 6 5
440R-S12R2 440R-D22R2 440R-D22S2
S21 S22 A2 L11 Y32 14 24 S32 S42 L11 L12 A2 14 24 Y32 S32 S42 L11 L12 34 44 14 24
K5 K5
Aux. Aux.
to PLC to PLC K6
K6 Start
E-Stop E-Stop
800FM-MT44 800FM-MT44 Stop
800F-MX02S 800F-MX02S
100S- K3
700S- 100S-
K1 K2 K4 K5 K6
C09EJ14BC CFB440EJC C43EJ14BC
24 DC Com

GuardShield Light Curtain and Bulletin 800Z Zero-Force Touch Buttons

Circuit Components
GuardShield light curtain
Bulletin 800Z Zero-Force Touch Buttons
SI and MSR35H safety relay
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 off and ready to run.
The light curtain 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: Removal of one or both hands from the Bulletin 800Z 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. The MSR35H
safety relay detects faults (opens and shorts) at the inputs and prevent the outputs from being energized. The
GuardShield light curtain also performs checks on its Output Signal Switching Device (OSSD) output signals for cross
faults, shorts, and opens. The SI safety relay 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 safety relay detects if one of the
contactors are stuck in the energized position, and prevents restart.
Ratings
The GuardShield light curtain provides a safety function that 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. 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 1 2 Brown
6 Pink
5 Grey
Blue 3 Blue
7
GuardShield Reset
440L-P4J0640YD 800FM-F6MX10
889D-F4AC-2 889D-F8AC-2
Brown
To PLC
White
Black
L1 L2 L3
800Z-GL3Q5 S1
S21 S11 S34 Y41 A1 Y2 S11 S12 A1 S34 13 23
889N-F5AE-6F
0
Blue
K1
Grey
RESET
AM
Two-Hand MSR35H SI
MM K2
Control 24VDC 440R-D23202 440R-S12R2
Brown
White
S21 S22 A2 L11 Y32 14 24

Black
S12 S22 A2 14 24 32
800Z-GL3Q5 S2
889N-F5AE-6F To PLC M
Grey
Blue
K1 K2
100S-C09EJ14BC
24V DC Com

SI/DIS Safety Relays, SensaGuard Interlock, E-stops, and PowerFlex 525 Drive with Contactor
Circuit Components
SensaGuard integrated latch interlocks
Bulletin 800F E-stop
SI and DIS safety relays
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 (S32 and S42) 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) are 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 safety relay, DIS safety relay, SensaGuard, and PowerFlex 525
drive, the drive awaits the closure of the safety outputs. If the DIS safety relay fails, the drive does not energize the motor,
and non-operation of the motor indicates a fault. The DIS safety relay 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. The drive detects a fault in the safe-circuit of the
drive and issues a safety stop. The DIS safety relay monitors the mechanically linked contacts of K1 to verify that the
contactor is de-energized before resetting the safety system.
Ratings
The SensaGuard integrated latch interlocks and the E-stop initiate safety functions that meet the safety performance
requirements of SIL CL2 per IEC 62061:2005 and 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 Stop Category 0.

Figure 9 - SI/DIS Safety Relays, SensaGuard Interlock, E-stops, and PowerFlex 525 Drive with Contactor
+ 24V DC
SensaGuard
Yellow
Brown
Brown
Brown
Integrated E-stops
Red
Latches 800FM-MT44
800F-MX02S K1
440N-Z21SS3PA
Grey L1 L2 L3
Grey Red Grey Red
Pink
Pink Yellow Pink Yellow
PowerFlex R S T
Reset 525
Blue
White
White
White
Blue
Blue
1 Stop
2 Start
Gate 4 Gnd
Open
S12 S22 A1 S34 13 23 S12 S22 S11 S21 S42 S32 A1 S34
Gate 0
Open RESET 0 LOGIC 1
2 A1 Gate control
AM 8 3 power supply
SI 7 6 5 4
Gate MM
DIS
Open 440R-S12R2 440R-D22S2 Gate control
S11 S21 A2 L11 Y32 14 24 L11 L12 A2 34 44 14 24 Y32
circuit
S1
S2
Status UV W
To PLC Status
K1 To PLC
K1
100S-C09EJ14BC
M
24V DC Com

Interlock Switch - Multiple Gate Access

Circuit Components
Trojan T15 and Elf GD2 tongue interlock switch
Compatible Input (CI) safety relay
Circuit Status
The circuit is shown with the safety gates closed and the E-stop released. The CI safety relay is de-energized. The motor
is off. The monitoring circuit is connected to S34 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 logic
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. The safety relay detects a single fault (open or short) across one of the interlocks and the motor is turned
off. The motor remains off until the fault is corrected or power is cycled. If either contactor K1 or K2 sticks ON - the
motor stops on command due to the other contactor, but the CI safety relay cannot be reset (which reveals the fault). A
single fault that is detected on the CI safety relay input circuits results in the lockout of the system to a safe state (OFF) at
the next 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 configuration 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.
Ratings
The Trojan T15 and ELF-GD2 safety gate interlocks and the Bulletin 800F E-stop initiate a safety function that 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 Category0.

Figure 10 - Interlock Switch - Multiple Gate Access

+24V DC
Start K1
Trojan T15-GD2 ELF-GD2 800FM-
440K-T11287 440K-E33046 F3MX10
E-stop K2
800FM-
MT44MX02L Stop
800FM-
E4MX01
11 12 11 12
L1 L2 L3
21 22 21 22
K1
S11 S12 A1 S34 13 23 33 41
RESET 0
Input PLC Output K2
CI AM
1756-IB16 Processor 1756-OW16I MM
1769-IQ16 1769-OW8 440R-S13R2
1746-IB16 1746-OW4 S21 S22 A2 L11 14 24 34 42
1734-IB4 1734-OW2
1793-IB6 1793-OW4 100S- K1 K2 M
C09EJ14BC
24V DC Com

SensaGuard Interlock Switches

Circuit Components
SensaGuard non-contact interlock switches
CI safety relay
Bulletin 800F push buttons
Circuit Status
The first and third gates are closed. The second gate is open. The CI safety relay S12 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 machine
control system (for example, a PLC) can replace the Stop/Start circuit since the circuit is not part of the safety system.
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
continuously check for short circuits to 24V, ground, and cross faults. Upon detection of a fault, the OSSD outputs turn
off. The CI safety relay also performs internal checks on power-up. It then 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 fault at the next attempt to
start the motor. The contactors have mechanically linked auxiliary contacts to help verify 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 safety relay is rated to Category 4. The
design and connection of the contactors meets category 4. This circuit performs a Stop Category 0.

Figure 11 - SensaGuard Interlock Switches

+24V DC
Shown Open
Start
SensaGuard SensaGuard 800FM- K1
2 3 7 1 4 8 5 6 2 3 7 1 4 8 56 2 3 7 1 4 8 56 F3MX10
White (Aux)
Brown
Green
Blue
Yellow
Red
Gray (OSSD1)
Pink (OSSD2)
K2
Stop
800FM-
E4MX01
18mm Cylindrical
Plastic SensaGuard
440N-Z21S26H L1 L2 L3
Cordset S12 S22 L11 A1 13 23 33 41
Machine Control
889D-F8AB-2
PLC Input RESET 0 K1
Auxiliary RP
(1756-IB16 Signals AM
CI
1769-IQ16 to Machine MM
440R-S13R2
1746-IB16 Control K2
1792-IB16 I0 S11 S21 S34 A2 14 24 44 42
System
1734-IB4 I1
1793-IB6 I2
or similar) I3
Com M
K1 K2 100S-C43EJ14BC
24V DC Com

Magnetically Coded Sensor

Circuit Components
MC2 magnetically coded non-contact interlock switch
CI safety relay
Circuit Status
The first gate is open. The second and third gates are closed. The CI safety relay S12 and S22 inputs are open due to the
I0 from the first gate because the gate is open. The second and third auxiliary signals are off, as their gates are closed. The
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 machine control
system (for example, a PLC) can replace the Stop/Start circuit since the circuit is not part of the safety system.
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 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.

Figure 12 - Magnetically Coded Sensor

+24V DC
Shown Open
MC2 MC2 MC2 K1

Start
2 3 7 1 4 8 5 6 2 3 7 1 4 8 56 2 3 7 1 4 8 56 800FM-
White (Aux)
Brown
Green
Blue
Yellow
Red
K2
Gray
Pink
F3MX10
Stop
800FM-
MC2 Sensor E4MX01
440N-Z21W1PH
Cordset
889D-F8AB-2 L1 L2 L3
Machine Control S12 S22 L11 A1 13 23 33 41
Auxiliary RP
CI
440R-S13R2
1792-IB16 I0 S11 S21 S34 A2 14 24 44 42
System
1734-IB4 I1
1793-IB6 I2
or similar) I3
Com M
24V DC Com

Stainless Steel Ferrogard GD2 Non-contact Interlock Switch

Circuit Components
Ferrogard GD2 non-contact interlock switch
CI safety relay
Circuit Status
The first gate is open. The second and third gates are closed. The CI safety relay S12 and S22 inputs are open due to the
I0 from the first gate because the gate is open. The second and third auxiliary signals are off, as their gates are closed. The
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 machine control
system (for example, a PLC) can replace the Stop/Start circuit since the circuit is not part of the safety system.
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 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.

Figure 13 - Stainless Steel Ferrogard GD2 Noncontact Interlock Switch

+24V DC
Stainless Steel
Ferrogard Shown Open
FRS21 GD2
440N-G02149 K1
889D-F8AB-10 Start
3 4 8 1 2 5 6 3 4 8 1 2 5 6 3 4 8 1 2 56 800FM-
Green
Yellow
Red
Brown
K2
Gray
Pink
White
F3MX10
Stop
800FM-
E4MX01
L1 L2 L3
Machine Control S12 S22 L11 A1 13 23 33 41
Auxiliary RP
CI
440R-S13R2
1792-IB16 I0 S11 S21 S34 A2 14 24 44 42
System
1734-IB4 I1
1793-IB6 I2
or similar) I3
Com M
24V DC Com

Light Curtain - Point of Operation Control

Circuit Components
DI safety relay
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).
Operating 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 GuardShield light curtain initiates a safety function that 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. This circuit executes a Stop Category 0.

Figure 14 - Light Curtain - Point of Operation Control

+24V DC
Start K1
Transmitter Receiver 800FM-
Brown F3MX10
1 2 K2
Red
8 Restart (not used)
Brown Yellow
4 EDM (not used) Stop
Pink 800FM-
6
Grey E4MX01
5
White Aux Signal
1
Blue to PLC
7
Blue 3 Green
3
L1L2 L3
440L-P4KL0960YD S11 S21 S12 S22 A1 13 23 S34
889D-F4AC-2 889D-F8AC-2
0 K1
1
LOGIC 2
DI 8 3
7 4
440R-D22R2 6 5 K2
S32 S42 L11 L12 A2 14 24 Y32
Aux Signal
to PLC
M
24V DC Com

Two Light Curtains - Point of Operation Control

Circuit Components
GuardShield light curtains
DI safety relay
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 power 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 cross fault 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
configuration 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 GuardShield light curtains initiate a safety function that 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. This circuit executes a Stop Category 0.

