GSR Wiring Diagrams

NHP SAFETY REFERENCE GUIDE
WIRING DIAGRAMS
Guardmaster Safety Relays

(GSR)
Safeguarding Applications and Wiring Diagrams
Next Generation ‘GSR” Safety Monitoring Relays
Table of Contents
Page Safety Relay Input Devices Output Devices SIL PL Cat. Stop
Modules CL No. Cat
5 SI E-Stop Powerflex 525 2 d 3 0
6 SI Trojan T15 Flex IO 2 d 3 0
7 SI, EM, EMD 4 E-Stops 100S-C, 700S-DCP 2 d 3 0
8 SI, EMD E-Stop Kinetix 6000 Guardmotion w/RBM 3 e 4 1
9 SI, EMD GuardShield Safe 4 100S, 700S-C 3 e 4 0
10 SI, DI, DIS 3 E-Stops, Trojan T15, Safety Mat 100S, 700S-C 3 e 4 0
11 SI, MSR35H GuardShield, 800Z 100S-C 3 e 4 0
12 SI, DIS 3 SensaGuards with Integrated Latch, 2 E-Stops Powerflex 525 3 e 4 0
13 CI Trojan T15, Elf, E-Stop, PLC on Ch 2 100S-C 2 d 3 0
14 CI 3 SensaGuards 100S-C 3 e 4 0
15 DI GuardShield 100S-C 3 e 4 0
16 DI 2 GuardShields 100S-C 3 e 4 0
17 DI 2 Lifeline 4 100S-C 3 e 4 0
18 DI 5 SensaGuards, Distribution Block, E-Stop Kinetix K350 2 d 3 0
19 DI GuardShield, E-Stop Pneumatic Safety Valve 3 e 4 0
20 DI SensaGuard with Integrated Latch, E-Stop Powerflex 525 2 d 3 0
21 DI, EMD MT-GD2, GripSwitch Powerflex 70 2 d 3 0
22 DI, EMD TLS1-GD2, Trojan T15, E-Stop 700S-CF 3 e 4 0
23 DI, EMD 440G-MT, MT-GD2, GripSwitch 100S-D 2 d 3 0
24 DI, DI, DI 2 E-Stops, 2 GuardShueld Safe 4, Mat, SensaGuard 100S-C 2,3 d,e 3,4 0
25 DI E-Stop Powerflex 755 3 e 3 0
26 DI SafeZone Mini, E-Stop Kinetix 350 2 d 3 0
27 DI SafeZone Multizone, E-Stop Kinetix 350 2 d 3 0
28 DI SC300 Safety Sensor, E-Stop Kinetix 350 2 d 3 0
29 DIS Galvanic Isolator 897H, Trojan T15, E-Stop Powerflex 525 2 d 3 0
30 DIS Galvanic Isolator 897H, Safedge, MatGuard, E-Stop Powerflex 525 2 c,d 1,3 0
31 DIS Trojan 5, MT-GD2 Powerflex 70 2 d 3 0
32 DIS Trojan 5 2 Powerflex 70 2 d 3 0
33 DIS, MSR41 Micro 400 GuardShield, E-Stop 100S-C 3 e 4 0
34 DIS, MSR42 Micro 400 GuardShield, SensaGuard, E-Stop 100S-C 3 e 4 0
35 GLP 871TM, TLS53-GD2 Powerflex 70 2 d 3 1
36 GLP 872C, TLS-ZR Powerflex 525 2 d 3 1
37 GLP 871TM, TLS-ZR Powerflex 70 2 d 3 SLS
38 GLP 872C Powerflex 525 2 d 3 0
39 GLP, DIS 872C, TLS3-GD2, E-Stops Powerflex 70 2 d 3 1
40 GLP, DI 872C, TLS3-GD2, E-Stops Powerflex 525 2 d 3 SLS
41 GLP, DI 872C, TLS3-GD2, E-Stops 100S 2 d 3 0
42 GLP, DI 872C, TLS3-GD2, E-Stops Kinetix K300 2 d 3 SLS
43 GLP, DI, EMD 872C, TLS-ZR, E-Stops Powerflex 525 2 d 3 0
NHP Safety Reference Guide > GSR Wiring Diagrams 3-2

Notes for Example Wiring Diagrams:
Note 1 Certain faults are only detected at a change of state of the input
In the following circuits the type of Allen-Bradley/Guardmaster switching device (interlock switch or E-Stop switch). If the re are
device is shown as an example to illustrate the circuit principle. long periods (e.g. months as opposed to days) between switching
For specific applications the choice of device type should be actions, it may be possible for multiple faults to accumulate which
based on the suitability of its characteristics for its intended use. could lead to a dangerous situation. Therefore a regular check
should be performed on the system in order to detect single
Note 2 faults before an accumulation occurs. This check may be manual
In most of the following examples showing dual channel or initiated by part of the machines control system.
applications, one interlock switch is shown switching both
If, for example, 3 interlock switches are connected to the
channels (one contact set per channel). If it is foreseeable that
monitoring unit, certain faults will only be detected at the switch
damage to the guard (e.g., at the actuator mounting point) could
on the rst guard to be opened and the switch on the last guard to
allow it to be opened without operating the switch then two
be closed. This is because any switching between the rst opening/
separate switches may be required. The electrical principle of the
last closing will not change the state of the monitoring unit input
circuit will remain the same.
circuits. Therefore in some applications it may be necessary to use
Note 3 one monitoring device per switch.
In most cases the circuits are shown with the guard door closed Most of the following examples show an interlock switch and
and ready for motor starting by operating the normal start an emergency stop switch combined in the circuit. When a
control. monitoring safety relay (e.g. Guardmaster Minotaur) is used for
It must be possible to start the machine only by voluntary fault detection it is important to note the following:
actuation of the control provided for the purpose (see ISO • All safety critical single faults, except for certain faults over
12100-2 4.11.8). For the purposes of these examples the use of a the contact sets at the E-Stop, will be detected at the next
conventional contactor latching circuit has been assumed. If this opening of the guard.
is not the case, then a restart interlock will be required to prevent
an automatic or unintended starting of the motor when the guard • All safety critical single faults, except for certain faults over
is closed. For example, a Minotaur safety relay with a momentary the contact sets at the interlock switch, will be detected at the
action push button installed in the output monitoring circuit can next operation of the E-Stop.
be used to achieve this. • Because the E-Stop device is not likely to be operated
• If the guard is designated as a Control Guard (see ISO 12100-2 frequently, it is recommended that its function is checked
5.3.2.5) these requirements do not apply but the use of control (with the gua rd closed) on a regular basis (start of shift or
guards is only allowed under certain conditions including: daily) to enable the Minotaur to detect single faults. If the
guard is rarely opened, the interlock switch should be checked
• A control guard can only be used where there is no possibility in a similar manner.
of an operator or part of his body staying in or reaching into
the danger zone whilst the guard is closed. Note 5
This symbol indicates that the associated component or
• The control guard must be the only access to the hazard area.
device features direct opening (positive opening) operation.
• The interlocking system must have the highest possible In the event of a fault, welded contacts will be forced open
reliability. It is often advisable to use a solenoid locking switch by the motion of the safety guard.
such as the Guardmaster Atlas or TLS-GD2.
This symbol denotes mechanically linked contacts; if
Note 4 one contact welds closed, all other dependent (auxiliary)
Safety monitoring relay units used in dual channel circuits with contacts remain in position, i.e. they cannot change state.
infrequent operation or with more than one switching device
connected. This note applies to all monitoring devices which use
the technique of comparing the signal at the change of state of
dual channels.

General Safety Information:
This application example is for advanced users and assumes that you are trained
IMPORTANT and experienced in safety system requirements.
Contact NHP to find out more about our safety risk assessment services.
ATTENTION A risk assessment should be performed to make sure all tasks and hazard
combinations have been identied and addressed. The risk assessment may require
additional circuitry to reduce the risk to a tolerable level. Safety circuits must take
into consideration safety distance calculations which are not part of the scope of
this document.

SI with E-stop to 525 Drive Safeguarding Applications and Wiring Diagrams
E-Stop, SI, and PowerFlex 525: SI with E-stop to 525 Drive
E-Stop, SI, and PowerFlex 525
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
Circuit Status
Circuit is set to MM, monitored manual reset. The e-stop is released. TheFault
Status
The SI Logic Detection
SI safety outputs (13/14 and 23/24) are off. The PowerFlex 525
The SI isLogic
drive is setbut
powered todisabled.
MM, monitored
The motormanual
is off. reset. The e-stop Upon successful completion of internal checks by the SI and
is released. The SI safety outputs (13/14 and 23/24) are o. The PowerFlex 525 drive, the drive awaits the closure of the safety
Operating
PowerFlex 525Principle
drive is powered but disabled. The motor is off. outputs. If the SI fails, the drive will not energize the motor, and
STARTING: Press the Reset button to turn on the SI safety outputs. This enables thethe drive
fault andbe
will also applies power
detected to the Start and
by non-operation ofStop buttons.The sI
the motor.
Operating Principle
Press the Start buttons to start the motor. generates test pulses through the E-stop circuits to detect cross
STOPPING: Press
STARTING: Press the
theStop button
Reset to stop
button the motor
to turn on thefor
SI production stops. Press the e-stop to initiate a safety stop; the motor coasts to a stop.
safety outputs. channel shorts and shorts to power and ground. A fault in the
This enables the drive and also applies power to the Start and safe-circuit of the drive will be detected by the drive and the drive
Fault
Stop Detection
buttons. Press the Start buttons to start the motor. will execute a safe torque off stop.
Upon successful completion of internal checks by the SI and PowerFlex 525 drive, the drive awaits the closure of the safety outputs. If the SI fails,
STOPPING: Press
the drive will the Stopthe
not energize button
motor,toand
stop
thethe motor
fault will befor production
detected by non-operation
Ratingsof the motor. The sI generates test pulses through the
E-stopPress
stops. circuits
thetoe-stop
detect cross channel
to initiate shorts stop;
a safety and shorts to power
the motor and ground. A fault in the safe-circuit of the drive will be detected by the drive
coasts
The safety function initiated by the e-stop meets the safety
toand the drive will execute a safe torque off stop.
a stop.
performance requirements of SIL CL2 per IEC 62061:2005 and
Ratings has a Category 3 structure that can be used in systems requiring
Performance
The safety function initiated by the e-stop meets the safety performance requirements of SIL Levels
CL2 perup
IECto PLd per ISO
62061:2005 and13849-1: 2006.3The circuit
has a Category
structure that can be used in systems requiring Performance Levels up to PLdexecutes a Safe 2006.
per ISO 13849-1: Torque TheOffcircuit
(i.e., executes
a Category 0) stop.
a Safe Torque Off (i.e., a
Category 0) stop.
- 03 -
Safety Relay to Flex I/O Safety Applications and Wiring Diagrams
Trojan T15 GD2, 800F, SI, Flex I/O: Safety Relay to Flex I/O
Trojan T15 GD2, 800F, SI, 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
Circuit Status
Circuit Status
The safety
STOPPING: Press the Stop button to stop the machine. Then,
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 its
The
11/12safety
contactgate is closed. The outputs of the SI safety relay are
is closed. open the gate to access the machine. While the gate is open, the
open and the machine actuators are o. Control Relay CR1 is de- machine actuators cannot operate because power is removed
Operating
energized andPrinciple
its 11/12 contact is closed. from the output module. If the gate is inadvertently opened while
The SI is chosen for this application because its thermal (non-switching) current the machine
carrying is running,
capacity is 6A inpower will be
one circuit. Theremoved
Flex output from output
module
Operating
performs the Principle
normal switching of the machine actuators during the manufacturing module and the
process. The machine actuators
safety system enableswillthe be de-energized.
machine functions by
providing
The power to
SI is chosen forthe FLEX
this Output Module.
application because Oneitsofthermal
the Flex (non-
outputs must drive an electro-mechanical device (CR1) whose normally closed
Fault Detection
switching) current carrying capacity is 6A in one circuit. The logic
contact is in the monitoring loop of the safety relay. The machine Flex must energize this output while the machine is running, as it is used by the
SI to confirm that power is removed from the output module, before restarting.Upon successful completion of internal checks on power up, the
output module performs the normal switching of the machine
actuators SI checks the input circuits. With the gates closed, the SI checks
STARTING:duringPress thethe manufacturing
reset process.
button to energize The safety
the output system
contacts 13/14 of the SI. This connects the 24V supply to terminal C34 of Flex 1974-OB16
enables the machine the dual circuits and then waits for the reset signal. A single fault,
output module and alsofunctions by providing
sends a signal power to
to the A3 terminal of the FLEX
the 1794-IB16. The logic system is informed that the gate is closed and the machine is
Output
ready toModule.
run. Press Onethe of thebutton
Start Flex outputs must
to start the driveprocess.
machine an electro- a short from 24V to terminal 14 of the SI, may lead to the loss
STOPPING: Press
mechanical devicethe(CR1)
Stop button
whosetonormally
stop the machine. is inthe gate to of
Then, open
closed contact the the
access safety function.
machine. With
While the the
gateSIis and
open,Flex
the system
machinemounted
actuators in
cannot
the operate because
monitoring loop ofpower is removed
the safety relay. from the outputlogic
The machine module.mustIf the gatethe same cabinet
is inadvertently and with
opened whileproper validation,
the machine this fault
is running, powermaywill be
be removed from output module and the machine actuators
energize this output while the machine is running, as it is used by will be de-energized.
excluded. If not mounted in the same cabinet, a signal from the
the SI to conrm that power is removed from the output module, output (A0) should be fed back into the input module (A2). The
Fault Detection
before restarting. logic can perform a comparison of input A2 and A3, and turn the
Upon successful completion of internal checks on power up, the SI checks the input machinecircuits.
o if With
thesethe gates closed,
signals are notthein SI checks the dual
agreement. circuits
If CR1 is not de-
and then waits
STARTING: Pressforthe
thereset
reset signal.
buttonAto single fault, athe
energize short from 24V
output to terminal 14 of the SI, may lead to the loss of the safety function. With the SI
contacts energized when the gate is closed, the SI will not close its outputs.
and Flex
13/14 of system mounted
the SI. This in the the
connects same cabinet
24V andto
supply with properC34
terminal validation,
of this fault may 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 Ratings can perform a comparison of input A2 and A3, and turn the
Flex 1974-OB16 output module and also sends a signal to the A3
machine off if these signals are not in agreement. If CR1 is not de-energized when the gate is closed, the SI will not close its outputs.
terminal of the 1794-IB16. The logic system is informed that the The safety function initiated by the Trojan T15-GD2 gate interlock
gate is closed and the machine is ready to run. Press the Start meets the safety performance requirements of SIL CL 2 per IEC
Ratings
button to start the machine process.
The safety function initiated by the Trojan T15-GD2 gate interlock meets the safety 62061:2005
performanceand requirements
has a Category 3 structure
of SIL CL 2 per IEC that can be used
62061:2005 and in
has a Category 3 structure that can be used in systems requiring Performance Levels systems up requiring Performance Levels
to PLd per ISO13849-1:2006. Thisup to PLd
circuit per ISO13849-
executes a
Category 0 stop. 1:2006. This circuit executes a Category 0 stop.
- 04 -
Expansion Modules with Immediate and Delayed Outputs
800F, SI, EM , EMD, 100S, 700S:Expansion Modules with Immediate and Delayed Outputs
800F, SI, EM , EMD, 100S, 700S
+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 TIME 1
1 2
RESET 0 9
8
2
3
10
9
3
4
7 4 5
E-Stops 6 5 8
7 6
AM
800FM-MT44MX02L SI EM EMD
MM
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
with
C43EJ14BC K9
199-FSMZ-1
K2 K4 K6
K8 K10
24VC DC Com
Circuit Status Fault Detection

Circuit
The Status
e-stops are reset. The safety outputs of the SI, EM and EMD Upon power-up, the SI, EM and EMD perform internal checks. The
The e-stops are reset. The safety outputs of the SI, EM and EMD are de-energized. All of the contactors are off. The EMD Range setting is 2 (10s
are de-energized. All of the contactors are o. The EMD Range SI then looks for dual signals from the e-stop circuit. A crossfault
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
setting is 2 (10s OFF
monitored manual reaset. Delay) and the Time setting is 2 (20%), on the e-stop circuit will be detected by the SI. With the E-stop
therefore the time delay is 2 seconds. The reset and monitoring signals made, closing the reset button places a voltage to the
circuit are connected
Operating Principleto S34 for monitored manual reaset. S34 terminal. The external devices (K1 through K10) are checked
Additional outputs are added to the SI (CI, DI, or DIS) relay by the EM (Expansion toModule
conrmwith
theyimmediate
are o. A fault in K1and
outputs) through
the EMD K10 will cause their
(Expansion
Operating Principle
Module with Delayed outputs). A single wire, safety-rated signal from terminalnormally L11 of theclosed contacts to
SI communicates theremain
output open, and
status to L12this fault
of the EMwill
andbe
Additional
EMD relays.outputs are added to the SI (CI, DI, or DIS) relay by the detected by the SI.
EM (Expansion
STARTING: Press Module with
and release theimmediate
reset buttonoutputs) and
to energize the
the EMD of the SI, EM and EMD. K1-K10 safety contactors or safety control relays
outputs
energize to control
(Expansion Modulethe hazardous
with Delayed portion of theAmachine.
outputs). single wire, safety- Ratings
STOPPING:
rated signalWhen
fromanterminal
e-stop isL11pressed, theSIsafety
of the outputs of the
communicates theSIoutput
and EM turnTheoff immediately and de-energize
safety function initiated byK1the
- K6. Four connection
series seconds later,ofthe
the 800F
safety outputs of the EMD turn off and de-energize K7 through K10.
status to L12 of the EM and EMD relays. e-stop buttons meets the safety performance requirements of SIL
CL 2 per IEC 62061:2005 and has a Category 3 structure that can
Fault Detection
STARTING: Press and release the reset button to energize the
Upon power-up,
be used in systems requiring Performance Levels up to PLd per
outputs of the SI,the
EMSI,and
EM and
EMD. EMD perform
K1-K10 internal
safety checks. The
contactors SI then looks for dual signals from the e-stop circuit. A crossfault on the e-stop
or safety
circuit will be detected by the SI. With the E-stop signals made, closing the ISO13849-1:2006.
reset The Category
button places a voltage to the S343terminal.
rating requires the redundant
The external devices
control relays energize to control the hazardous portion of the
(K1 through K10) are checked to confirm they are off. A fault in K1 through K10 usage of K1-K10
will cause to de-energize
their normally the machine
closed contacts actuators,
to remain open, andandthisthe
machine.
fault will be detected by the SI. contactors must be monitored by the safety system. This circuit
STOPPING: When an e-stop is pressed, the safety outputs of the SI executes a Category 0 stop (coast to stop).
Ratings
and EM turn o immediately and de-energize K1 - K6. Four seconds
The safety
later, function
the safety initiated
outputs of by
thethe series
EMD connection
turn of the 800F e-stop
o and de-energize K7 buttons meets the safety performance requirements of SIL CL 2 per IEC
62061:2005
through K10.and has a Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO13849-1:2006. The
Category 3 rating requires the redundant usage of K1-K10 to de-energize the machine actuators, and the contactors must be monitored by the
safety system. This circuit executes a Category 0 stop (coast to stop).
- 05 -
Safety Motion - Delayed Braking Safety Applications and Wiring Diagrams
800F, SI, EMD, Kinetix GuardMotion, RBM: Safety Motion - Delayed Braking
800F, SI, EMD, Kinetix GuardMotion, RBM
+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
EN2- Safety
8 3 9
5
4 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
CircuitStatus
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 (1s OFF Delay) and the Time is
The e-stop is reset. The outputs of the
set to 10 (100%), therefore the off delay time is 1s. safety relay are open, and Upon power-up, the Kinetix drive and SI and EMD perform
the motor is o. The EMD Range switch is set to 1 (1s OFF Delay) internal checks. The SI then looks for dual signals from the e-stop.
and the TimePrinciple
Operating is set to 10 (100%), therefore the o delay time is 1s. The e-stop has a self-monitoring contact, which opens if the
STARTING: Press
Operating and release the reset button to energize the outputs of the SI.contact
Principle This action
block energizes
falls o the
thefeedback relays inWith
control panel. the Kinetix.
the e-stopThe signals
L11
signal from the SI to the EMD instructs the EMD to close its safety outputs, which energizes
made, the SIthe 100S contactor
checks in the resistor
the S34 monitoring braking
circuit module.
when The
the reset
STARTING:
motor is now Press and release
connected to thethe reset
drive. When button to energize
the Kinetix drive is the
enabled, an internal signal is sent back to itschecks
controller
button is pressed. If these are(not
OK,shown) to inform
the output it
energizes. If
outputs
that the of theisSI.
drive This action
enabled. energizes
The motor is thenthe feedback
controlled relays
by its in the
controller. the delayed outputs of the SI fault to the ON state, the motor is
Kinetix.
STOPPING:TheWhenL11 signal fromis the
the e-stop SI tothe
pressed, theimmediate
EMD instructsoutputstheofEMD
the SI open and disable the drive. The motor begins to execute a stop. The L11
stopped by the SI immediate outputs. The fault will be detected
tosignal
closefrom
its safety
the SI tooutputs,
the EMDwhich
turns offenergizes
and the EMD the 100S
beginscontactor
its timing cycle. After the time delay of the EMD expires, the delayed outputs open
by the S34 monitoring circuit on the next attempt to re-start
inand
thedrop out the
resistor 100S contactor
braking module.in The themotor
Resistor is Braking Module. This
now connected to disconnects the motor from the drive and engages the braking resistors,
which rapidly stop the motor. because K1 will remain energized. If the drive faults to an ON
the drive. When the Kinetix drive is enabled, an internal signal is
state, the motor will stop because it will be disconnected by K1.
sent back to its controller (not shown) to inform it that the drive is
Fault Detection This fault will be detected by the S34 monitoring circuit on the
enabled. The motor is then controlled by its controller.
Upon power-up, the Kinetix drive and SI and EMD perform internal checks. The next attempt
SI then looks forto re-start because
dual signals from thethee-stop.
Kinetix Thefeedback
e-stop hascircuit
a will
STOPPING: When
self-monitoring the e-stop
contact, whichisopens
pressed, if thethe immediate
contact outputs
block falls remain
off theofcontrol panel. o. Ifthe
With K1e-stop
gets stuck
signalsormade,
welded closed,
the SI checksthethemotor
S34 will stop
the SI open and
monitoring disable
circuit thereset
when the drive.button
The motor begins
is pressed. to execute
If these checks aare OK, the byoutput
the drive and the
energizes. fault
If the will be
delayed detected
outputs of thebySIthe
faultS34 monitoring
to the ON
stop.
state,The
theL11
motorsignal from the
is stopped SI toSI the
by the EMD turns
immediate o and
outputs. the
The EMD
fault circuit
will be detected byof the
the S34TDmonitoring
on the next attempt
circuit on theto re-start.
next attempt to re-start
because
begins itsK1 will remain
timing cycle.energized.
After the time If thedelay
drive faults
of thetoEMD
an ON state, the motor will stop because it will be disconnected by K1. This fault will be
expires,
detected by outputs
the S34 monitoring Ratings
the delayed open and circuit
drop out on the
thenext
100Sattempt
contactorto re-start
in thebecause the Kinetix feedback circuit will remain off. If K1 gets stuck or
welded closed, the motor will stop by the drive
Resistor Braking Module. This disconnects the motor from the driveand the fault will be detected The
by thesafety function initiated
S34 monitoring by the
circuit of the TD on800F e-stop
the next meetstothe safety
attempt
re-start. performance requirements of SIL CL3 per IEC 62061:2005 and
and engages the braking resistors, which rapidly stop the motor.
has a Category 4 structure that can be used in systems requiring
Ratings Performance Levels up to PLe per ISO13849-1:2006. This circuit
The safety function initiated by the 800F e-stop meets the safety performanceexecutes requirements of SIL CL31 per
a Category IEC 62061:2005 and has a Category 4
stop.
structure that can be used in systems requiring Performance Levels up to PLe per ISO13849-1:2006. This circuit executes a Category 1 stop.
- 06 -
Light Curtain with Immediate and Delayed Outputs
Safe 4, SI, EMD, 100S, 700S: Light Curtain with Immediate and Delayed Outputs
Safe 4, SI, EMD, 100S, 700S
+24V DC
Reset
800FM-F6MX10
Transmitter Receiver K1 K2 K3 K4 K5 K6
Brown Brown
1 1
2
4
Black A1 13
4 S11 S21 S34 23 B1 B2 X32 A1 17 27 37 47
White
2 RANGE 0
1 TIME 1
2
RESET 0 9
8
2
3
10 3
4
4 9
7 8 5
6 5 7 6
Blue Blue AM
3 3 SI EMD
MM
Grey Grey 440R-S12R2 440R-EM4R2D
5 5
S12 S22 Y32 L11 A2 14 24 L12 L11 A2 18 28 38 48
POC Type 4 Safe 4
445L-P4S1200YD
Patchcord: 2 x 889D-F5AC-2
K1 100S- K3 K5 700S-
C43EJ14BC CFB440EJC
K2 K4 K6
24VC DC Com

