Safety Applications and Wiring Diagrams: Application Selection Table 10-2

Safety Applications and Wiring Diagrams
Table of Contents
General
Safeguarding Applications and Wiring Diagrams
Application Selection Table 10-2
Notes for Use with Application Circuit Examples 10-4
Principles
Safeguarding Applications and Wiring Diagrams 10-5
Light CurtainPoint of Operation Control . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Cable Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Interlock SwitchesMultiple Gate Access . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Light Curtain & Two-Hand ControlPunch Press . . . . . . . . . . . . . . . . . . . . 10-8
Configurable RelayTwo Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Interlock SwitchesMultiple Gate Access . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Configurable RelayTwo Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Enabling Device & DriveSafe Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Interlock SwitchesGuard Locking with Time Delay . . . . . . . . . . . . . . . . 10-13
Interlock SwitchGuard Locking with Time Delay . . . . . . . . . . . . . . . . . . 10-14
Interlock Switch and Enabling Device Guard Locking with Time Delay. 10-15
Interlock Switch & Modular RelayGuard Locking with Standard Drive . 10-16
Configurable RelaySingle Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
DriveMultiple Gate Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
DriveGate & Cascaded Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
9-
Drive & Safety I/OIntegrated Architecture. . . . . . . . . . . . . . . . . . . . . . . . 10-20
Interlock Switch Gate with High Current Outputs . . . . . . . . . . . . . . . . . . . 10-21
Safety MotionDelayed Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Safety MotionDelayed Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
Safety Motion & Safety I/OIntegrated Architecture . . . . . . . . . . . . . . . . 10-24
Safety PLCTwo Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Safety PLCTwo Zones with Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
Safety PLCTwo Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
Safety I/OTwo Zones Distributed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
Safety I/OSingle Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
Safety Valve & E-StopAir Supply Release . . . . . . . . . . . . . . . . . . . . . . . 10-30
10-Table of
Safe Limited Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
Contents
Modular RelaySingle Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Light CurtainMuting with Two Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
Light CurtainMuting with Four Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Configurable RelayMuting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Expandable OutputsE-Stop with Immediate and Delayed Outputs. . . . 10-36
Mat Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Micro 400 Light Curtain with Controller and Expansion Module . . . . . . . . 10-38
Two Sensor Muting with Micro 400 Light Curtain . . . . . . . . . . . . . . . . . . . 10-39
Four Sensor Muting with Micro 400 Light Curtain . . . . . . . . . . . . . . . . . . . 10-40
Operator
Interface
Logic
Power
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Publication S117-CA001A-EN-P 10-1
Application Selection
Light
Curtain E-Stop Cable Pull
Guard- Laser Tongue Guard
General
Shield Mat Scanner Switch Non-Contact Locking 800F Lifeline

Page No. SIL CL PL Cat.1 Stop Cat. Input Device
5 3 e 4 0
6 2 d 3 0
7 2 d 4 0 Trojan 5 SensaGuard
8 2 d 3 0
9 3 e 4 0 Sipha
Elf
10 2 d 3 0
Trojan 15
Principles
11 3 e 4 0 Sipha
12 2 d 3 0 MT-GD2
13 3 e 3/4 0/1 TLS-GD2
14 3 e 4 0
Cadet 3
15 2 d 3 0 Trojan 5
MT-GD2
16 2 d 3 0 Trojan 5
17 2 d 3 1
18 2 d 3 0 Trojan 15
19 3 e 3/4 0
9-
20 3 e 3/4 1
21 3 e 4 0
22 3 e 4 0 SensaGuard 440G-MT
23 3 e 3/4 0/1 SensaGuard 440G-MT
10-Application
26 3 e 4 0/1 440G-MT
Selection
27 3 e 4 0
28 3 e 4 1
TLS3-
29 2 d 3 1
GD2
30 2 d 3 0
31 3 e 4 0
32 3 e 4 0
33 3 e 4 0
TLS3-
34 3 e 4 0
GD2
Operator
Interface
35 3 e 4 1
36 3 e 4 0/1
37 2 d 3 1
38 3 e 4 0
39 3 e 4 0
40 3 e 4 0
1 These ratings are general guidelines that would likely apply in most instances. Safety performance ratings are applied to safety functions. The safety rating
must be applied from an input device through a logic device to an output device. Many of the application examples contain multiple devices and may have
mulitple safety functions. Therefore, a detailed analysis of the application and complete implementation of the standard is required and may result in ratings
Logic
that differ from the guidelines provided.

Power

10-2 Publication S117-CA001A-EN-P R
Application Selection
Enabling
Device Drive Motion
Grip Standard 100 200 300 Drive- Guard-
General
Switch PLC Series Specialty Series Series GuardPLC SmartGuard Guard I/O Contactors Guard Motion
Input Device Logic Output Devices Page No.
MSR127 100S 5
MSR127 100S 6
MSR127 100S 7
MSR126 MSR35H 100S 8
700S 9
MSR127 100S 10
Principles
100S-700S 11
MSR127 MSR178 12
MSR138 700S 13
100S 14
MSR127 15
MSR127 16
CompactBlock 17
MSR126 Flex I/O 18
MSR138 100S 19
9-
MSR138 20
CompactBlock 100S 21
1600 100S 22
1800 100S-700S 23
100S 24
CompactBlock 100S-700S 25
10-Application
CompactBlock 100S-700S 26
Selection
MSR142 Valve 27
MSR138 MSR178 100S 28
MSR57 29
MSR211 100S 30
MSR22LM 100S 31
100S 32
100S 33
MSR138 100S 34
Operator
Interface
MSR144 100S-700S 35
MSR230/
MSR210 100S 36
MSR238
Mat
100S 37
Manager
MSR41 100S 38
MSR42 100S 39
MSR42 100S 40 Logic
Power

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Notes for Use with Application Circuit Examples
Note 1
In the following circuits the type of Allen-Bradley/Guardmaster device is shown as an example to illustrate the circuit principle. For specific
applications the choice of device type should be based on the suitability of its characteristics for its intended use.
General
Note 2
In most of the following examples showing dual channel applications, one interlock switch is shown switching both channels (one contact set
per channel). If it is foreseeable that damage to the guard (e.g., at the actuator mounting point) could allow it to be opened without operating
the switch then two separate switches may be required. The electrical principle of the circuit will remain the same.
Note 3
In most cases the circuits are shown with the guard door closed and ready for motor starting by operating the normal start control.
It must be possible to start the machine only by voluntary actuation of the control provided for the purpose (see ISO 12100-2 4.11.8). For the
Principles
purposes of these examples the use of a conventional contactor latching circuit has been assumed. If this is not the case, then a restart
interlock will be required to prevent an automatic or unintended starting of the motor when the guard is closed. For example, a Minotaur
safety relay with a momentary action push button installed in the output monitoring circuit can be used to achieve this.
If the guard is designated as a Control Guard (see ISO 12100-2 5.3.2.5) these requirements do not apply but the use of control guards is only
allowed under certain conditions including:
A control guard can only be used where there is no possibility of an operator or part of his body staying in or reaching into the danger zone
whilst the guard is closed.
The control guard must be the only access to the hazard area.
The interlocking system must have the highest possible reliability. It is often advisable to use a solenoid locking switch such as the
Guardmaster Atlas or TLS-GD2.
Note 4
9-
Safety monitoring relay units used in dual channel circuits with 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.
Certain faults are only detected at a change of state of the input switching device (interlock switch or E-Stop switch). If there are long periods
(e.g. months as opposed to days) between switching actions, it may be possible for multiple faults to accumulate which could lead to a
dangerous situation. Therefore a regular check should be performed on the system in order to detect single faults before an accumulation
occurs. This check may be manual or initiated by part of the machines control system.
If, for example, 3 interlock switches are connected to the monitoring unit, certain faults will only be detected at the switch on the first guard
10-Notes
to be opened and the switch on the last guard to be closed. This is because any switching between the first opening/last closing will not
change the state of the monitoring unit input circuits. Therefore in some applications it may be necessary to use one monitoring device per
switch.
Most of the following examples show an interlock switch and an emergency stop switch combined in the circuit. When a monitoring safety
relay (e.g. Guardmaster Minotaur) is used for fault detection it is important to note the following:
All safety critical single faults, except for certain faults over the contact sets at the E-Stop, will be detected at the next opening of the guard.
All safety critical single faults, except for certain faults over the contact sets at the interlock switch, will be detected at the next operation of
the E-Stop.
Because the E-Stop device is not likely to be operated frequently, it is recommended that its function is checked (with the guard closed) on
a regular basis (start of shift or daily) to enable the Minotaur to detect single faults. If the guard is rarely opened, the interlock switch should
Operator
Interface
be checked in a similar manner.
Note 5
This symbol indicates that the associated component or device features direct opening (positive opening) operation. In the event of a fault, welded contacts
will be forced open by the motion of the safety guard.
This symbol denotes mechanically linked contacts; if one contact welds closed, all other dependent (auxiliary) contacts remain in position, i.e. they cannot
change state.
General Safety Information

This application example is for advanced users and assumes that you are trained and experienced in safety system requirements.
IMPORTANT
Logic
Contact Rockwell Automation 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 identified 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.
Power
For other Important User Information and Safety Guidelines, please review pages G-2 and G-3 in the General section of this catalog.

Light CurtainPoint of Operation Control
GuardShield, 800F, MSR127, 100S
+24V DC
Machine control system
K1 can replace this circuit
Start
Transmitter Receiver arrangement.
General
800FM-F3MX10
Brown Brown K2
1 2
Red
8 Restart (not used)
Stop
Yellow 800FM-E4MX01
4 EDM (not used)
Pink
6 Reset
Grey
5
Principles
L1 L2 L3
1 White
Aux Signal S11 S12 S52 A1 13 23 33 41
To PLC K1
Blue
7 RP
MSR127TP
Blue Green 440R-N23135
3 3 K2
440L-P4K0960YD S21 S22 S34 A2 14 24 34 42
889D-F4AC-2 889D-F8AC-2
Aux Signal
To PLC M
9-
K1 K2 100S-C43DJ404BC
24V DC Com
Circuit Status
The light curtain is configured with the factory default settings (Guard only mode) and is unobstructed. The outputs of the safety relay are open. The motor is off and
Applications
10-Safety
ready to run.
Operating Principle
STARTING: Press the Reset button to close the outputs of the MSR127. Press the Start button to energize contactors K1 and K2. The motor starts with the two
normally open contacts of K1 and K2 holding the circuit energized.
STOPPING: Obstructing the light curtain de-energizes the safety outputs of the MSR127, which in turn drops out K1 and K2. The contactors disconnect the motor from
its power source, and the motor coasts to a stop. Clearing the obstruction in the light curtain does not cause the motor to energize (the Reset and Start buttons must
be pressed). The motor can also be turned off by pressing the stop button.
Fault Detection
Operator
Interface
Upon successful completion of internal checks on power up, the GuardShield light curtain energizes its outputs with no objects present. The GuardShield light curtain
outputs turn on. If a crossfault is detected, the GuardShield light curtain goes to a lockout state with its outputs off. After successful completion of internal checks, the
MSR127 checks the signals from the light curtain. If OK, the MSR127 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. The MSR127 will detect the faulted contactor and will not allow the motor to restart until the fault is corrected.
Contactors K1 and K2 are controlled by the safety system. Contactor K2 is controlled by both the machine control system and the safety system. This increases the
probability of performance of the safety function because K1 is significantly less likely to weld at the same time as K2 due to the diversity of expected wear out times.
Ratings
The safety function intiated by the GuardShield light curtain meets the safety performance requirements of SIL CL 3 per IEC 62061:2005 and has a Category 4
structure that can be used in systems requiring Performance Levels up to PLe per ISO 13849-1:2006. This circuit executes a Category 0 stop.
Logic
Power

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Cable Pull
Lifeline, 800F, MSR127, 100S
+24V DC
Start K1 can replace this circuit
800FM- arrangement.
General
F3MX10 K2
Stop
800FM-
Lifeline Lifeline E4MX01
440E-L13042 440E-L13043
(M20) (1/2in NPT)
43 31 21 11 11 21 31 43
Principles
Cable
L1 L2 L3
44 32 22 12 12 22 32 44 S11 S52 S12 A1 13 23 33 41
K1
MSR127TP
855D-T10SC20B24Y4 440A-A17123 440R-N23132
800T-N319R K2
S21 S22 S34 A2 14 24 34 42
Aux Signal M
9-
K2 To PLC
K1
100S-C43DJ404BC
24V DC Com
Circuit Status
Both Lifeline cable pull switches are taut and reset; their contacts are closed. The MSR127 safety relay is energized, as its inputs and monitoring circuits are satisfied.
Applications
The motor is off and ready to run.

10-Safety
Operating Principle
Two cable pull switches are used to protect an area over 10 meters in length. Auxiliary lights provide indication as to which switch has been actuated to stop the motor.
The difference between the two switches is the conduit thread and is shown for example purposes.
STARTING: Press the Start button to energize contactors K1 and K2. The motor starts and the two normally open contacts of K1 and K2 close to hold the circuit
energized across the Start button.
STOPPING: Pull the Lifeline cable or press the e-stop button on the Lifeline switch to de-energize the outputs of the MSR127 and turn off the motor. To restart the motor,
make sure the area is clear of hazards, pull out the e-stop button (if pressed) and rotate the reset knob on the Lifeline 4 to the Run position. Then press the Start button
to start the motor. As an alternative, the motor can be stopped by pressing the Stop pushbutton. It can then be restarted by pressing the Start pushbutton.
Operator
Interface
Fault Detection
Upon successful completion of internal checks on power up, the MSR127 checks its input circuits. With both Lifeline switches reset, the MSR127 checks the output
contactors through the S12/S34 circuit. If the contactors are off, the MSR127 energizes its outputs and turns on the contactors which turn on the motor. A short or open
circuit fault in the Lifeline cable pull switches will be detected by the MSR127. If either the K1 or K2 faults in the energized state, the motor will be stopped by the other
contactor and the fault will be detected by the MSR127 on the next attempt to restart. An internal fault in the MSR127 will be detected by itself. Depending on the type of
fault, the result will be de-energization of the K1 and K2 contactors or prevention of re-start.
Ratings
The safety function initiated by the Lifeline cable pull switches meets the safety performance requirements of SIL CL 2 per IEC 62061:2005 and has Category 3
structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006. The series connection of the Lifeline cable switches limits
Logic
the circuit to SIL CL2 and Category 3. This circuit executes a Category 0 stop.
Power