Figure 15 - Two Light Curtains - Point of Operation Control

+24V DC
Start K1
800FM-
F3MX10
Brown Brown K2
1 2
Pink
6
Grey
5 Stop
Blue 800FM-
7
Blue 3 3 Green E4MX01
440L-P4KL0960YD
889D-F4AC-2 889D-F8AC-2
S11 S21 S12 S22 A1 13 23 S34
L1L2 L3
0
1
LOGIC 2 K1
8 3
DI 7 4
440R-D22R2 6 5
Brown Brown S32 S42 L11 L12 A2 14 24 Y32
1 2 K2
Pink
6
Grey Aux Signal
5
Blue to PLC
7
Blue 3 3 Green
K2
M
440L-P4KL0960YD K1
889D-F4AC-2 889D-F8AC-2 100S-C43EJ14BC
24V DC Com

Lifeline
Circuit Components
Lifeline cable pull switches
DI safety relay
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 32.8229.7 ft (1070 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
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 button. It
can then be restarted by pressing the Start 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/S34 circuit. If the contactors
are off, the DI safety relay energizes its outputs and turns on the contactors, which turn on the motor. The DI safety relay
detects a short or open circuit fault in the Lifeline cable pull switches. 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. The DI safety relay detects
its own internal faults. Depending on the type of fault, the result is de-energization of the K1 and K2 contactors or
prevention of restart.
Ratings
The Lifeline cable pull switches initiate a safety function that 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
K1
Start
800FM-
F3MX10 K2
Stop
800FM-
LifeLine LifeLine E4MX01
440E-L13042 440E-L13043 L1 L2 L3
(M20) (1/2in NPT)
43 31 21 11 11 21 31 43 S11 S21 S12 S22 A1 13 23 S34
Cable
K1
0
44 32 22 12 12 22 32 44 1
LOGIC 2
8 3 K2
7 4
DI 6 5
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
M
Aux Signal
440A-A17173 To PLC
855D-T10SC20B24Y4
800E-N157R
K1 K2 100S-C09EJ413BC
24V DC Com

Safety Distribution Block and DI Safety Relay with Kinetix 350 Drive
Circuit Components
SensaGuard non-contact interlock switch
Safety Distribution Block
DI safety relay
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 S22). The SensaGuard switches are closed and are connected in
series through the Distribution Block to Input 2 (S32 and S42). 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 signals 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: Open any gate or press any E-stop to de-energize the safety outputs of the DI safety relay, which in turn
cause the output of the Kinetix drive to turn OFF. The motor coasts 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 SensaGuard interlocks and the E-stop buttons initiate safety functions that 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.

Figure 17 - Safety Distribution Block and DI Safety Relay with Kinetix 350 Drive
+24V DC
Status Signals
Yellow
Brown
Grey/Pink
Input Input Output
Red
Red/Blue
SensaGuard White/Green 1756-IB16 1756-IV16 1756-OB16
SensaGuard 440N-Z21SS2HN Brown/Green 1769-IQ16 1769-IV16 1769-OB8
440N-Z21S17H White/Yellow PLC
Yellow/Brown
1746-IB16 1746-IV16 Processor 1746-OB4
White/Grey 1734-IB4 1734-IV4 1734-OB2
Grey/Brown 1793-IB6 1793-IV16 1793-OB4
+
E-Stop Reset
800FM-MT44
800F-MX02S
889D-P88RT-M19
S11 S12 S21 S22 A1 13 23 S34

L1 L2 L3
LOGIC 0
1
2
Kinetix 350 Drive
8 3
Shorting Plugs DI 7 4
Device Patchcord 440R-D22R2
6 5
889D-81RU-DM 1 +24V DC
889D-F8ABDM-2
S32 S42 L11 L12 A2 14 24 Y32 2 Com
Homerun Patchcord 3 Status
Pink 4 Safety Input 1
889M-R19RMMU-2 Bulk Head Grey 5 Safety Common
use with bulkhead Receptacle 6 Safety Input 2
or 888M-F19AE-1
Homerun Cordset
Blue
889M-R19RM-2 M
24V DC Com

Safety Valve - Air Supply Release

Circuit Components
DI safety relay
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: Press the E-stop or block the light curtain to de-energize the safety outputs of 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 Bulletin 800F E-stop and the GuardShield light curtain initiate a safety function that meets the safety performance
Performance Levels up to PLe per ISO13849-1:2006. This circuit performs a Stop Category 0.

Figure 18 - Safety Valve - Air Supply Release

+24V DC
E-Stop
800FM-MT44 Reset
800F-MX02S 800FM- DM2 CrossFlow
Reset F6MX10 Air
SERPAR
800FM- Supply
Safety Rated Valve
F6MX10
Air Exhaust
Ch1
S11 S12 S21 S22 A1 13 23 S34
LOGIC 0
1
2
8 3
DI 7 4
440R-D22R2
6 5 Status
S32 S42 L11 L12 A2 14 24 Y32 Ch2
Aux Signal
to PLC
Brown
2
Brown 1 Pink
6
Grey
5
Blue Air Outlet to other
7 pneumatic valves
Blue 3 Green
3
440L-P4K0960YD
889D-F4AC-2 889D-F8AC-2
24V DC Com

DI Safety Relay with SensaGuard Integrated Latch and PowerFlex 525 Drive
Circuit Components
SensaGuard integrated latch
DI safety relay
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 S22). The E-stop is connected to input 2 of the DI (S32 and S42).
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: Press 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 non-
operation of the motor indicates the fault. 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. The drive detects a fault in the safe circuit of the drive and the drive
issues a safety stop.
Ratings
The SensaGuard latch and the E-stop initiate safety functions that meet 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.

Figure 19 - DI Safety Relay with SensaGuard Integrated Latch and PowerFlex 525 Drive
24V DC
Yellow
Brown
Red
Reset
L1 L2 L3
PowerFlex R S T
White
Grey
SensaGuard Integrated Latch
Blue
Pink
525
440N-Z21SS3PA
E-Stop 11 +24V DC
800FM-MT44
800F-MX02S 1 Stop
S11 S21 S12 S22 A1 13 23 S34
0 2 Start
LOGIC 1
2
8 3
7 4 Gate control
DI 6 5 power supply
440R-D22R2
S42 S32 L11 L12 A2 14 24 Y32 Gate control
circuit
S1
S2
UV W
Gate
Open M
24V DC Com

Interlock Switch with Enabling DeviceGuard Locking with Time Delay

Circuit Components
Bulletin 440J grip switch enabling switch
MT-GD2 latch release
Bulletin 440G-MT guard locking switch
GLT, EM, SI, and EMD safety relays
Circuit Status
The Bulletin 440J enabling switch is held by one MT-GD2 tongue interlock by its mounting plate accessories. The
enabling switch is disabled when it is mounted in the MT-GD2 switch. The Bulletin 440G-MT guard locking switch
closes and locks the safety gate.
The GLT safety relay is set for Stop Cat 0 (Logic =1) and a time delay of 4 seconds (Range = 4 and Time =4, 40% of
10seconds). The SI safety relay is set from automatic reset (AM). The EMD safety relay range switch is set to 8 ( Jog
10seconds) and the Time is set to 6 (60%), therefore the Jog occurs for 6 seconds.
The EM safety relay allows the parallel switching of the contactors from the GLT safety relay or the enabling switch. If
the EM safety relay is not used and K1 and K2 are connected to terminals 14 and 24 of the GLT safety relay, the GLT
safety relay faults when the enabling switch is used because the 14 and 24 terminals detect a short circuit to 24V.
Due to the higher solenoid current of the Bulletin 440G-MT guard locking switch, the interposing relay CR1 is required.
Contactors K1 and K2 are de-energized. The motor is off and the application ready to run.
Operating Principle
With the safety gate unlocked, you can remove the enabling switch from its holder and jog (energize) the motor for the
duration set by the EMD safety relay (6 seconds), by pressing and holding the Jog switch. After the EMD safety relay
time expires, you can jog the motor again by releasing and then pressing/holding the Jog button again. When placed in
the MT-GD2 interlock, the enabling switch is disabled.
STARTING: With the enabling switch placed in the MT-GD2 interlock and the safety gate closed, press the Lock and
Reset button. Contactors K1 and K2 turn ON.
STOPPING: With the enabling switch placed in the MT-GD2 interlock, press the Unlock Request. Contactors K1 and
K2 turn off immediately and the motor coasts to a stop. After a 4-second delay, the safety gate is unlocked.
If the enabling switch is removed from the MT-GD2 holder while the motor is ON, contactors K1 and K2 turn off
immediately. The safety gate remains locked. The motor can still be jogged with the enabling switch. The GLT safety
relay shows a recoverable fault state; the PWR/Fault status indicator is green with five red flashes. You must put the
enabling switch back in the MT-GD2 holder and press the Reset button to clear the fault. Press the Reset button again to
turn the contactors ON.
STOPPING DURING JOG: Release the Jog switch. Also, if you release or squeeze the trigger switch on the enabling
switch the contactors turn OFF. The motor coasts to a stop.

Fault Detection
Upon successful completion of internal checks on power-up, the GSR modules check external devices. The GLT safety
relay checks for dual pulse-tested input signals from the interlock and potential short circuits on its outputs (51, L61, and
L11). If the inputs are closed, and no short circuits exist, the GLT safety relay waits for the reset signal. The reset signal is
sourced from X32 of the EM safety relay. If the EM safety relay has a fault, the X32 output remains OFF, and the GLT
safety relay cannot turn on its L11 output.
The SI safety relay checks for dual pulse-tested input signals from the MT-GD2 interlock and the enabling switch. If the
input signals are closed, the SI safety relay checks the reset circuit. If K1 and K2 are both OFF, then the SI safety relay
turns its L11 output ON. If K1 or K2 becomes faulted in an energized position, the SI safety relay does not turn on.
When not used, the enabling switch is placed in the MT-GD2 interlock. This placement helps prevent inadvertent
jogging of the motor when the enabling switch is not needed.
Ratings
The Bulletin 440G-MT guard locking interlock initiates a safety function that meets the safety performance
requirements of SILCL 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.
The MT-GD2 interlock and the enabling switch button initiate a safety function that 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 DeviceGuard Locking with Time Delay
24V DC
MT-GD2 Grip Switch 7
Latch Release Jog Button
440K-MT55050 8
Grip Switch
11 12 11 12 440J-N21TNPM-NP
440J-A01N
21 22 21 22
33 34 33 34 1 2 L1 L2 L3
43 44 CR1 K1
43 44 3 4
K2
440G-MT47045
Lock &
M
Unlock
Request Reset
Request
S11 S21 S12 S22 B2 S54 A1 S44 X32 A1 13 23 33 43 S11 S21 S34 A1 13 23 B1 B2 X32 A1 17 27 37 47
LOGIC 0 RANGE 0 TIME 1 RANGE 0 1 TIME 1
1 1 2 2
2 2 10 3 RESET 0 9 2 10 3
9 9
3 3 9 4 8 3 9 4
8 8 5
7 4 7 6 5 4 8 5 AM 7 6 54 8
7 6
6 5 7 6
GLT EM SI MM EMD
440R-GL2S2T 440R-EM4R2 440R-S12R2 440R-EM4R2D
L12 L11 Y32 A2 51 L61 14 24 L12 L11 A2 14 24 34 44 S12 S22 Y32 L11 A2 14 24 L12 L11 A2 18 28 38 48
700-HPSXZ24
A1 CR1 A2 700-ADL1R
K1 K2 100S-C43QJ14BC
700-HN123
24V Com