Circuit
The lightStatus
curtain is clear. The safety outputs of the SI and EMD are Upon power-up, the SI and EMD perform internal checks. The SI
The light curtain is clear. The safety outputs of the SI and EMD are de-energized. All of the contactors are off. The EMD Range setting is 2 (10s OFF
de-energized. All of the contactors are off. The EMD Range setting
Delay) and the Time setting is 2 (20%), therefore the time delay is 2 seconds.
then looks for dual signals from the light curtain. A crossfault on
The reset and monitoring circuit are connected to S34 for monitored
ismanual
2 (10s reaset.
OFF Delay) and the Time setting is 2 (20%), therefore the light curtain
the time delay is 2 seconds. The reset and monitoring circuit are
will be detected by the light curtain. With the light curtain
connected
OperatingtoPrinciple
S34 for monitored manual reaset.
signals made, closing the reset button places a voltage to the
Additional outputs are added to the SI relay by the EMD (Expansion Module with Delayed outputs). A single wire, safety-rated signal from terminal
Operating Principle S34 terminal. The external devices (K1 through K6) are checked
L11 of the SI communicates the output status to L12 of the EMD relay.
Additional outputs
STARTING: Press and are added
release to the
the reset SI relay
button by the EMD
to energize to confirm
the outputs of the SI and theysafety
EMD. K1-K6 are off. A fault in
contactors or K1 through
safety controlK6 willenergize
relays cause their
(Expansion Module
to control the withportion
hazardous Delayed outputs).
of the machine.A single wire, safety- normally closed contacts to remain open, and this fault will be
STOPPING: When the light curtain is interrupted, the safety
rated signal from terminal L11 of the SI communicates the output outputs of the SI detected
turn off by the
immediatelySI.
and de-energize K1 - K2. Two seconds later, the
safety to
status outputs
L12 ofofthe
the EMD
EMD turn off and de-energize K3 through K6.
relay. Ratings
STARTING: Press and release the reset button to energize the
Fault Detection The safety function initiated by the slight curtain meets the safety
outputs of the SIthe
Upon power-up, and EMD.
SI and K1-K6
EMD safety
perform contactors
internal checks.orThe SI then looks forperformance
safety requirements
dual signals from of SILA CL
the light curtain. 3 per IEC
crossfault 62061:2005
on the and
light curtain
will be detected
control by the light
relays energize curtain. the
to control Withhazardous
the light curtain signals
portion made, closing
of the hasthe reset button
a Category places a voltage
4 structure that canto the
beS34 terminal.
used The requiring
in systems
external devices (K1 through K6) are checked to confirm they are off. A fault inPerformance
machine. K1 through K6Levels
will cause their
up to PLenormally closed contacts toThe
per ISO13849-1:2006. remain
Category
open, and this fault will be detected by the SI.
4 rating requires the redundant usage of K1-K6 to de-energize
STOPPING: When the light curtain is interrupted, the safety
the machine actuators, and the contactors must be monitored by
Ratingsof the SI turn o immediately and de-energize K1 - K2.
outputs
the safety system. This circuit executes a Category 0 stop (coast to
Two seconds
The safety later, initiated
function the safety outputs
by the slight of the EMD
curtain meetsturn o andperformance
the safety de- requirements of SIL CL 3 per IEC 62061:2005 and has a Category 4
structure K3
thatthrough
can be used stop).
energize K6. in systems requiring Performance Levels up to PLe per ISO13849-1:2006. The Category 4 rating requires the redundant
usage of K1-K6 to de-energize the machine actuators, and the contactors must be monitored by the safety system. This circuit executes a Category
0 stop (coast to stop).
- 07 -
Global E-Stop, Cascaded Safety Functions
800F, Trojan T15, MatGuard, SI, DI, DIS, 100S, 700S

Global E-Stop, Cascaded Safety Functions
800F, Trojan T15, MatGuard, SI, DI, DIS, 100S, 700S
+24V DC
Trojan T15-GD2 MatGuard
440K-T11287 Safety Mat & Trim
K1 K3 440F-M2030BYNN K5
Start
Start 440F-T2030
K2 K4 K6
Stop
E-Stop 11 12 11 12
800FM-MT44 Reset Stop
800F-MX02S 21 22 21 22 Reset
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
3 3
AM 8
7 4
8
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
Circuit
Circuit Status
Status the DI turns off the outputs of both the DI and DIS, while the SI is
The E-Stops are reset. The safety gate is closed. The safety mat is unoccupied. The outputs of all
unaffected. three controls
Pressing are off.or
the E-Stop K1-K6 are ready
stepping ontothe
be safety mat of
Theenergized.
E-Stops are reset. The safety gate is closed. The safety mat is
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
unoccupied. The outputs
safet gate provides full bodyof access.
all threeThecontrols are off.
DIS has logic K1-K6
set to
the DIS turns o the outputs of the DIS only.
are IN2) AND L12] with automatic reset as operators cannot get between the
8 [(IN1AND
ready to be
safety matenergized. The SI is set for monitored manual reset.
and the hazard. Fault Detection
The DI has logic set to 4 [(IN1 AND IN2) AND L12] with monitored
Operating
manual Principle
reset because the safet gate provides full body access. Upon successful completion of internal checks on power up,
The SI is connected to provide a Global E-Stop function. The DI and DIS safety relays the are cascaded
SI, DI and DIS from the SIcheck
relays relay. their input circuits. Shorts from
The DIS has logic set to 8 [(IN1AND IN2) AND L12] with automatic
reset as operators cannot get between the inputs to power, ground or other inputs will be detected
STARTING: Press the reset button for the SIthe safety mat
to energize and the
its outputs. Then press the Start button energize K1 and K2 and send the L11 link signal to
hazard. immediately and will
the DI Relay. This enables the DI relay. Press the reset button to energize to energize the DI relay. This sends a L11 linkprevent energization
signal to theorDIS
will de-energize
relay. The the
outputs of the DIS energize automatically. Press the respective Start buttons to respective energize the outputs.
contactorsIfK3, oneK4,ofK5the
and contactors
K6. (K1 - K6) is stuck in an
Operating
STOPPING: Principle
Pressing the E-Stop of the SI shuts down all three relays. Opening theactuated interlockedstate,
gate orthe respective
pressing control
the E-Stop will
of the DI prevent startup because
turns off the
outputs of both theto
The SI is connected DI provide
and DIS, while the SIE-Stop
a Global is unaffected. Pressing
function. ThetheDI E-Stop orthe
stepping on the safety
S34 feedback matwill
loop of the DIS turns
remain off the outputs of the
open.
andDIS
DISonly.
safety relays are cascaded from the SI relay.
Ratings
Fault Detection
STARTING: Press the reset button for the SI to energize its outputs. The safety functions initiated by the e-stop devices and the two
Upon
Then successful
press completion
the Start button of internal checks
energize K1 andonK2 power
andup,sendthethe
SI, DI and DIS relays check their input circuits. Shorts from the inputs to power,
Trojan interlocks meet the safety performance requirements of
ground or other inputs will be detected immediately and will prevent energization or will de-energize the respective outputs. If one of the
L11 link signal to the DI Relay. This enables the DI relay. Press the SIL startup
CL3 per IEC 62061:2005 and have Category 4 structures that
contactors (K1 - K6) is stuck in an actuated state, the respective control will prevent because the S34 feedback loop will remain open.
reset button to energize to energize the DI relay. This sends a can be used in systems requiring Performance Levels up to PLe
L11Ratings
link signal to the DIS relay. The outputs of the DIS energize per ISO13849-1:2006. The safety function initiated by the safety
automatically. Press the
The safety functions respective
initiated Start devices
by the e-stop buttons andtothe
energize
two Trojantheinterlocksmat
meetmeets
the safety
theperformance requirements
safety performance of SIL CL3 perof
requirements IECSIL CL2 per
contactors
62061:2005 K3,and
K4,have
K5 and K6. 4 structures that can be used in systems requiring
Category IECPerformance
62061:2005 Levels
anduphasto PLe per ISO13849-1:2006.
a Category 3 structureThethatsafety
can be used
function initiated by the safety mat meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that
STOPPING: Pressing
can be used therequiring
in systems E-Stop of the SI shuts
Performance down
Levels up toall
PLdthree in systems
per ISO13849-1:2006. requiring
This circuit Performance
executes Levels up to PLd per ISO13849-
a Category 0 stop.
relays. Opening the interlocked gate or pressing the E-Stop of 1:2006. This circuit executes a Category 0 stop.
- 08 -
R

GuardShield, 800Z Safety Applications and Wiring Diagrams
GuardShield, 800Z
GuardShield, 800Z, MSR35H, SI,100S: GuardShield, 800Z, MSR35H, SI,100S
+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
To PLC
Brown
White
Black
L1 L2 L3
800Z-GL3Q5 S1
S21 S11 S34 Y41 A1 Y2 S11 S12 A1 S34 13 23
889N-F5AE-6F
RESET 0 K1
Blue
Grey
AM
Two-Hand MSR35H SI
MM K2
Control 24VDC 440R-D23202 440R-S12R2
Brown
White
S12 S22 A2 14 24 32 S21 S22 A2 L11 Y32 14 24

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

Circuit Status
The
Theoperator’s handsare
operator's hands arenot
notonon
thethe
twotwo
800Z800Z
palmpalm buttons.
buttons. Upon
The outputs of the power
MSR35H are up,
off. the
The800Z, GuardShield,
light curtain MSR35H
is configured andfactory
with the SI perform
The outputs
default of the
settings (GuardMSR35H are o.and
only mode) Theislight curtain isThe
unobstructed. outputs of the SIinternal
congured checks.
safety relay are off.After
The passing internal
motor is off checks,
and ready the MSR35H waits
to run.
The light
with curtain isdefault
the factory protecting one portion
settings (Guardofonly
the machine.
mode) and An is
operator, using for
two-hand
a changecontrol is accessing
of state a different
of its inputs. portion
Faults (opensof the
and machine
shorts) at the
and has full view
unobstructed. Theof his or her of
outputs area.
the SI safety relay are off. The motor inputs will be detected by the MSR35H and prevent the outputs
is off and ready to run. fro being energized. the GuardShield light curtain also performs
Operating Principle checks on its OSSD output signals for crossfaults, shorts and
The light curtain
STARTING: is protecting
Press the Reset buttonone portionthe
to energize of the machine.
output of the SI.AnThe operator places both hands on the 800Z buttons simultaneously (within
0.5s). The outputs of the MSR35H (terminals 14, 24) and energize the 100S
opens. The
contactors,
SI looks for dual signals at its inputs. It then checks
which start the motor.
operator, using two-hand control is accessing a dierent portion of
STOPPING: the status of theMSR35H
contactors. If one contactors failsK1
inand
theK2actuated
the machineRemoving
and has onefull or both
view ofhands
his orfrom the 800Z palm buttons causes the outputs of the
her area. to turn off, which drops out
and stops the motor. Obstructing the light curtain de-energizes the safety outputs state, of
the other
the contactor
SI, which in turn will stop
drops out the motor.
K1 and K2 andTheturns
SI will
thedetect
Operating Principle
motor off. Clearing if onehas
the light curtain does not restart the motor, even if the operator of their
the contactors
hands on the are stuck
palm in theThe
buttons. energized position,
reset button must and
be pressed after the light curtain is cleared. prevents restart.
STARTING: Press the Reset button to energize the output of
the SI. The operator places both hands on the 800Z buttons Ratings
Fault Detection
simultaneously (within 0.5s). The outputs of the MSR35H
Upon power up, the 800Z, GuardShield, MSR35H and SI perform internal checks. TheAfter
safety function
passing provided
internal by the
checks, the GuardShield
MSR35H waits for alight curtain
change of
(terminals 14, 24) Faults
state of its inputs. and energize
(opens andtheshorts)
100S atcontactors, which
the inputs will start by the MSR35H and prevent the outputs fro being energized. the
be detected meets the safety performance requirements of SIL CL 3 per IEC
the motor. light curtain also performs checks on its OSSD output signals for crossfaults, shorts and opens. The SI looks for dual signals at its
GuardShield 62061:2005 and has a Category 4 structure that can be used in
inputs. It then checks the status of the contactors. If one contactors fails in the actuated state, the other contactor will stop the motor. The SI will
STOPPING: Removing one or both hands from the 800Z palm systems requiring Performance Levels up to PLe per ISO13849-
detect if one of the contactors are stuck in the energized position, and prevents restart.
buttons causes the outputs of the MSR35H to turn off, which 1:2006. This circuit executes a Category 0 stop.
drops out
Ratings K1 and K2 and stops the motor. Obstructing the light
curtain de-energizes
The safety the safety
function provided outputs
by the of thelight
GuardShield SI, which
curtain in turnthe safety performance requirements of SIL CL 3 per IEC 62061:2005 and has
meets
drops out K1
a Category and K2 and
4 structure that turns
can bethe
usedmotor off. Clearing
in systems requiringthe light
Performance Levels up to PLe per ISO13849-1:2006. This circuit executes a Category
curtain
0 stop. 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.

- 09 -
Interlock Switch - Multiple Gate Access Safety Applications and Wiring Diagrams
Interlock Switch - Multiple Gate Access
Trojan T15, Elf-GD2, 800F, CI, 100S: Trojan T15, Elf-GD2, 800F, CI, 100S
+24V DC
Machine control system
Start K1 can replace this circuit
Trojan T15-GD2 ELF-GD2 800FM- arrangement.
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 Y32 14 24 34 42
1734-OW2
1734-IB4
1793-IB6 1793-OW4 M
K1 K2 100S-
C09EJ14BC
24V DC Com
Circuit
Circuit Status
Status STOPPING: Opening any one of the safety gates or pressing the
Circuit shown with the safety gates closed and e-stop released. The CI safety relay is de-energized. The motor is off. The monitoring circuit is
Circuit showntowith
connected theautomatic
S34 for safety gates
reset closed
of the CIand e-stop released. The
relay. e-stop causes the motor to turn o. Closing the gate or releasing
CI safety relay is de-energized. The motor is off. The monitoring the e-stop does not cause the motor to start due to the start-stop
Operating
circuit Principle
is connected to S34 for automatic reset of the CI relay. interlocking circuit. To restart the motor, close the safety gate or
With 2NC + 1NO interlocks, a potential exists for the gate to be slightly open which release the
results in e-stop. Thencontact
the auxiliary pressbeing
the start
closedbutton.
and the safety
Operating
being open. Principle
The machine cannot start and the PLC does not know which gate is open. By sending the second safety channel through the PLC,
the2NC
machine control system knows which door is open, when Fault Detection
With + 1NO interlocks, a potential exists for the gatethetosafety
be system is off due to a gate that may be slightly open. The infinite
simultaneity feature of safety relays like the CI allow enough time for the PLC toIfprocess the PLC all fails
the gates
withand close theclosed,
its output second channel
the safety of the safety
relay will detect
slightly open which results in the auxiliary contact being closed
relay without creating a lockout condition. the dierence between the safety gate and the PLC and stop the
and the safety being open. The machine cannot start and the PLC
does not know which gate is open. By sending the second safety motor. A single fault (open
When a safety gate is opened, the interlock opens Ch1 directly to the safety relay and opens Ch2 which is connected to the input of a PLC. The
or short) across one of the interlocks
channel
PLC must through
then open the Ch2
PLC,ofthe
the machine
safety relay. control
The logic system PLC must open thewill
in the knows Ch2be detected
signal byor
if any one the safety
more of therelay and
safety theare
gates motor
open will
and be turned
must only close the Ch2 circuit when all of the
which door is open, when the safety system is off due to a gate safety gates and e-stop are o.
closed. The
The motor
PLC can will
also remain
use the off until
information the
on fault
the is
inputs corrected
on or power
thatPanelView
may be or similar open.
slightly device.The Theinnite
auxiliary signal (Y32) from
simultaneity the CIofmust
feature is cycled.
be an input
safety If either
to the PLC. This contactor
PLC program K1must
or K2
onlysticks
closeON - the motor
its output when will
all the safety inputs are closed and the auxiliary signal from the CI is closed. Thisstop allowsonthe PLC to indirectly
command due toconfirm
the otherthat contactor,
its own output butis the SI cannot
relays like the CI allow enough time for the PLC to process all the
working properly.
gates and close the second channel of the safety relay without be reset (thus the fault is revealed to the operator). A single
creating a lockout condition. fault detected on the SI input
STARTING: Channel 1 input (S11/S12) of the SI is satisfied. Using isolated relay contacts in its output module, the PLC closes the second safety
circuits will result in the lock-out
channel (21/22 of the SI). The safety outputs of the SI close. Press the Start button of the system
to start to a safe state (OFF) at the next operation of the
the motor.
When a safetyOpening
STOPPING: gate isany opened,
one of the interlock
the safety gatesopens Ch1 directly
or pressing the e-stop tocauses the
safety
motor gate
to turnor e-stop device.
off. Closing Contactors
the gate or releasingK1 the
ande-stop
K2 are controlled
does
thenotsafety
cause relay and opens
the motor to startCh2
duewhich is connected
to the start-stop to the circuit.
interlocking input of To restartby
thethe safety
motor, closesystem.
the safetyContactor K2 is the
gate or release controlled
e-stop. Thenby both
pressthe
a PLC.
the The
start PLC
button. must then open Ch2 of the safety relay. The logic machine control system and the safety system. This increases the
in the PLC must open the Ch2 signal if any one or more of the probability of performance of the safety function because K1 is
Fault
safety gatesDetection
are open and must only close the Ch2 circuit when signicantly less likely to weld at the same time as K2 due to the
If the
all of thePLC fails with
safety gatesitsand
output closed,
e-stop arethe safetyThe
closed. relayPLC will can
detect theuse
also difference between the safety gate and the PLC and stop the motor. A single
diversity of expected wear out times.
thefault (open or short) across one of the interlocks will be detected by the safety relay and the motor will be turned off. The motor will remain off
information on the inputs on PanelView or similar device. The
until the fault is corrected or power is cycled. If either contactor K1 or K2 sticks ON - the motor will stop on command due to the other contactor,
Ratings
auxiliary
but thesignal
SI cannot (Y32)
be from the CI
reset (thus themust
fault be an input
is revealed to to
thethe PLC. This
operator). A single fault detected on the SI input circuits will result in the lock-out of
PLCthe program
system to must
a safeonly
stateclose
(OFF)itsat output
the nextwhenoperationall the
of thesafety
safety inputs
gate or e-stopThe safety
device. functionK1initiated
Contactors and K2 are bycontrolled
the Trojan by T15 and ELF-GD2 safety
the safety
aresystem.
closed Contactor
and the auxiliary signalby
K2 is controlled from
boththe theCI is closed.
machine Thissystem
control allowsand thegate
safetyinterlocks
system. This and the 800F
increases the e-stop meets
probability the safety of
of performance performance
thethePLCsafety function because
to indirectly conrm K1 thatis significantly
its own output less likely to weldproperly.
is working at the same time as K2 due to the
requirements ofdiversity
SIL CL2ofper expected wear out times.
IEC 62061:2005 and has a Category
3 structure that can be used in systems requiring Performance
STARTING:
RatingsChannel 1 input (S11/S12) of the SI is satised. Using Levels up to PLd per ISO13849-1:2006. This circuit executes a
isolated relay
The safety contacts
function in itsby
initiated output module,
the Trojan T15 and theELF-GD2
PLC closessafetythegate interlocks and the 800F e-stop meets the safety performance
Category 0 stop.
second safety channel
requirements of SIL CL2(21/22
per IEC of the SI). The
62061:2005 and safety outputs3 of
has a Category the that can be used in systems requiring Performance Levels up to PLd
structure
per ISO13849-1:2006.
SI close. Press the StartThis circuitto
button executes
start the a Category
motor. 0 stop.
- 10 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R 3-12
SI, DIS, SensaGuard, E-Stops, PF525 with Contactor
SensaGuard Integrated Latch, E-Stop, SI, DI, 100S and PowerFlex 525:
SI, DIS, SensaGuard, E-Stops, PF525 with Contactor
SensaGuard Integrated Latch, E-Stop, SI, DI, 100S and PowerFlex 525
24V DC
SensaGuard
E-Stops
Yellow
Brown
Brown
Brown
Integrated
800FM-MT44
Red
Latches
800F-MX02S K1
440N-Z21SS3PA
Grey Red
Grey L1 L2 L3
Grey Red Pink
Pink Yellow Pink Yellow
PowerFlex R S T
Reset 525
Blue
White
White
White
1 Stop
Blue
Blue
2 Start
Gate 4 Gnd
Open
S12 S22 A1 S34 13 23 S12 S22 S11 S21 S42 S32 A1 S34
Gate
Open RESET 0 LOGIC 0
1
2
A1 Gate control
AM 8
4
3 power supply
7
6 5
Gate SI DIS
MM
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
Circuit Status
The DIS
Circuit Logic is set to 4: [(IN1 AND IN2) AND L12] with monitored reset. The SI Fault
Status is set for automatic reset. The SensaGuard Intgreated Latch
Detection
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
Thegates,
DIS Logic
monitoredis setbytothe
4:SensaGuard
[(IN1 AND Intergrated
IN2) AND L12]Latch with monitored
interlocks, are closed andUpon
safetysuccessful completion
outputs of the of internal
SI (L11, 13/14 and 23/24) checks
are ON.byBoth
the SI, DIS,
reset. Theare
e-stops SI isreleased.
set for automatic
The DIS safetyreset.
outputsThe(14,
SensaGuard
24, 34 and 44)Intgreated SensaGuard
are off and waiting and PowerFlex
for a reset signal. The PowerFlex525525drive, the
drive drive awaits
is powered but the closure
Latch interlocks
disabled. are connected
Contactor in series
K1 is de-energized. Thetomotor
the SI. The two
is off. of the safety outputs. If the DIS fails, the drive will not energize
e-stops are connected to inputs 1 (S12 and S22) and 2 (S32 and the motor, and the fault will be detected by non-operation of the
Operating
S42) of the DIS.Principle
The three gates, monitored by the SensaGuard motor. The DIS generates test pulses through the e-stop circuits
STARTING: Press the Reset button to turn on the DIS safety outputs. This energizes K1, enables the drive and also applies power to the Start and
Intergrated Latch interlocks, are closed and safety outputs of to detect cross channel shorts and shorts to power and ground.
Stop buttons. Press the Start buttons to start the motor.
theSTOPPING: Press the Stop button to stop the motor for production stops. PressThe
SI (L11, 13/14 and 23/24) are ON. Both e-stops are released. SensaGuard
either e-stop or open interlocks
any safetygenerate test pulses
gate to initiate a safety on
stop;their
the outputs
Themotor
DIS safety
coasts to outputs
a stop. (14, 24, 34 and 44) are o and waiting for to detect cross channel shorts and shorts to power and ground.
a reset signal. The PowerFlex 525 drive is powered but disabled. A fault in the safe-circuit of the drive will be detected by the drive
Fault Detection
Contactor K1 is de-energized. The motor is off. and issue a safety stop. The mechanically linked contacts of K1 are
Upon successful completion of internal checks by the SI, DIS, SensaGuard and PowerFlex monitored 525by
drive,
thetheDISdrive awaits the
to ensure closure
that of the safety
the contactor is de-energized
Operating
outputs. IfPrinciple
the DIS fails, the drive will not energize the motor, and the fault will be detected by non-operation
before resetting the safetyofsystem.
the motor. The DIS generates test
pulses through
STARTING: Press the thee-stop
Resetcircuits
button to to
detect
turncross channel
on the shorts and shorts to power and ground. The SensaGuard interlocks generate test pulses
DIS safety
on their outputs to detect cross channel shorts and shorts to power and ground.
outputs. This energizes K1, enables the drive and also applies Ratings
A fault in the safe-circuit of the drive will be detected by the
drive and issue a safety stop. The mechanically linked contacts of K1 are monitored by the DIS to ensure that the contactor is de-energized before
power to the
resetting theStart
safetyand Stop buttons. Press the Start buttons to
system. The safety functions initiated by the SensaGuard Integrated
start the motor. Latch interlocks and the e-stop meets the safety performance
Ratings requirements of SIL CL3 per IEC 62061:2005 and a Category 3
STOPPING: Press the Stop button to stop the motor for production
The safety functions initiated by the SensaGuard Integrated Latch interlocks and structure
the e-stopthat can
meets thebe usedperformance
safety in systemsrequirements
requiring Performance
of SIL CL3
stops. Press
per IEC either e-stop
62061:2005 or open4any
and a Category safetythat
structure gate
cantobeinitiate a
used in systems requiring Performance
Levels up to PLe Levels
per ISO up 13849-1:
to PLe per 2006.
ISO 13849-1: 2006. The
The circuit executes a
safety stop;
circuit the motor
executes coasts
a Category to a stop.
0 stop. Category 0 stop.
- 11- NHP Safety Reference Guide > GSR Wiring Diagrams 3-13
R
SensaGuard Safeguarding Applications andWiring Diagrams
SensaGuard, CI, 800F, 100S:

SensaGuard
SensaGuard, CI, 800F, 100S
+24V DC
Shown Open
SensaGuard SensaGuard 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-
F3MX10 K2
Brown
Green
Blue
White (Aux)
Yellow
Red
Gray (OSSD1)
Pink (OSSD2)
Stop
800FM-
E4MX01
18mm Cylindrical
L1 L2 L3
Plastic SensaGuard
Machine Control A1 S11 S12 L11 13 23 33 41
440N-Z21S26H
Cordset PLC Input RESET 0 K1
Auxiliary RP
889D-F8AB-2 (1756-IB16 Signals AM
CI
1769-IQ16 to Machine MM
440R-S13R2
1746-IB16 Control K2
1792-IB16 I0 S21 S22 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