Interlock SwitchesMultiple Gate Access
SensaGuard, Trojan 5, 800F, MSR127, 100S
+24V DC
Shown Open Remove for Cat 4.
K1
General
Start
800FM- K2
Trojan 5-GD2 F3MX10
440K-T11471
11 12
SensaGuard SensaGuard Stop
2 3 7 1 4 8 5 6 2 3 7 1 4 8 5 6 2 3 7 1 4 8 5 6 21 22 800FM-
Pink (OSSD2)
Red
Gray (OSSD1)
Brown
White (Aux)
Yellow
E4MX01
Green
Blue
33 34
Principles
Machine control
system
SensaGuard can replace
440N-Z21S26H this circuit
Cordset arrangement.
889D-F8AB-2 L1 L2 L3
S11 S52 S12 A1 13 23 33 41
Machine Control K1
PLC Input RP
MSR127TP
(1756-IB16 Auxiliary
1769-IQ16 Signals 440R-N23132
1746-IB16 to Machine K2
I0 S21 S22 S34 A2 14 24 44 42
1792-IB16 Control
9-
I1
1734-IB4 System
I2
1793-IB6
I3
or similar) I4 M
Com K1 K2 100S-C43DJ404BC
24V DC Com
Applications
10-Safety
Circuit Status
The first, third and fourth gates are closed. The second gate is open. The MSR127 safety relay S12 and S52 inputs are open due to the open gate, and therefore, the
MSR127 safety outputs are open. The machine control PLC has a 24V auxiliary signal at terminal I1 from the second gate because the gate is open. The 1st, 3rd and
4th auxiliary signals are off, as their gates are closed. The PLC also has an auxiliary signal from the MSR127 indicating that the safety system is not ready. The motor
is off.
Operating Principle
STARTING: Closing the second gate satisfies the input of the MSR127. The MSR127 verifies that both K1 and K2 contactors are off and energizes its safety outputs.
Operator
Interface
Pressing the start button energizes the motor. The Stop/Start circuit is not part of the safety system and can be replaced by the machine control system (e.g., a PLC).
STOPPING: Press the Stop button to turn the motor off, without affecting the status of the safety system. Opening any of the gates will cause the safety system to stop
the motor.
Fault Detection
Upon successful completion of internal checks on power up, the SensaGuard interlocks check for 24V at pins 4 and 8. If the actuator is within range, the SensaGuard
will activate its OSSD outputs. The OSSD outputs perform continuous checking for short circuits to 24V, ground and crossfaults. Upon detection of a fault, the OSSD
outputs turn off. The MSR127 also performs internal checks on power-up. It then checks for input signals. If okay, the MSR127 checks the S12/S34 monitoring circuit
to determine whether both contactors are off. If one of the contactors gets stuck on, the other contactor will de-energize the motor, and the MSR127 will detect the fault
at the next attempt to start the motor. The contactors have mechanically linked auxiliary contacts to help ensure fault detection of the contactors. Contactors K1 and
K2 are controlled by the safety system. Contactor K2 is controlled by both the machine control system and the safety system. This increases the probability of
Logic
performance of the safety function because K1 is significantly less likely to weld at the same time as K2 due to the diversity of expected wear out times.
Ratings
The safety function initiated by the Lifeline cable pull switches meets the safety performance requirements of SIL CL 2 per IEC 62061:2005 and has Category 3
structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006. When a device with two mechanically operated contacts is
connected in series with the SensaGuard, the maximum rating is Category 3. If the Trojan 5 GD2 were removed from the circuit, the safety performance meets the
requirements of Category 4. The SensaGuard interlocks are designed to meet Category 4 when connected in series. The MSR127 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).
Power

R
Light Curtain & Two-Hand ControlPunch Press
GuardShield, 800Z, MSR35H, MSR126, 100S
+24V DC
Transmitter Receiver
Brown 1 2 Brown
6 Pink
General
5 Grey
Blue 3 Blue
7
GuardShield
440L-P4K0640YD
889D-F4AC-2 889D-F8AC-2
Reset
800FM-F6MX10
Brown
White
Black
Principles
L1 L2 L3
800Z-GL3Q5B S1
S21 S11 S34 Y41 A1 Y2 S12 S22 A1 S33 13 23
889N-F5AE-6F
K1
MSR126R
Blue
Grey
MSR35H
440R-D23202 440R-N23123
Two-Hand
Control 24VDC
K2
Brown
White
S12 S22 A2 14 24 32
Black
S21 A2 S34 14 24
800Z-GL3Q5B S2
889N-F5AE-6F
Motor
Blue
Grey
9-
K1 K2
100S-C09DJ14BC
24V DC Com
Circuit Status
The operator's hands are not on the two 800Z palm buttons. The outputs of the MSR35H are off. The light curtain is configured with the factory default settings (Guard
Applications
only mode) and is unobstructed. The outputs of the MSR126R safety relay are off. The motor is off and ready to run.
10-Safety
The light curtain is protecting one portion of the machine. An operator, using two-hand control is accessing a different portion of the machine and has full view of his or
her area.
Operating Principle
STARTING: Press the Reset button to energize the output of the MSR126. The operator places both hands on the 800Z buttons simultaneously (within 0.5 s). The
outputs of the MSR35H (terminals 14, 24) energize the 100S contactors, which start the motor.
STOPPING: Removing one or both hands from the 800Z palm buttons causes the outputs of the MSR35H to turn off, which drops out K1 and K2 and stops the motor.
Obstructing the light curtain de-energizes the safety outputs of the MSR126R, which in turn drops out K1 and K2 and turns the motor off. Clearing the light curtain does
not restart the motor, even if the operator has their hands on the palm buttons. The reset button must be pressed after the light curtain is cleared.
Operator
Interface
Fault Detection
Upon power up, the 800Z, GuardShield, MSR35H and MSR126 perform internal checks. After passing internal checks, the MSR35H waits for a change of state of its
inputs. Faults (opens and shorts) at the inputs will be detected by the MSR35H and prevent the outputs from being energized. The GuardShield light curtain also
performs checks on its OSSD output signals for crossfaults, shorts and opens. The MSR126 looks for dual signals at its inputs. It then checks the status of the
contactors. If one contactor fails in the actuated state, the other contactor will stop the motor. The MSR126 will detect if one of the contactors are stuck in the energized
position, and prevents restart.
Ratings
The safety function initiated by the light curtain meets the safety performance requirements of SIL CL 3 per IEC 62061:2005 and has a Category 4 structure, which can
be used in systems requiring Performance Levels up to PLe per ISO 13849-1: 2006. The safety function initiated by the 800Z palm buttons meets the safety performance
requirements of SIL CL 2 per IEC 62061:2005 and has a Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1:2006.
Logic
This circuit executes a Category 0 stop.

Power

Configurable RelayTwo Zones
GuardShield, Sipha, MatGuard, 800F, MSR310P, MSR320P, 100S, 700S
+24V DC
General
GuardShield Light Curtain
440L-P4K0960YD
Sipha S21 E-Stop

440N-S32015 800FM-MT44
OSSD1 OSSD2 Start-up Test 800F-MX02V
L1 L2 L3
S12 S22 S32 S12 S22 S32 S12 S22 S32 S11 S21 S31 A1 Y31 Y40 Y41 Y42 13 23 31
Principles
K1
MSR MSR
MSR210P
221P 220P K2
440R-H23176
440R-H23179 440R-H23178
S42 S52 S62 S42 S52 S62 S62 S41 S42 S51 S52 A2 Y30 Y32 Y33 S34 Y1 Y2 14 24 32
OSSD1 OSSD2 K1
MatGuard 700S-CFB440DJC
Sipha S21 Safety Mat & Trim Reset K2
440N-S32015 440F-M2030BYNN 800FM-F6MX10
440F-T2030
GuardShield Light Curtain No Startup Test
9-
440L-P4K0960YD Output
Active MSR210
Ready
24V DC Com
Applications
Circuit Status
10-Safety
The light curtains are unobstructed. The safety gates are closed. The e-stop is reset and the safety mat is unoccupied. The MSR210 outputs are off. The motor is ready to
run.
Operating Principle
The MSR200 is chosen as the safety relay for its modularity and ability to handle diverse devices, and to allow each device to be connected to individual inputs. The
MSR200 has communication modules (not shown) to allow individual status information to be transmitted to the machine control system.
STARTING: Press the reset button to energize the outputs of the MSR210 and turn the motor on.
STOPPING: Activating any one of the safety devices (light curtain, e-stop, safety mat, or gate) de-energizes the MSR210 outputs and the motor coasts to a stop. If a
safety device is activated, the motor cannot start.
Operator
Interface
Fault Detection
Upon successful completion of internal checks on power up, the MSR210P checks the input circuits. Shorts from the inputs to power, to ground or to other inputs will be
detected immediately by the MSR210P and will prevent energization or will de-energize all of its outputs. If one of the 700S safety control relays (K1 or K2) fails in an
actuated state, the motor will be able to stop by the 2nd relay (K2 or K1). This type of fault will be detected by the MSR210P on the next attempt to restart, and the
MSR210P will not energize its outputs when the reset button is pressed. Upon power-up, one of the safety gates must be opened and closed to confirm proper operation.
Since the noncontact sensor uses a N.O. contact, a broken wire may exist prior to usage. A startup test confirms the operation of the N.O. contact. For Start-up test,
connect terminal S12 or S42 to terminal S31. If startup test is not desired, connect S12 or S42 to S21. With the start-up test, the gates must be opened and closed to
confirm operation of both the N.O. and N.C. contacts. After successful completion of the start-up test, the reset button must be pressed momentarily to energize the
outputs of the MSR210P.
Logic
Ratings
The safety functions initiated by the GuardShield light curtains, Sipha non-contact interlocks, and the 800F e-stop button meet the safety performance requirements
of SIL CL 3 per IEC 62061:2005 and has Category 4 structure that can be used in systems requiring Performance Levels up to PLe per ISO 13849-1: 2006. The
safety functions initiated by the safety mat are limited to SIL CL 2 and Category 3, PLd. This example circuit performs a Stop Category 0 function (coast to stop).
Power

R
Interlock SwitchesMultiple Gate Access
Trojan T15, Elf-GD2, 800F, MSR127, 100S
+24V DC
Start K1 can replace this circuit
800FM- arrangement.
General
Trojan T15-GD2 ELF-GD2

F3MX10 K2
440K-T11397 440K-E33046
E-stop
800FM-MT44MX02V Stop
800FM-
E4MX01
11 12 11 12
21 22 21 22
Principles
L1 L2 L3
S52 S11 S12 A1 13 23 33 41
K1
Input PLC Output RP

MSR127TP
1756-IB16 Processor 1756-OW16I 440R-N23132
1769-IQ16 1769-OW8 K2
1746-IB16 1746-OW4 S21 S22 S34 A2 14 24 34 42
1734-IB4 1734-OW2
1793-IB6 1793-OW4
M
9-
K1 K2 100S-C43DJ404BC
24V DC Com
Circuit Status
Circuit shown with the safety gates closed and e-stop released. The safety relay is de-energized. The motor is off.
Applications
10-Safety
Operating Principle
With 2 N.C. + 1 N.O. interlocks, a potential exists for the gate to be slightly open which results in the auxiliary contact being closed and the safety being open. The
machine cannot start and the PLC does not know which gate is open. By sending the second safety channel through the PLC, the machine control system knows which
door is open, when the safety system is off due to a gate that may be slightly open. The infinite simultaneity feature of safety relays like the MSR127 allow enough time
for the PLC to process all the gates and close the second channel of the safety relay without creating a lockout condition.
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 PLC must then open
Ch2 of the safety relay. The logic in the PLC must open the Ch2 signal if any one or more of the safety gates are open and must only close the Ch2 circuit when all of
the safety gates and e-stop are closed. The PLC can also use the information on the inputs on PanelView or similar device. The auxiliary signal (41/42) from the
MSR127 must be an input to the PLC. This PLC program must only close its output when all the safety inputs are closed and the auxiliary signal from the MSR127 is
closed. This allows the PLC to indirectly confirm that its own output is working properly.
Operator
Interface
STARTING: Channel 1 input (S11/S12) of the MSR127 is satisfied. Using isolated relay contacts in its output module, the PLC closes the second safety channel (21/22
of the MSR127). The safety outputs of the MSR127 close. Press the Start button to start the motor.
STOPPING: Opening any one of the safety gates or pressing the e-stop causes the motor to turn off. Closing the gate or releasing the e-stop does not cause the motor
to start due to the start-stop interlocking circuit. To restart the motor, close the safety gate or release the e-stop. Then press the start button.
Fault Detection
If the PLC fails with its output closed, the safety relay will detect the difference between the safety gate and the PLC and stop the motor. A single fault (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 until the fault is corrected or power is cycled. If
either contactor K1 or K2 sticks ONthe motor will stop on command due to the other contactor, but the MSR127 cannot be reset (thus the fault is revealed to the
Logic
operator). A single fault detected on the MSR127 input circuits will result in the lock-out of the system to a safe state (OFF) at the next operation of the safety gate or
e-stop device.
Ratings
The safety function initiated by the Trojan T15 safety gate interlocks and the 800F e-stop meets the safety performance requirements of SIL CL 2 per IEC 62061:2005
and has a Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006. This circuit executes a Category 0 stop.
Power

Configurable RelayTwo Zones
GuardShield, Sipha, MatGuard, 800F, MSR310P, MSR320P, 100S, 700S
+24V DC
General
MatGuard
Safety Mat & Trim E-Stop
440F-M2030BYNN 800FM-MT44
440F-T2030 440N-S32015 800F-MX02V
Sipha S21 Group1 Output Group2 Output
Start-up Test MSR330P MSR330P
440R-W23221 440R-W23222
S12 S22 S32 S12 S22 S32 S12 S22 S32 S11 S21 S31 S41 S51 Y40 Y41 Y42 A1 13 23 33 41 13 23 33 41
G1 F8 G2 F9 G3 F2
Principles
Group 1 Inputs Group 2 Inputs Group 1&2 Inputs
Minotaur
MSR310P
MSR320P MSR320P MSR320P 440R-W23219
440R-W23218 440R-W23218 440R-W23218
S42 S52 S62 S42 S52 S62 S42 S52 S62 A2 Y31 Y32 Y33 Y34 Y10 Y11 Y12 Y13 14 24 34 42 14 24 34 42
K1 K4
OSSD1 OSSD2 OSSD1 OSSD2
A B
Group 1 Active
K1 K4
Group 2 Active
K2 K5
E-Stop
800FM-MT44 K3 K6 K2 K5
GuardShield GuardShield
800F-MX02V
9-
Light Curtain Light Curtain
440L-P4K0960YD 440L-P4K0960YD Reset K3 K6
800FM-F6MX10
24V DC Com
100S Contactors or 700S Relays
Circuit Status
The light curtains are unobstructed. The safety gate is closed. The e-stops are reset, and the safety mat is unoccupied. The MSR330P outputs are off. K1-K6 are ready to
Applications
be energized.
10-Safety
Operating Principle
The MSR300 is chosen as the safety relay for its zoning capability. The two e-stops operate globallyturning off both sets of outputs for Groups 1 and 2. The light curtain
A and safety mat control the outputs of Group 1. The light curtain B and safety gate control the outputs of Group 2. With no connections to Y40-Y42, all outputs have
monitored manual reset.
STARTING: Press the reset button to energize all MSR330P outputs.
STOPPING: Obstructing the light curtain A or stepping on the safety mat turns off the Group 1 outputs while leaving the Group 2 outputs energized. The reset button must
be pressed to re-energize the Group 1 outputs after light curtain A and safety mat are cleared. Obstructing the light curtain B or opening the safety gate turns off the
Group 2 outputs. The reset button must be pressed to re-energize the Group 2 outputs after light curtain B is cleared and the safety gate is closed. Pressing either e-stop
de-energizes both Group 1 and Group 2 outputs. The e-stop must be released and the reset button must be pressed to re-energize the Group 1 and 2 outputs.
Operator
Interface
Fault Detection
Upon successful completion of internal checks on power up, the MSR310P checks the input circuits. Shorts from the inputs to power, ground or other inputs will be
detected immediately and will prevent energization or will de-energize the MSR330P outputs. If one of the 100S or 700S output devices (K1-K6) is stuck in an actuated
state, the MSR310P will prevent startup because the Y11 or Y12 feedback loop will remain open.
Ratings
The rating assumes that two contactors are connected in series to power a hazard (not shown). The safety function initiated by the GuardShield light curtains, Sipha
interlocks and 800F e-stop meet the safety performance requirements of SIL CL 3 per IEC 62061:2005 and has a Category 4 structure that can be used in systems
requiring Performance Levels up to PLe per ISO 13849-1: 2006. The safety function initiated by MatGuard safety mats meet the safety performance requirements of
Logic
SIL CL 2 per IEC 62061:2005 and has a Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1:2006. This circuit
executes a Category 0 stop.
Power