DI/EMD Safety Relays with Enabling Jog System

Circuit Components
Bulletin 440G-MT guard locking switch
Bulletin 440J grip switch enabling switch
DI and EMD safety relays
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 0.510 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 machine control system can control the drive. The machine control system disables the Jog switch.
STARTING: As shown, the PowerFlex drive is ready to run. Press the Start button.
JOGGING: Close the 3-position enabling switch 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 enabling switch
has been removed and enables the jog switch. Press the Jog button on the enabling switch 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. Release or squeeze the 3-position enabling switch to open the outputs of the DI safety relay
and causes the PowerFlex drive to execute 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 non-
operation of the motor indicates the fault. 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 interlock. The EMD safety relay detects a short across the
jog switch and helps prevent subsequent jog attempts. The DI safety relay detects a fault in the Safe-Off option of the
drive on the next attempt to restart the drive. Internal faults 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.
Ratings
The enabling switch initiates a safety function that 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
Grip Switch
440J N21TNPM-NP
Jog Button
7 8 L1 L2 L3
Machine Grip
Controlled PowerFlex 70 R S T
Lever w/ DriveGuard
Jog Enable 1 2
4 9 +24V DC
3 7 DC Comm
8 Dig Comm
2 Start
S11 S21 S12 S22 A1 13 23 S34 B1 B2 X32 A1 17 27 37 47 Gate Control
0 1
RANGE
0 9
1 TIME
2
10
2
3 1 Stop Power Supply
LOGIC 1 8
7 4
3 9
5
4
11 12 11 12 2 6 5 8
7 6 Safe Off Option
3 1
21 22 21 22 8 3
DI 7 4 EMD
6 5
33 34 33 34 440R-D22R2 440R-EM4R2D 4
S32 S42 L11 L12 A2 14 24 Y32 L11 L12 A2 18 28 38 48 2
43 44 43 44
5 Jog Gate
6 Enable Control
Circuit
MT-GD2 Remove Jumper U V W
440K-MT55050
To PLC Input 440K-MT55026
for Jog Enable
440J-A04N M
24V DC Com

Guard Locking with DI/EMD Safety Relays

Circuit Components
TLS1-GD2 guard locking switch
Trojan T15-GD2 tongue interlock switch
Bulletin 100S safety contactor
Circuit Status
The E-stop is reset and 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,
Time6: 60% of range). The EMD safety relay opens 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 100S safety contactors.
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, 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 DI safety relay contacts faults to the ON state, the redundant outputs stop the motor. The
Y32, K1, K2, K3, K4, and TLS1 monitoring circuit detects the fault on the next attempt to restart. If the gate is not
interlocked by the TLS1 solenoid or one of the 100S safety contactors fault to the ON state, the DI safety relay detects
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 help prevent potential single-point failures that are related to tongue style interlocks.
Ratings
The gate interlocks and the E-stop initiate a safety function that meets the safety performance requirements of SIL CL3
PLe per ISO13849-1:2006. This circuit executes Stop Category 0.

Figure 22 - Guard Locking with DI/EMD Safety Relays

+24V DC
Reset
800FM-F6MX10
CR1 L1 L2 L3
K1
800FM-MT44
Gate 800F-X02S
Release
K2
TLS1 GD2
440G-T27171
Remove internal
jumper from
M1
Power to 12 to 41
Release
L1 L2 L3
11 21 33 S11 S21 S12 S22 A1 13 23 S34 B1 B2 X32 A1 17 27 37 47
RANGE TIME
0 1
0
1
1
2
2
3 K3
12 22 41 53 LOGIC 9
8 3
10
9 4
2 7 4 8 5
A1 34 8 3 6 5 7 6
7 4
DI 6 5 EMD
42 54 440R-D22R2 K4
A2 440R-EM4R2D
S32 S42 L11 L12 A2 14 24 Y32 L11 L12 A2 18 28 38 48
M2
11 21 Trojan T15-GD2 700-HPS2Z24
440K-T11397 CR1
K1 K2 K3 K4
12 22 100S-C43EJ14BC 100S-C43EJ14BC
24V DC Com

Guard Locking with DI/EMD Safety Relays

Circuit Components
MAB
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,
Time6: 60% of range). The EMD opens 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 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 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 gate interlocks and the E-stop initiate a safety function that meets the safety performance requirements of SIL CL3
PLe per ISO13849-1:2006. This circuit executes Stop Category 0.

Figure 23 - Guard Locking with DI/EMD Safety Relays

+24V DC
E-stop L1 L2 L3
800FM-MT44
800F-MX02 Reset
800FM-F6MX10 K1
442G-MABH-R K2
442G-MABR-URM-C00
S11 S21 S22 S12 A1 13 23 S34 B1 B2 X32 A1 17 27 37 47
LOGIC 0 RANGE 0 1 TIME 1
2
M1
1 2 10 3
9
2 8 3 9 4
3 7 6 54 8 5
8 7 6
DI 7 4 L1 L2 L3
6 5 EMD
Brown 440R-D22R2 440R-EM4R2D
S32 S42 L11 L12 A2 14 24 Y32 L12 L11 A2 18 28 38 48 K3
MAB Fault
Reset
K4
Grey/Pink
889M-F19RM-5 Blue Violet Unlock
800FM-SM220X M2
Green/Black K1 K2 K3 K4
Red/Blue 100S-C43EJ04BC 100S-C43EJ04BC
24V DC Com

Global E-stop and Zone Control

Circuit Components
GuardShield light curtains
Bulletin 440F MatGuard safety mats
DI safety relays
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. K1K6 are ready to be energized.
Operating Principle
The DI safety relay is chosen for its zoning capability. The two E-stops operate globally - turning off relays 1, 2, and3.
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 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 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 safety relays check 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 (K1K6) is stuck in an actuated state, the
respective DI safety relay prevents startup because the S34 feedback loop remains open. For fault detection purposes, all
GSR modules that are used in safety mat applications must be configured for monitored manual reset.
Ratings
The input devices, except the safety mat, initiate safety functions that 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 ISO13849-1:2006.

Figure 24 - Global E-stop and Zone Control

+24V DC
MatGuard SensaGuard
Safety Mat & Trim 440N-Z21S26H
K1 440F-M2030BYNN K3 Brown K5
E-Stop 2
440F-T2030 Red
800FM-MT44 8
Yellow
800F-MX02L K2 K4 4 K6
Blue
7
Green
3
Reset Reset White (Aux) Reset
1 To PLC
800FM- 800FM- Pink (OSSD2) 800FM-
F6MX10 F6MX10 6 Gray (OSSD1) F6MX10
5
S11 S21 S12 S22 A1 13 23 S34 S11 S21 S12 S22 A1 13 23 S34 S11 S21 S12 S22 A1 13 23 S34
1 0
1 2 0
1 3 0
1
LOGIC 2 LOGIC 2 LOGIC 2
8 3 8 3 8 3
DI 7 4 DI 7 4 DI 7 4
440R-D22R2 6 5 440R-D22R2
6 5
440R-D22R2
6 5
S32 S42 L11 L12 A2 14 24 Y32 S32 S42 L11 L12 A2 14 24 Y32 S32 S42 L11 L12 A2 14 24 Y32
2 4 Aux 2 4 Aux
Aux Signal 3
1 3 1
to PLC A 5 Signal B 5 Signal
to PLC to PLC
1 3 1 3
E-stop 2 4 5
K1 K2 2 4 5 K3 K4 K5 K6
800FM-MT44
800F-MX02L 100S-C09 100S-C09 100S-C09
GuardShield Safe 4 GuardShield Safe 4
EJ14BC Light Curtain EJ14BC Light Curtain EJ14BC
445L-P4L1920YD 445L-P4L0240YD
24V DC Com

E-stops for a PowerFlex 755 Drive

Circuit Components
DI safety relay
PowerFlex 755 drive
Circuit Status
Both safety mats are clear. The safety outputs of the DI safety relay are de-energized. The PowerFlex 755 drive is powered
and its safety circuit is disabled. The motor is off. The DI safety relay has a Logic setting of 2: [(IN1 AND IN2) OR
L12] with monitored manual reset.
IMPORTANT The safety mat wiring must be crossed as compared to an E-stop button: S11 connects to S22 & S42 and S21 connects to S12 &
S32, and safety mat applications require Logic settings with IN1 AND IN2.
Operating Principle
STARTING: Press the Reset button to energize the safety outputs of the DI safety relay and enable the PowerFlex 755
drive. Press the Start button to start the motor.
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 mats. A cross fault (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 one internal fault. For fault detection
purposes, all GSR modules that are used in safety mat applications must be configured for monitored manual reset.
Ratings
The safety mats initiate a safety function that meets the safety performance requirements of SIL CL2 per IEC
ISO13849-1:2006. This circuit executes a Safe Torque Off (Stop Category 0).

Figure 25 - E-stops for a PowerFlex 755 Drive

+24V DC
MatGuard
Safety Mat & Trim
440F-M2030BYNN L1 L2 L3
440F-T2030
Reset PowerFlex
755 Series
Stop
S11 S12 S21 S22 A1 13 23 S34

Status Start
LOGIC 0
1 to PLC
2 Start/Stop Common
8 3
7 4 24V DC Com
DI 6 5
440R-D22R2 Gate Control
S32 S42 L11 L12 A2 14 24 Y32 Power Supply
SP+ Gate
MatGuard Control
Safety Mat & Trim SE+ Circuit
440F-M2030BYNN SP-
440F-T2030
SE-
Motor
24V DC Com

SafeZone Mini Laser Scanner, E-stop, and DI Safety Relay with Kinetix 350 Drive
Circuit Components
SafeZone Mini safety laser scanner
DI safety relay
Kinetix 350 drive
Circuit Status
E-stop is in the released position and is connected to Input 2 (S32 and S42) of the DI safety relay. The scan area of the
SafeZone Mini scanner is clear and the signals to Input 1 of the DI (S12 and S22) 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 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 Do not 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 SafeZone Mini scanner and the E-stop buttons initiate safety functions that can meet the safety performance
Performance Level up to PLd per ISO13849-1:2006. This circuit executes a Stop Category 0.