The first and
Circuit third gates are closed. The second gate is open.
Status Upon successful completion of internal checks on power up, the
The CIfirst
The safety
and relay S12 and
third gates S22 inputs
are closed. are open
The second gate due to the
is open. CI safety relaySensaGuard
The open interlocks
S12 and S22 inputs check
are open duefor
to24V at pins
the open 4 and
gate, and 8. If the actuator
therefore,
gate,
the and therefore,
CI safety outputs the CI safety
are open. outputscontrol
The machine are open. Thea machine
PLC has 24V auxiliary signal is within range,
at terminal the the
I1 from SensaGuard
second gatewill activate
because theits OSSD
gate outputs. The
is open.
The first
control PLCand third
has auxiliary
a 24V signalssignal
auxiliary are off,at
asterminal
their gatesI1are closed.
from the The PLC alsoOSSD
has anoutputs
auxiliaryperform
signal from the CI indicating
continuous that for
checking the short
safety circuits to
systemgate
second is notbecause
ready. Thethe motor
gateisisoff.
open. 24V, ground and crossfaults. Upon detection of a fault, the OSSD
outputs turn off. The CI also performs internal checks on powerup.
The first and third
Operating auxiliary signals are off, as their gates are
Principle It then checks for input signals. If OK, the CI checks the K1/K2/
closed. The PLC
STARTING: alsothe
Closing has an auxiliary
second signal
gate satisfies thefrom
inputthe CI CI.
of the indicating
The CI verifies that both K1 and K2 contactors are off and energizes its safety
S34 monitoring circuit to determine whether both contactors are
that the safety
outptus. system
Pressing is not
the start ready.
button The motor
energizes is off.The Stop/Start circuit is not part of the safety system and can be replaced by the machine
the motor.
control system (e.g., a PLC). off. If one of the contactors gets stuck on, the other contactor will
Operating
STOPPING:Principle
Press the Stop button to turn the motor off, without affecting the status de-energize thesystem.
of the safety motor,Opening
and theanyCI will detect
of the gatesthe
willfault
causeatthe
the next
safety system
STARTING: to stop
Closing thesecond
the motor. gate satises the input of the CI. attempt to start the motor. The contactors have mechanically linked
The CI veries that both K1 and K2 contactors are o and energizes auxiliary contacts to help ensure fault detection of the contactors.
Fault Detection
itsUpon
safety outputs. Pressing the start button energizes the motor.
successful completion of internal checks on power up, the SensaGuard interlocks Ratingscheck for 24V at pins 4 and 8. If the actuator is within
The Stop/Start
range, circuit iswill
the SensaGuard not part of
activate its the
OSSDsafety system
outputs. and can
The OSSD be perform continuous checking for short circuits to 24V, ground and
outputs This safety performance of this circuit meets the requirements
replaced by the
crossfaults. Upon machine
detectioncontrol system
of a fault, (e.g.,
the OSSD a PLC).
outputs turn off. The CI also performs internal checks on powerup. It then checks for input
of SIL CL 3 per IEC 62061:2005 and has Category 4 structure and
signals. If OK, the CI checks the K1/K2/S34 monitoring circuit to determine whether both contactors are off. If one of the contactors gets stuck
STOPPING: Press
on, the other the Stop
contactor will button to turn
de-energize the motor
the motor, o,CIwithout
and the can
will detect the fault be used
at the in systems
next attempt requiring
to start the motor.Performance Levels
The contactors have up to PLe
aecting the status
mechanically linkedofauxiliary
the safety system.
contacts Opening
to help anydetection
ensure fault of the gates per ISO 13849-1:2006. The SensaGuard interlocks are designed
of the contactors.
will cause the safety system to stop the motor. to meet Category 4 when connected in series. The CI is rated to
Ratings Category 4. The design and connection of the contactors meets
This safety performance of this circuit meets the requirements of SIL CL 3 per IECcategory62061:2005 4. and
Thishas Category
example 4 structure
circuit and can
performs be used
a Stop in
Category 0
systems requiring Performance Levels up to PLe per ISO 13849-1:2006. The SensaGuard function interlocks
(coast toarestop).
designed to meet Category 4 when
connected in series. The CI is rated to Category 4. The design and connection of the contactors meets category 4. This example circuit performs a
Stop Category 0 function (coast to stop).
- 12 -
R 3-14
Light Curtain - Point of Operation Control Safety Applications and Wiring Diagrams
GuardShield, 800F, DI, 100S: Light Curtain - Point of Operation Control
GuardShield, 800F, DI, 100S
+24V DC
Transmitter Receiver 800FM-
arrangement.
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
Circuit Status
Circuit Status The DI will detect the faulted contactor and will not allow the
TheThe lgihtcurtain
light curtain isisclear
clearand
andthethe
motor
motoris ready to run.toThe
is ready DIThe
run. motor
RelayDIis set for Logic 5 (L12toorrestart until
IN1 or IN2 the
with fault is corrected.
Automatic Reset). Contactors K1 and K2
Relay is set for Logic 5 (L12 or IN1 or IN2 with Automatic Reset). are controlled by the safety system. Contactor K2 is controlled by
Operating Principle both the machine control system and the safety system diversity
Operating
STARTING:Principle
Press the Start button to energize contactors K2. The motor starts with of the two normally
expected wearopen contacts of K1 and K2 holding circuit
out times.
energized.
STARTING: Press the Start button to energize contactors K2. The
STOPPING: Obstructing the light curtain de-energizes the safety outputs of the DI Ratings
which in turn drops out K1 and K2. The contactors disconnect
motor starts with the two normally open contacts of K1 and K2
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
holding circuit energized. The safety function initiated by the GuardShield light curtain
meets the safety performance requirements of SIL CL 3 per IEC
Fault Detection
STOPPING: Obstructing the light curtain de-energizes the
Upon successful completion of internal checks on power up, the GuardShield light 62061:2005 and has
curtain energizes a Category
its outputs 4 structure
with no that can
objects present. Thebe used in
safety outputs of the DI which in turn drops out K1 and K2. The
successful completion of internal checks, the DI checks the signals from the lightsystems curtain. Ifrequiring
OK, the DIPerformance
then checks theLevels upthe
status of toK1
PLe
andper
K2ISO13849-
contactors
contactors.disconnect
If either K1 orthe
K2motor from
fails in the its power
actuated state,source, and
the other 1:2006. This
contactor will disconnect thecircuit
motor. executes
The DI willadetect
Category 0 stop.
the faulted contactor and
thewill
motor coasts
not allow to a stop.
the motor Clearing
to restart thefault
until the obstruction in Contactors
is corrected. the light K1 and K2 are controlled by the safety system. Contactor K2 is controlled
curtain
by bothdoes not cause
the machine the motor
control system and to restart.
the safety system. diversity of expected wear out times.
Fault Detection
Ratings
Upon successful
The safety completion
function initiated by of
theinternal checks
GuardShield lighton power
curtain up,the
meets thesafety performance requirements of SIL CL 3 per IEC 62061:2005 and has a
GuardShield light curtain
Category 4 structure energizes
that can be used inits outputs
systems with no
requiring objects Levels up to PLe per ISO13849-1:2006. This circuit executes a Category 0
Performance
stop. The successful completion of internal checks, the DI
present.
checks the signals from the light curtain. If OK, the DI then checks
the status of the K1 and K2 contactors. If either K1 or K2 fails in
the actuated state, the other contactor will disconnect the motor.
- 13 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-15

R
Two Light Curtains - Point of Operation Control
Safety Applications and Wiring Diagrams
GuardShield, 800F, DI, 100S: Two Light Curtains - Point of Operation Control
GuardShield, 800F, DI, 100S
+24V DC
800FM-
Transmitter Receiver arrangement.
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
M
440L-P4KL0960YD K1 K2
889D-F4AC-2 889D-F8AC-2 100S-C43EJ14BC
24V DC Com
Circuit Status
Circuit Status contactors. If either K1 or K2 fails in the actuated state, the other
contactor
The light curtains are configured with the factory default settings (Guard only mode) will disconnect
and is unobstructed. Thethe motor.
outputs The
of the DI will
safety relaydetect
are the faulted
The light curtains are congured with the factory default settings
closed, and the motor is ready to run. The DI Relay is set for Logic 6: [(IN1 AND IN2) OR L12] with
contactor and Automatic
will not Reset.the motor to restart until the fault is
allow
(Guard only mode) and is unobstructed. The outputs of the safety
relay are closed, and the motor is ready to run. The DI Relay is set corrected.
Operating Principle
forSTARTING:
Logic 6: [(IN1 AND IN2) OR L12] with Automatic Reset.
Press the Start button to energize contactor K2. The motor starts with Contactors K1 and
the two normally K2 contacts
open are controlled
of K1 andby
K2the safety
holding thesystem.
circuit
energized. Contactor K2 is controlled by both the machine control
Operating
STOPPING:Principle
Obstructing either light curtain deenergizes the safety outputs of the DI which in turn drops out K1 and K2. The contactors disconnect
system and the safety system. This increases the probability of
STARTING:
the motorPress the
from its Startsource,
power button tothe
and energize contactor
motor coasts K2.Clearing
to a stop. The 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 performance
by of the
pressing the stop safety function because K1 is signicantly
button.
motor starts with the two normally open contacts of K1 and K2
less likely to weld at the same time as K2 due to the diversity of
holding the circuit energized.
Fault Detection expected wear out times.
STOPPING: Obstructing
Upon successful completioneither light curtain
of internal deenergizes
checks on power up, thetheGuardShield light curtains energize their outputs with no objects present. If a
crossfault is detected, thewhich
GuardShield light curtain Ratings
safety outputs of the DI in turn drops outgoes
K1 to
anda lockout
K2. Thestate with its outputs off. After successful completion of internal checks, the
DI checks the signals from the light curtains. If OK, the DI then checks the statusThe safety
of the function
K1 and initiated
K2 contactors. by the
If either GuardShield
K1 or K2 fails in thelight curtains
actuated
contactors disconnect the motor from its power source, and the
state, the other contactor will disconnect the motor. The DI will detect the faulted contactor
meets the and willperformance
safety not allow the motor to restart until
requirements of theCL
SIL fault
3 per IEC
motor coasts to a stop. Clearing the obstruction in either light
is corrected.
curtain doesK1
Contactors not
andcause
K2 arethe motor by
controlled to the
energize (the Start
safety system. buttonK2 is controlled by both the machine control system and the safety system. used in
Contactor
62061:2005 and has a Category 4 structure that can be
must
Thisbe pressed).
increases The motorofcan
the probability also be turned
performance o byfunction
of the safety pressing the K1 is
because systems requiring
significantly Performance
less likely to weld at theLevels up to
same time asPLe pertoISO13849-
K2 due the
diversity
stop of expected wear out times.
button. 1:2006. This circuit executes a Category 0 stop.
Fault Detection
Ratings
Upon successful completion of internal checks on power up,
theThe safety function initiated by the GuardShield light curtains meets the safety performance requirements of SIL CL 3 per IEC 62061:2005 and has
GuardShield light curtains energize their outputs with no
a Category 4 structure that can be used in systems requiring Performance Levels up to PLe per ISO13849-1:2006. This circuit executes a Category
objects
0 stop.present. If a crossfault is detected, the GuardShield light
curtain goes to a lockout state with its outputs o. After successful
completion of internal checks, the DI checks the signals from the
light curtains. If OK, the DI then checks the status of the K1 and K2

R
Lifeline Safeguarding Applications and Wiring Diagrams
Lifeline, 800F, DI, 100S: Lifeline
Lifeline, 800F, DI, 100S
+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
Circuit Status Then press the Start button to start the motor. As an alternative,
Circuit
Both Status
Lifeline cable pull switches are taut and reset; their contacts the motor can be stopped by pressing the Stop pushbutton. It
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 are closed. can
The thensetting
DI Logic be restarted
is 6: [(IN1by pressing
AND IN2) OR the
L12]Start pushbutton.
with automatic reset.
The DI safety
automatic relay is energized, as its inputs and monitoring circuits are satisfied. The motor is off and ready to run.
reset. Fault Detection
The DI safety relay is energized, as its inputs and monitoring Upon successful completion of internal checks on power up, the
Operating Principle
circuits are satised. The motor is o and ready to run.
Two cable pull switches are used to protect an area from 10m to 70m in length. Auxiliary DI checks its input
lights providecurcuits.
indicationWith
as toboth
whichLifeline switches
switch has been reset, the
actuated to stop the motor. The difference between the two switches is the conduit DI checks
thread theand output
shown forcontactors through the K1/K2/S34 circuit.
examples purposes.
Operating Principle
STARTING: Press the Start button to energize contactors K1 and K2. The motor starts If theand
contactors are o, the
the two normally openDI energizes
contacts of K1its
andoutputs
K2 closeand
to turns on
Two
holdcable pull switches
the circuit energized are used
across the to protect
Start button.an area from 10m the contactors which turn on the motor. A short or open circuit
toSTOPPING:
70m in length.
Pull theAuxiliary lights
Lifeline cable provide
or press indication
the e-stop buttonas
ontothe
which
Lifeline switchfault
to de-energize the outputs
in the Lifeline cable of theswitches
pull DI and turn offbe
will thedetected
motor. To by the DI.
restarthas
switch the been
motor,actuated
make sureto thestop
area the
is clear of hazards,
motor. pull out the e-stop button (if pressed) and rotate the reset knob to the Run position.
The dierence If either the K1 or K2 faults in the energized state, the motor will
Then press the Start button to start the motor. As an alternative, the motor can be stopped by pressing the Stop pushbutton. It can then be
between the two switches is the conduit thread and shown for be stopped by the other contactor and the fault will be detected
restarted by pressing the Start pushbutton.
examples purposes. by the DI on the next attempt to restart. An internal fault in the
STARTING: Press the Start button to energize contactors K1 and DI will be detected by itself. Depending on the type of fault,
Fault Detection
K2.Upon
Thesuccessful
motor starts and the
completion two normally
of internal checks onopen
power contacts ofchecks
up, the DI K1 its input thecurcuits.
result wil beboth
With de-energization
Lifeline switchesofreset,
the K1
the and K2 contactors
DI checks the or
output contactors through the K1/K2/S34 circuit. If the
and K2 close to hold the circuit energized across the Start button.contactors are off, the DI prevention
energizes its of re-start.
outputs and turns on the contactors which turn on
the motor. A short or open circuit fault in the Lifeline cable pull switches will be detected by the DI. If either the K1 or K2 faults in the energized
STOPPING: Pull the
state, the motor will Lifeline
be stoppedcable or other
by the presscontactor
the e-stopandbutton
the faulton Ratings
will be detected by the DI on the next attempt to restart. An internal fault in
theLifeline
the DI will be detected
switch by itself. Depending
to de-energize on the type
the outputs of fault,
of the DI and result wil beThe
theturn safety function
de-energization of theinitiated
K1 and K2by the Lifeline
contactors cable pull
or prevention of switches
re-start.
o the motor. To restart the motor, make sure the area is clear of meets the safety performance requirements of SIL CL3 per IEC
hazards, pull out the e-stop button (if pressed) and rotate the 62061:2005 and has Category 4 structure that can be used in
Ratings
reset knob to the Run position. systems requiring Performance Levels up to PLe per ISO 13849-1:
2006. The circuit
The safety function initiated by the Lifeline cable pull switches meets the safety performance executes
requirements a Category
of SIL CL3 per IEC062061:2005
stop. and has
Category 4 structure that can be used in systems requiring Performance Levels up to PLe per ISO 13849-1: 2006. The circuit executes a Category 0
stop.

R
Safety Distribution Block and DI with Kinextix 350
Safety
SensaGuard, Safety Distribution Block, Distribution
E-stops, Block and DI with Kinextix 350
DI, Kinetix 350:
SensaGuard, Safety Distribution Block, E-stops, DI, Kinetix 350
24V DC
Yellow Status Signals
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 S21 S22 S12 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
4 Safety Input 1
889M-R19RMMU-2 Bulk Head Pink
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
Circuit
Circuit Status
Status Fault Detection
The Logic setting of the DI is set to 2 - monitored manual reset with [(Input 1 AND Input 2) OR L12]. The two E-Stops are in the released position
The
andLogic setting ofinthe
are connected DItoisInput
series set to1 (S12
2 - monitored
and S22). The manual reset are closedUpon
SensaGuards and aresuccessful
connectedcompletion of internal
in series through checks Block
the Distribution on power
to up,
with [(Input
Input 2 (S321and
AND Input
S42). 2) OR of
The status L12].
eachThe two E-Stops
SensaGuard are in the
is monitored theDI
by the PLC. The DI,safety
Kinetix 350(14
outputs and SensaGuard
and 24) are OFF.components
The Kinetix 350are prepared
Drive is
poweredposition
released but the safety inputs
and are are off; therefore
connected in seriestheto
motor
Input is OFF.
1 (S12The Y32 Aux Signal
and and 3 Status
for operation. Thesignal are OFF and
SensaGuard inform thegenerate
interlocks PLC that thetest pulses
safety system is ready to run. The PLC turns ON an output that enables the Reset of the safety system.
S22). The SensaGuards are closed and are connected in series to check for short circuit faults to power and ground. The DI
through the Distribution Block to Input 2 (S32 and S42). The generates test pulses through the e-stop
Operating
status of eachPrinciple
SensaGuard is monitored by the PLC. The DI safety
STARTING: Press the Reset button to energize the safety outputs of the DI. The Y32 circuit
andto checksignals
3 Status for short circuit
turn OFF. Thefaults to350
Kinetix power
driveand
is ground.
outputs
enabled. (14The
and
PLC24)canare
notOFF.
turn The Kinetix
the motor ON350(thisDrive
circuitisis powered
not shown).but
the safety inputs are o; therefore the motor is OFF. The Y32 Aux Ratings
Signal and 3Openting
STOPPING: Status signal
any gateareorOFF and any
pressing inform the
e-stop PLC
will that thethe safety The
de-energize outputs of the
safety DI, whichinitiated
functions in turn cause the output
by the of the Kinetix
SensaGuard interlocks
drivesystem
safety to turn OFF . The motor
is ready to run.will coast
The PLCtoturns
a stop.ON an output that
and the E-Stop buttons can meet the safety performance
enables the Reset of the safety system. requirements of SIL CL 2 per IEC 62061:2005 and Performance
Fault Detection
Operating Principle
Upon successful Level
completion of internal checks on power up, the DI, Kinetix 350 and PLd per ISO13849-1:2008.
SensaGuard This application
components are prepared for operation.executes
The a
Category
SensaGuard interlocks generate test pulses to check for short circuit faults to power 0 stop.
and ground. The DI generates test pulses through the e-stop
STARTING: Press the Reset button to energize the safety outputs
circuit to check for short circuit faults to power and ground.
of the DI. The Y32 and 3 Status signals turn OFF. The Kinetix 350
drive is enabled. The PLC can not turn the motor ON (this circuit is
Ratings
not shown).
The safety functions initiated by the SensaGuard interlocks and the E-Stop buttons can meet the safety performance requirements of SIL CL 2 per
IEC 62061:2005
STOPPING: and Performance
Openting Level
any gate or PLd perany
pressing ISO13849-1:2008. This application executes a Category 0 stop.
e-stop will de-
energize the safety outputs of the DI, which in turn cause the
output of the Kinetix drive to turn OFF . The motor will coast to a
stop.
-16 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-18
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Safety Valve - Air Supply Release Safeguarding Applications and Wiring Diagrams
GuardShield, 800F, DI, Pneumatic Safety Valve: Safety Valve - Air Supply Release
GuardShield, 800F, DI, Pneumatic Safety Valve
+24V DC
E-Stop
800FM-MT44 Reset
800F-MX02S 800FM- DM
2TM
CrossflowTM
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
Circuit Status
Circuit Status circuit is detected, the DI will not energize its outputs. If both
The
Thelight
lightcurtain
curtain isisclear
clear and
and thethe e-stop
e-stop button
button is released.
is released. inputare
The relay outputs
The DI safety circuits
off andare
theclosed, thevalve
pneumatic DI checks theThe
is closed. status of the safety
DI safety
DIrelay
safetyLogic is set
relay to 2: [(IN1
outputs areAND IN2)the
o and OR L12] with monitored
pneumatic valve ismanual
closed.reset. valve. If one or both solenoids of the safety valve are energized,
The DI safety relay Logic is set to 2: [(IN1 AND IN2) OR L12] with the Status contact will be open, and the DI will not energize its
Operating
monitored Principle
manual reset. outputs. If both solenoids are de-energized, the Status contact
STARTING: Press the reset button to energize the output contacts of the safety relay. Theclosed
will be two solenoids
and the in DI
theReset
valve energize and allow air
button energizes to flow
the DI safety
from the AirPrinciple
Operating Supply to the Air Outlet.
outputs and opens the safety valve.
STOPPING: Pressing the e-stop button or blocking the light curtain de-energizes the safety outputs of the DI, which in turn drops out the solenoids
STARTING: Press
of the safety the
valve. Thereset
valvebutton to energize
closes the Air Supply theand output contacts
releases the air pressure to thesafety
Air Exhaust.
The valve Releasing
performsthe itse-stop button orchecks.
own internal clearing the
If one of the
oflight
the curtain
safety does
relay.not
The twothe
cause solenoids in the
valve to turn back valve
on. energize and
valves remains actuated, gets stuck or moves too slowly, the Air
allow air to flow from the Air Supply to the Air Outlet.
Outlet ow will be re-directed to the exhaust. To clear the fault
Fault Detection
STOPPING: Pressing the e-stop button or blocking the light
Upon successful completion of internal checks on power up, the DI checks the e-stop condition, both
and light valves
curtain must
status. If anbe deenergized
open andis the valve reset
or short circuit
curtain de-energizes
detected, the DI will not the safetyitsoutputs
energize outputs.ofIf the
bothDI, which
input are closed, thebutton
in turn
circuits pressed.
DI checks the status of the safety valve. If one or both solenoids
drops
of theout thevalve
safety solenoids of the the
are energized, safety valve.
Status Thewill
contact valve closes
be open, and the DI will not energize its outputs. If both solenoids are de-energized, the
Status contact will Ratings
the Air Supply andbereleases
closed and
thethe
airDIpressure
Reset button energizes
to the the DI safety outputs
Air Exhaust. and opens the safety valve.
Releasing the e-stop button or clearing the light curtain does not This safety function initiated by the 800F e-stop and the
The safety valve performs its own internal checks. If one of the valves remains actuated, gets stuck
GuardShield or curtain
light moves too slowly,
meets thesafety
the Air Outlet flow will be
performance
cause the valve
re-directed toexhaust.
to the turn back on. the fault condition, both valves must be deenergized
To clear and the valve reset button pressed.
requirements of SIL CL 3 per IEC 62061:2005 and has a Category
Fault Detection 4 structure that can be used in systems requiring Performance
Ratings
Upon successful
This safety completion
function initiated by of
theinternal checks
800F e-stop on GuardShield
and the power up, the Levels
light curtain meetsuptheto PLeperformance
safety per ISO13849-1:2006.
requirementsThis example
of SIL circuit
CL 3 per IEC
DI62061:2005
checks theand e-stop and light4 curtain
has a Category structurestatus.
that canIfbeanused
open or shortrequiringperforms
in systems Performance a Stop
LevelsCategory
up to PLe 0perfunction (coast toThis
ISO13849-1:2006. stop).
example circuit performs a Stop Category 0 function (coast to stop).

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DI with SensaGuard Integrated Latch and 525 Drive
SensaGuard Integrated Latch, E-Stop,DI
DI,with
and SensaGuard
PowerFlex 525:Integrated Latch and 525 Drive
SensaGuard Integrated Latch, E-Stop, DI, and PowerFlex 525
24V DC
Yellow
Brown
Red
Reset
L1 L2 L3
PowerFlex R S T
White
SensaGuard Integrated Latch 525
Grey
Blue
Pink
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
Circuit Status
The DI 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
Circuit Status
and S22). Fault Detection
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.
The DI Logic is set to 2: [(IN1 AND IN2) OR L12] with monitored Upon successful completion of internal checks by the DI,
reset. The SensaGuard
Operating PrincipleLight Latch interlock is connected to input SensaGuard and PowerFlex 525 drive, the drive awaits the closure
1 ofSTARTING:
the DI (S12Press the Reset button to turn on the DI safety outputs. This enablesofthe
and S22). The e-stop is connected to input 2 of the the safety
drive and outputs.
also applies power to the Start and Stop buttons.
DI (S32
Press and S42).
the Start The gate,
buttons monitored
to start the motor.by the SensaGuard Light
If the DI fails, the drive will not energize the motor, and the
Latch, is closed
STOPPING: Pressand
thethe
Stope-stop
buttonistoreleased. The DI
stop the motor forsafety outputs
production stops. Press the e-stop or open the safety gate to initiate a safety stop; the
fault will be detected by non-operation of the motor. The DI
aremotor coasts
off. The to a stop.525 drive is powered but disabled. The
PowerFlex
generates test pulses through the E-stop circuits to detect cross
motor is off.
Fault Detection channel shorts and shorts to power and ground. The SensaGuard
Operating Principle
Upon successful generates
completion of internal checks by the DI, SensaGuard and PowerFlex testthe
525 drive, pulses
drive on its outputs
awaits toofdetect
the closure cross
the safety channel shorts
outputs.
If the DI fails, the drive will not energize the motor, and the fault will be detected
andby non-operation
shorts to of the
power motor.
and The DI
ground. A generates
fault in testsafe-circuit
the pulses of the
STARTING: Press the Reset button to turn on the DI safety outputs.
through the E-stop circuits to detect cross channel shorts and shorts to power and ground. The SensaGuard generates test pulses on its outputs
This enables the drive and also applies power to the Start and drive will be detected by the drive and issue a safety stop.
to detect cross channel shorts and shorts to power and ground. A fault in the safe-circuit of the drive will be detected by the drive and issue a
Stop buttons.
safety stop. Press the Start buttons to start the motor. Ratings
STOPPING: Press the Stop button to stop the motor for production The safety functions initiated by the SensaGuard Integrated Latch
Ratings
The safety functions initiated by the SensaGuard Integrated Latch and and
stops. Press the e-stop or open the safety gate to initiate a safety the e-stop
the e-stop meetsmeets the safety
the safety performance
performance requirements
requirements of of SIL
stop; the motor coasts to a stop. CL2 per IEC 62061:2005 and category 3 structure that
SIL CL2 per IEC 62061:2005 and category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISOcan be used
13849-1: 2006. The circuit executes a Category 0 stop. in systems requiring Performance Levels up to PLd per ISO 13849-
1: 2006. The circuit executes a Category 0 stop.