R
Enabling Device & DriveSafe Jog
440G-MT, GripSwitch, MSR127, MSR178, PowerFlex DriveGuard
24V DC
GripSwitch
440J-N21TNPM-NP
General
Jog Button
5 6 Machine control system
Trigger can replace this circuit
arrangement. L1L2 L3
Switch
1 2
PowerFlex R S T
DriveGuard
3 4 24V DC
Start DC Comm
Dig . Comm
Stop Start
Principles
Gate Control
11 12 S21 S52 S11 A1 13 23 33 41 + Y21 Y22 B11 B21 B12 B22 17 27 37 46 45 Stop Power Supply
21 22 Minotaur Minotaur
MSR178DP Safe Off Option
MSR127TP 1
33 34 440R-N23132 440R-M23227 3
44 Single Pulse 0,5...10s
43 4
S22 S12 S34 A2 14 24 34 42 Y31 Y32 Y10 Y11 18 28 38 49 2
MT-GD2
440K-MT55050 Jog Gate
Enable Control
Circuit
Remove Jumper U V W
9-
24V DC Com M
Circuit Status
The 440J GripSwitch is held by the MT-GD2. The MSR127 safety outputs are closed. The PowerFlex Enable and Safe-off option are energized. The MSR178 safety
outputs are de-energized. The motor is ready to run.
Applications
10-Safety
Operating Principle
The MSR178 is chosen for its ability to perform timing functions. In this case, the MSR178 is set up to jog the PowerFlex drive with a single pulse having a duration set
between 0.5 to 10 s (no jumpers form Y10 to Y31 or Y32 and fine adjustment made by potentiometer on front of MSR178). While in the MT-GD2 holder, the GripSwitch is
disabled, and the drive can be controlled by the machine control system (not shown).
STARTING: Close the three-position trigger switch to the mid-position. Remove the enabling switch from the MT-GD2 holder. Press and hold the Jog button on the
GripSwitch to initiate the operation of the MSR178. The MSR178 closes its safety outputs for the set duration.
STOPPING: The jog function stops after the set time expires. To restart, momentarily release the jog button and then re-close it to repeat the jog. Releasing or squeezing
the three-position switch opens the outputs of the MSR127, and the PowerFlex drive executes a coast to stop.
Fault Detection
Operator
Interface
Upon successful completion of internal checks by the MSR127, MSR178 and the PowerFlex drive, the drive awaits the closure of the MSR127 safety outputs. If the
MSR127 fails, the drive will not energize the motor and the fault will be detected by non-operation of the motor. The MSR127 uses dual channel to detect faults to power,
ground and cross channel faults on the GripSwitch or the MT-GD2. A short across the jog switch will be detected as a subsequent jog attempt will be prevented by the
MSR178. A fault in the Safe-Off option of the drive will be detected by the MSR127 on the next attempt to restart the drive. Internal faults in the MSR127 will result in
non-operation of the motor. Internal faults of the MSR178 will result in non-operation of the jog function.
Ratings
The safety function initiated by GripSwitch enabling device meets the safety performance requirements of SIL CL 2 per IEC62061:2005 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 0 stop.
Logic
Power

Interlock SwitchesGuard Locking with Time Delay
800F, MSR138, TLS1 GD2, 700S
+24V DC
General
800FM-MT44
800F-MX01V
800F-MX01S
Reset L1 L2 L3
800FM-F6MX10
Lock
Release
Power to
Release
Principles
S11 S52 S21 A1 S33 S34 13 23 37 47 55
11 21 33
K1
MSR138.1DP
41 53
A1 12 22 34 440R-M23084 K2
A2
42 54 S12 S22 A2 Y1 Y2 Y39 Y40 14 24 38 48 56
TLS1 GD2
440G-T27171
U V W
M
Remove internal
9-
jumper from
12 to 41
Gate
700S-CFB440DJC K1 K2 Release
Enabled
24V DC Com
Applications
10-Safety
Circuit Status
The e-stop is reset and the safety gate is closed. The outputs of the safety relay are open and the motor is off.
Operating Principle
STARTING: Press the Reset button to energize the outputs of the MSR138. The immediate outputs of the MSR138 energize the 700S control relays and start the motor.
STOPPING: When the e-stop is pressed, the immediate outputs of the MSR138 open and the motor coasts to stop. After the time delay of the MSR138 expires, the
delayed N.C. output closes and provides voltage to the Lock Release button. Press the Lock Release button to power the solenoid and open the Gate.
Closing the Gate or resetting the e-stop does not re-energize the 700S safety control relays. Press the reset to re-energize the 700S control relays.
Operator
Interface
Fault Detection
Upon power-up, the MSR138 perform internal checks. The MSR138 then looks for dual signals from the e-stop and the TLS1 GD2. The e-stop has a self-monitoring
contact, which opens if the contact block falls off the control panel. With the e-stop signals made, the MSR138 checks the Y1/Y2 monitoring circuit when the reset button
is pressed. If these checks are okay, the output energizes. The Reset button is linked to the delayed N.C. output in order to supply +24V for reset only when delay time
has lapsed. If any of the MSR138 contacts faults to the ON state, the motor is stopped by the redundant outputs. The fault will be detected by the S56/S34 monitoring
circuit on the next attempt to re-start. If the Gate is not interlocked by the TLS1 solenoid or one of the 700S control relays faults to the ON state, the MSR138 will detect
the fault in the Y1/Y2 circuit on the next attempt to start. Single point failures related to the tongue interlock are excluded if actuator speed, alignment and mechanical
stops meet installation instruction requirements, and a periodic proof test confirms proper operation.
Logic
Ratings
The safety function intiated by TLS1-GD2 guard locking interlock and the 800F e-stop meets the safety performance requirements of SIL CL 2 per IEC 62061:2005 and
has a Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1:2006. This circuit executes a Category 0 stop.
Power

R
Interlock SwitchGuard Locking with Time Delay
TLS3-GD2, 800F, MSR138, 100S
+24V DC
E-Stop K2 Start
K1
800FM-MT44 800FM-F3MX10
General
800F-MX01V Machine control system

800F-MX01S can replace this circuit
arrangement.
Stop
Lock Release 800FM-E4MX01 L1 L2 L3
800FM-F2MX10 Reset
800FM-F6MX10
TLS3-GD2
Principles
440G-T27260 S11 S52 S21 A1 S33 S34 13 23 37 47 55

A1 42 52 K1
41 MSR138.1DP
51 440R-M23084 K2
12 22 34
A2 11 21 33 S12 S22 A2 Y1 Y2 Y39 Y40 14 24 38 48 56
M
9-
K1 K2 100S-C85DJ14BC
24V DC Com
Applications
10-Safety
Circuit Status
The e-stop is reset and the safety gate is closed. The outputs of the safety relay are open, and the motor is off.
Operating Principle
The guard locking interlock and delayed outputs of the safety relay keep the guard closed and locked during the rundown time of the motor.
STARTING: Press the reset button to energize both the immediate and delayed outputs of the MSR138. Press the start button to energize contactors K1 and K2, which
start the motor.
STOPPING: Press the e-stop to initiate a stop command. The immediate outputs of the MSR138 de-energize and the MSR138 timing cycle starts. Contactor K1 drops out
and the motor begins a coast to stop. After the time delay of the MSR138 expires, the N.C. output closes and provides voltage to the lock release button. Press the lock
Operator
Interface
release button to power the solenoid and open the gate. After the time delay, the normally open safety contact opens, dropping out K2.
Fault Detection
Upon power-up, the MSR138 performs internal checks. The MSR138 then looks for dual signals from the e-stop and the TLS3 GD2. The e-stop has a self-monitoring
is pressed. If these checks are OK, the output energizes. If any of the MSR138 contacts faults to the ON state, the motor is stopped by the redundant outputs. The fault
will be detected by internal crosschecking in the MSR138. With K1 on the immediate output of the MSR138, if performs the primary breaking of the motor circuit. If K1 fails
due to welded contacts, the K2 will break the motor circuit. The failure of K1 will be detected by the Y1/Y2 monitoring circuit on the next attempt to restart the motor.
Single point failures related to the tongue interlock are excluded if actuator speed, alignment and mechanical stops meet installation instruction requirements, and a
periodic proof test confirms proper operation.
Logic
Ratings
The safety function initiated by the TLS3-GD2 guard locking interlock and the 800F e-stop button meets the safety performance requirements of SIL CL 2 per IEC
62061:2005 and has Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006. This example circuit performs a
Stop Category 0 function (coast to stop).
Power

Interlock Switch and Enabling DeviceGuard Locking with Time Delay
GripSwitch, MT-GD2, 400G-MT, 800F, MSR138, 100S
24V DC
Primary K1
Safeguard Start
GripSwitch
General
800FM-F3MX10
440J-N21TNPM-NP K2
Safety Stop 440J-A03N
A B
800FM-E4MX02 440J-A04N Reset
800FM-F6MX10 Stop
11 12 11 12 11 12 800FM-E4MX01
21 22 21 22 21 22
33 34 1 2 Machine control system
33 34 33 34
43 44 can replace this circuit
Principles
7 8 43 44 arrangement.
43 44 3 4
GripSwitch
Jog Button MT-GD2
Guardlocking MT-GD2 440T-MT55076
Interlock Latch Release
440G-MT47045 440T-MT55080
L1 L2 L3
S11 S52 S21 S22 S12 A1 S33 S34 13 23 37 47 55

K1
MSR138.1DP
440R-M23084
9-
Lock Release 0.15...3s K2
800FM-F2MX10 X1 X2 X3 X4 Y39 Y40 A2 Y1 Y2 14 24 38 48 56
M Mirror
Contacts
A1 A1
Safety Contactors
Applications
K1 K2
10-Safety
100S-D95DJ22C
A2 A2
24V Com
Circuit Status
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 locking interlock is
locked. The MSR138DP safety outputs are open. Contactors K1 and K2 are de-energized. The motor is off and the application ready to run.
Operating Principle
The GripSwitch enabling device is used to access the hazardous area while the motor is running. The access is of the full body type. With the safety gate unlocked, the
Operator
Interface
operator walks into the hazardous area with the GripSwitch. Before accessing the hazard area, the motor must be stopped. After entering the hazard area, the motor can
be restarted with the GripSwitch. One MT-GD2 interlock is used to bypass the gate interlock safety circuit. The other MT-GD2 is used to reset the safety system and
prevent the starting of the motor from outside the cell, when the GripSwitch is used.
STOPPING: Press the Safety Stop. The immediate outputs of the MSR138.1DP open and the motor initiates a coast to stop. After the time expires on the MSR138.1DP,
the delayed outputs change state. The contacts across 55 and 56 close and the safety gate can be unlocked. Press the lock release button to momentarily power the
solenoid of the 440G-MT and open the gate.
STARTING: Remove the enabling switch from the MT-GD2 holders. Squeeze the GripSwtich trigger to the middle position. The MSR138.1DP resets and closes its
safety outputs and the motor is ready to run. Press the jog button on the GripSwitch to momentarily turn on the motor.
STOPPING DURING ENABLING: Release the jog switch to stop the motor. Releasing or applying further pressure to the trigger switch on the GripSwitch will stop the
motor.
Logic
Fault Detection
Upon successful completion of internal checks on power-up, the MSR138.1DP checks the gate and GripSwitch circuit. If both circuits have been closed, the
MSR138.1DP checks the reset circuit. Upon closure of the reset button, the MSR138.1DP checks the status of the contactors. Due to the size of the 100S-D contactors,
mirrored contacts (on either side of the unit) are used to safely reflect the staus of the armature. If all mirrored contacts are closed, then the MSR138.1DP energizes its
outputs. If one contactor welds in the closed state, the second contactor will shut off the motor and the fault will be detected by the MSR138.1DP, upon the next attempt
to start the motor. Single channel faults on the input devices (GripSwitch, Interlocks and Stop switch) will be detected by the MSR138.1DP either on or before a demand
is placed on the safety system (depending on the nature of the fault).
Ratings
Power
The safety function initiated by the MT-GD2 guard locking interlock and the GripSwitch button meets the safety performance requirements of SIL CL 2 per IEC62061:2005
and has Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006. This example circuit performs a Stop Category 0
function (coast to stop).