Figure 26 - SafeZone Mini Laser Scanner, E-stop, and DI Safety Relay with Kinetix 350 Drive
+24V DC
Brown
Input Input Output +
1756-IB16 1756-IV16 1756-OB16
White (Warning Field) 1769-IQ16 1769-IV16 PLC 1769-OB8
SafeZone Mini 1746-IB16 1746-IV16 Processor 1746-OB4
442L-SFZNMN 1734-IB4 1734-IV4 1734-OB2
Shield
Grey
442L-ACABL210 (Cable)
Blue
Pink
1793-IB6 1793-IV16 1793-OB4
Reset +
S11 S21 S22 S12 A1 13 23 S34 L1 L2 L3

LOGIC 0
1
2 Kinetix 350 Drive
8 3
7 4
DI 6 5
E-stop 440R-D22R2
800FM-MT44 1 +24V DC
800F-MX02S S32 S42 L11 L12 A2 14 24 Y32 2 Com
3 Status
4 Safety Input 1
5 Safety Common
6 Safety Input 2
Warning
Field
M
24V DC Com

Multizone Laser Scanner, E-stop, and DI Safety Relay with Kinetix 350 Drive
Circuit Components
SafeZone Multizone safety laser scanner
DI safety relay
Kinetix 350 drive
Circuit Status
SafeZone Multizone is clear and the signals to Input 1 of the DIS safety relay (S12 and S22) 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. and a N.O.) to the SafeZone Multizone scanner to switch the active zones
between Zones A and B. The OSSD outputs respond to either zone.
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.
Ratings
The SafeZone Multizone scanner and the E-stop buttons initiate safety functions that can meet the safety performance
Performance Levels up to PLd per ISO13849-1:2006. 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 & White/Orange)
A1 (Brown)
Select Zone B (White/Yellow & White/Green)
Warning Field (White/Brown) Input Input Output

1756-IB16 1756-IV16 1756-OB16
OSSD2 (Pink)
A2 (Blue) 1769-IQ16 1769-IV16 PLC 1769-OB8 +
OSSD1 (Grey) 1746-IB16 1746-IV16 Processor 1746-OB4
Reset 1734-IB4 1734-IV4 1734-OB2
1793-IB6 1793-IV16 1793-OB4
+
SafeZone
Multizone
442L-SFZNMZ S11 S21 S22 S12 A1 13 23 S34
Cable & Mem Module LOGIC 0 L1 L2 L3
1
442L-CSFZNMZ-10 2
8 3 Kinetix 350 Drive
7 4
DI 6 5
440R-D22R2 1 +24V DC
E-Stop
800FM-MT44 S32 S42 L11 L12 A2 14 24 Y32 2 Com
800F-MX02S 3 Status
4 Safety Input 1
5 Safety Common
6 Safety Input 2 Warning
Field
M
24V DC Com

Safety Sensor, E-stop, and DI Safety Relay with Kinetix 350 Drive
Circuit Components
SC300 hand detection safety sensor
DI safety relay
Kinetix 350 drive
Circuit Status
SC300 safety sensor is clear and the signals to Input 1 of the DI safety relay (S12 and S22) 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
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.
Ratings
The SC300 safety sensor and the E-stop buttons initiate safety functions that can meet the safety performance
Performance Levels up to PLd per ISO13849-1:2006. This circuit executes a Stop Category 0.

Figure 28 - Safety Sensor, E-stop, and DI Safety Relay with Kinetix 350 Drive
+24V DC
Teach Input Input Output +
Brown
Green
1756-IB16 1756-IV16 1756-OB16
White
1769-IQ16 1769-IV16 PLC 1769-OB8
Pink Reset 1746-IB16 1746-IV16 Processor 1746-OB4
Grey 1734-IB4 1734-IV4 1734-OB2
Blue Red 1793-IB6 1793-IV16 1793-OB4
Yellow +
SC300
442L-SAFCAM1
Cable
889D-F8FB-5 S11 S21 S22 S12 A1 13 23 S34
LOGIC 0
1
2
L1 L2 L3
8 3
7 4
E-Stop DI 6 5 Kinetix 350 Drive
800FM-MT44 440R-D22R2
800F-MX02S S32 S42 L11 L12 A2 14 24 Y32 1 +24V DC
2 Com
3 Status
4 Safety Input 1
5 Safety Common
6 Safety Input 2 Warning
Field
M
24V DC Com

Hazardous Location
Circuit Components
Trojan T15 tongue interlock switch
Bulletin 937TH isolator
DIS safety relay
PowerFlex 525 drive
Circuit Status
The DIS safety relay logic is set to 2: [(IN1 AND IN2) OR L12] with monitored reset. The Trojan T15 switch is
connected to input 1 of the DIS (S12 and S22) through the galvanic isolator. The E-stop is connected to input 2 of the
DIS safety relay (S32 and S42). 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 and enable 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 switch.
Ratings
The Trojan T15 switch initiates a safety function that 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.
and has a Category 3 structure that can be used in systems that require up to Performance Level PLd per ISO13849-
1:2006. This circuit executes a Stop Category 0.
See publication 937TH-WD001 for more safeguarding examples with the galvanic isolator.

Figure 29 - Hazardous Location

+24V DC
Hazardous Location Non-hazardous Location E-Stop L1 L2 L3
U.S. Galvanic Isolating Switching Amplifier 800FM-MT44
Reset
Class I,II,III, Div 1,2 800F-MX02S PowerFlex R S T
937TH-DISRS-DC1
European R1 525
Zone 0,1,2, EExia IIB 1+ 5
1 Stop
2 - 6
R2 7 2 Start
Switch 8
Settings S12 S22 S11 S21 S42 S32 A1 S34 4 Gnd
S1 I LOGIC 0
1
2
R1, R3: 1K ohm S2 I 3
10 8
7 4 Gate control
1492-JD3RB102 S3 I U DIS
6 5
power supply
9
S4 -- 440R-D22S2
R2, R4: 10K ohm L11 L12 A2 34 44 14 24 Y32 Gate control
DIN Rail Connections circuit
1492-JD3RB103
S1
937TH-DISRS-DC1 S2
R3 UV W
1+ 5
Status
2 - 6 To PLC
7 M
R4 8
Switch
Settings
21 S1 I
22
S2 I
11 12 S3 I 10
U 9
S4 --
DIN Rail Connections

S1: Normal Output
Trojan T15 S2: Output 2 Follows Output 1
440K-T11395 S3: Enable Line Fault Detection
S4: Not Used
24V DC Com

Hazardous Location
Circuit Components
DIS safety relay
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 S22) through the galvanic isolator. The E-stop is connected to input 2 of the DIS safety relay
(S32 and S42). 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 action enables the
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. 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
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.
and has a Category 3 structure that can be used in systems that require up to Performance Level PLd, per ISO 13849-


+24V DC
E-Stop
Hazardous Location Non-hazardous Location 800FM-MT44 L1 L2 L3
U.S. Galvanic Isolating Switching Amplifier 800F-MX02S Reset
PowerFlex R S T
Class I,II,III, Div 1,2 937TH-DISRS-DC1 525
R1
European 1+ 5 1 Stop
Zone 0,1,2, EExia IIB 2 - 6
R2
7 2 Start
8
S12 S22 S11 S21 S42 S32 A1 S34 4 Gnd
Switch LOGIC 0
440F-M2030BYNN Settings 1
9 2
Parallel Plate S1 II 3 Gate control
8
Safety Mat S2 I 10 7 6 5 4 power supply
DIS
S3 I U 9 440R-D22S2
S4 -- L11 L12 A2 34 44 14 24 Y32 Gate control
circuit
S1
937TH-DISRS-DC1
S2
UV W
1+ 5
Status
R4 2 - 6 To PLC
7 M
Switch 8
R3 Settings
S1 II
R1, R3: (1K) S2 I
1492-JD3RB102 S3 I 10
U 9
S4 --
R2, R4: (10K)
1492-JD3RB103
S1: Inverted Output
S2: Output 2 Follows Output 1
S3: Enable Line Fault Detection
S4: Not Used
24V DC Com

Hazardous Location
Circuit Components
Safedge pressure sensitive sensing edge
DIS safety relay
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 S22) through the galvanic isolator. The E-stop is connected to input 2 of the DIS safety relay
(S32 and S42). 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.
STARTING: Press the Reset button to turn the DIS safety outputs (14, 24, 34, 44 and L11) ON. This action enables the
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 sensing edge initiates a safety function that meets the safety performance requirements of SIL CL2 per IEC
62061:2005 and has a Category3 structure that can be used in systems that require up to Performance Level PLd, per
ISO 13849-1:2006.
and has a Category 3 structure that can be used in systems that require up to Performance Level PLd, per ISO 13849-


+24V DC
Hazardous Location Non-hazardous Location
E-Stop L1 L2 L3
800FM-MT44
U.S. Reset
Galvanic Isolating Switching Amplifier 800F-MX02S PowerFlex R S T
Class I,II,III, Div 1,2 525
937TH-DISRS-DC1
European R1
1 + 5 1 Stop
Zone 0,1,2, EExia IIB
2 - 6 2 Start
R2
7
8 S12 S22 S11 S21 S42 S32 A1 S34 4 Gnd
+ - Switch LOGIC 0
Settings 1
2
3
S1 II 8
7 4 Gate control
6 5
S2 I 10 DIS power supply
U 9 440R-D22S2
S3 I
L11 L12 A2 34 44 14 24 Y32 Gate control
S4 -- circuit
+ - S1
937TH-DISRS-DC1 S2
UV W
1+ 5
Status
R4 2 - 6 To PLC
7 M
440F Safedge 8
R3 Switch
Pressure Sensitive
Settings
Sensing Edge
e.g., 440F-EAAAA01000 S1 II
S2 I 10
S3 I U 9
R1, R3: (1K) S4 --
1492-JD3RB102
R2, R4: (10K) S1: Inverted Output
1492-JD3RB103 S2: Output 2 Follows Output 1
S3: Enable Line Fault Detection
S4: Not Used
24V DC Com

PowerFlex Drive - Multiple Gate Access

Circuit Components
Trojan 5 GD2 tongue interlock switch
MT-GD2 latch release
DIS safety relay
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 automatic 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 action 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 coasts to a stop. A cross fault (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 gate interlocks initiate a safety function that meets the safety performance requirements of SIL CL2 per IEC

Figure 32 - PowerFlex Drive - Multiple Gate Access

+24V DC
Guard Shown
L1 L2 L3
Open
11 21 33
PowerFlex 70
with DriveGuard
1 Stop
12 22 34
2 Start
440K-T11341
Trojan 5 GD2 7 DC Comm
8 Dig Comm
S11 S21 S12 S22 S32 S42 S34 A1 Gate Control

Power Supply
0
LOGIC 1
2 Safe Off Option
8 3 1
7 4
6 5 3
DIS
440R-D22S2
L12 L11 Y32 A2 34 44 14 24 4
2
Gate
6 Enable Control
11 21 33 43 Aux Circuit
Signal
to PLC Remove Jumper
12 22 34 44
440K-MT55080 Motor
MT-GD2 Latch Release
24V DC Com