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DI and EMD with Enabling Jog System Safeguarding Applications and Wiring Diagrams
DI and EMD with Enabling Jog System
440G-MT, Enabling GripSwitch, DI, EMD, PowerFlex DriveGuard:
440G-MT, Enabling GripSwitch, DI, EMD, PowerFlex DriveGuard
24V DC
GripSwitch
440J N21TMPM-NP
Jog Button
5 6 L1 L2 L3
Machine Grip
Controlled Lever PowerFlex 70 R S T
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
1 Stop Power Supply
RANGE 1 TIME 2
0 9 2
10 3
LOGIC 1 8
4
3 9 4
11 12 11 12 2
7
6 5 8
7 6
5
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
Circuit Status
The 440J Enabling Switch is held by two MT-GD2 interlocks. The DI safety outputs are closed. The PowerFlex Enable and Safe-off option are
Circuit StatusThe EMD safety outputs are de-energized. The DI Logic is set to 5: [(IN1
energized. STOPPING: The
OR IN2) OR jogwith
L12] function stops
automatic after
reset. Thethe
EMDset timeswitch
Range expires. To
The 440J Enabling Switch is held by two MT-GD2 interlocks. The
is set to 8 (Jog 10s) and the Time is set to 2 (20%), therefore the Jog will occur restart,
for 2s. momentarily
The motor is ready release
to run. the jog button and then re-close it to
DI safety outputs are closed. The PowerFlex Enable and Safe-o repeat the jog.
Operating
option Principle
are energized. The EMD safety outputs are de-energized. Releasing or squeezing the 3-position GripSwitch opens the
The EMD is chosen for its ability to perform timing functions. In this case, the EMD is set up to jog the PowerFlex drive with a single pulse having a
The DI Logic is set to 5: [(IN1 OR IN2) OR L12] with automatic reset. outputs of the
duration set between 0.5 to 10 s by adjustments made by potentiometers on the EMD. While in DI
theand the PowerFlex
MT-GD2 drive executes
holder, the Enabling switch isa coast to stop.
Thedisabled,
EMD Range switch
and the drive is
canset
beto 8 (Jog 10s)
controlled by theand the Time
machine is setsystem.
control to 2 The Jog switch is disabled by the machine control system.
(20%), therefore
STARTING: the Jog
As shown, thewill occur for
PowerFlex 2s.isThe
drive motor
ready is ready
to run. to Start
Press the
Fault Detection
run. button.
JOGGING: Close the 3-position GripSwitch to close the outputs of the DI and enable Uponthe successful completion
drive. Remove of internal
the enabling checks
switch from by the DI, EMD
the MT-GD2
Operating
holder. ThePrinciple
machine control system is notified that the GripSwitch has been removed and enables the jog switch. Pressawaits
the Jogthe
button on the
and the PowerFlex drive, the drive closure of the EMD
TheGripSwitch to initiate
EMD is chosen forthe
itsoperation
ability toofperform
the EMD.timing
The EMD closes its safety outputs for the set duration. The Jog button must be held closed for
functions. safety outputs. If the DI fails, the drive will not energize the motor
the duration
In this case, the ofEMD
the jogis time.
set up to jog the PowerFlex drive with
STOPPING: The jog function stops after the set time expires. To restart, momentarily and the fault
release thewill
jogbe detected
button byre-close
and then non-operation
it to repeatofthe
the motor.
jog.
a single pulse having a duration set between 0.5 to 10 s by
Releasing or squeezing the 3-position GripSwitch opens the outputs of the DI and ThetheDIPowerFlex
uses dualdrivechannel to detect
executes a coast tofaults
stop.to power, ground and
adjustments made by potentiometers on the EMD. While in the cross channel faults on the Enabling switch or the MT-GD2. A
MT-GD2
Fault holder,
Detection the Enabling switch is disabled, and the drive can short across the jog switch will be detected and a subsequent
be Upon
controlled by the
successful machine
completion controlchecks
of internal system. by The Jog
the DI, EMDswitch
and theis PowerFlex
jogdrive, the drive
attempt willawaits the closureby
be prevented of the
the EMD
EMD.safety outputs.
A fault in theIf Safe-O
disabled by the
the DI fails, the machine
drive will notcontrol system.
energize the motor and the fault will be detected by non-operation
option of the
of the drive motor.
will The DI uses
be detected bydual
thechannel to detect
DI on the next attempt
faults to power, ground and cross channel faults on the Enabling switch or the MT-GD2. A short across the jog switch will be detected and a
STARTING:
subsequent As jog
shown,
attemptthewill
PowerFlex drive
be prevented by is ready
the EMD. to run. in
A fault Press to restart the drive. Internal faults in the DI will
the option of the drive will be detected by the DI on the next attempt
the Safe-Off
result in non-
to
Start button.
restart the drive. Internal faults in the DI will result in non-opeation of the motor. opeation
Internal of theofmotor.
faults Internal
the DI will faults
result in of the DI of
non-operation will
theresult
jog in non-
function. operation of the jog function.
JOGGING: Close the 3-position GripSwitch to close the outputs
of the DI and enable the drive. Remove the enabling switch from Ratings
Ratings
theThe
MT-GD2 holder. initiated
safety function The machine control system
by the GripSwitch meets is notied
the The safety function
that the requirements
safety performance initiated
of SIL CL2 per by the GripSwitch
IEC 62061:2005 meets
and has Category 3 the safety
structure that
GripSwitch has can be removed
been used in systems requiring the
and enables Performance Levels
jog switch. up to PLd per
Press ISO 13849-1: requirements
performance 2006. The circuitof
executes a Category
SIL CL2 0 stop.
per IEC 62061:2005 and
the Jog button on the GripSwitch to initiate the operation of the has Category 3 structure that can be used in systems requiring
EMD. The EMD closes its safety outputs for the set duration. The Performance Levels up to PLd per ISO 13849-1: 2006. The circuit
Jog button must be held closed for the duration of the jog time. executes a Category 0 stop.

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Guardlocking with DI and EMD Safeguarding Applications and Wiring Diagrams
800F, TLS1-GD2, Trojan T15-GD2, DI, EMD, 700S:

Guardlocking with DI and EMD
800F, TLS1-GD2, Trojan T15-GD2, DI, EMD, 700S
+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
3
10
4
2 8
7 4
9
8 5
A1 34 8 3 6 5 7 6
4
DI 7
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 700S-CFB440EJC
700S-CFB440EJC
24V DC Com
Circuit Status T15. The e-stop has a self-monitoring contacts, which open if the
Circuit Status
The The
e-stop is reset
e-stop is reset and
andthe
thesafety
safety gate
gate isisclosed
closed and
and locked.
locked. outputs of thecontact
TheThe block
safety relays arefalls
open,o the
andcontrol
the motorspanel. WithThe
are off. the e-stop signals
rotary
switches
outputs of the
of the EMDrelays
safety deviceare
have the delay
open, and time set to 18are
the motors o. The(Range 3: “30made,
seconds seconds theOFFDI delay”,
checksTime the6:K1, K2,ofK3,
“60% K4 and
range”). TLS1
The EMDmonitoring
will open circuit
its switches
rotary contacts 18ofseconds
the EMD after the signal
device havefromthethe
delayDI L11
timeoutput turns
set to 18 off. when the reset button is pressed. If these checks are OK, the output
seconds (Range 3: “30 seconds OFF delay”, Time 6: “60% of range”). energizes. The Reset Button is linked to the delayed Y32 output in
Operating Principle
The EMD will open its contacts 18 seconds after the signal from the order to supply +24V for reset only when delay time has lapsed. If
STARTING: Press the Reset button to energize the outputs of the DI. The outputs anyofof the DI DI
the energize
contactsthe K1 and to
faults K2 the
control
ONrelays
state,and
themotor
motor M1is stopped
DI L11 output turns off.
starts. At the same time, the DI sends a signal via L11 to the EMD. The outputs of the EMD energize the K3 and K4 control relays and motor M2
starts.
by the redundant outputs. The fault will be detected by the Y32,
Operating Principle K1,coasts
K2, K3,toK4 andAfter
TLS1
STOPPING: When the e-stop is pressed, the outputs of the DI open and motor M1 stop. themonitoring
time delay ofcircuit
the EMD onexpires,
the next attempt to
motor
STARTING:
M2 coasts Press
to athe stopReset button
and the to energize
Y32 output energizes.theThe
outputs of be
gate can theunlocked by re-start.
pressing If the GateRelease
the Gate is not interlocked
button. Press bythethe
GateTLS1 solenoid
Release buttonor one of
to power
DI. The outputsthe ofsolenoid
the DIand open the
energize the Gate.
K1 andClosing the Gaterelays
K2 control or resetting
and the e-stop does not
the 700S re-energise
control relays the 700S
faults tocontrol
the ONrelays.
state, the DI will detect the
motor M1 starts. At the same time, the DI sends a signal via L11 to fault in the Y32, K1, K2, K3, K4 and TLS1 monitoring circuit on the
FaultThe
the EMD. Detection
outputs of the EMD energize the K3 and K4 control next attempt to reset. An additional interlock (Trojan T15) is added
Upon power-up, the DI and EMD perform internal checks. The DI then looks for signals from the e-stop and the TLS1 GD2 and Trojan T15. The
relays and motor M2 starts. to the gate to to prevent potential single point failures related to
e-stop has a self-monitoring contacts, which open if the contact block falls off the control panel. With the e-stop signals made, the DI checks the
K1, K2, K3,
STOPPING: K4 and
When theTLS1 monitoring
e-stop circuit
is pressed, the when the reset
outputs button
of the is pressed. Iftongue
DI open
styleare
these checks interlocks.
OK, the output energizes. The Reset Button is
linked to the delayed Y32 output in order to supply +24V for reset only when delay time has lapsed. If any of the DI contacts faults to the ON
and state,
motor M1 coasts to stop. After the time delay of the EMD Ratings
the motor is stopped by the redundant outputs. The fault will be detected by the Y32, K1, K2, K3, K4 and TLS1 monitoring circuit on the
expires,
nextmotor
attemptM2 coasts to
to re-start. a stop
If the Gateand the
is not Y32 output
interlocked energizes.
by the TLS1 solenoid or The
one of safety function
the 700S controlinitiated by the
relays faults gate
to the ON interlocks
state, the DIand
will the e-stop
The detect
gate can the be
fault unlocked
in the Y32,by K1,pressing
K2, K3, K4the
andGate
TLS1Release
monitoringbutton.
circuit on the next
meetsattempt
the to reset.performance
safety An additional interlock (Trojanof
requirements T15)
SILisCL3
added per IEC
Presstothe
the Gate
gate to Release button
to prevent to power
potential single the
pointsolenoid and open
failures related the style62061:2005
to tongue interlocks. and has a Category 4 structure that can be used in
Gate. Closing the Gate or resetting the e-stop does not re-energise systems requiring Performance Levels up to PLe per ISO13849-
Ratings
the 700S control relays. 1:2006. This circuit executes Category 0 stops.performance
The safety function initiated by the gate interlocks and the e-stop meets the safety performance requirements of SIL CL3 per IEC 62061:2005 and
Faulthas a Category 4 structure that can be used in systems requiring Performance requirements
Detection Levels up to PLeof perSIL CL2 per IEC 62061:2005
ISO13849-1:2006. and has Category
This circuit executes
Category 0 stops. 3 structure that can be used in systems requiring Performance
Upon power-up, the DI and EMD perform internal checks. The DI
Levels up to PLd per ISO 13849-1: 2006. The circuit executes a
then looks for signals from the e-stop and the TLS1 GD2 and Trojan
Category 0 stop.

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Interlock Switch with Enabling Device – Guard Locking with Time Delay
Safety Applications and Wiring Diagrams
Interlock Switch with Enabling Device—Guard Locking with Time Delay
GripSwitch, MT-GD2, 400G-MT, 800F, DI, EMD, 100S:
GripSwitch, MT-GD2, 400G-MT, 800F, DI, EMD, 100S
24V DC
Guardlocking Interlock GripSwitch K1
440G-MT47045 440J-N21TNPM-NP Start
MT-GD2 440J-A04N MT-GD2 800FM-F3MX10
Primary Latch Release 440T-MT55076 K2
Safeguard
A B
Reset
800FM-F6MX10 Stop
11 12 11 12 11 12 800FM-E4MX01
21 22 21 22 21 22
33 34 33 34 1 2 Machine control system
33 34
43 44 can replace this circuit
43 44 arrangement.
43 44 3 4
GripSwitch
Jog Button
E-Stop L1 L2 L3
800FM-MT64 S11 S21 S22 S12 A1 13 23 S34 B1 B2 X32 A1 17 27 37 47
800F-X02S 0 RANGE 0 1 TIME 1
2 K1
LOGIC 1
9 2 10 3
2 8 3 9 4 Mirror
Lock Release 8 3 7 6 54 8 5
7 4 7 6 Contacts
800FM- DI 6 5 EMD K2
F2MX10 440R-D22R2 440R-EM4R2D
S32 S42 L11 L12 A2 14 24 Y32 L12 L11 A2 18 28 38 48
M
K1 K2 100S-D1405ZJ33LC
24V Com
Circuit Status
Circuit Status and closes its safety outputs and the motor is ready to run. Press the
The 440J GripSwitch is held by two MT-GD2 tongue interlocks by its mounting plate accessories. The safety gate is closed and the 440G-MT guard
The 440Jlocking
GripSwitch isisheld
interlock byThe
locked. twoDIMT-GD2 tongue
and EMD safety are open. Contactorsjog
interlocks
outputs button
K1 and K2 areon the GripSwitch
de-energized. The EMDto momentarily turn
Range switch is set to 8on the motor.
(Jog
10s) and the
by its mounting Time
plate is set to 2 (20%),
accessories. Thetherefore
safety the Jogiswill
gate occur and
closed for 2s. The motor is off and the application ready to run.
STOPPING DURING ENABLING: Release the jog switch to stop the
the 440G-MT guard locking interlock is locked. The DI and EMD motor. Releasing or applying further pressure to the trigger switch
Operating
safety outputs Principle
are open. Contactors K1 and K2 are de-energized.
The GripSwitch enabling device is used to access the hazardous area while the motor on theis running.
GripSwitch will stop
The access thefull
is of the motor.
body type. With the safety
The EMDgateRange switch
unlocked, theisoperator
set to 8 (Joginto
walks 10s)theand the Time
hazardous is set
area with thetoGripSwitch.
2 Before accessing the hazard area, the motor must be stopped.
(20%), therefore the the
After entering Joghazard
will occur formotor
area, the 2s. Thecan motor is offwith
be restarted and thethe Fault Detection
GripSwitch. One MT-GD2 interlock is used to bypass the gate interlock safety
circuit.
application The other
ready to run.MT-GD2 is used to reset the safety system and prevent the starting Uponofsuccessful
the motor from outside the of
completion cell,internal
when thechecks
GripSwitch
on ispower-up, DI
used.
checks the e-stop, gate and GripSwitch circuit. If the circuits are
Operating Principle
STOPPING: Press the Safety Stop. The immediate outputs of the DI open and the motor initiates a coast to stop. After the time expires on the EMD,
the delayed outputs change state. The EMD outputs close and the safety gate can closed, the DIPress
be unlocked. checks therelease
the lock reset circuit.
button toUpon closure of the reset
momentarily
The GripSwitch
power the enabling
solenoid ofdevice is used
the 440G-MT and toopen
access the hazardous
the gate. button, the DI checks the status of the contactors. Due to the size
area while the motor
STARTING: is running.
Remove Theswitch
the enabling access fromis of
thethe full body
MT-GD2 holders. Squeeze theof GripSwitch
the 100S-D trigger to the middle
contactors, position. The
mirrored DI resets
contacts andeither
(on closes side of
its the
type. With safety outputs
safety andunlocked,
gate the motor is the
readyoperator
to run. Press the jog
walks intobutton
the on the GripSwitch to momentarily turn on the motor.
the unit) are used to safely reect
STOPPING DURING ENABLING: Release the jog switch to stop the motor. Releasing or applying further pressure to the trigger switch on the the staus of the armature. If all
hazardous area with the GripSwitch. Before accessing the hazard
GripSwitch will stop the motor. mirrored contacts are closed, then the DI energizes its outputs. If
area, the motor must be stopped. one contactor welds in the closed state, the second contactor will
Fault Detection
After entering the hazard area, the motor can be restarted with shut o the motor and the fault will be detected by the DI, upon the
Upon successful completion of internal checks on power-up, DI checks the e-stop, next gate and GripSwitch
attempt to startcircuit. If the circuits
the motor. are channel
Single closed, thefaults
DI on the input
the GripSwitch. One MT-GD2 interlock is used to bypass the gate
checks the reset circuit. Upon closure of the reset button, the DI checks the status of the contactors. Due to the size of the 100S-D contactors,
interlockmirrored
safety circuit.
contactsThe otherside
(on either MT-GD2 is used
of the unit) to reset
are used the
to safely the staus of the armature. If all mirrored contacts are closed, then the will
safety
reflect devices (GripSwitch, Interlocks and Stop switch) DI be detected by
system and prevent
energizes the starting
its outputs. of the motor
If one contactor welds infrom outside
the closed state,the
the cell, the DIwill
second contactor either onthe
shut off or motor
before and a the
demand
fault willisbe
placed onbythe
detected thesafety system
upon the next attempt to start the motor. Single channel faults on the input(depending on the natureand of the
Stop fault).
when theDI,GripSwitch is used. devices (GripSwitch, Interlocks switch) will be detected
by the DI either on or before a demand is placed on the safety system (depending on the nature of the fault).
STOPPING: Press the Safety Stop. The immediate outputs of the DI Ratings
open andRatings
the motor initiates a coast to stop. After the time expires The safety function initiated by the MT-GD2 guard locking
The safety function initiated by the MT-GD2 guard locking interlock and the GripSwitch button meets the safety performance requirements of SIL
on the EMD, theIEC62061:2005
CL 2 per delayed outputsand haschange
Categorystate. The that
3 structure EMDcan
outputs interlock
be used in systems requiringand the GripSwitch
Performance button
Levels up to PLd permeets the safety
ISO 13849-1: 2006. performance
close andThis
theexample
safetycircuit
gate performs
can be unlocked. Press
a Stop Category the lock release
0 function. requirements of SIL CL 2 per IEC62061:2005 and has Category 3
button to momentarily power the solenoid of the 440G-MT and structure that can be used in systems requiring Performance Levels
open the gate. - 21 - up to PLd per ISO 13849-1: 2006. This example circuit performs a
Stop Category 0 function.Levels up to PLd per ISO 13849-1: 2006. R
STARTING: Remove the enabling switch from the MT-GD2 holders.

The circuit executes a Category 0 stop.
Squeeze the GripSwitch trigger to the middle position. The DI resets

Global E-Stop and Zone Control Safeguarding Applications and Wiring Diagrams
GuardShield, SensaGuard, MatGuard, 800F, DI,100S: Global E-Stop and Zone Control
GuardShield, SensaGuard, MatGuard, 800F, DI,100S
+24VDC
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
Circuit Status
Circuit
The Status prevent
light curtains are unobstructed. The safety gate is closed. The e-stops are reset, andenergization
the safety mator will de-energize
is unoccupied. the respective
The outputs of all threeoutputs.
DI
relays are off. K1-K6 are ready to be energized.
The light curtains are unobstructed. The safety gate is closed. The If one of the 100S or 700S output devices (K1-K6) is stuck in an
e-stops are reset, and the safety mat is unoccupied. The outputs of actuated state, the respective DI will prevent startup because the
Operating Principle S34 feedback loop will remain open.
all three DI relays are off. K1-K6 are ready to be energized.
The DI is chosen as the safety relay for its zoning capability. The two e-stops operate globally - turning off relays 1, 2 and 3.
STARTING:
Operating Press the reset button for relay 1 to energize its outputs. Then pressRatings
Principle the reset button for relays 2 and 3 to energize their respective
outputs.
The STOPPING:
DI is chosen as the safety
Obstructing relay
the light for its
curtain zoning
A or capability.
stepping The two
on the safety
The safety functions initiated by the input devices, except the
mat turns off the outputs of relay 2 while leaving the outputs of relay 1 and
e-stops operate globally - turning o relays 1, 2 and 3.
relay 3 energized. Obstructing the light curtain B or opening the safety gate safety
with the mat, meet the
SensaGuard safetyturns
interlock performance requirements
off the outputs of SIL
to relay 3 while
leaving the outptus of relay 1 and relay 2 energized. . Pressing either e-stop shutsCL3 per
down IEC
all62061:2005
three relays. and have Category 4 structures that can
STARTING: Press the reset button for relay 1 to energize its outputs. be used in systems requiring Performance Levels up to PLe per
Then pressDetection
Fault the reset button for relays 2 and 3 to energize their ISO13849-1:2006. The safety function initiated by the safety mat
respective outputs.completion of internal checks on power up, the DI relays check
Upon successful their input
meets circuits.
the safety Shorts from the
performance inputs to power,
requirements ground
of SIL or IEC
CL2 per
other inputs will be detected immediately and will prevent energization or will de-energize the respective outputs. If one of the 100S or 700S
STOPPING: Obstructing 62061:2005 and has a Category 3 structure that can be used in
output devices (K1-K6) the light
is stuck in curtain A orstate,
an actuated stepping on the safety
the respective DI will prevent startup because the S34 feedback loop will remain open.
mat turns o the outputs of relay 2 while leaving the outputs of relay systems requiring Performance Levels up to PLd per ISO13849-
Ratings
1 and relay 3 energized. Obstructing the light curtain B or opening 1:2006. This circuit executes a Category 0 stop.
The safety
the safety gatefunctions
with theinitiated by the input
SensaGuard devices,
interlock except
turns theoutputs
o the safety mat, meet the safety performance requirements of SIL CL3 per IEC 62061:2005
and have
to relay Category
3 while 4 structures
leaving that can
the outptus be used
of relay in systems
1 and relay 2requiring Performance Levels up to PLe per ISO13849-1:2006. The safety function
energized.
initiated by the safety mat meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that can be
Pressing either e-stop shuts down all three relays.
used in systems requiring Performance Levels up to PLd per ISO13849-1:2006. This circuit executes a Category 0 stop.
Fault Detection
Upon successful completion of internal checks on power up, the DI
relays check their input circuits. Shorts from the inputs to power,
ground or other inputs will be detected immediately and will

R
E-Stops for a PowerFlex 755 Drive Safeguarding Applications and Wiring Diagrams
E-Stops for a PowerFlex 755 Drive
800F, DI, PowerFlex 755: 800F, DI, PowerFlex 755
+24V DC
L1 L2 L3
E-Stop
800FM-MT44 PowerFlex
800F-MX02S 755 Series
Stop
S11 S12 S21 S22 A1 13 23 S34
Status
LOGIC 0
1 to PLC Start
2
8 3 Start/Stop Common
7 4
DI 6 5 24V DC Com
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32 Gate Control
Power Supply
SP+ Gate
Control
SE+ Circuit
SP-
SE-
Motor
24V DC Com
Circuit Status
The E-Stop
Circuit Statusis released. The safety outputs of the DI are energized. The PowerFlex 755 isDetection
Fault powered and its safety circuit is enabled. The motor is off.
The DI has a Logic setting of 5: [(IN1 OR IN2) OR L12] with automatic reset. The connections to Input 2 (S32 and S42) are ignored.
The E-Stop is released. The safety outputs of the DI are energized. Upon power-up the PowerFlex drive and DI perform internal
The PowerFlex 755 is powered and its safety circuit is enabled. The checks. The DI then looks for dual signals from the e-stop. A
Operating Principle
motor is off. The
STARTING: PressDIthe
has a Logic
start buttonsetting
or otherofequivalent
5: [(IN1 OR IN2) OR
machine L12]system (not
control crossfault
shown) to (channel
start the1motor.
to channel
Although2) of
thethe E-Stop
DI is set forwill be detected
automatic
with automatic
reset, releasingreset. The connections
the E-stop to Input
will not cause the motor2to(S32
startand S42) are
rotating. immediately. The DI is rated for Category 4 and will not lose the
ignored.
STOPPING: Normal production is stopped by the Stop switch or other equivalent safety function
machine controldue to an
system accumulation
(not of faults.
shown). The E-stop Thewill
button PowerFlex 755
initiate a safety stop. The DI removes power to the Start/Stop circuit as well as the Gate
Drive is Control
rated atCircuit.
CategoryThe motor
3, as itexecutes a Safe Torque
will perform OFF function in
the safety
Operating Principle
function and the motor coasts to a stop.
the presence of a single internal fault.
STARTING: Press the start button or other equivalent machine
Faultsystem
control Detection
(not shown) to start the motor. Although the DI Ratings
Upon
is set for power-up
automatic the PowerFlex
reset, drive the
releasing and E-stop
DI perform
willinternal
not causechecks.
theThe DI then looks
The for dual
safety signalsinitiated
function from the e-stop.
by the A crossfault
e-stop (channel
meets 1 to
the safety
channel 2) of the E-Stop will be detected immediately. The DI is rated for Category 4 and will not lose the safety function due to an accumulation of
motor to start rotating. performance requirements of SIL CL3 per IEC 62061:2005 and
faults. The PowerFlex 755 Drive is rated at Category 3, as it will perform the safety function in the presence of a single internal fault.
has a Category 3 structure that can be used in systems requiring
STOPPING: Normal production is stopped by the Stop switch or
Performance Levels up to PLe per ISO13849-1:2006. This circuit
Ratings
other equivalent machine control system (not shown). The E-stop
executes a Safe Torque OFF (Category 0) stop.
The safety function initiated by the e-stop meets the safety
button will initiate a safety stop. The DI removes power to the Start/ performance requirements of SIL CL3 per IEC 62061:2005 and has a Category 3 structure
Stopthat can be
circuit asused
wellinassystems
the Gaterequiring
ControlPerformance
Circuit. TheLevels
motorup to PLe per ISO13849-1:2006.
executes a This circuit executes a Safe Torque OFF (Category 0) stop.
Safe Torque OFF function and the motor coasts to a stop.
- 23 -
R 3-25
SafeZone Mini, E-stop and DI with Kinetix 350
SafeZone Mini, E-stop and DI with Kinetix 350
SafeZone Mini, E-stop, DI, Kinetix 350:
SafeZone Mini, E-stop, DI, Kinetix 350
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
442L-ACABL210 (Cable)
Shield
Grey
1793-IB6 1793-IV16 1793-OB4

Blue
Pink
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
Circuit Status
The Logic
Circuit setting of the DI is set to 2 - monitored manual reset with [(Input 1 AND
Status Input
Fault 2) OR L12]. The E-Stop is in the released position and is
Detection
connected to Input 2 (S32 and S42) of the DI. The area scanned by the SafeZone Mini is clear and the signals to Input 1 of the DI (S12 and S22) are
The Logic
high. Thesetting
Warning ofField
the DI is set
signal to 2 - monitored
is connected to a PLC,manual Upon
reseton an indicator
which turns andsuccessful completion
may also perform of internal
other logic. The DI checks on power
safety outputs up, the
(14 and
with
24)[(Input
are OFF.1 AND Input350
The Kinetix 2) OR
DriveL12]. The E-Stop
is powered is insafety
but the the released SafeSone
inputs are off; therefore Mini, DI,
the motor and The
is OFF. Kinetix 350Signal
Y32 Aux are prepared for operation.
is high, which informs
position
the PLCandthatisthe
connected
safety system to Input 2 (S32
is ready and S42) of the DI. The
to run. The safety outputs of the SafeZone Mini generates test pulses to
area scanned by the SafeZone Mini is clear and the signals to check for cross channel shorts and short circuit faults to power and
Input 1 of the DI
Operating (S12 and S22) are high. The Warning Field signal
Principle ground . The DI generates test pulses through the e-stop circuit to
is connected to a the
STARTING: Press PLC,Reset
which turns
button toon an indicator
energize the safetyand of the DI. Thecheck
may also
outputs for cross
Y32 status signalchannel
turns OFF.shorts and short
The Kinetix circuit
350 drive faults to The
is enabled. power and
PLC canother
perform not turn theThe
logic. motorDI ON (thisoutputs
safety circuitry (14
is not
andshown).
24) are OFF. The ground.
Kinetix 350 Drive is powered but the safety inputs are o; therefore
STOPPING: Entering the warning field of the SafeZone Mini scanner does not cause NOTE:the Dosafety
not replace
system tothe DIoff;
turn withbutthe
theDIS
PLCas theon
turns pulse
an checking
theindicator.
motor isEntering
OFF. The theY32 Aux Signal
protective field is
ofhigh, which informs
the SafeZone the PLC
Mini scanner or pressingonthe
theE-Stop causes
outputs of the
theDI safety
DIS relayan
causes toF059
turn OFF,
faultwhich
on thedisables
K350 safety
that
thethe safety
Kinetixt 350system
drive. is ready
The motor tocoasts
run. to a stop.
inputs.
Operating Principle
Fault Detection Ratings
STARTING: Press the
Upon successful Reset button
completion to energize
of internal checks onthe safety
power up,outputs
the SafeSone Mini,The DI, and Kinetix 350 areinitiated
preparedby forthe
operation. TheMini
safetyand
outputs
safety functions SafeZone the E-Stop
of of
thethe
DI.SafeZone
The Y32Mini status signal test
generates turns OFF.to
pulses The Kinetix
check 350channel
for cross drive isshorts and short circuit faults to power and ground . The DI generates test
pulses through the e-stop circuit to check for cross channel shorts and short
buttons
circuit
can
faults to
meet
power
the
and
safety
ground.
performance requirements of SIL CL 2
enabled. The PLC can not turn the motor ON (this circuitry is not
per IEC 62061:2005 and has a Category
NOTE: Do not replace the DI with the DIS as the pulse checking on the outputs of the DIS causes an F059 fault on the K350 safety inputs. 3 structure that can be used
shown).
in systems requiring Performance Level up to PLd per ISO13849-
STOPPING:
Ratings Entering the warning eld of the SafeZone Mini scanner 1:2006. This application executes a Category 0 stop
does
Thenot cause
safety the safety
functions system
initiated by thetoSafeZone
turn o; butMinithe
andPLC turns on
the E-Stop an can meet the safety performance requirements of SIL CL 2 per IEC
buttons
62061:2005 and has a Category 3 structure that can be used in systems requiring Performance Level up to PLd per ISO13849-1:2006. This
indicator. Entering the protective eld of the SafeZone Mini scanner
application executes a Category 0 stop.
or pressing the E-Stop causes the DI safety relay to turn OFF, which
disables the Kinetixt 350 drive. The motor coasts to a stop.