R
Interlock Switch & Modular RelayGuard Locking with Standard Drive
TLS-GD2, 800F, MSR200, 100S, PowerFlex 4
+24V DC
L1 L2 L3
E-Stop
800FM-MT44MX02V
General
+24V 11 R S T
Stop SNK
SRC
Lock Release 1
800FM-F2MX10 Start
MSR238P PowerFlex 4
440R-H23196 2 22A-B3P6N114
S11 S21 S22 S32 S12 A1 Y31 Y40 Y41 Y42 13 23 31 Y3 Y4 Y5 Y6 17 18 35 U V W

A1 42 52
Principles
41 51 MSR210P 6 sec
K1
12 22 34 440R-H23176 delay
A2 11 21 33 S62 S42 S52 A2 Y30 Y32 Y33 S34 Y1 Y2 14 24 32 Y3 Y4 Y7 Y8 18 28 36

K2
TLS3-GD2
440G-T27260
M
Reset
800FM-F6MX10
9-
To PLC (Inputs Closed/Ready)

To PLC (Outputs Active)
24V Com
Circuit Status
The guard door is closed and locked (mechanical lock, power to release). The e-stop is released. K1 and K2 are off. The drive is powered, but not enabled. The motor is
Applications
off.
10-Safety
Operating Principle
Access to the hazard is prevented (i.e., locked) by the guard locking TLS3-GD2 while the motor is running and for a fixed duration (controlled by the MSR238) after the
e-stop command is initiated.
STARTING: Momentarily press the reset button. The contacts in the MSR210P and MSR238P close. K1 and K2 energize and connect the motor to the drive and also
connects 24V to the start button. This ensures that the motor is connected to the drive, before the start button becomes effective. The PowerFlex 4 drive is allowed to
start. Start the motor by momentarily pressing the start switch. The motor can be stopped by momentarily pressing the stop switch. The start and stop switches can be
replaced by more elaborate control devices (like a PLC).
STOPPING: Press the e-stop. The MSR210P opens its immediate output (13-14) and begins the timing sequence in the MSR238. The PowerFlex 4 also begins its
programmed deceleration as the stop signal is opened. After six seconds, the MSR238 times out and contacts 17-18 and 27-28 open. K1 and K2 de-energize and
Operator
Interface
disconnect the motor from the drive. Contacts 35-36 close and provide power to the release button of the TLS3-GD2. Press and hold the release button to open the gate.
Closing the gate or releasing the e-stop will not cause the motor to turn on. Two separate and deliberate actions are needed: 1) momentarily press the reset button to
activate the safety relay and then 2) momentarily close the start switch to turn the motor on. In this application, the user must ensure that the time delay of the MSR238P
provides sufficient time for the hazards, driven by the motor, to stop. Ramping to stop or dynamic braking are recommended to speed up the braking process. The time
delay of the MSR238P should be set longer than the stopping time of the PowerFlex 4 or the motor will coast to its final stop. The PowerFlex 4 will not be able to start
while the K1 and K2 contactors are de-energized.
Fault Detection
If the drive output faults to an energized state, the motor can be turned off by pressing the e-stop. If K1 welds in an energized state, the motor can be stopped by K2. If
either K1 or K2 welds closed, the MSR210P will not be able to start due to the feedback loop (Y1-Y2) being open. A short across the interlock or e-stop will be detected
Logic
by the MSR210P. The MSR210P will also detect if the reset is held or stuck in the closed position, and will prevent the motor from starting.
Ratings
The safety function initiated by the TLS3-GD2 guard locking interlock and the 800F e-stop button meets the safety performance requirements of SIL CL 2 per IEC
62061:2005 and has Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006. This example circuit performs a
Stop Category 1 function (brake and then remove power to motor).
Power

Configurable RelaySingle Zone
GuardShield, 800F, MSR310P, 100S
+24V DC
General
E-Stop
800FM-MT44 Aux light Group3 Output
800F-MX02V or signal MSR330P
to PLC Group1 Output 440R-W23223
Group 1 Auto Reset
MSR330P
Group 3 Monitored Reset 440R-W23221
S12 S22 S32 S12 S22 S32 S11 S21 S31 S41 S51 Y40 Y41 Y42 A1 13 23 33 41 13 23 33 41
Principles
G1 F9 G5 F2
Group 1 Group 1& 3
Inputs Inputs Minotaur
MSR310P
MSR320P MSR320P 440R-W23219
440R-W23218 440R-W23218
Brown
Brown
S42 S52 S62 S42 S52 S62 A2 Y31 Y32 Y33 Y34 Y10 Y11 Y12 Y13 14 24 34 42 14 24 34 42
Transmitter Receiver
1 2 K1
Group 1 Output Active
Group 3 Output Active

6 Pink Aux light
Grey or signal K2 K1
5
Blue Blue to PLC
3 7
GuardShield K3 100S- C09DJ14BC K2
9-
440L-P4K1600YD
889D-F4AC-2 889D-F8AC-2 Reset K3
800FM-F6MX10
24V DC Com
Circuit Status
Applications
The light curtain is set at the factory default setting (guard only) and is unobstructed. The e-stop is reset. The Group 1 MSR330P safety outputs (13/14, 23/24, 33/34) are
10-Safety
on. The Group 3 MSR330P safety outputs are off. K1-K3 are off and ready to be energized.
Operating Principle
Since the safety outputs of the two MSR330P modules are connected in series, both the light curtain and e-stop will control (turn on and off) the K1-K3 loads. The light
curtain is set to automatic reset mode. The e-stop stop operates in monitored reset mode. The jumper from Y40 to Y42 sets the Group 1 output to automatic reset and
the Group 3 output to monitored reset. The MSR310P must have the monitoring circuit connected to both Y11 and Y13 to allow both the Group1 and Group 3 outputs to
energize.
STARTING: Press the reset button to energize the Group 3 outputs, which energize the loads K1-K3.
STOPPING: Obstructing the light curtain turns off the Group 1 safety outputs and de-energizes K1-K3. Clearing the light curtain automatically re-energizes K1-K3. This
arrangement is known as presence sensing device initiation, and additional precautions (e.g., limited to partial body access, part sensing, limited speed) may be
Operator
Interface
necessary to ensure safe operation of the machine. Pressing the e-stop turns off both the Group 1 and Group 3 safety outputs and de-energizes K1-K3. Resetting the
e-stop re-energizes the Group 1 outputs, but the Group 3 outputs remain off. The Reset button must be pressed to turn on the Group 3 outputs and energize the loads
K1-K3.
Fault Detection
Upon successful completion of internal checks on power up, the GuardShield energizes its outputs. Cross-channel shorts and shorts to ground or power are detected by
the GuardShield. The MSR310P also performs internal checks, and then scans the input circuits. The MSR310P uses pulse testing from S11 and S21 to detect shorts
from the inputs to power, ground or other inputs. These faults will be detected immediately and will prevent energizating or will de-energize the MSR330P outputs. If one
of the 100S output devices (K1-K3) is stuck in an actuated state, the MSR310P will prevent start-up because the Y10/Y11/Y13 feedback loop will remain open.
Ratings
Logic
When two contactors are connected in series to power a hazard (not shown), the safety functions intiated by GuardShield light curtains and the 800F e-stop meet the
safety performance requirements of SIL CL 3 per IEC 62061:2005 and has a Category 4 structure that can be used in systems requiring Performance Levels up to PLe
per ISO 13849-1:2006. If only one contactor is used to power a hazard, the safety function can meet SIL CL 2, Category 2 structure and PLd.
Power

R
DriveMultiple Gate Access
Trojan 5 GD2, Cadet GD2, MT-GD2, MSR127, PowerFlex DriveGuard
+24V DC
Guard Shown can replace this circuit L1 L2 L3
Open
General
arrangement.
11 21 33
Aux PowerFlex
Signal DriveGuard
to PLC
12 22 34
24V DC
440K-T11341 Start DC Comm
Trojan 5 GD2 Dig Comm
Start
Stop
Principles
S21 S11 S52 A1 13 23 33 41 Gate Control

Stop Power Supply
11 21 33
Aux Safe Off Option
Signal MSR127TP 1
to PLC 440R-N23132 3
12 22 34
4
440K-C21074 S22 S12 S34 A2 14 24 34 42 2
Cadet GD2
Gate
Enable Control
Circuit
9-
11 21 33 43
Aux Remove Jumper
Signal
to PLC
12 22 34 44
Motor
440K-MT55080
MT-GD2 Latch Release
Applications
10-Safety
24V DC Com
Circuit Status
One of the gates is open. The safety outputs of the MSR127 are de-energized. The PowerFlex with DriveGuard is de-energized and not enabled. The motor is off.
Operating Principle
STARTING: When the last gate closes, the safety outputs of the MSR127 close and apply power to the drive enable circuit, Safe-Off option, Start and Stop buttons.
Pressing the Start and Stop buttons turns the motor on and off. The motor is controlled by parameters set within the PowerFlex drive.
STOPPING: Opening any of the guard doors causes the MSR127 safety outputs to de-energize. This removes power to the PowerFlex enable, Safe-Off, Start, and Stop
circuits. The motor performs a coast to stop.
Operator
Interface
Fault Detection
Upon power-up the PowerFlex drive and MSR127 perform internal checks. The MSR127 then looks for dual signals from the gate interlocks. With the gates closed, the
MSR127 checks the wiring of the drive Safe-Off option. If closed, then the MSR127 energizes its outputs and the motor can be started. A single open circuit fault at the
gate interlocks will be detected immediately, and the motor will coast to a stop. A crossfault (channel 1 to channel 2) at the gate interlocks will be detected immediately. A
short across one gate interlock contact will be detected when an attempt to re-start is made. This type of short can be masked by opening and closing another gate
interlock and may result in a loss of the safety function due to an accumulation of contact shorts. The MSR127 is rated for Category 4 and will not lose the safety function
due to an accumulation of faults. The PowerFlex 70 DriveGuard is rated at Category 3, as it will perform the safety function in the presence of a single internal fault.
Ratings
Logic
The safety function intiated by gate interlocks meets the safety performance requirements of SIL CL 2 per IEC 62061:2005 and has a Category 3 structure that can be
used in systems requiring Performance Levels up to PLd per ISO 13849-1:2006. This circuit executes a Category 0 stop.
Power

DriveGate & Cascaded Drives
Trojan 5 GD2, MSR127, PowerFlex with DriveGuard
+24V DC
L1 L2 L3 L1 L2 L3
General
PowerFlex R S T PowerFlex R S T
AC Drive with AC Drive with
DriveGuard DriveGuard
Trojan5-GD2 DeviceNet DeviceNet
440K-T11213
Dig. Comm Dig. Comm
11 21 33 A1 S52 S11 S21 13 23 33 41
Gate Control Gate Control
Power Supply Power Supply
MSR127TP
12 22 34 440R-N23132 Safe-Off Option Safe-Off Option
1 1
3 3
Principles
A2 S12 S22 S34 14 24 34 42
4 4
2 2
Gate shown
open 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
9-
1734-IB4 1734-PDN
1793-IB6 1794-ADN
24V DC Com
Circuit Status
Applications
The safety gate is open. The MSR127TP safety outputs (13/14, 23/24, 33/34) are open. The Enable and Safe-Off Option on both PowerFlex drives are off. Auxiliary
10-Safety
signals from the Trojan 5 GD2 (33/34) and the MSR127 (41/42) inform the PLC that the safety system is OFF. The motors of both drives are off.
This circuit is intended to show that multiple drives can be connected in parallel. The number of drives that can be connected in parallel is dependent on: the load (the
safe-off option plus the enable of each drive), appropriate de-rating to prevent early wear out of the MSR127TP contacts, the application requirements (e.g., zoning) and
the risk assessment (e.g., some drives may require separate safety systems).
Operating Principle
STARTING: Upon closing the gate, the Trojan 5 GD2 closes the safety inputs of the MSR127TP (S11/S12 and S21/S22) and opens the signal to the PLC. The safety
outputs of the MSR127TP close and enable both PowerFlex drives. The auxiliary signal of the MSR127TP opens. The PLC compares the gate and safety relay auxiliary
signals. When both signals are open, the PLC knows that the safety system is ready. The PLC can now start and control the drives over the DeviceNet network. The
Operator
Interface
PLC must ensure that the drives are not started upon the closing of the gate; a separate, intentional action must initiate the motor movement (this is not shown in the
diagram).
STOPPING: Normal stopping is performed by the PLC. If the gate is opened, the input signals to the MSR127TP open. The MSR127TP opens its safety outputs which
disable all the drives connected to them via the Safe-Off option. The drives perform an immediate coast to stop.
Fault Detection
Upon power-up, the MSR127TP performs internal checks. The MSR127TP then looks for dual signals from the Trojan5-GD2. If only one signal is present, or a crossfault
exists, the MSR127TP assumes a fault is present and does not energize its safety outputs. With the gate closed, the MSR127TP checks the S12/S34 monitoring circuit.
If the Safe-Off options are de-energized, the MSR127TP assumes the drives are off and are ready to be enabled. The MSR127TP energizes its safety outputs. If the
monitoring circuit remains open, the MSR127TP will assume a fault is present and not allow its safety outputs to energize. Single point failures related to the tongue
interlock are excluded if actuator speed, alignment and mechanical stops meet installation instruction requirements, and a periodic proof test confirms proper operation.
Logic
Ratings
The safety function intiated by the Trojan 5-GD2 gate interlocks meets the safety performance requirements of SIL CL 2 per IEC 62061:2005 and has a Category 3
structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1:2006. This circuit executes a Category 0 stop.
Power

R
Drive & Safety I/OIntegrated Architecture
800F, CompactBlock Guard I/O, PowerFlex DriveGuard
+24 VDC
Clear Fault Reset
800FM-F2MX10 800FM-F6MX10
General
E-Stop Machine control system

800FM-MT44M can replace this circuit
800F-MX01V arrangement.
800F-MX01S L1 L2 L3
Start PowerFlex
I0 I1 I2 I3 I4 I5 V0 V1 Start
DriveGuard
Stop
Principles
Stop
CompactBlock Guard I/O
DeviceNet 1791DS-IB8XOB8
Dig Com Gate Control
Power Supply
T0 T1 T2 T3 G0 G1 O0 O1 O2
Safe-Off Option
1
3
4
Safety Controller 2
SmartGuard, Gate
9-
GuardPLC, Enable Control

or Circuit
GuardLogix Remove Jumper
Motor
Applications
10-Safety
24V DC Com
Circuit Status
The e-stop is reset. The outputs of the CompactBlock Guard I/O are off. The PowerFlex output is off. The motor is off.
Operating Principle
STARTING: Press and release the reset button to energize the outputs of the 1791DS. This action energizes the Safe-Off option which connects the Gate Control Power
Supply to the Gate Control Circuit. It also provides the Enable signal which allows the Gate Control Circuit to turn the output drive transistor on and off. Output O2 applies
power to the Start and Stop controls, which can then be used to control the drive for production operations.
Operator
Interface
STOPPING: When the e-stop is pressed, the O2 output sends a stop command to the drive, which executes its pre-programmed stopping routine. After a short delay
(programmed in the safety controller), the O0 and O1 outputs turn off. This disables the drive. The normally closed contact in the Safe-Off option closes and sends a
signal back to terminal I4 to inform the safety system that the drive is ready for restart.
Fault Detection
Upon power-up, the PowerFlex drive and 1791DS perform internal checks. The 1791DS then looks for dual signals from the e-stop. The pulsed outputs T0 and T1 are
used to help check for open and short circuit fault conditions in the e-stop circuit. The e-stop has a self-monitoring contact, which opens if the contact block falls off the
control panel. With the e-stop signals made, the 1791DS checks the monitoring circuit (terminal I4) when the reset button is pressed. If these checks are OK, the outputs
energize. If the O2 output of the 1791DS faults to the ON state, the motor is stopped by the O0 and O1 outputs, and the fault will be detected on the next attempt to
re-start by the self-checking in the 1791DS. If the drive control faults to an ON state, the motor will stop because the power to the drive control circuit will be removed by
the Safe-Off option.
Logic
Ratings
The safety function intiated by the 800F e-stop meets the safety performance requirements of SIL CL 2 per IEC 62061:2005 and has a Category 3 structure that can be
used in systems requiring Performance Levels up to PLd per ISO 13849-1:2006. This circuit executes a Category 1 stop, by the program in the safety controller.
Power