Multiple PowerFlex Drives

Circuit Components
Trojan 5 GD2 tongue interlock switch
DIS safety relay
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 that can be
connected in parallel is dependent on:
The load (the safe-off option plus the enable of each drive)
Appropriate derating to help prevent early wear out of the DIS safety relay solid-state outputs
The application requirements (for example, zoning)
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
S42) 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.
Fault Detection
Upon power-up, 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 cross fault 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 S34 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 Trojan 5-GD2 gate interlock initiates a safety function that meets the safety performance requirements of SIL CL2
PLd per ISO 13849-1:2006. This circuit executes a Stop Category 0.
Figure 33 - Multiple PowerFlex Drives

+24V DC
Gate shown
open L1 L2 L3 L1 L2 L3
11 21 33
PowerFlex 70 R S T PowerFle 70x R S T
with DriveGuard with DriveGuard
12 22 34
DeviceNet DeviceNet
Dig. Comm Dig. Comm
Trojan5-GD2
440K-T11213 Gate Control Gate Control
S11 S21 S12 S22 S32 S42 S34 A1 Power Supply Power Supply
0
LOGIC 1 Safe-Off Option Safe-Off Option
2 1 1
8 3 3 3
7 4
6 5
DIS 4 4
440R-D22S2 2 2
L12 L11 Y32 A2 34 44 14 24 Gate Gate
Enable Control Enable Control
Circuit Circuit
U V W U V W
Remove Jumper Remove Jumper
Motor
Motor
Input PLC DeviceNet
1756-IB16 Processor 1756-DNB
1769-IQ16 1769-SDN
1746-IB16 1747-SDN
1734-IB4 1734-PDN
1793-IB6 1794-ADN
24VC DC Com

Micro 400 Light Curtain

Circuit Components
Micro 400 light curtain
MSR41 controller module
DIS safety relay
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 pressing 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 cross faults. The E-stop signals are pulse tested to check for cross faults. 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 ISO13849-1:2006. This circuit
executes a Stop Category 0.

Figure 34 - Micro 400 Light Curtain

+24V DC
Micro 400 E-Stop K1
445L-P4C0300FP 800FM-MT44
800F-MX02S
445L-AC8RJ5 (2x) K2
Reset
800FM-
F6MX10
Status
to PLC L1L2 L3
IN1 IN2 24V S11 S12 S21 S22 L12 A1 Y32 S34
Rcv LOGIC 0
K1
1
2
RJ45 3
8
7 4
6 5
Trans MSR41 K2
RJ45 DIS
440R-P221AGS 440R-D22S2
S32 S42 A2 34 44 14 24 L11
0V INFO1 INFO2 OSSD1 OSSD2
M
K1
Start
Lockout Status K2
to PLC
Safety Output Stop

Status to PLC
24V DC Com

Micro 400 Light Curtain

Circuit Components
Micro 400 light curtain
MSR42 controller module
DIS and DI safety relays
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, which
makes the E-stop always effective (and the SensaGuard switch or Micro 400 light curtain).
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 SensaGuard switch does not detect the machine position or pressing 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 MSR42 module are pulse tested to
check for cross faults. The OSSD outputs of the SensaGuard switch are pulse tested to check for cross faults. 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 cross faults. 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
structure that can be used in systems that require Performance Levels up to PLe per ISO13849-1:2006. This circuit

Figure 35 - Micro 400 Light Curtain

+24V DC
Mounted on Machine
Micro 400 to Indicate
445L-P4E0300FP Machine Position
445L-AC8RJ5 (2x) Start K1
Transmitter Receiver 800FM-
E-Stop F3MX10
SensaGuard 800FM-MT44 K2
440N-Z21S26H 800F-MX02S
889D-F8AB-2 2 3 7 1 4 8 5 6 Stop
Reset
White (Aux)
Brown
Green
Blue
Yellow
Red
Gray (OSSD1)
Pink (OSSD2)
800FM-
800FM-
E4MX01
F6MX10
To PLC
L1L2 L3
IN1 IN2 +24V GPIO1 GPIO2 GPIO3 GPIO4 S11 S21 S12 S22 L12 A1 Y32 S34 S11 S12 S21 S22 A1 13 23 S34
Rcv LOGIC 0 LOGIC 0
K1
1 1
2 2
RJ45 3 3
8 8
7 4 7 4
6 5 6 5
Trans MSR42 K2
RJ45 DIS DI
440R-P221AGS 440R-D22S2 440R-D22R2
S32 S42 A2 34 44 14 24 L11 S32 S42 L11 L12 A2 14 24 Y32
LAMP 0V INFO1 INFO2 OSSD1 OSSD2
M
To PLC
K1 K2
100S-C43EJ14BC
24V DC Com

Cat 1 Stop with Guard Locking Interlock and Proximity Sensors

Circuit Components
Bulletin 872C proximity sensors
Guard locking proximity (GLP) safety relay
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 & S21), 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 cross faults. 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 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 & 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
structure that can be used in systems that require Performance Levels up to PLd per ISO13849-1:2006. This circuit

Figure 36 - Cat 1 Stop with Guard Locking Interlock and Proximity Sensors
+24V DC
L1 L2 L3
Gate Reset &

Unlock Gate Lock PowerFlex 70 R ST
Request Request with DriveGuard

2 Start
1 Stop
Safety
Gate
11 21 33 X14 X24 51 A1 S54 S44 Y32 L12
LOGIC SLS1 SLS2/TIME
0 0 0
1 1 1
41 51 9 2 9 2 9 2 7 DC Comm
A1 12 22 34 8 3 8 3 8 3
7 6 5 4
7 6 5 7 6 5 4 4 8 Digital In Com
GLP
A2 440R-GL2S2P Gate Control
42 52 S12 S22 L61 A2 AP P12 P22 L11 Power Supply
1
3
Brown
Black
Black
TLS3 GD2 4
440G-T27183 2
Gate
6 Enable Control
Circuit
Gate
Blue
Blue
Open Proximity Sensors Remove Jumper U V W

872C-D8NP18-E5
M
24V DC Com

Stop Motion with Guard Locking by PLC

Circuit Components
TLS-ZR guard locking switch
Guard locking proximity (GLP) safety relay
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 (20Hz). The safety outputs (X14 & X24), the single wire safety output (L11), and the
auxiliary output (Y32) are OFF.
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 S44 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 S54 of the GLP safety relay. When the proximity sensors 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 help 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 a GuardLogix safety PLC must control them.
OVERSPEED: If the proximity sensors detect a speed above the maximum speed (20 Hz), the safety outputs at
terminals X14 & 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.
Ratings

Figure 37 - Stop Motion with Guard Locking by PLC

+24V DC
Ethernet I/P Unlocked Lock and
to Guardlogix Request Reset
Request
1734-AENTR 1734-IB8S 1734-OB8S
0 1 I0 I1 I4 I5 O0 O1 O4 O5
2 3 I2 I3 I6 I7 O2 O3 O6 O7
4 5 COM COM COM COM COM COM COM COM

A1 X14 X24 51 L61 Y32 S54 S44
6 7 T0 T1 T2 T3 COM COM COM COM
0 0 0
1 1 1
9 2 9 2 9 2
8 3 8 3 8 3
7 6 5 4
7 6 5 7 6 5 4 4
GLP
440R-GL2S2P Safety Gate
S12 S22 A2 AP P12 P22 L11 L12 Brown (Pwr)
Red (OSSD+)
Brown
Black
Black
Yellow (OSSD+)
Pink (OSSD)
Grey (OSSD)
Green (Lock)
White (Aux)
Blue
Blue
Proximity Sensors Blue (Com) Gate

Unlocked
872C-D8NP18-E5 TLS-ZR
440G-TZS21UPRH
889D-F8AC-2
24V DC Com

Guard Locking Interlock with High Current Solenoid

Circuit Components
Bulletin 440G-MT solenoid guard locking switch
Bulletin 871TM proximity sensors
GLP and EM safety relays
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 (0.5 Hz) and a Maximum (SLS2) speed setting of 0 (unlimited). The proximity
sensors detect speed below 0.5 Hz. The single wire safety output (L11) and the auxiliary output (Y32) are OFF.
Terminals X14 & 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 SWS 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.

Ratings
structure that can be used in systems that require Performance Levels up to PLd per ISO13849-1:2006. The safety
function performs a Stop Category 1.
Figure 38 - Guard Locking Interlock with High Current Solenoid

+24V DC
Lock and Reset
Gate
Request
Unlock
Request L1 L2 L3
PowerFlex R S T
525
X14 X24 51 S54 A1 S44 Y32 L12 X32 A1 13 23 33 43
CR1 LOGIC SLS1 SLS2/TIME
Gate 0 0 0 1 Stop
1 1 1
9 2 9 2 9 2
3 3 3
2 Start
11 21 31 43 A1 8 8
4
8
4
7 6 5 4 7 6 5 7 6 5
GLP EM 4 Digital Com
440R-GL2S2P 440R-EM4R2
12 22 32 44 A2 S12 S22 L61 A2 AP P12 P22 L11 L12 L11 A2 14 24 34 44 Gate control
power supply
Gate control
Brown
440G-MT47037
Black
Black
circuit
(Power to Unlock)
CR1 S1
S2
UV W
700-HPSXZ24 (relay)
Proximity Sensors
Blue
Blue
700-HN123 (base)
871TM-N40NP30-D4 M
700-ADL1R (diode)
889D-F4AC-2
700-HN119 (retainer)
24V DC Com

Stop Category 1 with Logic IN, Guard Locking, and Proximity Sensors
Circuit Components
Bulletin 440G-LZ guard locking switch
SI and GLP safety relays
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). 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.
Operating Principle
This example is a cascaded safety system with a 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, pressing the Gate Unlock Request
button turns off the motor and allows 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 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: Initiate a safety stop by taking either of the following actions:

Press the E-stop, which turns off K1 and K2 and initiates the Gate Unlock Request function in the GLP safety
relay.
Press 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 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 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 & 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
Figure 39 - Stop Cat 1 with Logic IN, Guard Locking, and Proximity Sensors
+24 VDC
440G-LZS21SPRA
Reset L1 L2 L3
Yellow
Brown
Gate Reset &

Red
Unlock Gate Lock PowerFlex 70 R ST
Request Request with DriveGuard

K1
2 Start
K2 Green 1 Stop
Grey
Pink 7 DC Comm
8 Digital In Com
S11 S21 S34 A1 13 23 S12 S22 51 A1 S54 S44 Y32 L11
Gate Control
0 LOGIC SLS1 SLS2/TIME Power Supply
RESET 0 0 0
1 1 1
9 2 9 2 9 2
AM 3 3 3
8 8 8 1
MM 7 6 5 4
7 6 5 7 6 5 4 4
SI GLP 3
440R-S12R2 440R-GL2S2P 4
S12 S22 Y32 A2 14 24 L11 L12 L61 A2 AP P12 P22 X14 X24 2
Gate
Brown
Black
Black
6 Enable Control
White
Blue
Circuit
Remove Jumper U V W
K1 K2
Gate M
Unlocked
Blue
Blue
Proximity Sensors
871TM-N10NP12-D4
24V DC Com 889D-F4AC-2

Safe Limited Speed with Guard Locking Interlock and Proximity Sensors
Circuit Components
TLSZR-GD2 guard locking switch
GLP safety relays
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 & X24), the
single wire safety output (L11), and the auxiliary output (Y32) are OFF.
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 safety 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 10Hz 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 cross
faults. 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.
Ratings
executes Stop Category 0 for fault conditions.