R
Multizone Scanner, E-Stop and DI with Safeguarding
Kinetix 350Applications and Wiring Diagrams
Multizone Scanner, E-Stop and DI with Kinetix 350
SafeZone Multizone, 800F, DI, Kinetix 350:
SafeZone Multizone, 800F, DI, Kinetix 350
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)
1769-IQ16 1769-IV16 PLC 1769-OB8 +
OSSD1 (Grey)
A2 (Blue)
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
Circuit Status
The Logic
Circuit setting of the DI is set to 2 - monitored manual reset with [(Input 1 AND
Status Input
Fault 2) OR L12]. The E-Stop is in the released position and are
Detection
connected to Input 2 (S32 and S42) of the DI. The area scanned by the SafeZone Multizone is clear and the signals to Input 1 of the DIS (S12 and
The Logic
S22) setting
are high. TheofWarning
the DI isField
set signal
to 2 - is
monitored
connectedmanualto a PLC,reset
which turns on anUpon successful
indicator and may completion
also performofother
internal
logic.checks
The DIon power
safety up,
outputs
with
(14[(Input
and 24)1are AND OFF.Input
The 2) OR L12].
Kinetix The E-Stop
350 Drive is powered is inbut
thethe safety inputs arethe
released off;SafeSone Multizone,
therefore the DIS, and
motor is OFF. Kinetix
The Y32 Aux 350 areis prepared
Signal high, whichfor
position
informsandthe are
PLC connected to Input
that the safety system2is(S32readyand S42) of the DI. The
to run. operation. The safety outputs of the SafeZone Multizone generates
area scanned by the SafeZone Multizone is clear and the signals to test pulses to check for cross channel shorts and short circuit faults
Input 1 of the DIS
Operating (S12 and S22) are high. The Warning Field signal
Principle to power and ground . The DI generates test pulses through the
is connected
The PLC sends to aa pair
PLC,ofwhich
signalsturns
(a NCon andan indicator
a NO) and mayMultizone
to the SafeZone also e-stop
to switch thecircuit
activeto check
zones for cross
between Zoneschannel
A and B.shorts and short
The OSSD outputscircuit
respond
perform to either
other logic.zone.
The DI safety outputs (14 and 24) are OFF. The faults to power and ground.
Kinetix 350 Drive is powered but the safety inputs are o; therefore
STARTING: Press the Reset button to energize the safety outputs of the DI. TheNOTE: Do not
Y32 status replace
signal the DI
turns OFF. with
The the350
Kinetix DISdrive
as the pulse checking
is enabled. The
thePLC
motor
can notis OFF.
turn The Y32 Aux
the motor ON Signal is high,
(this circuitry which
is not informs the PLC
shown). on the outputs of the DIS causes an F059 fault on the K350 safety
that the safety system is ready to run.
inputs.
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
Operating Principle
indicator. Entering the protective field of the SafeZone Multizone scanner or pressing Ratingsthe E-Stop causes the DI safety relay to turn OFF, which
The PLC sends
disables a pair 350
the Kinetixt of signals (a NC
drive. The andcoasts
motor a NO)totoa thestop.SafeZone
The safety functions initiated by the SafeZone Multizone and the
Multizone to switch the active zones between Zones A and B. The
Fault Detection E-Stop buttons can meet the safety performance requirements of
OSSD outputs respond to either zone.
Upon successful completion of internal checks on power up, the SafeSone Multizone, SIL CL DIS,
2 per IECKinetix
and 62061:2005 and has aforCategory
350 are prepared operation.3 The
structure
safety that
STARTING:
outputs ofPress the Reset
the SafeZone button generates
Multizone to energize testthe safety
pulses outputs
to check can be
for cross channel used
shorts andinshort
systems requiring
circuit Performance
faults to power and groundLevels
. TheupDIto PLd per
of generates
the DI. The Y32
test status
pulses signalthe
through turns OFF.
e-stop Theto
circuit Kinetix
check 350 drive
for cross is
channel ISO13849-1:2006.
shorts This application
and short circuit faults to power andexecutes
ground. a Category 0 stop.
NOTE: Do
enabled. The not replace
PLC the DI
can not with
turn thethemotor
DIS as ONthe pulse checking is
(this circuitry onnot
the outputs of the DIS causes an F059 fault on the K350 safety inputs.
shown).
Ratings
STOPPING:
The safetyEntering
functionsthe warning
initiated eld
by the of the SafeZone
SafeZone Multizone
Multizone and the E-Stop buttons can meet the safety performance requirements of SIL CL 2 per IEC
scanner doesand
62061:2005 nothas
cause the safety
a Category systemthat
3 structure to turn o; used
can be but the PLC requiring Performance Levels up to PLd per ISO13849-1:2006. This
in systems
turns on an indicator.
application executes aEntering
Categorythe protective eld of the SafeZone
0 stop.
Multizone scanner or pressing the E-Stop causes the DI safety relay
to turn OFF, which disables the Kinetixt 350 drive. The motor coasts
to a stop.

R
Safety Sensor, E-Stop and DI with Kinetix 350
Safety Sensor, E-Stop and DI with Kinetix 350
SC300, 800F, DI, Kinetix 350:
SC300, 800F, DI, Kinetix 350
24V DC
Teach Input Input Output +
1756-IB16 1756-IV16 1756-OB16
Brown
Green
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
Circuit Status
The Logic setting of the DI is set to 2 - monitored manual reset with [(Input 1 AND Input 2) OR L12]. The E-Stop is in the released position and is
connected to Input 2 (S32 and S42) of the DI. The area scanned by the SC300 safety sensor is clear and the signals to Input 1 of the DI (S12 and
The Logic
S22) setting
are high. TheofWarning
the DI is setsignal
Field to 2 - ismonitored
connected manual
to a PLC, reset
which turns on an Upon successful
indicator and may completion
also performofotherinternal
logic.checks
The DI on power
safety up, the
outputs
(14[(Input
with and 24) 1areANDOFF.Input
The Kinetix 350 Drive
2) OR L12]. The is powered
E-Stop is inbut
thethe safety inputs areSC300
released off; therefore
safetythe motor
sensor, DI,is and
OFF. Kinetix
The Y32350Auxare
Signal is high, for
prepared which
operation.
informsand
position the PLC that the safety
is connected system
to Input is ready
2 (S32 andtoS42)
run. of the DI. The The safety outputs of the SC300 safety sensor generates test pulses
area scanned by the SC300 safety sensor is clear and the signals to to check for cross channel shorts and short circuit faults to power
Operating
Input 1 of the DI Principle
(S12 and S22) are high. The Warning Field signal and ground . The DI generates test pulses through the e-stop circuit
STARTING: Press
is connected to athe Reset
PLC, which button
turnsto on
energize the safety
an indicator andoutputs of the DI. Theto
may also Y32 statusfor
check signal
crossturns OFF. The
channel Kinetix
shorts and350 drive
short is enabled.
circuit faultsThe
to power
PLC can not turn the motor ON (this circuitry is not shown).
perform other logic. The DI safety outputs (14 and 24) are OFF. The and ground.
Kinetix 350 Drive
STOPPING: is powered
Entering the warning butfield
theofsafety inputssafety
the SC300 are o; therefore
sensor does not cause the safety system to turn
NOTE: Do not replace theoff;
DI but
with the PLC
the turns
DIS on an
as the indicator.
pulse checking
theEntering
motor theis OFF. The Y32
protective Aux
field Signal
of the SC300is high,
safetywhich
sensor informs
or pressingthethe
PLCE-Stop causes the DI safety relay to turn OFF, which disables the Kinetixt
on the outputs of the DIS causes an F059 fault on the K350 safety
that the safety system is ready to run.
350 drive. The motor coasts to a stop.
inputs.
Operating Principle
Fault Detection Ratings
STARTING: Press the
Upon successful Reset button
completion to energize
of internal checks onthe powersafety
up, outputs
the SC300 safety sensor, DI, and Kinetix 350 are prepared for operation. The safety
The shorts
safetyandfunctions initiated
faultsby
to the SC300 safety sensor
. The DIand the
of outputs of the
the DI. The SC300
Y32 safety
status sensor
signal generates
turns OFF. The testKinetix
pulses to 350check foriscross channel
drive short circuit power and ground
generates test pulses through the e-stop circuit to check for cross channel shorts E-Stop buttons
and short circuitcan meet
faults the safety
to power performance requirements of
and ground.
enabled. The PLC can not turn the motor ON (this circuitry is not
NOTE: Do not replace the DI with the DIS as the pulse checking on the outputs of SILthe
CLDIS
2 per IEC an
causes 62061:2005
F059 fault onand thehas a Category
K350 3 structure that
safety inputs.
shown).
can be used in systems requiring Performance Levels uo to PLd per
STOPPING:
Ratings Entering the warning eld of the SC300 safety sensor ISO13849-1:2006. This application executes a Category 0 stop.
does
Thenot cause
safety the safety
functions system
initiated by theto turn safety
SC300 o; butsensor
the PLC andturns on anbuttons can meet the safety performance requirements of SIL CL 2 per IEC
the E-Stop
62061:2005
indicator. and hasthe
Entering a Category
protective 3 structure
eld of thethatSC300
can besafety
used insensor
systemsorrequiring Performance Levels uo to PLd per ISO13849-1:2006. This
application executes a Category 0 stop.
pressing the E-Stop causes the DI safety relay to turn OFF, which
disables the Kinetixt 350 drive. The motor coasts to a stop.

R
Hazardous Location Safeguarding Applications and Wiring Diagrams
Hazardous Location
T15, 800F, 897H, DIS, PowerFlex 525: T15, 800F, 897H, DIS, PowerFlex 525
+24V DC
Wiring intrinsically safe systems must be identified as such through the use of
light blue jacketing or appropriate labels. Such labels are required by NEC E-Stop
Article 504 and ANSI/ISA RP-12.6 to be placed at no more than 25 foot intervals. 800FM-MT44
Reset
When installing intrinsically safe equipment, the user should refer to all relevant 800F-MX02S L1 L2 L3
national standards and those standards set forth by the authority under
jurisdiction at the installation site. PowerFlex R S T
525
Hazardous Location Non-hazardous Location 1 Stop
U.S. Galvanic Isolator
Class I,II,III, Div 1,2 897H-G231 2 Start
European
S12 S22 S11 S21 S42 S32 A1 S34 4 Gnd
Zone 0,1,2, EExia IIB 15 4
See Entity Parameters 5 LOGIC 0
1 A1
2
for 897H for Groups 14 6 8 3
Gate control
7 4
6 5
11 3 DIS power supply
1 440R-D22S2
1492-LD4RB272 (2.7K) L11 L12 A2 34 44 14 24 Y32 Gate control
10 2
circuit
7
DIP Switch 1 2 3 4 Line S1
8 Fault
Settings 1 0 1 0 9 S2
UV W
1492-LD4RB223 (22K)
Status
15 4 To PLC
5 M
21 22 14 6
11 12 11 3
1
10 2
7
DIP Switch 1 2 3 4 8 Line
Settings 1 0 1 0 Fault
Trojan T15 9
440K-T11395
24V DC Com
Circuit
Circuit StatusStatus well as opening the gate. The tongue interlock switch should be
The DIS Logic is set to 2: [(IN1 AND IN2) OR L12] with monitored reset. The Trojan T15 is connected to input 1 of the DIS (S12 and S22) through
The the
DISGalvanic
Logic isIsolator.
set to 2: [(IN1 AND IN2) OR L12] with wired to both inputs (terminals 7 and 8) of the galvanic isolator to
The e-stop is connected to input 2 ofmonitored
the DI (S32 and S42). The gate is closed and the e-stop is released. The DIS safety
reset. The Trojan
outputs are off.T15
TheisPowerFlex
connected 525 to input
drive 1 of the
is powered butDIS (S12 and
disabled. The motor isdrive
off. both outputs (1/5 and 2/3) of the galvanic isolator. A single
S22) through the Galvanic Isolator. The e-stop is connected to fault will not cause a loss of safety function. If one output of the
inputOperating
2 of the DIPrinciple
(S32 and S42). The gate is closed and the e-stop galvanic isolator fails in the closed state, the DIS safety relay will
The galvanic
is released. The isolator limitsoutputs
DIS safety energy toaretheo.interlock switch, which
The PowerFlex considered adetect
525isdrive simple opening
apparatus of thehazardous
in the 2nd output and The
location. turnDISthe drive
safety and motor
relay
checks the
is powered butoutputs of theThe
disabled. galvanic
motor isolator o. The motor
is off.upon power-up and each time the gate/e-stop will remain o until the fault is corrected or power
is actuated.
STARTING: Press the Reset button to turn the DIS safety outputs (14, 24, 34, 44 and L11) ON.The
is cycled. ThisIsolator
enables DIP
the PF525 drive.must
switches Pressbe
theset
Start
forbutton
Line to
Fault
Operating
turn the Principle
motor ON. Detection (1) and non inverted (0) output. The 1492 resistors are
The STOPPING:
galvanic isolator limits energy to the interlock switch, which requried to detect line faults. Two isolators must be used to avoid
Normal production stopping is performed by pressing the Stop button. Opening the gate or pressing the e-stop initiates a safety stop;
is considered a simple
the motor coasts to a stop.apparatus in the hazardous location. The potential common cause failures.
DIS safety relay checks the outputs of the galvanic isolator upon
Ratings
power-up and each time the gate/e-stop is actuated.
Fault Detection
The DIP switch setting of the galvanic isolator allows for open and short circuit The safety
detection of function
the tongueinitiated by theasTrojan
interlock switch, well asT15 interlock
opening the meets
STARTING: Press the Reset button to turn the DIS safety outputs
gate. The tongue interlock switch should be wired to both inputs (terminals 7 and the8)safety performance
of the galvanic isolatorrequirements of SIL(1/5
to drive both outputs CL2andper2/3)
IECof
(14, the
24, galvanic
34, 44 and L11)AON.
isolator. This
single enables
fault will not the
causePF525 drive.
a loss of safetyPress the If one62061:2005
function. output of theand has aisolator
galvanic Category
fails in1 the
structure thatthe
closed state, canDISbe used in
Startsafety
buttonrelaytowill
turn theopening
detect motor ON.of the 2nd output and turn the drive and motorsystems requiring
off. The motor up tooff
will remain Performance
until the faultLevel PLc per
is corrected ISO13849-
or power
is cycled. The Isolator DIP switches must be set for Line Fault Detection (1) and 1:2006. non inverted (0) output.
Although the The 1492shows
circuit resistors are channel,
dual requried tothe
detect
very low
STOPPING: Normal
line faults. production
Two isolators must bestopping
used to avoidis performed by pressing
potential common cause failures.
the Stop button. Opening the gate or pressing the e-stop initiates diagnostic coverage of the Galvanic Isolator limits structure to
a safety stop; the motor coasts to a stop. Cat 1. The safety function initiated by the E-stop meets the safety
Ratings performance requirements of SIL CL2 per IEC 62061:2005 and has
The safety function initiated by the Trojan T15 interlock meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a
FaultCategory
Detection1 structure that can be used in systems requiring up to Performance Level a Category 3 structure thatAlthough
PLc per ISO13849-1:2006. can be used in systems
the circuit requiring up to
shows dual
The channel,
DIP switch setting
the very of the galvanic
low diagnostic coverage isolator allows for
of the Galvanic open
Isolator limits structure to Cat 1. The safety function initiated by the E-stop meets the
Performance Level PLd per ISO13849-1:2006. This circuit executes
and safety
shortperformance requirements
circuit detection of theoftongue
SIL CL2 per IEC 62061:2005
interlock switch, and
as has a Category 3 structure that can be used in systems requiring up to
a Category 0 stop.
Performance Level PLd per ISO13849-1:2006. This circuit executes a Category 0 stop.
- 27 -
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Hazardous Location Safeguarding Applications and Wiring Diagrams
Hazardous Location
SafedgeTM, MatGuardTM, 800F, 897H, DIS, PowerFlex 525: , MatGuard , 800F, 897H, DIS, PowerFlex 525
Safedge TM TM
+24V DC
Wiring intrinsically safe systems must be identified as such through the use of
light blue jacketing or appropriate labels. Such labels are required by NEC E-Stop
Article 504 and ANSI/ISA RP-12.6 to be placed at no more than 25 foot intervals. 800FM-MT44
Reset
When installing intrinsically safe equipment, the user should refer to all relevant 800F-MX02S L1 L2 L3
national standards and those standards set forth by the authority under
jurisdiction at the installation site. PowerFlex R S T
525
Hazardous Location
U.S. 1 Stop
Non-hazardous Location
Class I,II,III, Div 1,2 Galvanic Isolator 2 Start
European 897H-G231 B
Zone 0,1,2, EExia IIB S12 S22 S11 S21 S42 S32 A1 S34 4 Gnd
See Entity Parameters
LOGIC 0
for 897H for Groups 1
2
A1
15 4 8
7
6 5
4
3
Gate control
1492-LD4RB223 (22K) 5 DIS power supply
14 6 440R-D22S2
L11 L12 A2 34 44 14 24 Y32 Gate control
11 3 circuit
1
10 2 S1
Safedge S2
UV W
7
with cable termination DIP Switch 1 2 3 4 Line
8 Fault Status
e.g. 440F-EAAAA00300 Settings 1 0 1 0 9 To PLC
or M
MatGuard
e.g. 440F-M2030BYNN
1492-LD4RB272 (2.7K)
24V DC Com
Circuit Status
Circuit Status
The DIS Logic is set to 2: [(IN1 AND IN2) OR L12] with monitored reset. The Safedge FaultorDetection
MatGuard is connected to input 1 of the DIS (S12 and S22)
through
The the Galvanic
DIS Logic is set toIsolator.
2: [(IN1The
ANDe-stop
IN2)isORconnected
L12] withto input 2 of the DI (S32The
monitored and DIP
S42).switch
The gate is closed
setting and galvanic
of the the e-stopisolator
is released. The DIS
allows for open
safety outputs are off. The PowerFlex 525 drive is powered but disabled. The motor is off.
reset. The Safedge or MatGuard is connected to input 1 of the and short circuit detection of the Safedge or MatGuard. The
DIS (S12 and S22) through the Galvanic Isolator. The e-stop is 897H-G231 has a Hardware fault tolerance of zero. A single fault
Operating Principle
connected to input 2 of the DI (S32 and S42). The gate is closed can lead to the loss of the safety function. The motor will remain
The galvanic isolator limits energy to the Safedge or MatGuard, which is considered a simple apparatus in the hazardous location. The DIS safety
and thechecks
relay e-stop theisoutputs
released. Thegalvanic
of the DIS safety outputs
isolator are o. Theand each timeothe
upon power-up until the faultisisactuated.
gate/e-stop corrected or power is cycled. The Isolator DIP
PowerFlex
STARTING:525 drive
Press is powered
the Reset button tobut
turndisabled. The motor
the DIS safety outputsis(14, switches
off.24, 34, 44 and L11) ON.must
Thisbe set for
enables theLine Fault
PF525 Detection
drive. Press the (1) and
Start nontoinverted
button
turn the motor ON. (0) output. The 1492 resistors are requried to detect line faults.
Operating Principle
STOPPING:
The galvanicNormal
isolator production stopping
limits energy is performed
to the Safedgeby orpressing Ratings
the Stop button.
MatGuard, Depressing the Safedge, stepping on the MatGuard or pressing
the e-stop
which initiates a a
is considered safety stop;
simple the motor in
apparatus coasts
the to a stop.
hazardous location. The safety function initiated by the Safedge and MatGuard
The DIS safety relay checks the outputs of the galvanic isolator meets the safety performance requirements of SIL CL2 per IEC
Fault
upon Detection
power-up and each time the gate/e-stop is actuated. 62061:2005 and has a Category 1 structure that can be used in
The DIP switch setting of the galvanic isolator allows for open and short circuit detection of the Safedge or MatGuard. The 897H-G231 has a
Hardware fault tolerance of zero. A single fault can lead to the loss of the systems
safety function.requiring
The motorup willtoremain
Performance Level
off until the faultPLc, per ISOor13849-
is corrected
STARTING: Press the Reset button to turn the DIS safety outputs
power is cycled. The Isolator DIP switches must be set for Line Fault Detection 1:2006. Theinverted
(1) and non safety (0)
function
output.initiated
The 1492by the e-stop
resistors meetstothe
are requried
(14, 24, 34, 44 and L11) ON. This enables the PF525 drive. Press the
detect line faults. safety performance requirements of SIL CL2 per IEC 62061:2005
Start button to turn the motor ON.
and has a Category 3 structure that can be used in systems
Ratings Normal production stopping is performed by pressing
STOPPING: requiring up to Performance Level PLd, per ISO 13849-1:2006. This
theThe safety
Stop function
button. initiated bythe
Depressing the Safedge,
Safedge and MatGuard
stepping onmeets
the the safety performance requirements
circuit executes of SIL CL2
a Category per IEC 62061:2005 and has a
0 stop.
Category 1 structure that can be used in systems requiring up to Performance Level PLc, per ISO 13849-1:2006. The safety function initiated by the
MatGuard or pressing the e-stop initiates a safety stop; the motor
e-stop meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that can be used in systems
coasts to a up
requiring stop.
to Performance Level PLd, per ISO 13849-1:2006. This circuit executes a Category 0 stop.