Interlock Switch Gater with High Current Outputs
Trojan T15 GD2, 800F, MSR126, Flex I/O
+24V DC
Reset
Start
800FM-F3MX10
General
Stop
800FM-F6MX10
800FM-E4MX01
12 11
Brown
700-HLT2Z24
Black Limited to 6 Amps
34 16 0 0 16 34
S21 S12 S33 S34 A1 13 23
11 21
35 17 CR1 1 1 17 35
MSR126.1R
Principles
440R-N23120 36 18 2 2 18 36
12 22
37 19 CR 3 3 19 37
Trojan T15 GD2 S22 S52 S11 A2 14 24
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
9-
FLEX Output Module FLEX Input Module
24V DC Com
Circuit Status
The safety gate is closed. The outputs of the MSR126.1R safety relay are open and the machine actuators are off. Control Relay CR1 is de-energized and its 11/12
contact is closed.
Applications
10-Safety
Operating Principle
The MSR126.1R is chosen for this application because its thermal (non-switching) current carrying capacity is 6 A in one circuit. The Flex output module performs the
normal switching of the machine actuators during the manufacturing process. The safety system enables the machine functions by providing power to the FLEX Output
Module. One of the Flex outputs must drive an electro-mechanical output whose normally closed contact is in the monitoring loop of the safety relay. The machine logic
must energize this output while the machine is running, as it is used by the MSR126.1R to confirm that power is removed from the output module, before restarting.
STARTING: Press the reset button to energize the output contacts 13/14 of the MSR126.1R. This connects the 24V supply to terminal C34 of Flex 1974-OB16 output
module and also sends a signal to the A3 terminal of the 1794-IB16. The logic system is informed that the gate is closed and the machine is ready to run. Press the Start
button to start the machine process.
STOPPING: Press the Stop button to stop the machine. Then, open the gate to access the machine. While the gate is open, the machine actuators cannot operate
Operator
Interface
because power is removed from the output module. If the gate is inadvertently opened while the machine is running, power will be removed from output module and the
machine actuators will be de-energized.
Fault Detection
Upon successful completion internal checks on power up, the MSR126.1R checks the input circuits. With the gates closed, the MSR126.1R checks the dual circuits and
then waits for the reset signal. A single fault, a short from 24V to terminal 14 of the MSR126.1R, may lead to the loss of the safety function. With the MSR126.1R and Flex
system mounted in the same cabinet and with proper validation, this fault may be excluded. If not mounted in the same cabinet, a signal from the output (A0) should be
fed back into the input module (A2). The logic can perform a comparison of input A2 and A3, and turn the machine off if these signals are not in agreement. If CR1 is not
de-energized when the gate is closed, the MSR126.1R will not close its outputs.
Ratings
Logic
The safety function intiated by the Trojan T15-GD2 gate interlocks meets the safety performance requirements of SIL CL 2 per IEC 62061:2005 and has a Category 3
structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1:2006. This circuit executes a Category 0 stop.
Power

R
Safety MotionDelayed Braking
800F, MSR138, Kinetix GuardMotion, RBM
+24V DC
E-Stop L1 L2 L3
800FM-MT44 Reset
800F-MX01V 800FM-F6MX10
Kinetix AC Drive
General
800F-MX01S Gate
with GuardMotion Control
2099-BMxx-s Power
Supply
S11 S52 S21 A1 S33 S34 13 23 37 47 55
EN1+ R2
R1
MSR138.1DP EN1-
440R-M23084 Gate
EN2- Safety
Control
Monitor
Principles
R2 Circuit
S12 S22 A2 Y1 Y2 Y39 Y40 14 24 38 48 56
EN2+
FBK1 R1
R1
FBK1
FBK2 Gate
R2 Control
FBK2 Enable
Resistor Braking Module U V W

COIL A1
9-
CONSTAT41
K1
CONSTAT42
COIL A2
100S-C
T1 Contactor U V W
Applications
10-Safety
M
24V DC Com
Circuit Status
The e-stop is reset. The outputs of the safety relay are open, and the motor is off.
Operating Principle
STARTING: Press and release the reset button to energize the outputs of the MSR138. This action energizes the 100S contactor in the resistor braking module, which
Operator
Interface
connects the motor to the drive and enables the operation of the Kinetix drive. When the Kinetix drive is enabled, an internal signal is sent back to its controller (not
shown) to inform it that the drive is enabled. The motor is then controlled by its controller.
STOPPING: When the e-stop is pressed, the immediate outputs of the MSR138 open and disable the drive. The motor begins to coast to a stop. After the time delay of
the MSR138 expires, the delayed outputs open and drop out the 100S contactor in the Resistor Braking Module. This disconnects the motor from the drive and engages
the braking resistors, which rapidly stop the motor.
Fault Detection
Upon power-up, the Kinetix drive and MSR138 perform internal checks. The MSR138 then looks for dual signals from the e-stop. The e-stop has a self-monitoring
is pressed. If these checks are OK, the output energizes. If the delayed outputs of the MSR138 fault to the ON state, the motor is stopped by the MSR138 immediate
outputs. The fault will be detected by the Y1/Y2 monitoring circuit on the next attempt to re-start because K1 will remain energized. If the drive faults to an ON state, the
Logic
motor will stop because it will be disconnected by K1. This fault will be detected by the Y1/Y2 monitoring circuit on the next attempt to re-start because the Kinetix
feedback circuit will remain off. If K1 gets stuck or welded closed, the motor will stop by the drive and the fault will be detected by the Y1/Y2 monitoring circuit of the
MSR138 on the next attempt to re-start.
Ratings
Power

Safety MotionDelayed Stop
800F, MSR138, Kinetix GuardMotion, 100S
+24V DC
E-Stop L1 L2 L3
800FM-MT44
Reset
Kinetix 6000 or 7000
General
800F-MX01V Gate
800FM-F6MX10
800F-MX01S AC Drive Control
with GuardMotion Power
2099-BMxx-s Supply
S11 S52 S21 A1 S33 S34 13 23 37 47 55 EN1+ R2

R1
EN1-
MSR138.1DP Gate
440R-M23084 EN2- Safety
Control
Monitor
Principles
R2 Circuit
S12 S22 A2 Y1 Y2 Y39 Y40 14 24 38 48 56 EN2+
FBK1 R1
R1
FBK1
FBK2 Gate
R2 Control
FBK2 Enable
U V W
To PLC
(Initiate Controlled Stop)
M
9-
24V DC Com
Applications
10-Safety
Circuit Status
The e-stop is reset. The outputs of the safety relay are open, and the motor is off.
Operating Principle
STARTING: Press and release the reset button to energize the outputs of the MSR138. This action enables the operation of the Kinetix drive. When the Kinetix drive is
enabled, an internal signal is sent back to its controller (not shown) to inform it that the drive is enabled. The motor is then controlled by its controller.
STOPPING: When the e-stop is pressed, the immediate outputs of the MSR138 open and sends a signal the to the machine control PLC to initiate a controlled stop. After
the time delay of the MSR138 expires, the delayed outputs open and drop out the GuardMotion feature which disables the drive.
Fault Detection
Operator
Interface
Upon power-up, the Kinetix drive and MSR138 perform internal checks. The MSR138 then looks for dual signals from the e-stop. The e-stop has a self-monitoring contact,
which opens if the contact block falls off the control panel. With the e-stop signals made, the MSR138 checks the Y1/Y2 monitoring circuit when the reset button is
pressed. If these checks are OK, the output energizes. If the delayed outputs of the MSR138 fault to the ON state, the motor is stopped by the MSR138 immediate
outputs. The fault will be detected by the S33/S34 monitoring circuit on the next attempt to re-start. If one of the safe-off relays faults to the ON state, the MSR138 will
detect the fault in the Y1/Y2 circuit on the next attempt to start the drive.
Ratings
Logic
Power

R
Safety Motion & Safety I/OIntegrated Architecture
800F, CompactBlock Guard I/O, Kinetix GuardMotion, RBM
+24V DC
Clear Fault Reset L1 L2 L3
800FM-F2MX10 800FM-F6X10
General
Kinetix 6000 and 7000 Gate

E-Stop AC Drive Control
800FM-MT44 with GuardMotion Power
800F-MX01V Supply
800F-MX01S
EN1+ R2
R1
EN1-
I0 I1 I2 I3 I4 I5 V0 V1 Gate
EN2- Safety
Control
Monitor
Principles
R2 Circuit
CompactBlock Guard I/O
EN2+
DeviceNet 1791DS-IB8XOB8
FBK1 R1
R1
T0 T1 T2 T3 G0 G1 O0 O1 O2 FBK1
FBK2 Gate
R2 Control
FBK2 Enable
Safety Controller
Resistor Braking Module U V W
SmartGuard, COIL A1
9-
GuardPLC, CONSTAT41
or K1
GuardLogix CONSTAT42
COIL A2
100S-C
T1 Contactor U V W
Applications
10-Safety
24V DC Com M
Circuit Status
The e-stop is reset. The outputs of the CompactBlock Guard I/O are off. The Kinetix outputs are off. The Resistor Braking Module is off. The motor is off.
Operating Principle
STARTING: Press and release the reset button to energize the outputs of the CompactBlock Guard I/O. This action energizes the 100S contactor in the resistor braking
module, which connects the motor to the drive and enables the operation of the Kinetix drive. When the Kinetix drive is enabled, an internal signal is sent back to its
controller (not shown) to inform it that the drive is enabled. The motor is then controlled by its controller.
Operator
Interface
STOPPING: When the e-stop is pressed, the O1 and O2 outputs of the 1791DS open and disable the drive. The motor begins to coast to a stop. After a short delay
(determined by a risk assessment or stop time measurement and programmed in the safety controller), the O0 output turns off and drops out the 100S contactor in the
resistor braking module. This disconnects the motor from the drive and engages the braking resistors, which rapidly stop the motor.
Fault Detection
Upon power-up, the Kinetix drive and 1791DS perform internal checks. The 1791DS then looks for dual signals from the e-stop. The pulsed outputs T0 and T1 are used
to help check for open and short circuit fault conditions in the e-stop circuit. The e-stop has a self-monitoring contact, which opens if the contact block falls off the control
panel. With the e-stop signals made, the 1791DS checks the monitoring circuit when the reset button is pressed. If these checks are OK, the outputs energize. If the O0
output of the 1791DS faults to the ON state, the motor is stopped by the O1 and O2 outputs. The fault will be detected by the safety controller on the next attempt to
re-start because K1 will remain energized. If the drive faults to an ON state, the motor will still be able to stop because it will be disconnected by K1. This fault will be
Logic
detected on the next attempt to re-start because the Kinetix feedback circuit will remain off. If K1 gets stuck or welded closed, it will still be possible to stop the motor by
the drive, and the fault will be detected by the safety controller on the next attempt to re-start.
Ratings
used in systems requiring Performance Levels up to PLe per ISO 13849-1:2006. This circuit executes a Category 0 stop. To achieve a Category 1 stop, the machine
control system must be notified of the e-stop command through DeviceNet, command the Kinetix to execute a stop, and delay the outputs O0, O1, and O2 until the stop
condition is completed.
Power

Safety PLCTwo Zones
GuardShield, SensaGuard, SafeZone, 800F, 440G-MT, GuardPLC 1600, 100S, 700S
+24V DC
Brown 1 2
Brown Brown
1 Lock
General
Pink Pink Release
6 4
5 Gray 3 Gray 440G-MT47045
Blue 3 Blue
7 Blue A1 11 21 33 43
2
800FM-MT44MX11S
Sender Receiver
GuardShield SafeZone Scanner
440L-P4K1760YD 442L-SFZNMZ A2 12 22 34 44
889D-F4AC-2
889D-F8AB-10 442L-CSFZNMZ-10
E-Stop
Brown
Reset Zone 1
Reset Zone 2
2
Principles
Fault Reset Zone 2
Fault Reset Zone 1
Yellow
4
Red
8
6 Pink
5 Gray
Blue
7
SensaGuard
440N-Z21S26H K1 K2
889D-F8AC-2
K3 K4
L+ L+ Ls+ 1 2 3 4 Ls+ 5 6 7 8 9 10 11 12 13 14 15 16
Input Terminals
GuardPLC 1600
9-
1753-L28BBBM
Output Terminals
L- L- L- 1 2 3 4 L- 5 6 7 8 L-
K1 K3
K2 K4
100S-C or 700S-C or 700S-P
Contactors or Safety Relays
Applications
24V DC Com
10-Safety
Circuit Status
The GuardPLC is programmed to control two zones without a DIO connection. The GuardShield and SensaGuard are associated with Zone 1 and contactors K1 and
K2. The SafeZone Laser Scanner and 440G-MT are associated with Zone 2 and contactors K3 and K4. The SafeZone, located behind the locked safety gate, is used
to detect someone in the hazard area. The E-Stop applies to both zones. The two safety gates are closed, the light curtain and zone scanner are clear and the e-stop is
released. Both zones are ready to be activated.
Operating Principle
STARTING: Press the reset button for each zone to energize the safety outputs of the GuardPLC. The safety contactors K1 through K4 become energized and allow
the zones to operate. The GuardPLC signals the machine control system over an Ethernet/IP connection that the zones are ready to run. The machine control system
Operator
Interface
(not shown) controls the zones.
STOPPING: Obstructing the light curtain or opening the SensaGuard gate will de-energize the K1 and K2 contactors. Clearing the light curtain or closing the gate will
not cause the contactors to re-energize. The Zone 1 Reset button must be pressed to restart Zone 1. The e-stop acts as a global stop. When pressed, both zones are
de-energized. The GuardPLC energizes Output 5 to provide voltage for the 440G-MT guard locking solenoid. Pressing the Gate Release button allows the gate to be
opened. Closing the gate or resetting the e-stop does not re-energize the K1-K4 contactors. The respective Zone Reset buttons must be pressed after the input
devices are cleared.
Fault Detection
Upon successful completion of internal checks on power up, the GuardPLC checks the input devices. Outputs 6 and 7 are configured as pulse test sources and are
used by the GuardPLC to help check for open and short-circuit fault conditions of the E-Stop and 440G-MT interlock. If a fault is detected, the GuardPLC will not
Logic
energize the respective outputs. The GuardPLC checks the status of the K1-K4 contactors. If the contactors are energized, stuck or welded closed, the GuardPLC will
detect this due to the open circuit to Inputs 15 or 16, and will not energize the respective zone. Output 8 is configured as a pulse test source to help detect wiring faults
on these contactor feedback circuits. The programmable safety function blocks associated with each device performs self checking. If a fault occurs, the respective
Fault Reset button must be pressed, after the fault is cleared. Then, the Reset button must be pressed and released for the machine to restart.
Ratings
The ratings assume that two contactors are connected in series to power the hazards. The safety function intiated by the SensaGuard interlock, GuardShield light
curtains, and 800F e-stop meet the safety performance requirements of SIL CL 3 per IEC 62061:2005 and has a Category 4 structure that can be used in systems
requiring Performance Levels up to PLe per ISO 13849-1:2006. The safety functions initiated by the SafeZone scanner and 440G-MT interlock meet the safety
performance requirements of SIL CL 2 per IEC 62061:2005 and have a Category 3 structure that can be used in systems requiring Performance Levels up to PLd per
Power
ISO 13849-1:2006. This circuit executes a Category 0 stop.