Figure 40 - Safe Limited Speed with Guard Locking Interlock and Proximity Sensors
+24V DC
Start
Input EtherNet/IP
Stop 1756-IB16 1756-ENBT
1769-IQ16 PLC
Gate Reset & 1746-IB16 Processor
Unlock Gate Lock 1734-IB4
Request Request 1793-IB6
L1 L2 L3
Safety
Gate
Brown S12 S22 51 S54 A1 S44 Y32 L12 Kinetix 300
Red LOGIC SLS1 SLS2/TIME
0 0 0
30 Clear Faults
Yellow 1 1 1
2
29 Enable
Green 9 9 2 9 2
3 8 3 8 3 26 Gnd
Grey 8 4 4
7 6 5 4
7 6 5 7 6 5
Pink GLP 1 +24V DC
White 440R-GL2S2P 2 Com
Blue L61 A2 AP P12 P22 L11 X14 X24 3 Status
4 Safety Input 1
TLS-ZR 5 Safety Common
Brown
Black
Black
440G-TZS21UPRH 6 Safety Input 2

889D-F8AC-2
Gate Proximity Sensors
Unlocked 871TM-N40NP30-D4 U VW
889D-F4AC-2
M
Blue
Blue
24V DC Com

Safe Limited Speed with Logic In, Guard Locking and Proximity Sensors
Circuit Components
SI, GLP, and EM safety relays
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 K1K4
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.
Operating Principle
This example 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,
which 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: Initiate safe limited speed by taking either of the following actions:
Press the E-stop, which turns off K1 and K2 and initiates the Gate Unlock Request function in the GLP safety
relay
Press 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.
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 & 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
executes a Stop Category 0 for fault conditions.
Figure 41 - Safe Limited Speed with Logic In, Guard Locking and Proximity Sensors
+24V DC
440G-LZS21SPRA
Reset L1 L2 L3
Yellow
Brown
Red
PowerFlex R S T
525
Gate Reset &
K1 K3 11 +24V DC
Unlock Gate Lock
Request Request 1 Stop
K2 Green K4 2 Start
Grey
Pink 5 Preset Freq
S11 S21 S34 A1 13 23 S12 S22 51 L61 S54 A1 S44 Y32 X32 A1 13 23 33 43 4 Gnd
0 LOGIC SLS1 SLS2/TIME 19 Output Gnd
RESET 0 0 0
1 1 1
9 2 9 2 9 2
AM 3 3 3 Gate control
8 8 8
MM 7 6 5 7 6 5 47 6 5 4 4 power supply
SI GLP EM
440R-S12R2 440R-GL2S2P 440R-EM4R2
Gate control
S12 S22 Y32 A2 14 24 L11 L12 A2 AP P12 P22 X14 X24 L11 L12 L11 A2 14 24 34 44 circuit
Brown
S1
Black
Black
S2
UV W
White
Blue
Status
to PLC
Proximity
K1 K2
Sensors K3 K4 M
Gate
871TM-N10NP12-D4
Blue
Blue
Unlocked
889D-F4AC-2
24V DC Com

Stop Motion with Guard Locking and E-stop

Circuit Components
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 outputs for faults. The GLP safety relay uses redundant proximity sensors that must be mounted on
independent fixtures.
Ratings
structure that can be used in systems that require Performance Levels up to PLd per ISO13849-1:2006.

Figure 42 - Stop Motion with Guard Locking and E-stop

+24V DC
Yellow
Brown
440G-LZS21SPRA
Red
Green
Grey
Pink
S12 S22 51 L61 S54 A1 S44 Y32

0 0 0
1 1 1
9 2 9 2 9 2
8 3 8 3 8 3
7 6 5 7 6 5 47 6 5 4 4
GLP
440R-GL2S2P
L12 A2 AP P12 P22 X14 X24 L11
White
Blue
Brown
Black
Black
Gate
Unlocked
Blue
Blue
872C-D8NP18-E5 (2)
24V DC Com

Stop Motion to PLC

Circuit Components
GLP safety relay
CR30 configurable safety relay
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
When 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 a GuardLogix safety PLC must control them.
Ratings

Figure 43 - Stop Motion to PLC

+24V DC
EtherNet/IP
to Guardlogix
Controller
1734-AENTR 1734-IB8S 1734-OB8S
0 1 I0 I1 I4 I5 O0 O1 O4 O5
2 3 I2 I3 I6 I7 O2 O3 O6 O7
A1 X14 X24 51 L61 Y32 S54 S44 4 5 COM COM COM COM COM COM COM COM
0 0 0
1 1 1 6 7 T0 T1 T2 T3 COM COM COM COM
9 2 9 2 9 2
8 3 8 3 8 3
7 6 5 4
7 6 5 7 6 5 4 4
GLP
440R-GL2S2P
S12 S22 A2 AP P12 P22 L11 L12
Brown
Black
Black
00 01 02 03 04 05 06 07 08 09 10 11
CR30
440C-CR30-22BBB
A1 A2 12 13 14 15 16 17 18 19 20 21
Blue
Blue
Proximity Sensors
872C-D8NP18-E5
24V DC Com

Speed Status Only

Circuit Components
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,
10.1seconds) 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 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

Figure 44 - Speed Status Only

+24V DC
Speed Exceeds SLS1
OSSD Outputs
Speed Exceeds SLS2

Single Wire Safety Output
OSSD Outputs
Auxiliary Output
A1 L12 51 L61 L11 X14 X24 Y32
0 0 0
1 1 1
9 2 9 2 9 2
8 3 8 3 8 3
7 6 5 7 6 5 4
7 6 5 4 4
GLP
440R-GL2S2P
A2 AP P12 P22 S12 S22 S44 S54
Brown
Black
Black
Proximity Sensors
872C-D8NP18-D4
989D-F4AC-2
Blue
Blue
24V DC Com

Guard Locking with Time Delay

Circuit Components
Guard Locking with Time-delay (GLT) safety relay
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 Time setting of 7 (70%). The delay is 7 seconds (70% of 10 seconds).
TIP Start the GLT safety relay configuration from 0 to generate test pulses as S11, S21, 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 S11 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 performs
Stop Category 0.

Figure 45 - Guard Locking with Time Delay

+24V DC
L1 L2 L3
Door
Unlock
PowerFlex R S T
Request 525
Door Lock
and Reset 11 +24V DC
Safety
Gate Request
1 Stop
S11 S21 S12 S22 B2 S54 S44 A1 2 Start

11 21 33 LOGIC 0 RANGE 0 TIME 1
1 1 2
9 2 9 2 10 3 Gate control
8 3 8 3 9 4 power supply
41 51 7 6 5 4 7 6 5 4 8
7 6
5
A1 12 22 34 GLT Gate control
440R-GL2S2T circuit
A2
42 52 L12 L11 Y32 A2 51 L61 14 24
S1
TLS3-GD2 S2
To PLC UV W
Gate
M
Unlocked
24V DC Com


Circuit Components
GLT safety relay
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
TIP Start the GLT safety relay configuration from 0 to generate test pulses as S11, S21, 14, and 24. S11 and S21 are not used with
the 440G-LZ.
The TLS-ZR guard locking switch can replace the 440G-LZ guard locking switch with the same wiring connections.
Operating Principle
STARTING: Press the Door Lock and Reset Request. After verifying that the gate is closed and locked, the GLT turns
on its 14 and 24 outputs. The PowerFlex 525 drive is enabled. Press the Start button to start the motor.
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
Stop Category 0.


+24V DC
440G-LZS21SPRA
L1 L2 L3
Door
Safety Unlock
PowerFlex R S T
Yellow
Brown
Gate Request 525

Red
Door Lock
Request
1 Stop
Pink S11 S21 S12 S22 B2 S54 S44 A1 2 Start

Grey LOGIC 0 RANGE TIME 1
0
Green 1 1 2
7 6 5 4 7 6 5 4 8 5
7 6
White
Blue
GLT Gate control

440R-GL2S2T circuit
L12 L11 Y32 A2 51 L61 14 24
S1
To PLC S2
UV W
Gate
M
Unlocked
24V DC Com


Circuit Components
Bulletin 440G-LZ guard locking switches
GLT safety relay
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
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 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 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
Stop Category 0.


+24V DC
Door L1 L2 L3
Unlock
Brown
Yellow
Brown
Safety Safety Request Door Lock

PowerFlex R S T
Red
Gate Gate and Reset 525

Request
440G-LZS21SPRA 440G-LZS21SPRA 11 +24V DC
1 Stop
Pink S11 S21 S12 S22 B2 S54 S44 A1 2 Start

Pink Red Grey LOGIC 0 RANGE 0 TIME 1
Grey Yellow Green 1 1 2
7 6 5 4 7 6 5 4 8 5
7 6
White
White
Blue
Blue
GLT Gate control

440R-GL2S2T circuit
L12 L11 Y32 A2 51 L61 14 24
S1
To PLC S2
UV W
Green
Gate
M
Unlocked
24V DC Com

Guard Locking with Delayed Unlock

Circuit Components
MAB
GLT safety relay
PowerFlex 525
Circuit Status
The gate is closed and locked. The MAB is a power-to-release guard locking interlock. The 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).
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.
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
Stop Category 0.

Figure 48 - Guard Locking with Delayed Unlock

+24V DC
L1 L2 L3
Door
Unlock
PowerFlex R S T
Fault Request 525
Door Lock
Reset
Safety
Gate Request
1 Stop
S11 S21 S12 S22 B2 S54 S44 A1 2 Start

UA UB 4.6 4.4 4.5 LOGIC 0
1
RANGE 0 TIME 1
Close 1 2
MAB 8 3 8 3 9 4 power supply
7 6 5 4 7 6 5 4 8 5
Multifunction 7 6
Open Access Box GLT Gate control

440R-GL2S2T circuit
3.7 0V 5.1 5.3 L12 L11 Y32 A2 51 L61 14 24
S1
To PLC S2
UV W
24V DC Com
Gate Gate
Closed Locked


Circuit Components
MAB
SI and GLT safety relays
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 safety relay configuration from 0 to generate test pulses as S11, S21, 14, and 24. The MAB does not use S11 and
S21 because terminals 4.4 and 4.5 are OSSD outputs. The E-stop is released; the SI outputs, including L11, are closed.
The MAB is configured with three buttons:

A latching dual-channel E-stop
A momentary Unlock
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.
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 Fault Reset switch clears a fault within the MAB. The SI performs pulse
testing of the E-stop button. The SI safety relay generates a single wire safety output (L11) to the GLT safety relay (L12)
to initiate a shutdown. 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.

Ratings
can be used in systems that require Performance Levels up to PLe per ISO 13849-1: 2006. The safety function performs
Stop Category 0.