R
PowerFlex Drive - Multiple Gate AccessSafeguarding Applications and Wiring Diagrams
Trojan 5 GD2, MT-GD2, DIS, PowerFlex 70: PowerFlex Drive - Multiple Gate Access
Trojan 5 GD2, MT-GD2, DIS, PowerFlex 70
+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
DIS 6 5 3
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

OneCircuit
of theStatus
gates is open. The safety outputs of the DIS are de- Upon power-up the PowerFlex drive and DIS perform internal
One of the gates is open. The safety outputs of the DIS are de-energized. The PowerFlex with DriveGuard is de-energized and not enabled. The
energized. The PowerFlex with DriveGuard is de-energized and checks. The DIS then looks for dual signals from the gate
motor is off. The DIS has a Logic setting of 6: [(IN1 AND IN2) OR L12] with automatic reset.
not enabled. The motor is o. The DIS has a Logic setting of 6: [(IN1 interlocks. With the gates closed, the DIS checks the wiring of the
AND IN2) OR L12]
Operating with automatic reset.
Principle drive Safe-O option. If closed, then the DIS energizes its outputs
STARTING: When the last gate closes, the safety outputs of the DIS close and apply andpower
the motor
to the can
Drivebe started.
Enable A single
circuit, Safe-Offopen circuit
option, Start fault
and at the
Operating Principle
Stop buttons. Pressing the Start and Stop buttons turns the motor on and off. The gate interlocks
motor will be
is controlled by detected
parametersimmediately, and the motor
set within the PowerFlex
STARTING:
drive. When the last gate closes, the safety outputs of the DIS will coast to a stop. A crossfault (channel 1 to channel 2) at the
close and apply
STOPPING: power
Opening anytoof the Drive doors
the guard Enable circuit,
causes the Safe-O option,
DIS safety outputs to de-energize. This removes
gate interlocks will bepower to theimmediately.
detected PowerFlex Enable,
TheSafe-Off,
DIS is rated
Start,
Start and and Stopbuttons.
Stop circuits. The motor performs
Pressing the Starta and
coastStop
to stop.
buttons turns for Category 4 and will not lose the safety function due to an
the motor on and o. The motor is controlled by parameters set accumulation of faults. The PowerFlex 70 DriveGuard is rated at
Faultthe
within Detection
PowerFlex drive.
Upon power-up the PowerFlex drive and DIS perform internal checks. The DIS then Category 3, dual
looks for as it signals
will perform
from thethe
gatesafety function
interlocks. With in
thethe presence
gates
closed, theOpening
STOPPING: DIS checksany
theof
wiring of the drive
the guard doorsSafe-Off
causes option. safetythen theofDIS
If closed,
the DIS a single internal
energizes fault.and the motor can be started. A single
its outputs
open circuit
outputs fault at the gate
to de-energize. Thisinterlocks
removeswill be detected
power to the immediately,
PowerFlex and the motor will coast to a stop. A crossfault (channel 1 to channel 2) at
the gate interlocks will be detected immediately. The DIS is rated for Category Ratings
4 and will not lose the safety function due to an accumulation of
Enable, Safe-O, Start, and Stop circuits. The motor performs a
faults. The PowerFlex 70 DriveGuard is rated at Category 3, as it will perform theThe safety
safety function
function in the initiated byathe
presence of gate
single interlocks
internal fault. meets the
coast to stop.
safety performance requirements of SIL CL2 per IEC 62061:2005
Ratings and has a Category 3 structure that can be used in systems
The safety function initiated by the gate interlocks meets the safety performance requirements
requiring of SIL CL2 Levels
Performance per IEC up
62061:2005
to PLd perandISO138429-1:2006.
has a Category 3
structure that can be used in systems requiring Performance Levels up to PLd per ISO138429-1:2006. This circuit executes a Category 0 stop.
This circuit executes a Category 0 stop.

- 29 -
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Multiple PowerFlex Drives Safeguarding Applications and Wiring Diagrams
Multiple PowerFlex Drives
Trojan 5 GD2, DIS, PowerFlex 70 with DriveGuard: Trojan 5 GD2, DIS, PowerFlex 70 with DriveGuard
+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
Circuit Status
Circuit
TheStatus
safety gate is open. The DIS safety outputs (14, 24, 34, and 44) are off The Enable STOPPING: Normal
and Safe-Off stopping
Option on bothisPowerFlex
performed byare
drives theoff.PLC. If the gate is
Auxiliary signals from the Trojan 5 GD2 (33/34) and
The safety gate is open. The DIS safety outputs (14, 24, 34, and 44)the DIS (Y32) inform the PLC opened,
that the the
safetyinput
systemsignals
is OFF. to
The the DIS
motors open.
of both The
drives DIS
are opens
off. its safety
The Logic setting of the DIS is set to 5: [(IN1 OR IN2) OR L12] with automatic reset. outputs which disable all the drives connected to them via the
are off The Enable and Safe-O Option on both PowerFlex drives
are off.
ThisAuxiliary signals to
circuit is intended from
show the Trojan
that 5 GD2
multiple drives(33/34) and the DIS
can be connected
Safe-O option. The drives perform an immediate coast to stop.
in parallel. The number of drives that can be connected in parallel is
(Y32)dependent
inform the on:PLC that(the
the load thesafe-off
safetyoption
system is the
plus OFF. The motors
enable of appropriate
of each drive), de-rating to prevent early wearout of the DIS solid state
Fault Detection
bothoutputs, the application
drives are off. The Logicrequirements
setting (e.g., zoning)
of the DIS isand setthetorisk assessment
5: [(IN1 OR (e.g., some drives may require separate safety systems).
Upon power-up, the DIS performs internal checks. The DIS then
IN2) OR L12] with automatic reset.
Operating Principle looks for dual signals from the Trojan5-GD2. If only one signal is
This STARTING:
circuit is intended
Upon closing to the
show gate,that
the multiple
Trojan 5 GD2drives
closescan present,
the safety inputs of the DIS (S32or a crossfault
and exists,
S42) and opens the the DIS
signal assumes
to the PLC. Thea fault
safetyis present
outputs of the
be connected DIS close and
in parallel. Theenable
number bothofPowerFlex
drives thatdrives.canThebeauxiliary signaland
of thedoes
DIS opens. The PLC compares
not energize its safetythe gate andWith
outputs. safetythe
relay aux closed, the
gate
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
connected in parallel is dependent on: the load (the safe-o option DIS checks the S34 monitoring circuit.
DeviceNet network. The PLC must ensure that the drives are not started upon the closing of the gate; a separate, intentional action must initiate
If the Safe-O options are
plus the
themotor
enable of each(this
movement drive),
is notappropriate
shown in the de-rating
diagram). to prevent de-energized, the DIS assumes the drives are off and are ready to
earlySTOPPING:
wearout Normal
of the stopping
DIS solidisstate outputs,
performed by thethe If the gate is opened, thebe
PLC.application enabled.
input The
signals to theDIS
DIS energizes
open. The DIS itsopens
safetyitsoutputs. If the monitoring
safety outputs
which disable
requirements all the
(e.g., drives and
zoning) connected to them
the risk via the Safe-Off
assessment option. The drives
(e.g., some perform
circuit an immediate
remains coast
open, the DISto stop.
assumes a fault is present and not
drives may require separate safety systems). allow its safety outputs to energize. Single point failures related
Fault Detection to the tongue interlock are excluded if actuator speed, alignment
Operating Principle
Upon power-up, the DIS performs internal checks. The DIS then looks for dual signals from the Trojan5-GD2. If only one signal is present, or a
crossfault exists, the DIS assumes a fault is present and does not energize its safety andoutputs.
mechanical
With thestops
gatemeet
closed,installation
the DIS checks instruction
the S34 requirements,
STARTING: Upon closing the gate, the Trojan 5 GD2 closes the and a periodic proof test conrms proper
monitoring circuit. If the Safe-Off options are de-energized, the DIS assumes the drives are off and are ready to be enabled. The DIS energizes its operation.
safety inputs
safety of the
outputs. DISmonitoring
If the (S32 andcircuitS42) and opens
remains open, thethesignal to a fault is present and not allow its safety outputs to energize. Single point
DIS assumes
the PLC. The
failures safety
related to outputs
the tongue ofinterlock
the DISareclose and enable
excluded if actuatorboth
speed, alignment Ratings
and mechanical stops meet installation instruction requirements,
and a periodic proof test confirms proper operation.
PowerFlex drives. The auxiliary signal of the DIS opens. The PLC The safety function initiated by the Trojan 5-GD2 gate interlock
compares the gate and safety relay aux signals. When both signals meets the safety performance requirements of SIL CL2 per IEC
Ratings
are open, the PLC knows that the safety system is ready. The PLC 62061:2005 and has a Category 3 structure that can be used in
The safety function initiated by the Trojan 5-GD2 gate interlock meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has
can now start and control the drives over the DeviceNet network.
a Category 3 structure that can be used in systems requiring Performance Levels systems
up to PLd requiring Performance
per ISO 13849-1:2006. ThisLevels
circuit up to PLd
executes per ISO 13849-
a Category
The PLC must ensure that the drives are not started upon the
0 stop. 1:2006. This circuit executes a Category 0 stop.
closing of the gate; a separate, intentional action must initiate the
motor movement (this is not shown in the diagram).
- 30 -
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Micro 400 Light Curtain Safeguarding Applications and Wiring Diagrams
Micro 400, 800F, MSR41, DIS, 100S:

Micro 400 Light Curtain
Micro 400, 800F, MSR41, DIS, 100S
+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
Trans MSR41
6 5
K2
RJ45 DIS
440R-P221AGS 440R-D22S2
0V INFO1 INFO2 OSSD1 OSSD2 S32 S42 A2 34 44 14 24 L11
M
K1
Start
Lockout Status K2
to PLC
Safety Output Stop

Status to PLC
24V DC Com
Circuit
Circuit Status
The light curtain is clear and the e-stop is released. The MSR41 outptus are energized. The safety outputs of the DIS are OFF. The motor is off. The
The light
DIS iscurtain
ready forisreset.
clearThe
and
DISthe
hase-stop
a Logic is released.
setting TheAND
of 2: [(IN1 MSR41 Upon
IN2) OR L12] with power-up,
monitored the reset.
manual safety devices perform internal checks.
outptus are energized. The safety outputs of the DIS are OFF. The The OSSD outputs of the MSR41 are pulse tested to check for
motor is off. The Principle
Operating DIS is ready for reset. The DIS has a Logic setting crossfaults. The e-stop signals are pulse tested to check for
of 2: STARTING:
[(IN1 ANDPress IN2)the
ORreset
L12]button
with monitored
to turn the DISmanual reset. ON. Press thecrossfaults.
safety outputs Start button The mechanically
to turn the motor ON.linked contacts
The Start of theoperates
/Stop circuit 100S ensure
only K2, as a planned maintnenace feature. K1 does not switch motor currentthat on, but
theitcontactors
can switch the
aremotor current
o after off whenisaplaced
a demand demandon is placed
the safety
Operating Principle
on the safety stystem. system.
STOPPING:
STARTING: Press Normal production
the reset button stopping
to turnisthe
performed by pressing
DIS safety outputs 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.
ON. Press the Start button to turn the motor ON. The Start /Stop Ratings
circuit operates only K2, as a planned maintnenace feature. K1 The safety function meets the safety performance requirements
Fault Detection
doesUpon
not switch motor current on, but it can switch the motor
power-up, the safety devices perform internal checks. The OSSD outputs of of
SILthe
CL3 per are
MSR41 IECpulse
62061:2005
tested to and
checkhas
for acrossfaults.
CategoryThe 4 structure
e-stop that
current o when
signals a demand
are pulse tested toischeck
placed on the safety
for crossfaults. The stystem. can be
mechanically linked contacts used
of the inensure
100S systemsthatrequiring Performance
the contactors are off afterLevels
a demandup to
is PLe
placed on the safety system. per ISO13849-1:2006. This circuit executes a Category 0 stop.
STOPPING: Normal production stopping is performed by
pressing the Stop button. A safety stop can be accomplished by
Ratings
obstructing
The safety the light curtain
function meets the orsafety
by pressing the e-stop.
performance The motor
requirements of SIL CL3 per IEC 62061:2005 and has a Category 4 structure that can be used in
performs
systemsa coast to stop.
requiring Performance Levels up to PLe per ISO13849-1:2006. This circuit executes a Category 0 stop.
- 31 -
R

Micro 400 Light Curtain Safeguarding Applications and Wiring Diagrams
Micro 400, SensaGuard, 800F, MSR42, DIS, DI, 100S:

Micro 400 Light Curtain
Micro 400, SensaGuard, 800F, MSR42, DIS, DI, 100S
+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
800FM-
Brown
Green
Blue
White (Aux)
Yellow
Red
Gray (OSSD1)
Pink (OSSD2)
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
Trans MSR42
6 5 6 5
K2
RJ45 DIS DI
440R-P221AGS 440R-D22S2 440R-D22R2
LAMP 0V INFO1 INFO2 OSSD1 OSSD2 S32 S42 A2 34 44 14 24 L11 S32 S42 L11 L12 A2 14 24 Y32
M
To PLC
K1 K2
100S-C43EJ14BC
24V DC Com
Circuit
Circuit Status
The light curtain is clear; the SensaGuard is closed; and the e-stop is released. The MSR42 and DIS safety outptus are energized. The safety outputs
Theoflight curtain
the DI are OFF. is The
clear; the isSensaGuard
motor is closed;
off. The DI is ready andThe
for reset. theDIS has a LogicUpon
e-stop settingpower-up,
of 6: [(IN1 ANDtheIN2)
safety devices
OR L12] with perform
automaticinternal
reset. Whenchecks.
the
is released.
machine Theis in aMSR42
specifiedand DIS safety
postion, outptus
as detected areSensaGuard,
by the energized.the The TheisOSSD
light curtain outputs
bypassed. Whenofthethe MSR42moves
machine are pulse tested
away from theto check for
specified
position,
safety outputsthe SensaGuard
of the DI are turns OFF
OFF. Theand the Micro
motor is o.400
Thelight curtain
DI is readybecomes active. The DI The
crossfaults. has aOSSD
logic setting
outputs of 3:of[(IN1
theOR IN2) AND L12]
SensaGuard arewith
pulse tested
monitored
for reset. The manual
DIS hasreset; this makes
a Logic settingtheofE-Stop
6: [(IN1effective
AND IN2)(and the
OR SensaGuard
L12] or
toMicro
check400 forlight curtain) atThe
crossfaults. all times.
single wire safety signal (L11 to L12)
with automatic reset. When the machine is in a specied postion, tests for faults to power and ground when active. The e-stop
Operating
as detected by Principle
the SensaGuard, the light curtain is bypassed. signals are pulse tested to check for crossfaults. The mechanically
When STARTING: Press the
the machine reset button
moves away to turnthe
from the specied
DI safety outputs
position,ON.the
Press the Start button
linked to turn of
contacts thethe
motor
100SON.ensure
The Start /Stop
that thecircuit operatesare o after
contactors
only K2, as a planned maintnenace feature. K1 does not switch motor current on, but it can switch the motor current off when a demand is placed
SensaGuard turns
on the safety stystem.OFF and the Micro 400 light curtain becomes a demand is placed on the safety system.
active. The DINormal
STOPPING: has a logic setting
production of 3: [(IN1
stopping OR IN2)by
is performed AND L12]the
pressing withStop button. A safety stop can be accomplished by obstructing the light
Ratings
monitored manual
curtain when reset; this
the machine makes
postion thedetected
is not E-Stopby eective (and theor pressing the e-stop. The motor performs a coast to stop.
the SensaGuard
SensaGuard or Micro 400 light curtain) at all times. The safety function meets the safety performance requirements
Fault Detection of SIL CL3 per IEC 62061:2005 and has a Category 4 structure that
Operating Principle
Upon power-up, the safety devices perform internal checks. The OSSD outputscan beMSR42
of the used in aresystems requiring
pulse tested to checkPerformance
for crossfaults.Levels up to PLe
The OSSD
outputs of
STARTING: the SensaGuard
Press are pulse
the reset button totested
turn theto check for crossfaults.
DI safety outputs TheON.singleperwireISO13849-1:2006.
safety signal (L11 toThis
L12) circuit
tests forexecutes
faults to power and ground
a Category 0 stop.
when active. The e-stop signals are pulse tested to check for crossfaults. The mechanically linked contacts of the 100S ensure that the contactors
Press the Start button to turn the motor ON. The Start /Stop circuit
are off after a demand is placed on the safety system.
operates only K2, as a planned maintnenace feature. K1 does not
switch motor current on, but it can switch the motor current o
Ratings
when a demand
The safety is placed
function meets onthe the safety
safety stystem.
performance requirements of SIL CL3 per IEC 62061:2005 and has a Category 4 structure that can be used in
systems requiring Performance Levels up to PLe per ISO13849-1:2006. This circuit executes a Category 0 stop.
STOPPING: Normal production stopping is performed by
pressing the Stop button. A safety stop can be accomplished by
obstructing the light curtain when the machine postion is not
detected by the SensaGuard or pressing the e-stop. The motor
performs a coast to stop.
- 32 -
R

Cat 1 Stop with Guardlocking Interlock Safeguarding
and Proximity Sensors
Applications and Wiring Diagrams
TLS3-GD2, 871TM, GLP, PowerFlex 70:
Cat 1 Stop with Guardlocking Interlock and Proximity Sensors
TLS3-GD2, 871TM, GLP, PowerFlex 70
+24 VDC
L1 L2 L3
Gate Reset &

Unlock Gate Lock PowerFlex 70 R ST
Request Start with DriveGuard

Request
2 Start
1 Stop
Stop
Safety
Gate
11 21 33 X14 X24 51 A1 S54 S44 Y32 L12
0 0 0
LOGIC 1 SLS1 1 SLS2 1
2 9 2 2
9
41 51 9
3 8 3 3 7 DC Comm
A1 12 22 34 GLP
8
7
6 5
4 7 6 5
4
8
7 6 5 4
8 Digital In Com
440R-GL2S2P
A2 Gate Control
42 52 S12 S22 L61 A2 AP P12 P22 L11 Power Supply
1
3
Brown
Black
Black
TLS3 GD2 4
2
Gate
6 Enable Control
Circuit
Gate
Proximity Sensors
Blue
Blue
Remove Jumper U V W
Open
871TM-N40NP30-D4
889D-F4AC-2 M
24V DC Com
Circuit Status
The gate is closed and locked. The motor is off. The GLP is ready for reset. The GLP has a Logic setting of 2: (Category 1 Stop with Logic IN OFF), an
Circuit Status OVERSPEED: If the proximity sensors detect a speed greater than
Safe Limited Speed (SLS) setting of 3 (3Hz) and a Maximum speed setting of 2 (20Hz). The safety outputs (S11 & S21), the single wire safety output
The(L11)
gateand
is closed and locked.
the auxiliary Theare
output (Y32) motor
OFF. is o. The
NOTE: GLP
Start theisGLP
ready the maximum
logic configuration from “0” to speed (20Hz),
configure S11 andtheS21
auxiliary output
for use as (Y32), the safety
safety outputs.
for reset. The GLP has a Logic setting of 2: (Category 1 Stop with outputs (S11 & S21) and the single wire safety output (L11) turn
Operating Principle
Logic IN OFF), a Safe Limited Speed (SLS) setting of 3 (3Hz) and off. The PWR/Fault indicator ashes at a 3X rate. When the speed
STARTING: speed
a Maximum Press the Reset button
setting to lock The
of 2 (20Hz). the gate andoutputs
safety turn the GLP
(S11safety
& outputsdropsON.below theStart
Press the maxbutton
speedto limit, press
turn the theON.
motor Reset button to clear
S21), the single wire safety output (L11) and the auxiliary output the fault and energize the safety outputs.
STOPPING: Normal production stopping is performed by pressing the Stop button. Access through the safety gate is initiated by pressing the Gate
(Y32) are OFF.
Unlock NOTE:
Request Start
button. the
The Y32GLP logic
output of conguration
the GLP turns OFFfrom “0”initiates
and to Fault
a stop Detection
command to the drive. When the speed detected by the
congure S11sensors
proximity and S21 forbelow
drops use asthe
safety outputs.
safe limited speed, the gate becomes unlocked and the safety outputs turn OFF. The PowerFlex drive goes to a
safe off state. If the motor has not already stopped, the motor coasts to a stop.
Upon power-up, the safety devices perform internal checks. The
Operating Principle TLS3 has dual channel signals but does not checks for crossfaults.
OVERSPEED:
STARTING: If the
Press theproximity sensorsto
Reset button detect
lock athe
speed greater
gate themaximumThe
than the
and turn GLP
speed safety
(20Hz), theoutputs
auxiliary are pulse
output tested
(Y32), to check
the safety for(S11
outputs faults.
& The
S21) and the single wire safety output (L11) turn off. The PWR/Fault indicator flashes proximity
at a 3Xsensors are
rate. When continuously
the speed dropstested by
below the requiring
max speed that
GLP safety outputs ON. Press the Start button to turn the motor
limit, press the Reset button to clear the fault and energize the safety outputs. both sensors cannot be OFF at the same time. The PowerFlex 70
ON.
requires two safety signals to enable the drive.
Fault Detection
STOPPING: Normal production stopping is performed by pressing
theUpon
Stoppower-up, the safety
button. Access devicesthe
through perform internal
safety gate checks. by has dual Ratings
The TLS3
is initiated channel signals but does not checks for crossfaults. The GLP safety
outputs
pressing areGate
the pulseUnlock
tested toRequest
check forbutton.
faults. The
Theproximity
Y32 outputsensors
ofare
thecontinuously tested by
The safety requiringmeets
function that both
thesensors
safety cannot be OFF atrequirements
performance the
same time. The PowerFlex 70 requires two safety signals to enable the drive.
GLP turns OFF and initiates a stop command to the drive. When of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that
the speed detected by the proximity sensors drops below the safe can be used in systems requiring Performance Levels up to PLd
Ratings
limited speed,
The safety the gate
function becomes
meets unlocked
the safety performance andrequirements
the safety outputs per62061:2005
of SIL CL2 per IEC ISO13849-1:2006.
and has a This circuit
Category executes
3 structure thata can
Category
be used1instop.
turnsystems
OFF. The PowerFlex
requiring drive goes
Performance Levelsto
upatosafe
PLdoperstate. If the motorThis circuit executes a Category 1 stop.
ISO13849-1:2006.
has not already stopped, the motor coasts to a stop.
- 33 -
NHP Safety Reference Guide > GSR Wiring DiagramsR 3-35
Cat 1 Stop with Guardlocking Interlock and Proximity
Safeguarding Sensors
Cat 1 Stop with Guardlocking Interlock and Proximity Sensors
TLS3-GD2, 871TM, GLP, PowerFlex 70:
TLSZR-GD2, 872C, GLP, PowerFlex 525
+24 VDC
Gate Reset & L1 L2 L3