R
Safety PLCTwo Zones with Encoders
GuardShield, SensaGuard, SafeZone, 800F, 440G-MT, 842 Encoders, GuardPLC 1800, 100S, 700S
+24V DC
Brown 1 Brown Brown
2 1
Pink Lock
Pink 4 Release
General
6
5 Gray 3 Gray 440G-MT47045
Blue 3 Blue Blue A1 11 21 33 43
7 2
800FM-MT44MX11S
Sender Receiver
440L-P4K1760YD 442L-SFZNMZ A2 12 22 34 44
889D-F4AC-2 442L-CSFZNMZ-10
889D-F8AB-10
E-Stop
Brown
Reset Zone 1
2
Reset Zone 2
4 Yellow
Principles
Fault Reset Zone 2

Fault Reset Zone 1
8 Red
6 Pink
5 Gray
Blue
7
SensaGuard
440N-Z21S26H
889D-F8AC-2 K1 K2
K3 K4
L+ L+ Ls+ 1 2 3 4 Ls+ 5 6 7 8 9 10 11 12 13 14 15 16
Input Terminals
GuardPLC 1800
1753-L32BBBM8A
9-
High Speed Counter Input Terminals Output Terminals

L- L- A1 B1 Z1 L- A2 B2 Z2 L- 1 2 3 4 L- 5 6 7 8 L-
24V Z1 24V Z2
B1 B2 K1 K3
A1 A2 100S-C or 700S-C or 700S-P
+ + K2 K4
Applications
842 Encoders
10-Safety
24V DC Com
Circuit Status
The GuardPLC is programmed to control two zones. The GuardShield and SensaGuard control Zone 1 with contactors K1 and K2. The SafeZone Laser Scanner and
440G-MT control Zone 2 with contactors K3 and K4. The SafeZone, located behind the locked safety gate, is used to detect someone in the hazard area. The E-Stop
applies to both zones. The dual encoders monitor the machine for zero speed and safe speed. The safety gates are closed; the light curtain and zone scanner are
clear; the machine is at zero speed; and the e-stop is released. Both zones are ready to be activated.
Operating Principle
Operator
Interface
STARTING: Press the reset button for each zone to energize the safety outputs of the GuardPLC. The safety contactors K1 through K4 become energized and allow
the zones to operate. The GuardPLC signals the machine control system over an Ethernet/IP connection that the zones are ready to run. The machine control system
(not shown) controls the zones.
not cause the contactors to re-energize. The Zone 1 Reset button must be pressed to restart Zone 1. The e-stop acts as a global stop. When pressed, both zones are
de-energized. The GuardPLC energizes Output 5 to provide voltage for the 440G-MT guard locking solenoid. Pressing the Lock Release button allows the gate to be
opened. Closing the gate or resetting the e-stop does not re-energize the K1-K4 contactors. The respective Zone Reset buttons must be pressed after the input
devices are cleared.
Fault Detection
Upon successful completion of internal checks on power up, the GuardPLC checks the input devices. Outputs 6 and 7 are configured as pulse test sources and are
Logic
used by the GuardPLC to help check for open and short-circuit fault conditions of the E-Stop and 440G-MT interlock. If a fault is detected, the GuardPLC will not
energize the respective outputs. The GuardPLC checks the status of the K1-K4 contactors. If the contactors are energized, stuck or welded closed, the GuardPLC will
detect this due to the open circuit to Inputs 15 or 16, and will not energize the respective zone. Output 8 is configured as a pulse test source to help detect wiring faults
on these contactor feedback circuits. The programmable safety function blocks associated with each device performs self checking. If a fault occurs, the respective
Fault Reset button must be pressed, after the fault is cleared.
Ratings
Power

Safety PLCTwo Zones
GuardShield, SensaGuard, MatGuard, 800F, 440G-MT, SmartGuard 600, 100S, 700S
+24V DC
Brown 1 Brown
2
Pink
General
6
MatGuard Safety Mat

5 Gray Lock
440F-M2030BYNN
Release 440G-
Blue 3 Blue MT47045
7
Reset Zone 1
Reset Zone 2
A1 11 21 33 43
Sender Receiver
GuardShield
800FM-MT44MX02V
440L-P4K1280YD
Fault Reset Zone 2

Fault Reset Zone 1
Brown A2 12 22 34 44
2
800F E-Stop
4 Yellow
8 Red
Principles
6 Pink
5 Gray
Blue
7
SensaGuard K1 K2 K3
440N-Z21SS2A
K4 K5
V0 V0 V1 V1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Input Terminals
USB
SmartGuard 600
DeviceNet Pulse Output
Output Terminals Terminals
G0 G0 G1 G1 0 1 2 3 4 5 6 7 T0 T1 T2 T3
9-
Zone 1 Active K1 K4
Zone 2 Active K2 K5
K3 100S-C or 700S-C or 700S-P
24V DC Com
Circuit Status
Applications
The SmartGuard is programmed to control two zones without a DeviceNet connection. The GuardShield and SensaGuard control zone 1 with contactors K1, K2 and
10-Safety
K3. The MatGuard and the 440G-MT control zone 2 with contactors K4 and K5. The MatGuard, located behind the locked safety gate, is used to detect someone in the
hazard area. The e-stop applies to both zones. The two safety gates are closed, the light curtain and safety mat are clear and the e-stop is released. Both zones are
ready to be activated.
Safety Mat Principles

Outputs T0 and T1 are configured as standard diverse outputs to source the 24V for the safety mat circuits. When a demand is placed on the mat, the circuits short
together and both inputs (IN8 and IN9) are HI. Software detects the non-diversity and de-energizes zone 2. In this application, stepping on the mat cannot be
differentiated from an actual channel to channel short between the mat circuits. Due to this, stepping on the mat must stop the hazard, and a manual reset is required
to restart after each demand on the mat.
Operator
Interface
Operating Principle
STARTING: Press the reset button for each zone to energize the safety outputs of the SmartGuard. Two indicators are illuminated to show the zones are active. The
safety contactors K1 through K5 become energized and allow the zones to operate. Spare contacts (not shown) on the K1-K5 devices signal the machine control
system that the zones are ready to run. The machine control system (not shown) controls the zones.
STOPPING: Obstructing the light curtain or opening the SensaGuard gate will de-energize the K1-K3 contactors. Clearing the light curtain or closing the gate will not
cause the contactors to energize. The zone 1 Reset button must be pressed to restart zone 1. The e-stop acts as a global stop. When pressed, both zones are
de-energized. The guard locking gate is associated with the e-stop. After pressing the e-stop, the SmartGuard energizes output 7 which provides voltage for the
guard locking solenoid. Press the Lock Release push button to power the solenoid and open the gate. Closing the gate or resetting the e-stop does not re-energize
the K1-K5 contactors. The respective zone reset buttons must be pressed after the input devices are cleared.
Logic
Fault Detection
Upon successful completion of internal checks on power up, the SmartGuard checks the input devices. The pulsed outputs T2-T3 are used by the SmartGuard to
help check for open and short-circuit fault conditions. If a fault is detected, the SmartGuard will not energize the respective outputs. When the zone reset buttons
are pressed, the SmartGuard checks the status of the K1-K5 contactors. If the contactors are energized, stuck or welded closed, the SmartGuard will detect this
due to the open circuit to Inputs 14 or 15, and will not energize the respective zone. The programmable safety function blocks associated with each device
performs self-checking. If a fault occurs, the respective fault reset button must be pressed, after the fault is cleared.
Ratings
Power
requiring Performance Levels up to PLe per ISO 13849-1:2006. The safety functions initiated by the MatGuard safety mat and 440G-MT interlock meet the safety
ISO 13849-1:2006. This circuit executes a Category 0 stop. If only one contactor is used to power a hazard, the safety function can meet SIL CL 2, Category 2 structure
and PLd.

R
Safety I/OTwo Zones Distributed
GuardShield, SensaGuard, SafeZone, 800F, 440G-MT, CompactBlock Guard I/O, 100S, 700S
+24V DC
Brown 1 Brown Brown
2 1
Pink Pink
4
General
6 Lock
5 Gray Gray Release
3
Blue 3 Blue Blue 440G-MT47045
7 2
A1 11 21 33 43
Sender Receiver
800FM-MT44MX02V
440L-P4K1280YD
Reset Zone 1
Fault Reset Zone 1
Reset Zone 2
Fault Reset Zone 2
Brown A2 12 22 34 44
2
Yellow
4
Red
8
Principles
E-Stop
6 Pink
5 Gray
Blue
7
SensaGuard K1 K2
440N-Z21S17B
DeviceNet K3 K4
V0 V1 2 3 4 50 1 6 7 V0 0 1 2 3 4 5 6 7
Input Terminals Input Terminals
CompactBlock Guard I/O CompactBlock Guard I/O
1791DS-IB8xOB8 1791DS-IB12 Pulse Output
Output Terminals Input Terminals Terminals
Safety Controller
G0 G1 0 1 2 3 4 5 6 7 G0 8 9 10 11 T0 T1 T2 T3
9-
SmartGuard,
Zone 1 Active
K1 K3
GuardPLC & Scanner,
Zone 2 Active
or GuardLogix K2 K4
100S-C or 700S-C or 700S-P
24V DC Com
Safety Control System

Applications
Compact Block Guard I/O resides on a DeviceNet safety network and operates as a safety slave. Safety Masters that can 'own' the Compact Block Guard I/O modules
10-Safety
include GuardLogix, SmartGuard, and the GuardPLC safety controllers. Note the GuardPLC requires a 1753-DNSI Safety Scanner to 'own' Compact Block Safety I/O.
For the remainder of this application note, the Safety Master will be referred to as the 'safety controller.' Since the various Safety Controllers have varied
communication interfaces to the standard machine control system, this application note will make no references to this link.
Circuit Status
The safety controller is programmed to control two zones. The GuardShield and SensaGuard control zone 1 with contactors K1 and K2. The SafeZone Laser Scanner
and 440G-MT control zone 2 with contactors K3 and K4. The SafeZone, located behind the locked safety gate, is used to detect someone in the hazard area. The
E-Stop applies to both zones. The two safety gates are closed, the light curtain and laser scanner are cleared and the e-stop is released. Both zones are ready to be
activated.
Operator
Interface
Operating Principle
STARTING: Press the reset button for each zone to allow the safety controller to energize the safety outputs of the CompactBlock Guard I/O. The safety contactors K1
through K4 become energized and allow the zones to operate. The safety controller signals the machine control system that the zones are ready to run. The machine
control system (not shown) controls the zones.
not cause the contactors to energize the zone 1 Reset button must be pressed to restart zone 1. The e-stop acts as a global stop. When pressed, both zones are
de-energized. The safety controller energizes Output 6 to provide voltage for the 440G-MT guard locking solenoid. Press the Lock Release button and open the gate.
Closing the gate or resetting the e-stop does not re-energize the K1-K4 contactors. The zone reset buttons must be pressed after clearing the input devices.
Fault Detection
Logic
Upon successful completion of internal checks on power up, the CompactBlock Guard I/O checks the input devices. Test outputs T2 and T1 are configured as pulse
test sources and are used by the CompactBlock Guard I/O to help check for open and short-circuit fault conditions of the E-Stop and Gateswitch. If a fault is detected,
the safety controller will not energize or will de-energize the respective outputs. The safety controller checks the status of the K1-K4 contactors. If the contactors are
energized, stuck or welded closed, the safety controller will detect this due to the open circuit to Inputs 6 or 7 on the IB12, and will not energize the respective zone.
Test outputs T2 and T3 are used to help detect wiring faults on these contactor feedback circuits. The programmable safety function blocks associated with each
device performs self checking. If a fault occurs, the respective Fault Reset button must be pressed, after the fault is cleared.
Ratings
Power

Safety I/OSingle Zone
GuardShield, 440G-MT, CompactBlock Guard I/O, 100S, 700S
+24V DC
Brown
General
Brown 1 2 440G-MT47045
Pink
800FM-F2MX10V
800FM-F6MX10V
6
5 Gray
A1
43 33 21 11
Fault Reset
Blue K1 K3
Blue 3 7
Reset
Sender Receiver
44 34 22 12 A2
GuardShield Light Curtain
440L-P4J1280YD K2 K4
Principles
Safety Controller 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
5 1 Node
4 Out T1 I1 C I0 T0 T1 I1 C I0 T0 T1 I1 C I0 T0 T1 I1 C
3
2 I0 T0
Addr
SmartGuard, A B C D
GuardPLC & Scanner, DeviceNet CompactBlock Guard I/O 1791DS-IB8XOBV4
E F G H Power
or GuardLogix & Scanner 1 5
4 In 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 4 1
2
3
+ N C P C + N C P C + N C P C + N C P C
3 2
FE
K1 K2 K3 K4
<2A <2A <1A <1A Safety
100S-C or 700S-C or 700S-P System
Contactors or Safety Relays Active
9-
24V DC Com
Circuit Status
The light curtain is cleared, and the 440G-MT guard locking switch is closed and locked. The contactors K1-K4 are off. The safety system is ready to be energized.
Operating Principle
Applications
The 1791DS-IB8X0BV4 has bi-polar outputs, which allows the module to switch both the positive and negative side of the load device (e.g. contactors and solenoids)
10-Safety
and to check for faults on both the positive and negative side of the load.
STARTING: Press the reset button to energize the contactors K1-K4. The safety controller verifies that the monitoring circuits at terminals in the "C" connector are
closed. The safety contactors K1 through K4 become energized and allow the machine to run. The Safety System Active indicator is turned on by the safety controller.
The safety controller signals the machine control system that the safety system is ready to run. The machine control system (not shown) controls the machine.
STOPPING: Obstructing the light curtain de-energizes contactors K1-K4. The contactors may also be de-energized by the safety controller due to other safety demands
(like a system level e-stop). When the contactors K1-K4 are de-energized, the solenoid of the 440G-MT can be energized and allow the gate to be opened. While the
gate is open, the program in the safety controller must not allow the contactors to re-energize. Closing the gate or clearing the light curtain do not re-energize the
contactors. Press the reset button to re-energize the contactors.
Fault Detection
Operator
Interface
Upon successful completion of internal checks on power up, the safety controller checks the input devices. Test outputs T0 and T1 in the "D" connector are configured
as pulse test sources and are used by the safety controller to help check for open and short-circuit fault conditions of the 440G-MT gateswitch. If a fault is detected, the
safety controller will not energize the K1-K4 contactors. The safety controller checks the status of the K1-K4 contactors. The safety controller will detect contactors that
are energized, stuck or welded closed by the open circuits at inputs I0 and I1 and will not energize the respective zone. The contactors and the 440G-MT solenoid are
switched on both the positive and negative side, so shorts to either the supply voltage or to ground will be detected. After clearing a fault, press the Fault Reset button
to reset the module. Press the Reset button to allow the contactors to be energized.
Programming
The safety outputs of the 1791DS-IB8XOBV4 are configured in firmware as four (4) dual channel pairs. Both outputs in the pair must be complementary or a fault
occurs. Outputs TO and T` in the "D" connector must be configured as pulse outputs. Test outputs T0 in the "B" connector must be configured in software as 'standard
outputs' to drive the Safety System Active indicators.
Logic
Ratings
The ratings assume that two contactors are connected in series to power the hazards. The safety function intiated by the GuardShield light curtain meets the safety
performance requirements of SIL CL 3 per IEC 62061:2005 and has a Category 4 structure that can be used in systems requiring Performance Levels up to PLe per
ISO 13849-1:2006. The safety functions initiated by the 440G-MT interlock meet the safety performance requirements of SIL CL 2 per IEC 62061:2005 and have a
Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1:2006. This circuit executes a Category 0 stop. If only one
contactor is used to power a hazard, the safety function can meet SIL CL 2, Category 2 structure and PLd.
Power

R
Safety Valve & E-StopAir Supply Release
800F, MSR142, Pneumatic Safety Valve
+24V DC
E-Stop
Reset
800FM-MT44MX02V
General
800FM-F6MX10 DM2TM CrossflowTM