+24V DC
K1 K2
Safety
Fault Reset
Lock & Reset
Gate
Unlock
UB UA 3.2 2.7 4.6 4.4 4.5 2.3 2.4 S11 S21 S34 A1 13 23 S11 S21 S12 S22 B2 S54 S44 A1
RST Closed & LOGIC 0
1
RANGE 0 TIME 1
1 2
Close Locked RESET 0 9 2 9 2 10 3
8 3 8 3 9 4
7 6 5 4 5
MAB SI
AM 7 6 5 4 8
7 6
MM GLT
Open Closed Locked 440R-S12R2 440R-GL2S2T
3.7 0V 3.3 3.1 5.1 5.3 2.1 2.2 S12 S22 Y32 L11 A2 14 24 L12 L11 Y32 A2 51 L61 14 24
442G-MABH-L
442G-MABR-UT-C03 K1 K2 100S-C43EJ14BC
24V DC Com

Guard Locking with Time Delay and Stop Cat 1

Circuit Components
GLT safety relay
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 connection to the
Logic IN terminal L12, the GLT only uses the S12 and S22 inputs to initiate its safety function.
the TLS-ZR guard locking switch.
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.
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 guard locking 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
Stop Category 1.

Figure 50 - Guard Locking with Time Delay and Stop Cat 1

+24V DC
L1 L2 L3
Door
Unlock
440G- PowerFlex R S T
Request 525
TSZ21UPRH Door Lock
Request
1 Stop
S11 S21 S12 S22 B2 S54 S44 A1 2 Start

TLS-ZR LOGIC 0 RANGE 0 TIME 1
1 1 2
Brown
Yellow
2 2 10 3 Gate control
Grey
9 9
Red
Pink
7 6 5 4 7 6 5 4 8 5
7 6
GLT Gate control
889D-F8AC-5 440R-GL2S2T circuit
Green
White
Blue
L12 L11 Y32 A2 51 L61 14 24

S1
S2
UV W
Gate
Unlocked M
24V DC Com

Guard Locking with Time Delay and Stop Cat 1

Circuit Components
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).
the TLS-ZR guard locking switch. The GLT safety relay requires both S12, S22 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.
safety gate is needed, you have two options:
Press the Door Unlock Request button
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 guard locking 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
guard locking 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 PowerFlex525 has redundant safety inputs and is safety rated.
Ratings
Stop Category 1.

Figure 51 - Guard Locking with Time Delay and Stop Cat 1

+24V DC
Door Lock L1 L2 L3
Door and Reset
Unlock Request
440G- PowerFlex R S T
Request 525
TSZ21UPRH
11 +24V DC
1 Stop
S11 S21 S34 A1 13 23 S11 S21 S12 S22 B2 S54 S44 A1 2 Start
TLS-ZR LOGIC 0 RANGE 0 TIME 1
1 1 2
Brown
Yellow
RESET 0 9 2 9 2 10 3 Gate control
Grey
Red
Pink
AM 7 6 5 4 7 6 5 4 8 5
7 6
SI MM GLT
440R-S12R2 889D-F8AC-5 440R-GL2S2T Gate control
circuit
Green
White
Blue
S12 S22 Y32 L11 A2 14 24 L12 L11 Y32 A2 51 L61 14 24
S1
S2
UV W
Gate
Unlocked M
24V DC Com

E-stop with Monitored Reset and Stop Cat 0 and 1

Circuit Components
GLT safety relay
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 15
seconds (50% of 30 seconds).
TIP Start the GLT safety relay configuration from 0 to generate test pulses at S11, S21, 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 GLT safety relay reset circuit monitors the
K1K4 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.
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 K1K4 contactors perform Stop Category 0.

Figure 52 - E-stop with Monitored Reset and Stop Cat 0 and 1

+24V DC
K1 K2 K3 K4 L1 L2 L3
PowerFlex R S T
525
Reset
1 Stop
S11 S21 S22 S12 B2 S54 A1 S44 X32 A1 13 23 33 43 2 Start
LOGIC 0 RANGE 0 TIME 1 4 Digital Com
1 1 2
9 2 9 2 10 3
8 3 8 3 9 4
7 6 5 4 7 6 5 4 8 5 Gate control
7 6
GLT EM power supply
440R-GL2S2T 440R-EM4R2
L12 L11 Y32 A2 51 L61 14 24 L12 L11 A2 14 24 34 44 Gate control
circuit
S1
S2
UV W
K1 K2 K3 K4
100S
M
100S
or 700S-C or 700S-C
24V DC Com


Circuit Components
MC2 magnetically coded non-contact interlock switch
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 (3 seconds) and a Time setting of 6 (60%). The delay is 1.8 seconds
(60% of 3 seconds).
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 safety relay 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
safety relay checks the status of the K1 and K2 contactors.
Ratings
Category 3 structure, and can be used in systems that require Performance Levels up to PLd per ISO 13849-1: 2006. The
The contactors complete a safety function that meets the performance requirements of SIL2 per IEC 62061: 2005, has a
safety function performs Stop Category 0.


+24V DC
MC2 Sensor L1 L2 L3
Reset
440N-Z21W1PH
MC2 Cordset
PowerFlex R S T
2 3 7 1 4 8 5 6 889D-F8AB-2 K1 525
White (Aux)
Brown
Green
Blue
Yellow
Red
Gray
Pink 1 Stop
K2 2 Start
S11 S21 S34 A1 13 23 S11 S21 S22 S12 B2 S54 A1 S44 4 Digital Com
LOGIC 0 RANGE 0 TIME 1
1 1 2
RESET 0 2 3 Gate control
9 9 2 10
AM 7 6 5 4 7 6 5 4 8 5
SI 7 6
MM GLT
440R-S12R2 440R-GL2S2T Gate control
circuit
S12 S22 Y32 A2 L11 14 24 L12 L11 Y32 A2 51 L61 14 24
S1
S2
UV W
Gate
Open 100S- K1 K2 M
C43EJ14BC
24V DC Com

E-stop with Auto Reset and Stop Cat 0 and 1

Circuit Components
GLT safety relay
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 OR IN1 with
Auto Reset), a Range setting of 9 (30min) and a Time setting of 10 (100%). The delay is 30 minutes (100% of 30min).
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-circuit 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 K1K4 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.
Ratings
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 K1K4 contactors perform Stop Category 0.

Figure 54 - E-stop with Auto Reset and Stop Cat 0 and 1

+24V DC
K1 K2 K3 K4 L1 L2 L3
PowerFlex R S T
525
1 Stop
S11 S21 S22 S12 B2 S54 A1 S44 X32 A1 13 23 33 43 2 Start
LOGIC 0 RANGE 0 TIME 1 4 Digital Com
1 1 2
9 2 9 2 10 3
8 3 8 3 9 4
7 6 5 4 7 6 5 4 8 5 Gate control
7 6
GLT EM power supply
440R-GL2S2T 440R-EM4R2
L12 L11 Y32 A2 51 L61 14 24 L12 L11 A2 14 24 34 44 Gate control
circuit
S1
S2
UV W
K1 K2 K3 K4
100S
M
100S
or 700S-C or 700S-C
24V DC Com

Stop Cat 1 by Gate or E-stop

Circuit Components
Ferrogard GD2 non-contact interlock switch
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
3seconds).
TIP Start the GLT safety relay configuration from 0 to generate test pulses as S11, S21, 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 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 safety relay 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.
Ratings
The contactors complete a safety function that meets the performance requirements of SIL2 per IEC 62061: 2005, has a
safety function performs Stop Category 0.

Figure 55 - Stop Cat 1 by Gate or E-stop

+24V DC
Ferrogard
FRS21 GD2
440N-G02149 L1 L2 L3
889D-F8AB-10
PowerFlex R S T
3 4 8 1 2 5 6 K1 525
Green
Yellow
Red
Brown
Gray
Pink
White
1 Stop
K2 2 Start
S11 S21 S34 A1 13 23 S11 S21 S22 S12 B2 S54 A1 S44 4 Digital Com
LOGIC 0 RANGE 0 TIME 1
1 1 2
RESET 0 2 3 Gate control
9 9 2 10
AM 7 6 5 4 7 6 5 4 8 5
SI 7 6
MM GLT
440R-S12R2 440R-GL2S2T Gate control
circuit
S12 S22 Y32 A2 L11 14 24 L12 L11 Y32 A2 51 L61 14 24
S1
S2
UV W
100S- K1 K2 M
C43EJ14BC
24V DC Com

EtherNet/IP to Logix Controllers

Circuit Components
Bulletin 440R-ENETR EtherNet/IP network interface
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 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 with an Add-on Profile in the Logix
Controller. The information can be used for ON/OFF status and troubleshooting.
TIP The CI and SI safety relays do not function with the ENETR network interface.

Figure 56 - EtherNet/IP to Logix Controllers

+24V DC
Logix5563 EtherNet/IP SOE INTPUT SOE INTPUT SOE INTPUT SOE INTPUT EtherNet/IP
A1 A2 S12 S22 S32 S42 33 34 43 44 S12 S22 S32 S42 37 38 47 48 S12 S22 B2 S54 S12 S22 AP S44
LNK1 A1 A2 S11 S21 A1 A2 A1 A2 S11 S21 A1 A2 B1 B2 A1 A2 S11 S21 A1 A2 P12 P22
MS PWR/Fault PWR/Fault PWR/Fault
IP:192.168.1.ABC
PWR/Fault PWR/Fault PWR/Fault
LNK1 IN 1 IN 1 B1 IN 1 IN 1
LNK2 IN 2 IN 2 51/L61 51/L61
NS Logic IN Logic IN Logic IN Logic IN LOGIC IN LOGIC IN
OUT OUT OUT OUT/Config OUT X14/X24

0 L11 0
9 01 0 1 1
A 0 33 34 43 44 0
RANGE 1 LOGIC LOGIC
2 3
1 1
7 8
LOGIC
9 2 9 2
4 5 6
LOGIC 2 2 9 2 3 3
3 3 8 8
8 3 8 8 7 6 5 4 7 6 5 4
7 4 7
6 5
4 7 6 5 4 0 0
9 01
6 5 RANGE 1 SLS1 1
A1 TIME X 10% 1
B 2 9 2 9 2
2 3
7 8
10 3 3 3
4 5 6
8 8
9 4 7 6 5 4 7 6 5 4
13 14 23 24 13 14 23 24
8 7 6 5 TIME 1 SL2/TIME 0
9 01 34 44 14 24 2 1
DI EM EMD
C DIS 10 3 9 2
2 3
7 8
4 3
4 5 6
RANGE x1 x 100 9 8
8 5 7 6 5 4
GLT 7 6 GLP
L12 L11 Y32 S34 L12 L11 Y32 L12 L11 Y32 S34 L12 L11 X32 L12 L11 Y32 S54 L12 L11 Y32 S54
LNK2 13 14 23 24 13 14 23 24 34 44 14 24 17 18 27 28 14 24 51 L61 X14 X24 51 L61
24V DC Com