Unlock Gate Lock
Request Request PowerFlex R S T
525
1 Stop
2 Start
Safety
Gate
4 Gnd
Brown X14 X24 51 A1 S54 S44 Y32
Red 0 0 0
Yellow LOGIC 1 SLS1 1 SLS2 1
9 2 9 2 2 Gate control
Green 9
8 3 8 3 8 3 power supply
GLP 7 4 7 6 5 4 7 6 5 4
Grey 6 5
Pink 440R-GL2S2P
White Gate control
Blue S12 S22 L61 A2 AP P12 P22 L11 circuit
S1
Brown
TLS-ZR
Black
Black
S2
440G-TZS21UPRH UV W
889D-F8AC-2
M
Proximity Sensors
Blue
Blue
Gate 872C-D3NP12-D4
Unlocked 889D-F4AC-2
24V DC Com
Circuit Status
Circuit
The Status
gate is closed and locked. The motor is off. The GLP is ready for reset. The OVERSPEED:
GLP has a LogicIfsetting
the proximity sensors
of 2: (Category detect
1 Stop with a speed
Logic greater
IN OFF), an than
Safe Limited Speed (SLS1) setting of 3 (3Hz) and a Maximum
The gate is closed and locked. The motor is o. The GLP is ready (SLS2) speed the
setting maximum
of 2 (20Hz). speed
The safety(20Hz),
outputsthe auxiliary
(S11 & S21), output
the single (Y32),
wire the
safety safety
output (L11) and the auxiliary output (Y32) are OFF. NOTE: Start the GLP logic outputs
configuration
(S11from “0” to
& S21) andconfigure S11 and
the single wireS21 for use
safety as safety
output (L11) turn
for reset. The
outputs.
GLP has a Logic setting of 2: (Category 1 Stop with
Logic IN OFF), a Safe Limited Speed (SLS1) setting of 3 (3Hz) and off. The PWR/Fault indicator ashes at a 3X rate. When the speed
a Maximum (SLS2) speed setting of 2 (20Hz). The safety outputs drops below the max speed limit, press the Reset button to clear
Operating Principle
(S11STARTING:
& S21), the single
Press wirebutton
the reset safetytooutput
lock the(L11) andturn
gate and thethe
auxiliary the fault.
GLP safety outputs ON. Press the Start button to turn the motor ON.
output (Y32) are OFF. NOTE: Start the GLP logic conguration from Fault Detection
STOPPING:
“0” to congureNormal
S11 and production
S21 for stopping is performed
use as safety by pressing the Stop button. Access through the safety gate is initiated by pressing the Gate
outputs.
Unlock Request button. The Y32 output of the GLP turns OFF and initiates a stop Upon power-up,
command to thethe safety
drive. Whendevices perform
the speed detectedinternal
by the checks. The
Operating
proximityPrinciple
sensors drops below the safe limited speed, the gate becomes unlocked TLSZRandhas
theOSSD outputsturn
safety outputs andOFF.
checks for crossfaults.
The PowerFlex ThetoGLP
drive goes a
safe off state. If the motor has not already stopped, the motor coasts to a stop.safety outputs are pulse tested to check for faults. The proximity
STARTING: Press the reset button to lock the gate and turn the
GLPOVERSPEED:
safety outputs sensors are continuously tested by requiring that both sensors
If theON. Presssensors
proximity the Start button
detect to greater
a speed turn the motor
than the maximum speed (20Hz), the auxiliary output (Y32), the safety outputs (S11 &
cannotatbe
ON. S21) and the single wire safety output (L11) turn off. The PWR/Fault indicator flashes a 3XOFF
rate.atWhen
the same time.
the speed Thebelow
drops PowerFlex
the max45speed
performs its
limit, press the Reset button to clear the fault. own internal safety checks, and requires two safety signals to
STOPPING: Normal production stopping is performed by pressing enable the drive.
the Stop button. Access through the safety gate is initiated by
pressing Ratings
Faultthe Gate Unlock Request button. The Y32 output of the
Detection
GLPUpon
turnspower-up,
OFF andthe initiates a stop perform
safety devices command to the
internal drive.
checks. When
The Theoutputs
TLSZR has OSSD safety and
function
checksmeets the safety
for crossfaults. The performance requirements
GLP safety outputs are
the speed detected
pulse tested byfor
to check thefaults.
proximity sensorssensors
The proximity dropsare
below the safetestedof
continuously bySIL CL2 per
requiring thatIEC 62061:2005
both sensors cannotandbehas
OFFa at
Category
the same3time.
structure
The that
PowerFlex
limited speed,45theperforms its own internal
gate becomes safety and
unlocked checks,
theand requires
safety two safety signals
outputs can betoused
enable in the drive. requiring Performance Levels up to PLd
systems
turn OFF. The PowerFlex drive goes to a safe o state. If the motor per ISO13849-1:2006. This circuit executes a Category 1 stop.
has Ratings
not already stopped, the motor coasts to a stop.
The safety function meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that can be used in
systems requiring Performance Levels up to PLd per ISO13849-1:2006. This circuit executes a Category 1 stop.
- 34 -
R
3-36
Safe Limited Speed with Guardlocking Interlock
Safeguardingand Proximity
Applications Sensors
and Wiring Diagrams
Safe Limited Speed with Guardlocking Interlock and Proximity Sensors
TLSZR-GD2, 871TM, GLP, PowerFlex 70:
TLSZR-GD2, 871TM, GLP, PowerFlex 70
+24 VDC
L1 L2 L3
PowerFlex 70 R ST
Reset & with DriveGuard
Gate
Unlock Gate Lock 9 24VDC
Request Request
2 Start
1 Stop
3 Speed Select 1
7 DC Comm
Safety
Gate 8 Digital In Com
Brown X14 X24 51 A1 S54 S44 Y32 L12 Gate Control
Red Power Supply
0 0 0
Yellow LOGIC 1 SLS1 1 SLS2 1
9 2 9 2 2
9
Green 8 3 8 3 8 3
7 4 7 6 5 4 7 6 5 4
1
Grey GLP 6 5 3
Pink
440R-GL2S2P
White 4
2
Blue S12 S22 L61 A2 AP P12 P22 L11
Gate
6 Enable Control
Brown
TLS-ZR
Black
Black
Circuit
440G-TZS21UPRH Remove Jumper U V W
889D-F8AC-2
M
Proximity Sensors
Blue
Blue
871TM-N40NP30-D4
889D-F4AC-2
24V DC Com
Circuit Status
Circuit gate is closed and locked. The motor is off. The GLP is ready for reset. TheFault
TheStatus Detection
GLP has a Logic setting of 4: (Safe Limited Speed with Logic IN
OFF), a Safe Limited Speed (SLS) setting of 5 (5Hz) and a Maximum speed setting of 8 (2000Hz). The safety outputs (S11 & S21), the single wire
The gate is closed and locked. The motor is o. The GLP is ready for Upon power-up, the safety devices perform internal checks. The
safety output (L11) and the auxiliary output (Y32) are OFF. NOTE: Start the GLP logic configuration from “0” to configure S11 and S21 for use as
reset.safety
The GLP has a Logic setting of 4: (Safe Limited Speed with
outputs. TLSZR has OSSD outputs and checks for crossfaults. The GLP
Logic IN OFF), a Safe Limited Speed (SLS) setting of 5 (5Hz) and a safety outputs are pulse tested to check for faults. The proximity
Maximum
OperatingspeedPrinciple
setting of 8 (2000Hz). The safety outputs (S11 & sensors are continuously tested by requiring that both sensors
S21),STARTING:
the single wire
Press safety
the Reset output
button to(L11) andGLP
turn the thesafety
auxiliary output
outputs cannot
and single wire safetybe OFFON.
output at the same
Press time.button to turn the motor ON.
the Start
(Y32) are OFF. NOTE: Start the GLP logic conguration from “0” to
STOPPING: Normal The PowerFlex 70 requires
the safetytwogatesafety signals to enable
the the drive.
congure S11 and S21production
for use as stopping is performed by pressing the Stop button.
safety outputs. Access through is initiated by pressing
Gate Unlock Request button. The Y32 output of the GLP turns ON and commands If thethe
gate is unlocked
PowerFlex drive toand the
bring motor
the motorspeed increases
to a safe slow speedbeyond the
Operating
(less thanPrinciple
5Hz). When the speed detected by the proximity sensors drops below safethe safe limited
limited speed,speed
the(5Hz), the gate
GLP turns itsbecomes
safety andunlocked.
single The
wire safety
operator can enter the machine cell, as the motor continues to run at the safeoutputs
slow speed.OFF.After leaving the cell and closing the gate, press the
STARTING: Press the Reset button to turn the GLP safety outputs
reset button to lock the gate and return the machine to production speeds.
and single wire safety output ON. Press the Start button to turn OVERSPEED: If the proximity sensors detect a speed greater than
the motor ON.
Fault Detection the maximum speed (2000Hz), the safety and the single wire
Upon power-up, the safety devices perform internal checks. The TLSZR has OSSD outputs and checks for crossfaults. The GLP safety outputs
ashesare
STOPPING: Normal
pulse tested production
to check for faults.stopping is performed
The proximity sensors are by pressing testedsafety
continuously
outputs turn OFF. The PWR/Fault indicator
by requiring that both sensors cannot be OFF at the same time.
at a 3X
the Stop button. Access through the safety rate. When the speed drops below the max speed limit, press the
The PowerFlex 70 requires two safety signals gate is initiated
to enable the drive.byIf the gate is unlocked and the motor speed increases beyond the safe limited
pressing the
speed, theGate Unlock
GLP turns Request
its safety and button. The
single wire Y32outputs
safety outputOFF.
of Reset button to clear the fault.
the GLP turns ON and commands the PowerFlex drive to bring Ratings
OVERSPEED:
the motor If theslow
to a safe proximity
speed sensors detect5Hz).
(less than a speed greater
When thethan the maximum speed (2000Hz), the safety and the single wire safety outputs
speed
turn OFF. The PWR/Fault indicator flashes at a 3X rate. When the speed dropsThe safety
below function
the max meets
speed limit, thethe
press safety
Resetperformance
button to clearrequirements
the fault.
detected by the proximity sensors drops below the safe limited
of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that
speed (5Hz), the gate becomes unlocked. The operator can enter
Ratings can be used in systems requiring Performance Levels up to PLd
the machine
The safetycell, as the
function motor
meets continues
the safety to run requirements
performance at the safe slow
of SIL CL2 perper
IECISO13849-1:2006.
62061:2005 and has This
a Category
circuit3 executes
structure that can be
a Safe used inSpeed
Limited
speed. Afterrequiring
systems leaving Performance
the cell andLevels
closing the
up to PLdgate, press the reset This circuit executes a Safe Limited Speed function.
per ISO13849-1:2006.
function.
button to lock the gate and return the machine to production
speeds.
- 35 -
R 3-37
Overspeed Only Detection Safeguarding Applications and Wiring Diagrams
Overspeed Only Detection
872C, GLP, PowerFlex 525:
872C, GLP, PowerFlex 525
+24 VDC
L1 L2 L3
Reset PowerFlex R S T
525
1 Stop
2 Start
11 +24V DC
12 Analog
X14 X24 51 A1 S44 S54 Y32 L12 800F-POT6 13 Speed
0 0 0 14 Control
LOGIC 1 SLS1 1 SLS2 1
9 2 9 2 2 4 Gnd
9
8 3 8 3 8 3
7 4 7 4 7 6 5 4
GLP 6 5 6 5
440R-GL2S2P Gate control
power supply
S12 S22 L61 A2 AP P12 P22 L11
Gate control
circuit
Brown
Black
Black
S1
S2
U V W
Blue
Blue
Proximity Sensors M
872C-D8NP18-D4 (2)
889D-F4AC-2
24V DC Com
Circuit Status
The motor is off. The GLP is ready for reset. The GLP has a Logic setting of 1: (Cat 1Stop with Logic IN OFF), a Safe Limited Speed (SLS1) setting of 0
(0.5 Hz) and a maximum (SLS2) speed setting of 5 (200 Hz). Both E-Stops are closed. NOTE: Start the GLP logic configuration from “0” to configure
Circuit
X14Status
and X24 for use as safety outputs. OVERSPEED: When the GLP detects overspeed, X14, X24 and L11
The motor is off. The GLP is ready for reset. The GLP has a Logic will turn OFF and the PWR/Fault indicator wiil show green with
Operating
setting of 1: (CatPrinciple
1Stop with Logic IN OFF), a Safe Limited Speed 4 red ashes. To recover, reduce the speed below the SLS2 setting
The GLP is only used to execute a safety stop if the speed
(SLS1) setting of 0 (0.5 Hz) and a maximum (SLS2) speed setting detected by the and press
proximity the
sensors Reset200Hz.
exceeds button to re-enable the PowerFlex 525 drive.
of 5 (200 Hz). Both E-Stops are closed. NOTE: Start the GLP logic
STARTING: Press the Reset button to turn the GLP safety outputs (X14 and X24)Fault Detection
ON. This enables the PowerFlex 525 drive. Press the Start button to
conguration fromON.
turn the motor “0” Adjust
to congure X14 andtoX24
the 800F-POT6 for the
control usespeed
as safety
of the motor. Upon power-up, the GLP and PowerFlex 525 perform internal
outputs.
checks. If the checks are completed safely, the GLP will be ready
STOPPING: Normal production stopping is performed by manually reducing the speed of the motor by turning the 800F-POT6 or by pressing the
Operating Principle
Stop button. If the speed detected by the proximity sensors exceeds 200Hz, the forGLP
reset. At outputs
safety least one
turnproximity sensors must
OFF. The PowerFlex be ON.
525 drive executes a
The Category 0 stop
GLP is only andto
used theexecute
motor coasts to a stop
a safety stop. if the speed
Ratings
detected by the proximity sensors exceeds 200Hz.
OVERSPEED: When the GLP detects overspeed, X14, X24 and L11 will turn OFFThe safety
and the functions
PWR/Fault meetwiil
indicator the safety
show performance
green requirements
with 4 red flashes. To
recover, Press
STARTING: reducethe
the Reset
speed below
buttonthetoSLS2
turnsetting
the GLPandsafety
press the Reset button to
outputs ofre-enable the PowerFlex
SIL CL2 per 525 drive.
IEC 62061:2005 and has a Category 3 structure
(X14 and X24) ON. This enables the PowerFlex 525 drive. Press that can be used in systems requiring Performance Levels up to
the Start button to turn the motor ON. Adjust the 800F-POT6 to PLd per ISO13829-1:2008. This circuit executes a Category 0 stop
Fault Detection
control the speed of the motor. when the spped exceeds 200Hz.
Upon power-up, the GLP and PowerFlex 525 perform internal checks. If the checks are completed safely, the GLP will be ready for reset. At least
one proximity
STOPPING: Normalsensors must be ON.
production stopping is performed by
manually reducing the speed of the motor by turning the
Ratingsor by pressing the Stop button. If the speed detected
800F-POT6
The safety functions meet the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that can be used in
by the proximity
systems sensors
requiring exceeds
Performance 200Hz,
Levels up tothe
PLdGLP safety outputs This circuit executes a Category 0 stop when the spped exceeds 200Hz.
per ISO13829-1:2008.
turn OFF. The PowerFlex 525 drive executes a Category 0 stop and
the motor coasts to a stop.
- 36 -
R 3-38
Category 1 Stop with Guardlocking Interlock and Proximity
Safeguarding Sensors
Category 1 Stop with Guardlocking Interlock and Proximity Sensors
TLS3-GD2, 800F, 872C, GLP, DIS, PowerFlex 70: TLS3-GD2, 800F, 872C, GLP, DIS, PowerFlex 70
+24 VDC L1 L2 L3
Gate Reset & PowerFlex 70

R ST
Unlock Gate Lock Start with DriveGuard
Request Request
2 Start
800FM-MT44MX02V
E-Stop 1 Stop
Stop
Safety
Safety Status 7 DC Comm
Gate
to PLC 8 Digital In Com
X14 X24 51 A1 S54 S44 Y32 L12 S11 S21 S22 S12 S42 S32 A1 Y32
11 21 33
0 0 0 0 Gate Control
LOGIC 1 SLS1 1 SLS2 1 LOGIC 1 Power Supply
9 2 9 2 2 2 A1
9
41 51 8 3 3 3 8 3
4 8 8 4
A1 12 22 34 7
6 5 7 6 5
4 7 6 5 4 7
6 5 1
GLP DIS 3
440R-GL2S2P 440R-D22S2
A2 Reset
42 52 S12 S22 L61 A2 AP P12 P22 L11 L11 L12 A2 34 44 14 24 S34 4
2
Gate
Brown
Black
Black
6 Enable Control
Circuit
TLS3 GD2
440G-T27183 Remove Jumper U V W
Gate Status
to PLC Proximity Sensors M
Blue
Blue
872C-M8NP18-D4
889D-F4AC-2
24V DC Com
Circuit Status
The Status
Circuit gate is closed and locked. The motor is off. The GLP is ready for reset. The The
GLP has a Logic
E-stop settingcan
buttons of 1:be
(Cat 1 Stop
used towith Logica IN
initiate OFF), a Safe
“coast-to-stop”. Press
Limited Speed (SLS) setting of 9 (10 Hz) and a maximum (MAX) speed setting of 7 (1000 Hz). Both E-Stops are closed. The DI is configured to
The setting
gate is4closed
(IN1 ANDandIN2locked. TheINmotor
AND LOGIC is off. Themanual
with monitored GLP isreset). the e-stop and the DI outputs turn o, which causes the
readyNOTE: Start the GLP logic configuration from “9” to configure X14 and X24 for PowerFlex
for reset. The
use with GLPinputs.
safety has a Logic setting of 1: (Cat 1 Stop with Logic drive to execute a Safe-O function. The motor coasts to a stop.
IN OFF), a Safe Limited Speed (SLS) setting of 9 (10 Hz) and a Fault Detection
Operating
maximum (MAX)Principle
speed setting of 7 (1000 Hz). Both E-Stops are
STARTING: Press the Reset button to turn the GLP safety output (L11) ON. ThisUponenablespower-up,
the DI relay.the safety
Press devices
the Reset perform
button to turn internal checks. The
the DI outputs
closed. The DI is congured to setting 4 (IN1 AND IN2 AND LOGIC
ON and enable the Safe-Off Option of the PowerFlex Drive. Press the Start buttonGLPtoand
turnDI send
the motoroutON.test pulses on X14 and X24 to check for faults
IN with monitored manual reset). NOTE: Start the GLP logic
on the guardlocking switch and e-stops. The GLP checks to see
conguration
STOPPING:from “9”production
Normal to congure X14 and
stopping X24 for use
is performed with safety
by pressing the Stop button. Access through the safety gate is initiated by pressing the
that the proximiity sensors are connected, by requiring that both
inputs.
Unlock Request button. The Y32 output of the GLP turns OFF and initiates a stop command to the drive. When the motor speed drops below the
sensors
safe limited speed, the GLP unlocks the gate and turns its L11 safety output OFF. cannot the
Subsequently be DIOFF at the
turns sameoutputs
its safety time. The L11/L12
off, and the connection
Operating Principle is Single Wire
PowerFlex drive goes to a Safe-Off state. The motor, if not already stopped, coasts to a stop. Safety connection tested for shorts to power or
STARTING: Press the Reset button to turn the GLP safety output ground when active. The DIS outputs 14 & 24 are pulse tested to
The E-stop buttons can be used to initiate a “coast-to-stop”. Press the e-stop and the DI
check foroutputs
shortsturn off, which
to power andcauses the PowerFlex
ground. The DIS drive to 34 & 44,
outputs
(L11) ON. This enables the DI relay. Press the Reset button to turn
execute a Safe-Off function. The motor coasts to a stop. which are not pulse tested, should be used for compatibility with
the DI outputs ON and enable the Safe-O Option of the PowerFlex
Drive. Press the Start button to turn the motor ON. devices that cannot tolerate the pulse testing.
Fault Detection
Upon power-up, the safety devices perform internal checks. The GLP and DI send
STOPPING: Normal production stopping is performed by pressing Ratings
out test pulses on X14 and X24 to check for faults on the
guardlocking switch and e-stops. The GLP checks to see that the proximiity sensors are connected, by requiring that both sensors cannot be OFF
the Stop
at the button.
same time.Access through
The L11/L12 the safety
connection gate Wire
is Single is initiated by
Safety connection Thefor
tested safety functions
shorts to power ormeet thewhen
ground safety performance
active. requirements
The DIS outputs 14
pressing thepulse
& 24 are Unlock Request
tested to checkbutton.
for shortsThe Y32 output
to power of theThe
and ground. GLP of34SIL
DIS outputs CL2which
& 44, per IEC 62061:2005
are not and
pulse tested, has abeCategory
should used for 3 structure
turns OFF and initiates
compatibility a stop
with devices thatcommand to the
cannot tolerate thedrive.
pulse When
testing.the that can be used in systems requiring Performance Levels up to
motor speed drops below the safe limited speed, the GLP unlocks PLd per ISO13849-1:2006. This circuit executes a Category 1 stop
Ratings
the gate and turns its L11 safety output OFF. Subsequently the when requesting gate access through the GLP, and a Category 0
The safety
DI turns functions
its safety meet o,
outputs theand
safety
theperformance
PowerFlexrequirements
drive goes to of SIL
a CL2 perstop
IEC 62061:2005 and hasthe
when pressing a Category
e-stops.3 structure that can be used in
systems requiring Performance Levels up to PLd per ISO13849-1:2006. This circuit executes a Category 1 stop when requesting gate access
Safe-O state. The motor, if not already stopped, coasts
through the GLP, and a Category 0 stop when pressing the e-stops.
to a stop.
- 37 -
NHP Safety Reference Guide > GSR Wiring DiagramsR 3-39
Safe Limited Speed with Guardlocking Interlock and Proximity Sensors
TLS3-GD2, 800F,Safe
872C,Limited
GLP, DI, Speed with
PowerFlex Guardlocking Interlock and Proximity Sensors
525:
TLS3-GD2, 800F, 872C, GLP, DI, PowerFlex 525
+24 VDC
E-Stop L1 L2 L3
Gate Reset & 800FM-MT44
Unlock Gate Lock 800F-MX02S Reset PowerFlex R S T
Request Request 525
1 Stop
2 Start
5 Preset Freq
Safety (SLS)
Gate
X14 X24 51 A1 S54 S44 Y32 L12 S11 S12 S21 S22 A1 13 23 S34
11 21 33
LOGIC 0
1 SLS1
0 SLS2 0 LOGIC 0
1 1 1
9 2 9 2 2 2
3 3
9 4 DC Com
41 51 8
4 8 8 3 8 3
A1 12 22 34 7
6 5 7 6 5 4 7 6 5 4
6
7
5
4
GLP DI
440R-GL2S2P 440R-D22R2 Gate control
A2 power supply
42 52 S12 S22 L61 A2 AP P12 P22 L11 S32 S42 L11 L12 A2 14 24 Y32
Gate control
Brown
circuit
Black
Black
TLS3 GD2 S1
440G-T27183 S2
UV W
Gate Safety
Proximity Sensors
Blue
Blue
Open
872C-D8NP18-D4
Status M
to PLC
889D-F4AC-2
24V DC Com
Circuit Status
Circuit
The Status
gate is closed and locked. The motor is off. The GLP is ready for reset. Thespeed.
GLP hasAfter
a Logicleaving
setting the
of 3: cell
(Safeand closing
limited Speedthe gate,
with Logicpress the reset
IN OFF),
a Safe Limited Speed (SLS) setting of 9 (10 Hz) and a maximum (MAX) speed setting button of 7to(1000
lock Hz).
the Both
gate E-Stops
and are closed.
return the The DI is configured
machine to to
production
The gate is closed and locked. The motor is off. The GLP is ready
setting 4 (IN1 AND IN2 AND LOGIC IN with monitored manual reset). The single wire safety output (L11) and the GLP auxiliary output (Y32) are
speeds.
for reset. TheDIGLP
OFF. The hasoutputs
safety a Logicaresetting
off and of
the3:DI(Safe limited
auxiliary Speed
output (Y32) with
is ON . NOTE: Start the GLP logic configuration from “9” to configure X14 and
Logic IN OFF),
X24for a Safe
use with Limited
safety inputs.Speed (SLS) setting of 9 (10 Hz) and The E-stop buttons can be used to initiate a “coast-to-stop”. Press
a maximum (MAX) speed setting of 7 (1000 Hz). Both E-Stops are the e-stop and the DI outputs turn o, which commands the drive
Operating
closed. The DI isPrinciple
congured to setting 4 (IN1 AND IN2 AND LOGIC to a safe off state. The motor coasts to a stop.
STARTING:
IN with Press the
monitored Reset button
manual reset).to turn
The the GLP
single safety
wire outputs
safety (L11) ON. This enables the DI relay. Press the Reset button to turn the DI outputs
output
ON and enable the PowerFlex Drive. Press the Start
(L11) and the GLP auxiliary output (Y32) are OFF. The DI safety button to turn the motor Fault Detection
ON.
outputs are o and the DI auxiliary output (Y32) is ON . NOTE: Start
STOPPING: Normal production stopping is performed by pressing the Stop button. UponAccess
power-up,
throughthethesafety
safety devices perform
gate is initiated internalthe
by pressing checks.
Gate The
the GLP
Unlocklogic conguration
Request from
button. The Y32“9” to congure
output of the GLPX14 and
turns ONX24for use
and commands GLP
the and DI send
PowerFlex out
drive to testthe
bring pulses
motoronto S11
a safeand
slowS21 to (less
speed check for faults
than
with10Hz).
safetyWhen
inputs.
the speed detected by the proximity sensors drops below the safe onlimited
the guardlocking switch
speed (10Hz), the gate and e-stops.
becomes The GLP
unlocked. The checks
operatorto see
can enter the machine cell, as the motor continues to run at the safe slow speed. thatAfter
theleaving the cell
proximiity and closing
senors the gate, press
are connected, by the reset button
requiring that both
Operating Principle
to lock the gate and return the machine to production speeds. sensors cannot be OFF at the same time. The L11/L12 connection
STARTING: Press the Reset button to turn the GLP safety outputs is Single Wire Safety connection tested for shorts to power or
(L11)The E-stop buttons can be used to initiate a “coast-to-stop”. Press the e-stop and the DI outputs turn off, which commands the drive to a safe off
ON. This enables the DI relay. Press the Reset button to turn ground when active.
state. The motor coasts to a stop.
the DI outputs ON and enable the PowerFlex Drive. Press the Start
button to turn the motor ON. Ratings
Fault Detection
Upon power-up, Theout
safety functions
on S11meet thetosafety
check performance
for faults on therequirements
STOPPING: Normalthe safety devices
production performisinternal
stopping checks.by
performed The GLP and DI send
pressing test pulses and S21
of SILare
guardlocking switch and e-stops. The GLP checks to see that the proximiity senors CL2 per IEC 62061:2005
connected, andboth
by requiring that hassensors
a Category
cannot3bestructure
OFF that
the Stop
at the button. Access
same time. through
The L11/L12 the safety
connection gate Wire
is Single is initiated by
Safety connection tested
can for
beshorts
used toinpower
systemsor ground whenPerformance
requiring active. Levels up to PLd
pressing the Gate Unlock Request button. The Y32 output of the
per ISO13849-1:2006. This circuit executes a Safe Limited Speed
GLPRatings
turns ON and commands the PowerFlex drive to bring the
function when requesting gate access through the GLP, and a
motor
Theto a safe
safety slow speed
functions (less
meet the than
safety 10Hz). When
performance the speed
requirements of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that can be used in
Category 0 stop when pressing the e-stops.
detected
systemsbyrequiring
the proximity sensors
Performance drops
Levels up tobelow
PLd perthe safe limited This circuit executes a Safe Limited Speed function when requesting gate
ISO13849-1:2006.
access through the GLP, and a Category 0 stop when pressing
speed (10Hz), the gate becomes unlocked. The operator can enter the e-stops.
the machine cell, as the motor continues to run at the safe slow
- 38 -
R
3-40
E-Stops with Speed Monitored Guardlocking Interlock
Safeguarding andand
Applications Contactors
Wiring Diagrams
E-Stops with Speed Monitored Guardlocking Interlock and Contactors
TLS-GD2, 872C, GLP, DI and Contactors: TLS-GD2, 872C, GLP, DI and Contactors
+ 24V DC
E-Stops K1
800FM-MT44
Reset & Gate Unlock 800F-MX02S
Gate Lock K2
Request Request
External
Reset Start-
SLS Request
TLS3-GD2 to PLC Stop
440G-T27260 Control
X14 X24 51 A1 S44 S54 Y32 L12 S11 S12 S21 S22 A1 13 23 S34
11 21 33
0
LOGIC 0
1 SL1 0
1 SL2 1 LOGIC 0
1 K1
12 22 34 9 2 9 2 9 2 2
8 3 8 3 8 3
4 4 4 8 3
76 5 7 6 5 7 6 5 7 4
Solenoid
A1 41 51 GLP DI 6 5
K2
440R-GL2S2P 440R-D22R2
A2 42 52
S12 S22 L61 A2 AP P12 P22 L11 S32 S42 L12 L11 A2 14 24 Y32
M
Safety
Status
Black
Black
Gate Brown
to PLC
Blue
Open
Brown Blue 100S-C09EJ14BC
872C-D8NP18-E5 (2) K1 K2
24V DC COM
Circuit Status
The gate is closed and locked. The motor is off. The GLP is ready for reset. TheFault
Circuit Status GLP hasDetection
a Logic setting of 3: (Safe Limited Speed with Logic in OFF),
The gatea is closed
Safe Limitedand locked.
Speed The motor
(SL1) setting is o.
of 1(1 Hz) The
and (SL2) setting of 8Upon
GLP is ready
a maximum power-up,
(2000Hz). The singlethe wiresafety GLP and
safety output (L11)DIandperform internal checks.
the auxiliary
for reset.output
The GLP(Y32)hasare OFF. NOTE:
a Logic Start the
setting ofGLP configuration
3: (Safe Limited from “9” to configureThe
Speed X14 and
GLPX24and as test pulse outputs
DI check for usedevices
their input with the electro-
for faults. The proximity
mechanical TLS3-GD2 contacts. Both E-Stops are released. The DI is ready for reset.
with Logic in OFF), a Safe Limited Speed (SL1) setting of 1(1 sensors are constantly monitored by requiring that only one
Hz) and a maximum (SL2) setting of 8 (2000Hz). The single wire sensor is OFF at any time. An auxiliary NC contact from each
Operating
safety output (L11)Principle
and the auxiliary output (Y32) are OFF. NOTE: contactor is connected in series with the DI reset contact so that
Start theSTARTING:
GLP conguration from “9” to congure X14 and X24 as should a contactor become welded closed the DI cannot be reset;
Press and release the Reset button of the GLP. The gate locks, and the L11 output turns ON. Press and release the reset button of the
test pulse
DI. outputs
The DI safetyfor contacts
use with theand
close electromechanical
energize the contactor coils. The externalthe
TLS3-GD2 motor
start-stop cannot
control be started.
can now start the motor.
contacts. Both E-Stops are released. The DI is ready for reset.
Ratings
STOPPING: Normal production start-stop is performed by an external start-stop control. When an E-Stop is pressed the DI immediately de-energizes
Operating Principle
the two contactors. The motor coasts to a stop. When the speed detected by theEmergency proximity sensors stop initiated
drops below the bysafe
anlimited
E-Stop (2):(1Hz)
speed These safety
the GLP
STARTING:unlocks
Press thegate. The operator
and release thecan safely
Reset enter the
button ofguarded
the GLP. area.
TheAfter leaving the
gate area and closing
functions meetthe thegate the operator
safety presses and
performance releases the GLPof SIL3 per
requirements
reset button to lock the gate. The E-Stops must be released before the DI can be reset. Press and release the DI reset to energize the contactors. The
locks, and the L11 output turns ON. Press and release the reset IEC 62061: 2005 and have a Category 4 structure, can be used in
external circuit can nowstart the motor.
button of the DI. The DI safety contacts close and energize the systems requiring Performance Levels up to PLe per ISO 13849-
contactor coils. TheIf the
OVERSPEED: external start-stop
GLP detects a speedcontrol canthe
greater than now start the
maximum 1:2006
speed (2000Hz), the and execute
GLP single wire asafety
category
output 0L11 stops.
turns OFF. The DI
motor. de-energizes the two contactors and the motor coasts to a stop. The gate can not be unlocked until speed is less than 1 Hz. Should the speed
increase above safe limited speed while the gate is unlocked, the GLP turns OFF its safety Emergency
outputs.. stop initiated by an an Overspeed: This safety
STOPPING: Normal production start-stop is performed by an function meets the safety performance requirements of SIL2 per
externalFault
start-stop
Detection control. When an E-Stop is pressed the DI IEC 62061: 2005 and has a Category 3 structure, can be used in
immediately de-energizes
Upon power-up, theGLP
the safety twoand contactors. The motor
DI perform internal checks. The GLP and DIsystems
coasts check theirrequiring
input devicesPerformance Levelssensors
for faults. The proximity up toarePLd per ISO 13849-
constantly
to a stop. When the
monitored speedthat
by requiring detected by the
only one sensor proximity
is OFF at any time.sensors 1:2006
An auxiliary NC contact and
from each executes
contactor a category
is connected in series0with
stop.
the DI reset contact so
that should
drops below the asafe
contactor become
limited welded
speed closed
(1Hz) thetheGLP
DI cannot be reset; the motor cannot be started.
unlocks
Prevention of access while dangerous motion is present: This
thegate. The operator can safely enter the guarded area. After
Ratings safety function meets the safety performance requirements of
leaving the area and closing the gate the operator presses and
Emergency stop initiated by an E-Stop (2): These safety functions meet the safety SIL2 per IEC 62061:
performance 2005 and
requirements has per
of SIL3 a Category
IEC 62061: 3 structure
2005 and and can
releaseshave
the aGLP reset4button
Category structure,to
can lock the in
be used gate. Therequiring
systems E-StopsPerformance
must Levels up to PLe per ISO 13849-1:2006
be used in systems requiring and execute a category
Performance Levels0 upstops.
to PLd per
be released beforestop
Emergency theinitiated
DI can beby an reset. Press andThis
an Overspeed: release
safety the DI meets the safety performance requirements of SIL2 per IEC 62061: 2005 and
function ISO 13849-1:2006.
reset to has
energize
a Categorythe3contactors.
structure, can The external
be used circuit
in systems can Performance
requiring nowstart Levels up to PLd per ISO 13849-1:2006 and executes a category 0 stop.
the motor.
Prevention of access while dangerous motion is present: This safety function meets the safety
Prevention performance requirements
of unexpected start-up (Gate of SIL2Monitoring):
per IEC 62061: This
2005 and has a Category 3 structure and can be used in systems requiring Performance Levels up to PLd per ISO 13849-1:2006.
safety function meets the safety performance requirements of
OVERSPEED: If theofGLP
Prevention detectsstart-up
unexpected a speed(Gate greater than the
Monitoring): This safety function meets the safety performance requirements of SIL2 per IEC
SIL2 per IEC 62061:2005 and ISOhas a Category The3system
structure,
can can be
maximum speed (2000Hz),
62061:2005 the GLP
and has a Category single wire
3 structure, can besafety
used in output
systemsL11requiring Performance Levels up to PLd per 13849-1:2006.
not started if stopped nor put into production speed from safe limited speed used the
unless in systems
gate is requiring
closed and Performance Levels up to PLd per ISO
locked.
turns OFF. The DI de-energizes the two contactors and the motor
13849-1:2006. The system can not started if stopped nor put
coasts to a stop. The gate can not be unlocked until speed is less
into production speed from safe limited speed unless the gate is
than 1 Hz. Should the speed increase above safe limited speed - 39 -
closed and locked.
while the gate is unlocked, the GLP turns OFF its safety outputs. R