SERPAR Air Supply
Reset Safety Rated Valve
800FM-F6MX10 Air Exhaust
A1 S11 S12 S21 S22 S52 S11 Y31 S33 S34 13 23 33 81 91 43 53 63 73 101 111 Ch1
MSR142RTP
440R-G23216
Principles
Status
A2 X1 X2 X3 X4 Y30 Y32 Y35 Y2 Y1 14 24 34 82 92 44 54 64 74 102 112 Ch2
Connect to other safety related
loads and auxiliary signals
Ready
800FM-P6
800F-MQ3B Output Active
800FM-P3
800F-MQ3G Air Outlet to other
24V DC Com pneumatic valves
9-
Circuit Status
The e-stop button is released, the MSR142 safety relay outputs are off and the pneumatic valve is closed.
Operating Principle
STARTING: Press the reset button to energize the output contacts of the safety relay. The two solenoids in the valve energize and allow air to flow from the Air Supply
to the Air Outlet.
STOPPING: Pressing the e-stop button de-energizes the safety outputs of the MSR142, which in turn drops out the solenoids of the safety valve. The valve closes the
Applications
Air Supply and releases the air pressure to the Air Exhaust. Releasing the e-stop button does not cause the valve to turn back on.
10-Safety
Fault Detection
Upon successful completion of internal checks on power up, the MSR142 checks the e-stop status. If an open or short circuit is detected, the MSR142 will not energize
its outputs. If both input circuits are properly closed, the MSR142 checks the status of the safety valve. If one or both solenoids of the safety valve are energized, the
Status contact will be open, and the MSR142 will not energize its outputs. If both solenoids are de-energized, Status contact will be closed and the MSR142 will turn on
its Ready LED. Pressing the Reset button energizes the MSR142 safety outputs and opens the safety valve.
The safety valve performs its own internal checks. If one of the valves remains actuated, gets stuck or moves too slowly, the Air Outlet flow will be re-directed to the
exhaust. To clear the fault condition, both valves must be de-energized and the valve reset button pressed.
Operator
Interface
Ratings
The safety function initiated by the 800F e-stop button meets the safety performance requirements of SIL CL 3 per IEC 62061:2005 and has Category 4
structure that can be used in systems requiring Performance Levels up to PLe per ISO 13849-1: 2006. The MSR142 has seven safety rated outputs. To maintain the
highest safety levels, these outputs must drive redundant actuators which must be monitored for proper performance. This example circuit performs a Stop Category 0
function (coast to stop).
Logic
Power

Safe Limited Speed Control
845T, TLS3-GD2, 800F, 440J, MSR57, PF70
+24V DC
SLS Request Power to
SS 800FM-KM23 Release
General
Request 800F-MX02V 11 21 33
2 4 41 51
E-Stop A1
800FM-MT44 12 22 34
800F-MX01V 1 3
800F-MX01S A2 Remove 2
440J-N21TNPS 42 52
internal
Enabling Switch TLS3 GD2 jumpers
440G-T27260
Principles
L1 L2 L3
A1 S11 S21 S12 S22 S52 S62 S72 S82 51 52 X32 X42 S32 S42 13 PowerFlex 70
9 24VDC AC Drive with
Pulse SS SLS Enable Solenoid Lock Door
Outputs Input Input Input Control Status Input 8 DC Comm DriveGuard
Stop 7 Dig Comm
RJ 45 RJ 45 MSR57 A1 1 Stop
Encoder Encoder DPI Start Gate Control
Input 1 Input 2 2 Start
Isolated Diag & Pwr 3 SLS Input Power Supply
SLS Fault SS Output RL- Re- Feed SLS Stop 24V Gate SLS Safe Off Option
Req Status Cascading Feed start back Cmd Cmd Gnd DC Drive Cascading 1
9-
A2 Y35 Y37 34 44 Y1 S34 Y2 Y33 Y32 Y30 Y31 14 24 68 78 3
4
2
Reset Gate
800FM-F6MX10 6 Enable Control
Circuit
Applications
10-Safety
Safety Stop to Remove Jumper
next module
(optional)
Motor
Aux signals
to PLC 845T Encoder
24V DC Com
Circuit Status
Operator
Interface
The safe stop (SS) request e-stop button is released. The safe limited speed (SLS) request button is released. The enabling switch is released. The guard locking
interlock is closed and locked. The safety outputs (Gate Drive) of the MSR57 are off. The motor is off.
Operating Principle
The MSR57 performs the safe limited speed function. It provides a signal to the drive to initiate the slow speed. The MSR57 accepts encoder signals to monitor the speed.
When the speed is within the safe speed limit, the guard locking device is allowed to open. If the speed exceeds the limit, a safe shutdown is initiated.
STARTING: Press the reset button to energize outputs of the MSR57. Then press the start button to turn on the motor. The motor will execute its programmed function.
SAFE LIMITED SPEED: Turn the key operated selector switch to the SLS position and remove the key. The MSR57 sends a command to the drive to go to its configured
safe limited speed. When the motor reaches and stays at the limited speed, the guard locking door becomes unlocked. Grip the enabling switch to the middle position and
enter the hazard area. Exit the hazard area while holding the GripSwitch. Switch the SLS request to run. Then press the reset button to allow the drive to rotate the motor
at high speeds. The GripSwitch can then be released.
Logic
STOPPING: The e-stop can be pressed at any time to initiate a stop. If the speed exceeds the limit or the GripSwitch is released, a safe-off stop is initiated.
Fault Detection
Upon power-up the MSR57 and PowerFlex 70 perform internal checks. The MSR57 generates continuous test pulses to check for short circuit at the input devices. Dual
channel inputs and outputs provide single fault tolerance.
Ratings
The safety functions initiated by the 800F e-stop and TLS3-GD2 guardlocking device meet the safety performance requirements of SIL CL 2 per IEC 62061:2005 and has
Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006. This example circuit performs a Stop Category 1 function
Power
(brake and then remove power to motor).

R
Modular RelaySingle Zone
GuardShield, 800F, MSR211, 100S
24V DC
Brown 1 Brown
2
General
Pink (OSSD2)
6
5 Gray (OSSD1)
Blue Blue
3 7
3 Green
S12 S32 A1 Y31 Y40 Y41 Y42 13 23 31 L1 L2 L3
Sender Receiver
440L-P4K0960YD
889D-F4AC-2 889D-F8AC-2 K1
MSR211P
Principles
440R-H23177
K2
S42 S62 A2 Y30 Y32 Y33 S34 Y1 Y2 14 24 32
M
Brown Brown
1 2
Pink (OSSD2)
6
Reset
5 Gray (OSSD1) 800FM-F6MX10
Blue Blue 100S-C16DJ14BC
3 7 K1
3 Green Output Active
9-
800FM-P3
Sender Receiver 800F-MN3G K2 100S-C16DJ14BC
440L-P4K0960YD
889D-F4AC-2 889D-F8AC-2 Ready for Reset
800FM-P6
800F-MN3B
24V Com
Applications
10-Safety
Circuit Status
Both light curtains are clear. The MSR211P output contacts are de-energized. The motor is off and ready to run.
Operating Principle
The MSR211P accepts two light curtains and functions as an alternative to a cascaded arrangement of light curtains.
STARTING: Press the reset button to energize the outputs of the MSR211P, which turns the motor on.
STOPPING: Obstructing either light curtain causes the motor to stop.
Fault Detection
Operator
Interface
Upon successful completion of internal checks on power-up, the MSR211 checks the input signals from the GuardShield light curtains. If all four signals from the light
curtains are present and no shorts exist, the MSR211P checks for the reset button. With the jumper from Y40 to Y42, the MSR211P checks to make sure the reset
button is not held closed. When the reset button is pressed, the MSR211P checks the status of the two contactors. If the circuit on Y1/Y2 is closed, the MSR211
energizes its output. With the jumper from Y40 to Y41, the MSR2f11P confirms that both contactors are energized within 300 ms.
Ratings
The safety functions initiated by the two GuardShield light curtains meet the safety performance requirements of SIL CL 3 per IEC 62061:2005 and has Category 4
structure that can be used in systems requiring Performance Levels up to PLe per ISO 13849-1: 2006. This example circuit performs a Stop Category 0 function
(coast to stop).
Logic
Power

Light CurtainMuting with Two Sensors
GuardShield, RightSight, 800F, Control Tower, MSR22LM, 100S
+24V DC
LC2
General
Power/ MS1
Muting Sensors
Fault Reset
RightSight Transmitted Beam
LC1 Muted
800FM-SM22
Jumper S21-S22 42EF-E1EZB-F4 (Source)
800F-MQ10 Machine Object Conveyor
and S23-S24 42EF-R9MPBV-F4 (Receiver)
if LC2 is not used 889D-F4AC-2
MS2
Brown 1 Brown MS2 MS1
2
Muting lamp
Pink
6
Principles
5 Gray L1 L2 L3
Blue 3 Blue
7
Sender Receiver
A1 S12 S14 S21 S22 S23 S24 S31 S32 S33 S34 13 23 31 K3
GuardShield (LC2 -Not Muted)
440L-P4J0960YD MSR22LM
440R-P23071 3 3 K1
889D-F4AC-2 + 889D-F8AC-2
Auto Restart LC1 2 2 K2
30 sec Mute K4
Brown 1 Brown A2 M1 M2 48 58 X44 S43 S44 S41 S42 14 24 32

2
Pink
6
M
9-
5 Gray
Blue 3 Blue Aux Signal
7 Start/Restart
800FM-F6MX10 To PLC
Sender Receiver Muting Lamp
(Clear)
GuardShield PAC (LC1 -Muted)
440L-P4A3400YD Control Tower Start/Restart
889D-F4AC-2 + 889D-F8AC-2 Required K3 K4 100S-C23DJ14BC
Stack Light
Applications
855EP-B24Y6YL7 (Blue)
10-Safety
24V Com
Circuit Status
The light curtain is clear. The muting sensors are clear. The outputs of the safety relay are de-energized, and the motor is off.
Operating Principle
The MSR22LM is designed for automated conveyor applications, where an object moves through a light curtain into or out of a hazardous area. With two sensor muting,
the object can move in both directions.
STARTING: Upon initial power-up, the start/restart button must be pressed to energize the outputs of the MSR22LM and start the motor.
Operator
Interface
MUTING: The object must block the sensor MS1 and then MS2 prior to passing through the light curtain. After passing through the light curtain, the object must clear MS2
and then MS1 for the motor to continue running during the muting operation.
STOPPING: Obstructing the light curtain without blocking sensors MS1 and MS2 de-energizes the MSR22LM safety outputs. After clearing the light curtain, press the
start/restart button to re-energize the safety outputs of the MSR22LM.
Fault Detection
Upon power-up, the GuardShield and MSR22LM perform internal checks. If OK and clear, the GuardShield outputs turn on. The MSR22LM checks the muting inputs. If
OK, the MSR22LM checks the light curtain for dual channel signals. If OK, the muting lamp blinks continuously and the start/restart required lamp turns on to indicate that
the MSR22LM is ready to start. While running, an incorrect sequence of the muting sensors and light curtain operation or excessive time to move the object through the
light curtain will de-energize the safety outputs of the MSR22LM. The run LEDs or the muting lamp blink at certain rates to indicate the type of fault that has occurred. The
start/restart button can be held down for three seconds to manually move material through the conveyor. The motor will then run for 12 seconds. Some faults can be
Logic
cleared by removing the object from the sensors. The start/restart required indicator will turn on when the MSR22LM is ready to go. Other faults may have to be cleared by
cycling the power to the MSR22LM. The MSR22LM monitors the 100S contactors through mechanically linked contacts connected in series. If one contactor welds closed,
the second contactor will stop the motor, and the MSR22LM will detect the fault at the next attempt to start the motor.
Ratings
The safety functions initiated by the two GuardShield light curtains meet the safety performance requirements of SIL CL 3 per IEC 62061:2005 and has Category 4 structure
that can be used in systems requiring Performance Levels up to PLe per ISO 13849-1: 2006. This example circuit performs a Stop Category 0 function (coast to stop).
Power

R
Light CurtainMuting with Four Sensors
GuardShield, RightSight, 800F, Control Tower, MSR22LM, 100S
24V DC
General
Muting Sensors
MS4 MS3 MS2 MS1
RightSight Transmitted Beam MS3 MS1 Object
42EF-E1EZB-F4 (Source)
Power/
42EF-R9MPBV-F4 (Receiver)
LC11 Muted
Fault Reset Machine Conveyor
889D-F4AC-2
800FM-SM22
800F-MQ10
MS4 MS2
Muting Lamp
Principles
Brown 1 Brown
2
Pink
6
L1 L2 L3
5 Gray
Blue 3 Blue
7 A1 S12 S14 S21 S22 S23 S24 S31 S32 S33 S34 13 23 31
Sender Receiver MSR22LM
5 5 K1 K3
440R-P23071
GuardShield PAC (LC1- Muted)
Manual Restart 4 4 K2
440L-P4A3400YD
5 Minute Mute
889D-F4AC-2 + 889D-F8AC-2
855T-B24Y6YL7 A2 M1 M2 48 58 X44 S43 S44 S41 S42 14 24 32 K4
9-
Mirror
Contacts
Start/Restart Aux Signal
Muting Lamp
(Clear)
Control Tower
800FM-F6MX10 to PLC
M
Start/Restart
Stack Light Required K3 K4 100S-D95ZJ33LC
Applications
855T-B24Y6YL7 (Blue)
10-Safety
24V Com
Circuit Status
The light curtain is cleared. The muting sensors are cleared. The outputs of the safety relay are de-energized, and the motor is off.
Operating Principle
The MSR22LM is designed for automated conveyor applications, where an object moves through a light curtain into or out of a hazardous area. With four sensor muting,
the object can only move in one direction.
STARTING: Upon initial power-up, the start/restart button must be pressed to energize the outputs of the MSR22LM and start the motor.
Operator
Interface
MUTING: The object must block the sensors MS1 and MS2 prior to passing through the light curtain. The object must be large enough to block all four sensors, for the
motor to continue running during the muting operation.
STOPPING: Obstructing the light curtain without blocking sensors MS1 and MS2 de-energizes the MSR22LM safety outputs. After clearing the light curtain, press the
start/restart button to re-energize the safety outputs of the MSR22LM.
Fault Detection
Upon power-up, the GuardShield and MSR22LM perform internal checks. If OK and clear, the GuardShield outputs turn on. The MSR22LM checks the muting inputs. If
OK, the MSR22LM checks the light curtain for dual channel signals. If OK, the muting lamp blinks continuously and the start/restart required lamp turns on to indicate that
the MSR22LM is ready to start. While running, an incorrect sequence of the muting sensors and light curtain operation or excessive time to move the object through the
light curtain will de-energize the safety outputs of the MSR22LM. The run LEDs or the muting lamp blink at certain rates to indicate the type of fault that has occurred. The
start/restart button can be held down for three seconds to manually move material through the conveyor. The motor will then run for 12 seconds. Some faults can be
Logic
cleared by removing the object from the sensors. The start/restart required button will turn on when the MSR22LM is ready to go. Other faults may have to be cleared by
cycling the power to the MSR22LM. The MSR22LM monitors the 100S-D contactors through the mechanically linked "mirrored" contacts connected in series. If one
contactor welds closed, the second contactor will stop the motor, and the MSR22LM will detect the fault at the next attempt to start the motor.
Ratings
The safety function initiated by the GuardShield light curtain meets the safety performance requirements of SIL CL 3 per IEC 62061:2005 and has Category 4 structure
that can be used in systems requiring Performance Levels up to PLe per ISO 13849-1: 2006. This example circuit performs a Stop Category 0 function (coast to stop).
Power