Using 100S-D Contactors with GSR Modules

Circuit Components
SI and EM safety relays
Bulletin 100S-D safety contactors
Circuit Status
The SI safety relay is set for monitored manual (MM) reset. The E-stop is released. The safety outputs of the SI and EM
safety relays are de-energized. The control relays CR1 and CR2 are off. The contactors K1 and K2 are off. The motor is
off.
Operating Principle
Interposing relays are used in this circuit arrangement to minimize the impact of the inrush current of the 100S-D
contactors. In the first 20 milliseconds of energization, the peak inrush current of the Bulletin 100S-D contactor is 25 A.
For an additional 70 milliseconds, the Bulletin 100S-D contactor draws 10 A. Afterwards, the Bulletin 100S-D
contactor has an approximate steady state holding current of 250 mA. See Knowledgebase document 32186 for further
details on Bulletin 100S-D contactors.
When the Reset button is pressed, the SI and EM outputs turn on and energize interposing relays CR1 and CR2. The
CR1 and CR2 relay contacts switch a quick, high current pulse (~100 s). A signal through the 33/34 contacts of the
EM safety relay informs the PLC that the safety system is ON, and the contactors are ready. The PLC then turns the
Bulletin 100S-D contactors ON and OFF with low current (15 mA). To maximize life of the power supply and
contactors, the PLC must stagger the energization of the K1 and K2 contactors by at least 200 milliseconds.
To achieve the safety rating when the E-stop is pressed, the A1 and B1 terminals must be disconnected through the safety
circuits. When the E-stop is pressed, the SI and EM safety relays turn off immediately and disconnect the A1 and B1
circuits of both contactors.
The power supply (catalog number 1606-XLS480-3) is used to provide adequate inrush current (20 A rating with 30 A
reserve power). The A1 connection of each contactor is connected to interposing relays to minimize replacement cost at
End of Life due to contact wearout. The catalog number 700-HC2Z24 has a 15 A switching capability at 120V AC and
a 10 A resistive load rating. By closing the relay contacts before the contactors are energized, the catalog number
700-HC22Z24 relay carries the 25 A inrush current rather than switching the inrush current. The connections to A1 and
A2 must be a minimum of 2.5 mm (14 AWG), and the total wire length must be less than 65.6 ft (20 m) for each
contactor. The catalog number 700-HN103 relay base and 1492 terminal blocks can accommodate this wire size.
Fault Detection
Upon power-up, the SI and EM safety relays perform internal checks. Using pulse testing that is generated at S11 and
S21, the SI safety relay then looks for dual signals from the E-stop circuit on S12 and S22. The SI safety relay detects a
cross fault on the E-stop circuit. With the E-stop signals made, the SI safety relay looks for the closing and opening of the
reset signal on terminal S34. The Bulletin 100S-D contactors have mirrored contacts (one on each side of the housing).
The mirrored contacts must be connected in series. If any of these mirrored contacts are not closed, the SI safety relay
does not reset. CR1 and CR2 do not have to be monitored because the Bulletin 100S-D mirror contacts monitor them
indirectly. The EM safety relay provides the source of the reset signal. If a fault occurs within the EM safety relay, X32 is
not powered and the SI safety relay does not reset.

Ratings
The E-stop button initiates a safety function that 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 requiring Performance Levels up to PLe per
Figure 57 - Using 100S-D Contactors with GSR Modules

1492-J3-BR 2.5 mm2 (14 AWG) Wire
1492-CJJ5-3 PLC
24V DC
1492-J3-BL Reset Out1
1492-CJJ5-3 Out2
E-stop 800FM-
800FM- K1
F6MX10
MT44MX02 CR1 CR2
K2
In1
+ + - - 24V Com
DC 24V / 20 A S11 S21 S34 A1 13 23 X32 A1 13 23 33 43
RESET 0
L1 L2 L3
1606-XLS480E-3 AM
SI MM EM K1
INPUT 440R-S12R2 440R-EM4R2
3AC 380-480V S12 S22 Y32 L11 A2 14 24 L12 L11 A2 14 24 34 44 K2
L1 L2 L3
M
A1 B1 A1 B1
CR1 700-HC22Z24-4 CR2 100S-
K1 K2
700-HN103 D300EZJ22BC
A2 B2 A2 B2

Safe Limited Speed without Guard Locking

Circuit Components
SensaGuard integrated latch interlock
GLP safety relay
PowerFlex 70 drive
Circuit Status
The SensaGuard integrated latch interlock is closed, and the OSSD outputs are ON. The GLP safety relay is ready for
reset. The GLP safety relay has a Logic setting of 3: (Safe Limited Speed without Logic IN), a safe limited speed (SLS1)
setting of 0 (0.5 Hz), and a maximum speed setting (SLS2/Time) of 5 (200 Hz). The proximity sensors are rated for
400 Hz. The GLP safety relay outputs (X14 and X24), the single wire safety output (L11), and the auxiliary output
(Y32) are OFF. The motor is off.
Operating Principle
The GLP safety relay can be used without a guard locking type interlock. A safeguarding device with OSSD outputs or
mechanical contacts can be used with GLP safety relay. In this example, a SensaGuard with integrated latch has OSSD
outputs and does not have a locking feature. An interposing relay load (catalog number 700-TBR24, for example) or
LED indicator (catalog number 800L-18L24G, for example) can be connected between terminal 51 and ground to
indicate when safe limited speed is achieved. The risk assessment must verify that you cannot reach the hazard before the
motor speed falls below the SLS1 setting when the SensaGuard switch is opened and the motor coasts to a stop.
STARTING: Press the Reset button to turn the GLP safety outputs ON and enable the PowerFlex 70 drive. Press the
Start button to turn the motor ON.
STOPPING: Initiate a safety stop by taking either of the following actions:

Press the Stop button
Open the SensaGuard switch.
A press of the Stop button commands to PowerFlex 70 drive to execute the configured stop function (ramp the speed
down, for example). When the SensaGuard switch opens the GLP safety relay output immediately turn OFF, and the
PowerFlex 70 drive executes a coast to stop.
SAFE LIMITED SPEED: Press the SLS Request button. The Y32 output turns ON and commands the PowerFlex 70
drive to adjust the motor speed to the Speed Select 1 setting. When the speed drops below the SLS1 setting, terminal 51
turns ON the indicator to notify the user that the machine is running at a safe slow speed. You can open the SensaGuard
switch, and the motor continues to run at the safe slow speed. The PWR/Fault status indicator on the GLP safety relay is
green and flashes red six times. When the SensaGuard switch recloses, the GLP safety relay is ready to return to
production speeds. You press the Reset button, and the Y32 output turns OFF, which returns the PowerFlex 70 drive to
production operating speed.

Fault Detection
Upon power-up, the safety devices perform internal checks. The GLP safety relay has dual-channel pulse tested outputs
that check for faults. The PowerFlex 70 drive requires two safety signals to enable the drive.
OVERSPEED: If the proximity sensors detect a speed greater than the maximum speed (200 Hz), the auxiliary output
(Y32), the safety outputs (X14 & X24), and the single wire safety output (L11) turn OFF. The PWR/Fault status
indicator flashes at a 3X rate. When the speed drops below the maximum speed limit, press the Reset button to clear the
fault and energize the safety outputs.
Ratings
structure that can be used in systems requiring Performance Levels up to PLd per ISO13849-1:2006. This circuit
Figure 58 - Safe Limited Speed without Guard Locking

+24V DC L1 L2 L3
PowerFlex 70 R ST
with DriveGuard
SLS
Yellow
Brown
Reset 2 Start
Request
Red
1 Stop
9 +24V DC
White
Grey
Blue
SensaGuard Integrated Latch

Pink
5 Speed Select 1
440N-Z21SS3PA 7 DC Comm
8 Digital In Com
S12 S22 L61 S54 A1 S44 Y32 L11
Gate Control
LOGIC SLS1 SLS2/TIME Power Supply
0 0 0
1 1 1
9 2 9 2 9 2
8 3 8 3 8 3 1
7 6 5 7 6 5 47 6 5 4 4
GLP 3
440R-GL2S2P 4
L12 51 A2 AP P12 P22 X14 X24 2
Gate
Brown
Black
Black
6 Enable Control
Circuit
Remove Jumper U V W
800L- 800L-
18L24R 18L24G M
Gate Speed
Blue
Blue
Open Below Proximity Sensors

SLS1 871TM-N10NP12-D4
24V DC Com 889D-F4AC-2

Rockwell Automation Support
Use the following resources to access support information.
Knowledgebase Articles, How-to Videos, FAQs, Chat,

Technical Support Center www.rockwellautomation.com/knowledgebase
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Allen-Bradley, DriveGuard, Ferrogard, FLEX, GuardLogix, Guardmaster, GuardMotion, GuardShield, Kinetix, Lifeline, LISTEN. THINK. SOLVE., MatGuard, Minotaur, POINT Guard I/O, PowerFlex, Rockwell Automation, Rockwell Software,
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Publication SAFETY-WD001I-EN-P - October 2016

Supersedes Publication SAFETY-WD001H-EN-P - July 2016 Copyright 2016 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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Wiring Diagram

Next Generation Guardmaster Safety Relay (GSR)

46 DI, EMD MT-GD2, GripSwitch-Jog PowerFlex 70 2 d 3 0

2 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Notes for Example Wiring Diagrams

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 3

4 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

General Safety Information

You can view or download publications at http://www.rockwellautomation.com/literature/.

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 5

SI Safety Relay with E-stop to PowerFlex 525 Drive

6 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Figure 1 - SI Safety Relay with E-stop to PowerFlex 525 Drive

S11 S21 S34 A1 13 23 2 Start

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 7

SI Safety Relay with MAB Guard Locking to PowerFlex 525 Drive

8 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 9

SI Safety Relay to FLEX I/O

10 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Figure 3 - SI Safety Relay to FLEX I/O

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 11

Expansion Modules with Immediate and Delayed Outputs

12 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Figure 4 - Expansion Modules with Immediate and Delayed Outputs

S11 S21 S34 A1 13 23 X32 A1 13 23 33 43 B1 B2 X32 A1 17 27 37 47

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 13

Safety Motion - Delayed Braking

14 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Figure 5 - Safety Motion - Delayed Braking

Resistor Braking Module U V W

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 15

Light Curtain with Immediate and Delayed Outputs

16 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Figure 6 - Light Curtain with Immediate and Delayed Outputs

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 17

Global E-stop, Cascaded Safety Functions

18 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Figure 7 - Global E-stop, Cascaded Safety Functions

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 19

GuardShield Light Curtain and Bulletin 800Z Zero-Force Touch Buttons

20 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

S21 S22 A2 L11 Y32 14 24

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 21

22 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 23

Interlock Switch - Multiple Gate Access

24 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Figure 10 - Interlock Switch - Multiple Gate Access

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 25

SensaGuard Interlock Switches

26 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Figure 11 - SensaGuard Interlock Switches

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 27

Magnetically Coded Sensor

28 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Figure 12 - Magnetically Coded Sensor

MC2 MC2 MC2 K1

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 29

Stainless Steel Ferrogard GD2 Non-contact Interlock Switch

30 Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016

Figure 13 - Stainless Steel Ferrogard GD2 Noncontact Interlock Switch

Rockwell Automation Publication SAFETY-WD001I-EN-P - October 2016 31