Safe Limited Speed with Guardlocking, E-Stops and
Safeguarding Servo Drive
Safe Limited Speed with Guardlocking, E-stops and Servo Drive
440G, 800F, 872C, GLP, DI, K300 Servo 440G, 800F, 872C, GLP, DI, K300 Servo
+24V DC
Drive Status
Gate to PLC
Reset & Unlock Stop/Start/SLS
Brown
Yellow
LightLatch Gate Lock Request Reset Commands

Red
440G-LZS21SPRA Request SLS Safety from PLC

Green Request Status
to PLC to PLC
Grey
K300
White
Blue
Pink
X14 X24 51 A1 S44 S54 Y32 L12 S11 S12 S21 S22 A1 13 23 S34
LOGIC 0 1 SL1 0 SL2 0
2
1
2 9
1
2
LOGIC 0
1
9 9 2
8 3 8 3 8 3 Safe Torque-off (STO)
76 54 3
7 6 54 7 6 54 8
4
GLP DI 6 5
7
Connector With
440R-GL2S2P 440R-D22R2 Wiring Header
S12 S22 L61 A2 AP P12 P22 L11 S32 S42 L12 L11 A2 14 24 Y32
Status
Gate Open Safety Input 1
Black
Black
- Unlocked Safety Common

Safety Input 2
Brown
Blue
Brown E-Stops
Blue 800FM-MT44
M
872C-D8NP18-E5 (2) 800F-MX02S
24V DC COM
Circuit Status
Circuit Status
The gate is closed and locked. The motor is off. The E-Stops are released and the safety
DI iscontacts energizing
ready for reset.The GLP isthe Safe
ready forTorque
reset. The O GLP
andhasallowing
a Logic the PLC
setting of 3: Safe Limited Speed with Logic in OFF, a Safe Limited Speed (SL1)control setting ofto0 return
(0.5 Hz) and
the adrive
maximum (SL2) settingspeed.
to production of 4 (100Hz).
Should The the speed
The gate is single
closedwireand locked. The motor is o. The E-Stops are released
safety output (L11) and the auxiliary output (Y32) are OFF. NOTE: Start the GLP configuration from “0” to configure the GLP
and the DI is ready for reset.The GLP is ready for reset. The GLP has increase above safe limited speed while the gatetoisaccept
unlocked the GLP
OSSD inputs at S12 and S22.
a Logic setting of 3: Safe Limited Speed with Logic in OFF, a Safe turns OFF its single wire safety. The DI immediately opens its safety
Limited Speed (SL1) setting of 0 (0.5 Hz) and a maximum (SL2) setting contacts controlling the Safe Torque O of the drive. The drive removes
Operating Principle
of 4 (100Hz). The single
STARTING: The wire safety
GLP must outputbefore
be started (L11)theand
DI.the and release the Resetpower
Pressauxiliary button to theGLP.
of the motorPressand
and the motor
release coasts
the reset buttonto aofstop.
the DI to
output (Y32) areitsOFF.
close safetyNOTE: Start
contacts allowthestart
GLPofconguration
the motor by the from
PLC“0” to
system.
Fault Detection
congure theSTOPPING:
GLP to acceptNormal OSSD
productioninputs stopping
at S12 is performed
and S22. by the PLC control system. When an E-Stop is pressed the DI immediately opens its safety
contacts controlling the Safe Torque Off of the drive. The drive removes power Upon power-up,
to the motor and thethemotorSI coasts
and GLP perform internal checks. The SI and
to a stop.
Operating Principle
SAFE LIMITED SPEED (SLS): When the Unlock Request button is pressed and released GLP checkthe GLPtheir input sends
Y32 output devices
a SLSfor faults.
request to The
the PLC440G checks its OSSD
control
system. The PLC system instructs the drive to go to speed less than 0.5Hz. When the GLP senses
outputs for that the
faults. The motion is at, or sensors
prox-imity below, SLSare theconstantly
GLP unlocks monitored by
STARTING: The GLPThe
the gate. must be started
operator can open before
the gatethe
andDI. Press
enter theand release
guarded area. After leaving the guarded area the operator closes the gate and presses and
the Reset button requiring that only one sensor is OFF at any time. The K300 monitors
releasesofthethe GLP.
Reset andPress
gate Lockandbutton
release the the
to lock reset
gate button
and endofthe SLS request. The Y32 signal turns off and the PLC control system is free to instruct
the DI to close its safety
the drive contacts
to go back allow start
to production speed.of the motor by the PLC the status of its inputs and outputs performs internal checks.
system. OVERSPEED: When the GLP detects a speed greater than the maximum speed (100Hz), the GLP turns OFF its L11 single wire safety signal. The DI
Ratings
immediately opens its safety contacts de-energizing the Safe Torque Off of the drive. The drive removes power to the motor and the motor coasts
STOPPING: to Normal
a stop. production
The GLP PWR/Faultstopping is performed
LED flashes byWhen
at a 3X rate. the thePLCspeed drops Emergency
below 100(Hz) stop initiated
pressing by anthe
and releasing E-Stop
Reset/Gate (2): These safety
Lock button willfunctions
control system.
reset When
the GLPan andE-Stop
turn its is
L11pressed theSafety
Single Wire DI immediately opensand releasing
signal ON. Pressing meetthe theDIsafety performance
reset button requirements
closes its safety of SIL2 the
contacts energizing perSafe
IEC 62061:
Torque Off
its safety contacts and allowing
controlling thetheSafe
PLC Torque
control toOreturn
of thethedrive.
drive The
to production
drive speed. 2005Should the speed
and have increase above
a Category safe limited
3 structure, canspeed whileinthe
be used systems
gate is unlocked the GLP turns OFF its single wire safety. The DI immediately opens its safety contacts controlling the Safe Torque Off of the drive.
removes power to the motor and the motor coasts to a stop. requiring Performance Levels up to PLd per ISO 13849-1: 2006 and
The drive removes power to the motor and the motor coasts to a stop.
execute a category 0 stop.
SAFE LIMITED SPEED (SLS): When the Unlock Request button is
pressed andFault
released the GLP Y32 output sends a SLS request to the
Detection Emergency stop initiated by an an Overspeed: This safety function
PLC controlUpon
system. The PLC
power-up, the system
SI and GLP instructs the drive
perform internal to go
checks. toSIspeed
The and GLP checkmeets thedevices
their input safety forperformance requirements
faults. The 440G checks its OSSD outputs of SIL2 per IEC 62061:
for faults.
The prox-imity
less than 0.5Hz. When the sensors
GLParesenses
constantly monitored
that by requiring
the motion is at,that
oronly one sensor is2005
below, OFF at and
any time.
hasThe K300 monitors
a Category the status ofcan
3 structure, its inputs and outputs
be used in systems requiring
SLS the GLPperforms
unlocks internal checks.
the gate. The operator can open the gate and Performance Levels up to PLd per ISO 13849-1: 2006 and executes a
enter the guarded area. After leaving the guarded area the operator category 0 stop.
Ratings
closes the gate and presses and releases the Reset and gate Lock
Emergency stop initiated by an E-Stop (2): These safety functions meet thePrevention safety performanceof accessrequirements of SIL2 per IEC
while dangerous 62061: 2005
motion and
is present: This safety
button to lock
havethe gate and
a Category end thecan
3 structure, SLSberequest. The Y32
used in systems signalPerformance
requiring turns Levels up to meets
PLd per theISO 13849-1: 2006 and execute a category 0 stop.
o and the PLC controlstop system is free function safety performance requirements of SIL3 per IEC
Emergency initiated bytoaninstruct the drive
an Overspeed: to gofunction
This safety back tomeets the safety performance requirements of SIL2 per IEC 62061: 2005 and
productionhas speed. 62061: 2005 and has a Category 3 structure, can be used in systems
a Category 3 structure, can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006 and executes a category 0 stop.
Prevention of access while dangerous motion is present: This safety function requiring
meets the Performance
safety performanceLevelsrequirements
up to PLd per ISO
of SIL3 13849-1
per IEC 62061:: 2006
OVERSPEED: When
2005 and thehas aGLP detects
Category a speed
3 structure, cangreater
be usedthan the requiring Performance Levels up to PLd per ISO 13849-1 : 2006
in systems
maximum speed (100Hz),
Prevention the GLP turns
of unexpected start-upOFF its Monitoring):
(Gate L11 single wire Prevention of unexpected start-up (Gate
safetyfunction meets the safety performance requirements of SIL2 per IEC 62061:
This safety
Monitoring): This safety
2005,
signal. The DI has a Category
immediately 3 structure,
opens can be
its safety used in systems
contacts function meets the safety performance
requiring Performance Levels up to PLd per ISO 13849-1: 2006. The system can not be
de-energizing requirements of SIL2 per
started,
the Safe Torque O ifofstopped, nor put
the drive. Theinto driveproduction
removes speed fromto
power safethelimited
motor IEC 62061:
speed unless the gate 2005,
is closed has
anda locked.
Category 3 structure, can be used in systems
and the motor coasts to a stop. The GLP PWR/Fault LED ashes at a 3X- 40 - requiring Performance Levels up to PLd per ISO 13849-1: 2006. The
rate. When the speed drops below 100(Hz) pressing and releasing the system can not be started, if stopped, nor put into production speed R
Reset/Gate Lock button will reset the GLP and turn its L11 Single Wire from safe limited speed unless the gate is closed and locked.
Safety signal ON. Pressing and releasing the DI reset button closes its

Speed Monitoring with Guardlocking, E-Stops and
Safeguarding Drive and Wiring Diagrams
Applications
Speed Monitoring with Guardlocking, E-Stops and Drive
TLS-ZR, GLP, DI, EMD and PF 525: TLS-ZR, GLP, DI, EMD and PF 525
+24V DC
L1 L2 L3
E-Stop
Reset & 800FM-MT44 PowerFlex R S T
Gate 525
440G- Gate Lock 800F-MX02S
Unlock 1 Stop
TSZ21UPRH Request Request
Reset
2 Start
4 Gnd
X14 X24 51 A1 S44 S54 Y32 L12 S11 S12 S21 S22 A1 13 23 S34 B1 B2 X32 A1 17 27 37 47
Range Time
LOGIC 0 SL1 0 SL2 0 LOGIC 0
1 2 3 4 34 5
1 1 1 2 1 5 2 6
2 9 2 9 2 0 6 1 7
TLS-ZR 9
8 3 8 3 8 3 8
7 4
3
7 8 Gate control
4
Brown
4 4 9
Yellow
Green
7 6 5 6 5
GLP 7 6 5 7 6 5 DI 9 8 10 power supply
EMD
Red
440R-GL2S2P 440R-D22R2 440R-EM4R2D

S12 S22 L61 A2 AP P12 P22 L11 S32 S42 L12 L11 A2 14 24 Y32 L12 L11 A2 18 28 38 48 Gate control
889D-F8AC-5 circuit
White
Blue
Grey
Pink
S1
Black
Black
S2
UV W
Brown Safety
Blue
Status
Gate Brown Blue E-Stop to PLC M
Unlocked 800FM-MT44
872C-D8NP18-E5 (2)
800F-MX02S
24V DC COM
Circuit Status
Circuit Status and removes the signals to the safe o inputs fo the PF525. The
gate is closed and locked.The motor is off. The GLP is ready for reset. Themotor GLP hasthena Logiccoasts
settingtoof a
3: stop if it is still running.
The gateTheis closed and locked.The motor is o. The GLP is ready for (Safe Limited Speed with Logic In OFF),
a Safe Limited Speed (SL1) setting of 1(1 Hz) and a maximum speed (SL2) setting of 7 (1000Hz). The single wire safety output (L11) and the
reset. The GLP has
auxiliary a Logic
outputs (Y32)setting
are OFF.ofThe 3: E-Stops
(Safe Limited
are released Speedand thewith Fault
DI is ready for reset.Detection
The EMD is configured to provide a 9 second (30% of the
Logic In 30s
OFF), a Safe
Range) OFFLimited
delay . NOTE:Speed (SL1)
Start setting
the GLP of 1(1 Hz)
configuration from and“0”ato accept OSSD inputs at S12 and S22.
Upon power-up, the TLSZR, GLP, DI, EMD and PF 525 perform
maximum speed (SL2) setting of 7 (1000Hz). The single wire safety
internal checks. The GLP checks its prox, gate, reset and unlock
output (L11) and the
Operating auxiliary outputs (Y32) are OFF. The E-Stops
Principle inputs and its L11 output. The DI generates test pulses to check
are released and the
STARTING: The DIGLPismustreadybe for reset.
started Thethe
before EMD is congured
DI. Press and release tothe Reset button of the GLP. The gate locks. The single wire safety (L11) of the
for faults at its inputs and also checks for shorts at the L11 output.
provide aGLP9 second
turns ON.(30%Press andof the 30sthe
release Range) OFF delay
reset button of the .DI.
NOTE:
The DIStart
closes its safety contacts enabling the PF525 Start-Stop buttons and its L11 turns
The button
440G checks its motor.
OSSD outputs for faults.The proximity sensors
the GLP ON.
conguration
The EMD closes fromits“0” to accept
safety contactsOSSD enablinginputs at S12
the PF525 SafeandOff. S22.
Press the Start to start the
STOPPING: Normal production stopping and starting is performed using the Start-Stop are constantly
buttons. monitored
When an E-Stop byisrequiring
pressed the that only one sensor is
DI immediately
Operating Principle
turns OFF its (L11) single wire safety signal. Simultaneously the DI safety contactsOFF openatproviding
any time. The
a stop PF525
signal monitors
to the the status
drive. The drive controlsoftheits inputs and
motor to a stop. After the 9 second OFF delay the EMD contacts open removing outputs 24V from the PF252 Safe
performs Off inputs.
internal The PF525 removes power to
checks.
STARTING: The GLP must be started before the DI. Press and
the motor. The motor, if still turning, coasts to a stop. When the speed detected by the proximity sensors drops below the Safe Limited Speed
release the Reset
(1Hz), buttoncan
the operator ofpress
the GLP. The gate
the Unlock button locks. Thethe
and open single Ratings
gate. At any time, the operator can press the Unlock button to initiate a controlled
wire safety
stop.(L11)
Afterof
thetheEMD GLP
timeturns ON.
expires, Press
its X32 andgoes
output release
to 24V the reset the resetting of the DI relay.
to enable
Emergency stop initiated by an E-Stop (2): These safety
button of the DI. The
OVERSPEED: DIGLP
If the closes its safety
detects a speed contacts
greater thatenabling
1000Hz, the the
GLP single wire safety output (L11) turns OFF. The DI safety contacts open
providing a stop command to the drive. The drive stops the motor. After 9 functions
seconds the meet
EMD the
safety safetyopen
contacts performance
and removesrequirements
the signals to theof SIL2
PF525 Start-Stop buttons and its L11 turns ON. The EMD closes its
safe off inputs fo the PF525. The motor then coasts to a stop if it is still running. per IEC 62061: 2005, have a Category 3 structure, can be used in
safety contacts enabling the PF525 Safe O. Press the Start button
systems requiring Performance Levels up to PLd per ISO 13849-1 :
to start the motor.
Fault Detection 2006 and execute a category 1 stop.
STOPPING: Upon power-up,
Normal the TLSZR, GLP,
production DI, EMDand
stopping and PF 525 perform
starting internal checks. The GLP checks its prox, gate, reset and unlock inputs and its L11 output.
is performed
The DI generatesbuttons.
test pulses to check for Emergency
the L11 output.stop initiated byOSSD
an an Overspeed:
for faults.TheThis safety
using the Start-Stop When anfaults at its is
E-Stop inputs and alsothe
pressed checks for shorts at The 440G checks its outputs
proximity sensors are constantly monitored by requiring that only one sensor is OFF atfunction any time. Themeets
PF525the safety
monitors performance
the status requirements
of its inputs and outputs of SIL2
DI immediately turns OFF its (L11) single wire safety signal.
performs internal checks. per IEC 62061: 2005, has a Category 3 structure, can be used in
Simultaneously the DI safety contacts open providing a stop
systems requiring Performance Levels up to PLd per ISO 13849-1:
signal toRatings
the drive. The drive controls the motor to a stop. After
2006 and executes a category 1 stop.
the 9 second OFF delay
Emergency the EMD
stop initiated by an contacts
E-Stop (2):open
These removing 24V meet the safety performance requirements of SIL2 per IEC 62061: 2005, have a
safety functions
from theCategory
PF252 3Safe O inputs.
structure, can beThe
usedPF525 removes
in systems requiring power to theLevels upPrevention
Performance to PLd per ISOof access: 2006
13849-1 while anddangerous motion
execute a category is present: This safety
1 stop.
motor. TheEmergency
motor, stop if stillinitiated
turning, by an an Overspeed:
coasts to a stop.This Whensafetythefunction
speed meets the safety performance
function meets therequirements of SIL2 perrequirements
safety performance IEC 62061: 2005,of hasSIL2 per
detecteda Category 3 structure, sensors
by the proximity can be used in systems
drops below requiring
the SafePerformance
Limited Levels up IEC to PLd per ISO 13849-1: 2006 and executes a category 1 stop.
62061: 2005,has a Category 3 structure, can be used in systems
Prevention of access while dangerous motion is present: This safety function meets the safety performance requirements of SIL2 per IEC
Speed (1Hz), the operator can press the Unlock button and open requiring Performance
62061: 2005,has a Category 3 structure, can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006. Levels up to PLd per ISO 13849-1: 2006.
the gate.Prevention
At any time, the operator
of unexpected can(Gate
start-up pressMonitoring):
the Unlock button
This safety function meets the safety performance requirements of SIL2 per IEC 62061:
to initiate a controlled
2005, has a Category stop. After the
3 structure, canEMD time
be used expires,
in systems its X32
requiring
Prevention of unexpected start-up (Gate Monitoring): This
Performance Levels up to PLd per ISO 13849-1: 2006. The system cannot be
output goes
startedtoif 24V to enable
stopped, theproduction
nor put into resettingspeed of thefrom DI safe
relay.limited speed, unless safety function
the gate is closed meets the safety performance requirements
and locked.
of SIL2 per IEC 62061: 2005, has a Category 3 structure, can be
OVERSPEED: If the GLP detects a speed greater that 1000Hz, used in systems requiring Performance Levels up to PLd per ISO
the GLP single wire safety output (L11) turns OFF. The DI safety 13849-1: 2006. The system cannot be started if stopped, nor put
contacts open providing a stop command to the drive. The drive - 41 - into production speed from safe limited speed, unless the gate is
stops the motor. After 9 seconds the EMD safety contacts open closed and locked. R

GSR Wiring Diagrams

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GSR Wiring Diagrams

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NHP SAFETY REFERENCE GUIDE

Guardmaster Safety Relays

NHP Safety Reference Guide > GSR Wiring Diagrams 3-2

NHP Safety Reference Guide > GSR Wiring Diagrams 3-3

NHP Safety Reference Guide > GSR Wiring Diagrams 3-4

S11 S21 S34 A1 13 23 2 Start

NHP Safety Reference Guide > GSR Wiring Diagrams 3-5

NHP Safety Reference Guide > GSR Wiring Diagrams 3-6

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

Circuit Status Fault Detection

NHP Safety Reference Guide > GSR Wiring Diagrams 3-7

Resistor Braking Module U V W

Circuit Status Fault Detection

NHP Safety Reference Guide > GSR Wiring Diagrams 3-9

800F, Trojan T15, MatGuard, SI, DI, DIS, 100S, 700S

NHP Safety Reference Guide > GSR Wiring Diagrams 3-10

S12 S22 A2 14 24 32 S21 S22 A2 L11 Y32 14 24

Circuit Status Fault Detection

NHP Safety Reference Guide > GSR Wiring Diagrams 3-11

SensaGuard, CI, 800F, 100S:

Circuit Status Fault Detection

- 13 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-15

- 14 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-16

- 15 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-17

S11 S21 S22 S12 A1 13 23 S34

- 17 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-19

SensaGuard Integrated Latch 525

- 18 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-20

- 19 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-21

800F, TLS1-GD2, Trojan T15-GD2, DI, EMD, 700S:

- 20 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-22

STARTING: Remove the enabling switch from the MT-GD2 holders.

NHP Safety Reference Guide > GSR Wiring Diagrams 3-23

- 22 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-24

Input Input Output +

1793-IB6 1793-IV16 1793-OB4

S11 S21 S22 S12 A1 13 23 S34 L1 L2 L3

- 24 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-26

Select Zone B (White/Yellow & White/Green)

Warning Field (White/Brown) Input Input Output

1746-IB16 1746-IV16 Processor 1746-OB4

- 25 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-27

1769-IQ16 1769-IV16 PLC 1769-OB8

- 26 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-28

NHP Safety Reference Guide > GSR Wiring Diagrams 3-29

- 28 - NHP Safety Reference Guide > GSR Wiring Diagrams 3-30

S11 S21 S12 S22 S32 S42 S34 A1 Gate Control

Circuit Status Fault Detection

NHP Safety Reference Guide > GSR Wiring Diagrams 3-31

NHP Safety Reference Guide > GSR Wiring Diagrams 3-32

Micro 400, 800F, MSR41, DIS, 100S:

Safety Output Stop

NHP Safety Reference Guide > GSR Wiring Diagrams 3-33

Micro 400, SensaGuard, 800F, MSR42, DIS, DI, 100S:

NHP Safety Reference Guide > GSR Wiring Diagrams 3-34

Gate Reset &

Request Start with DriveGuard

Gate Reset & L1 L2 L3

Gate Reset & PowerFlex 70

Unlock Gate Lock Start with DriveGuard

NHP Safety Reference Guide > GSR Wiring Diagrams 3-41

LightLatch Gate Lock Request Reset Commands

440G-LZS21SPRA Request SLS Safety from PLC