Configurable RelayMuting
GuardShield, 872C WorldProx, 800F, MSR310P, 100S
+24VDC
Inductive Prox
Sensors/Cordset
872C-DH5NP18-D4 GuardShield
General
889D-F4AC-5 Light Curtain
Blue 440L-P4K0960YD
Brown Brown
1 1
Blue
3 3 1 3
4 2 7
4
Black Black 5 6
Group 3 Output
Principles
MSR330P
440R-W23223
A1 A2 S12 S22 S32 S12 S22 S32 S11 S21 S31 S41 S51 Y40 Y41 Y42 A1 13 23 33 41 L1 L2 L3
G8 F6 G1 F6
MSR310P K1
MSR329P MSR320P MSR320P 440R-W23219
440R-W23217 440R-W23218 440R-W23218
H11 G1 H12 S42 S52 S62 S42 S52 S62 A2 Y31 Y32 Y33 Y34 Y10 Y11 Y12 Y13 14 24 34 42
No K2
Connections
Muting Lamp
9-
Primary (required) Group 3 Active K1
Reserve (optional)
855T-B24YL7YL7
Reset
800FM-F6MX10
100S-C23DJ14BC
M
K2
Applications
24V DC Com
10-Safety
Circuit Status
The light curtain is clear. The inductive proximity sensors are clear. The MSR330P outputs are de-energized. The motor is off.
Operating Principle
The MSR300 is configured for a muting function. When both proximity sensors detect appropriate targets, the light curtain function is muted. The proximity sensors
operate as a pair and do not have to operate in a specific sequence. The application must be an automatic process where the muting function is temporary. A muting
lamp indicates when the muting function is active. The muting lamp is monitored. If the muting lamp burns out, the MSR300 will continue to function if a reserve lamp
is present; otherwise the output stay off until the primary muting lamp is replaced.
Operator
Interface
STARTING: Press the reset button to energize all MSR330P outputs. The contactors K1 and K2 energize and the motor is turned on.
STOPPING: Obstructing the light curtain when the proximity sensors are not active will cause the MSR310P to de-energize and stop the motor.
Fault Detection
Upon successful completion of internal checks on power up, the MSR310P checks the input circuits. Shorts from the inputs to power, ground or other inputs will be
detected immediately and will prevent energizing or will de-energize the MSR330P outputs. If one of the 100S output devices (K1 or K2) is stuck in an actuated state,
the MSR310P will prevent startup because the Y10/Y13 feedback loop will remain open. The proximity sensors must be located in a way that prevents easy
bypassing with spare targets.
Ratings
The safety function initiated by the GuardShield light curtain meets the safety performance requirements of SIL CL 3 per IEC 62061:2005 and has Category 4
Logic
structure that can be used in systems requiring Performance Levels up to PLe per ISO 13849-1: 2006. This example circuit performs a Stop Category 0 function
(coast to stop).
Power

R
Expandable OutputsE-Stop with Immediate and Delayed Outputs
800F, MSR144, MSR230, MSR238, 100S, 700S
+24V DC
General
Reset
800FM-F6MX10
Aux Signal
to PLC 4 sec Delay
Principles
S11 S52 S21 A1 X1 X2 S33 S34 13 23 41 51 13 23 33 43 Y3 Y4 Y5 Y6 17 27 35

E-Stops Up to 5
800FM-MT44MX02V MSR144 MSR238 Expansion
440R-C23205 440R-H23196 Modules
Delayed Allowed
S12 S22 A2 X3 X4 Y2 Y1 14 24 42 52 14 24 34 44 Y3 Y4 Y7 Y8 18 28 36
K1 K5 MSR230
440R-H23180 Aux Signal
Immediate to PLC
K2 K6
9-
K3 K7
K4 K8
K1-K8
K1 K3 K5 K7 100S Safety Contactors or
Applications
700S Safety Control Relays

10-Safety
K2 K4 K6 K8
24V DC Com
Circuit Status
The e-stop is reset. The safety outputs of the MSR144, MSR230 and MSR238 are de-energized. The motor is off.
Operating Principle
The MSR144 was chosen for its ability to expand its outputs with a combination of MSR230 and MSR238 modules. Up to five modules can be added to one MSR144.
Operator
Interface
Ribbon cables on the front of the relay extend control of the MSR144 to MSR230 and MSR238. Without jumpers to X1/X2 and X3/X4, the MSR144 is set to monitored
manual reset.
STARTING: Press and release the reset button to energize the outputs of the MSR144, MSR230 and MSR238. K1-K8 safety contactors or safety control relays energize
to control the hazardous portion of the machine.
STOPPING: When an e-stop is pressed, the safety outputs of the MSR144 and MSR230 immediately turn off and de-energize K1-K6. Four seconds later, the safety
outputs of the MSR238 turn off and de-energize K7 and K8.
Fault Detection
Upon power-up, the MSR144 performs internal checks. The checks also include verification that the MSR230 and MSR238 modules are in the off state. The MSR144 then
looks for dual signals from the e-stop circuit. A crossfault on the e-stop circuit will be detected by the MSR144. With the e-stop signals made, closing the reset button
places a voltage to the Y2 terminal. The external devices (K1 through K8) are checked to confirm they are off. A fault in K1 through K8 will cause their normally closed
Logic
contacts to remain open, and this fault will be detected by the MSR144.
Ratings
The safety function initiated by the series connection of 800F e-stop buttons meets the safety performance requirements of SIL CL 2 per IEC 62061:2005 and has
Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006. The Category 3 rating requires the redundant usage
of K1-K8 to de-energize the machine actuators, and the contactors must be monitored by the safety system. This example circuit performs a Stop Category 0 function
(coast to stop).
Power

Mat Manager
440F-M, 440F-C, 100S
+ 24V DC
Alternate Supply
110V/230V AC
General
440F-M2030CYNN Reset
800FM-F6MX10
L1 L2 L3
1 2 3 4 L1 +ue 13 23 31 MCa NO
Up to 8 Reset
Sensor Mats M K1
440F-C28013
A
K2
Principles
5 6 7 8 Case L2 -ue 14 24 32 MCb PB
Auxiliary Output
Motor
(e.g. Signal to PLC)
K1
K2 100S-C23DJ14BC
9-
24V Com
Circuit Status
There is no presence on the safety mats. The safety outputs of the Mat Manager are de-energized. The motor is off.
Operating Principle
Applications
The Mat Manager monitors up to eight mats, which are individually connected to the Mat Manager by M12 connectors. LEDs on the front of the Mat Manager indicate
10-Safety
which mat is actuated as well as providing status LED for power and safety outputs.
STARTING: Press the reset button to energize the outputs of the Mat Manager.
STOPPING: Stepping on any of the safety mats will turn off the safety outputs of the Mat Manager and de-energize the K1 and K2 contactors.
Fault Detection
Upon power-up, the Mat Manager performs internal checks. The Mat Manager then looks for current flowing through each of the safety mats. A short or open circuit on
any of the safety mats will be detected by the Mat Manager. With the safety mat signals made, the Mat Manager checks the reset button. With monitored manual reset
selected, a short circuit or stuck pushbutton will be detected by the Mat Manager. Pressing the reset button, the Mat Manager checks the K1 and K2 contactors. A stuck or
welded contactor will be detected by an open normally closed contact.
Operator
Interface
Ratings
The safety function initiated by the MatGuard safety mat meets the safety performance requirements of SIL CL 2 per IEC 62061:2005 and has Category 3 structure that can
be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006. This example circuit performs a Stop Category 0 function (coast to stop).
Logic
Power

R
Micro400 Light Curtain with Controller and Expansion Module
Micro400, MSR41, MSR45E, 100S
+24V DC
GuardShield Micro400
General
445L-P4CxxxxYD
Emitter Receiver
Start
800FP-F301PX10
440R-ACABL1
Principles
Receiver +24V In2 13 23

L1 L2 L3 L1 L2 L3
MSR41 MSR45E
440R-P221AGS 440R-P4NANS
K1 K3
Emitter Info1 Info2 0V OSSD1 OSSD2 14 24
K2 K4
445L-AC8RJx
x=3, 5, or 8 m
M1 M2
9-
Pair of Cables
Safety Output Aux Signal

to PLC or Indicator
K1 K2 K3 K4 100S-C09DJ14BC
Lockout Aux Signal
to PLC or Indicator
Applications
24V DC Com
10-Safety
Circuit Status
The light curtain is clear. K1, K2, K3 and K4 are off. The motors are off and ready to run.
Operating Principle
STARTING: Momentarily press the Start button. The OSSD safety outputs and the safety contacts 13/14 and 23/24 close. The contactors K1-K4
energize, and the motors M1 and M2 start.
STOPPING: Breaking the light curtain causes the OSSD safety outputs and the safety contacts 13/14 and 23/24 to open. The contactors K1-K4 drop
out and the motors coast to a stop.
Operator
Interface
Removing the object from the light curtain will not cause the motor to run. The operator must momentarily close the Start switch to turn the motor on.
Fault Detection
Upon successful completion of internal checks on power up, the GuardShield light curtain energizes its outputs with no objects present. The GuardShield
light curtain outputs turn on. If a crossfault is detected, the GuardShield light curtain goes to a lockout state with its outputs off. After successful completion
of internal checks, the MSR41 checks the signals from the light curtain. If its okay, the MSR41 then checks the status of the K1-K4 contactors. If one of the
pair of contactors fails in the actuated state, the other contactor will disconnect the motor. The MSR41 will detect the faulted contactor and will not allow the
motor to restart until the fault is corrected.
Logic
Ratings
This circuit can meet the safety performance requirements of PLe per ISO13849-1: 2006 and SIL CL3 per IEC62061:2005. This circuit executes a
Category 0 stop.
Power

Two Sensor Muting with Micro400 Light Curtain
42EF, Micro400, MSR42, 100S
+24V DC
LC LC
S2
S1 S2
S1
GuardShield Micro400 2 Muting Sensors
General
445L-P4CxxxxYD RightSight
Object
Emitter Receiver 42EF-D1KBAK-F4 Start Object
800FP-F301PX10
Muting lamp Muting lamp
2T Muting 2L Muting
Forward or Reverse Forward only
Principles
440R-ACABL1
Receiver GPIO1 GPIO2 +24V In1 In2 13 23
L1 L2 L3 L1 L2 L3
MSR42 MSR45E
440R-P221AGS 440R-P4NANS
K1 K3
Emitter Info1 Info2 0V OSSD1 OSSD2 14 24
K2 K4
445L-AC8RJx
x=3, 5, or 8 m
M1 M2
9-
Pair of Cables
Light Curtain Aux Signal

to PLC or Indicator
Low Intensity Aux Signal K1 K2 K3 K4 100S-C09DJ14BC
to PLC or Indicator
24V DC Com
Applications
10-Safety
Circuit Status
The light curtain and muting sensors are clear. K1, K2, K3 and K4 are off. The motors are off and ready to run.
Operating Principle
STARTING: Momentarily press the Start button. The OSSD safety outputs turn on and the safety contacts 13/14 and 23/24 close. The contactors K1-K4
energize, and the motors M1 and M2 start.
MUTING: The MSR42 must be configured for two sensor L-type or T-type sensing. When the object passes by the sensors in the proper sequence, the light
curtain becomes muted. The muting process is complete when the object passes by both sensors, and the light curtain becomes active again.
Operator
Interface
STOPPING: Breaking the light curtain causes the OSSD safety outputs and the safety contacts 13/14 and 23/24 to open. The contactors K1-K4 drop
out and the motors coast to a stop.
Fault Detection
of internal checks, the MSR42 checks the signals from the light curtain. If its okay, the MSR42 then checks the status of the four sensors and the K1 and K2
contactors. If a sensor is shorted in the ON state, the MSR42 will not allow the OSSD outputs to turn ON. If one of the contactors fails in the actuated state,
Logic
Ratings
Category 0 stop.
Power

R
Four Sensor Muting with Micro400 Light Curtain
42EF, Micro400, MSR42, 100S
+24V DC
LC
S4 S3 S2 S1
4 Muting Sensors
GuardShield Micro400 RightSight
General
445L-P4CxxxxYD 42EF-D1KBAK-F4 Object
Emitter Receiver Start

800FP-F301PX10
Muting lamp
4T Muting
Forward and Reverse
Principles
Receiver GPIO1 GPIO2 GPIO3 GPIO4 +24V In1 In2

L1 L2 L3
MSR42
440R-P221AGS
K1
Emitter Info1 Info2 0V OSSD1 OSSD2
K2
445L-AC8RJx
x=3, 5, or 8 m
M1
9-
Pair of Cables
Light Curtain Aux Signal

to PLC or Indicator
Low Intensity Aux Signal
to PLC or Indicator
Applications
24V DC Com
10-Safety
Circuit Status
The light curtain and muting sensors are clear. K1 and K2 are off. The motor is off and ready to run.
Operating Principle
STARTING: Momentarily press the Start button. The OSSD safety outputs turn on. The contactors K1-K2 energize, and the motor M1 starts.
MUTING: The MSR42 must be configured for four sensor T-type sensing, with appropriate time settings. When the object passes by the sensors in the
proper sequence, the light curtain becomes muted. The muting process is complete when the object passes by all the sensors and the light curtain
Operator
Interface
becomes active again.

STOPPING: Violating the muting timing constraints and breaking the light curtain causes the OSSD outputs to turn off. The contactors K1-K2 drop
out and the motors coast to a stop. If the object stops in the light curtain, the Start button can be used to temporarily override the muting function
and energize the OSSD outputs.
Fault Detection
of internal checks, the MSR42 checks the signals from the light curtain. If its okay, the MSR42 then checks the status of the four sensors and the K1 and K2
contactors. If a sensor is shorted in the ON state, the MSR42 will not allow the OSSD outputs to turn ON. If one of the contactors fails in the actuated state,
Logic
Ratings
Category 0 stop.
Power


Safety Applications and Wiring Diagrams: Application Selection Table 10-2

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Safety Applications and Wiring Diagrams

Application Selection Table 10-2

Notes for Use with Application Circuit Examples 10-4

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Shield Mat Scanner Switch Non-Contact Locking 800F Lifeline

that differ from the guidelines provided.

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be checked in a similar manner.

General Safety Information

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The motor is off and ready to run.

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This circuit executes a Category 0 stop.

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Sipha S21 E-Stop

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Trojan T15-GD2 ELF-GD2

Input PLC Output RP

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800F-MX01V Machine control system

440G-T27260 S11 S52 S21 A1 S33 S34 13 23 37 47 55

A2 11 21 33 S12 S22 A2 Y1 Y2 Y39 Y40 14 24 38 48 56

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S11 S52 S21 S22 S12 A1 S33 S34 13 23 37 47 55

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S11 S21 S22 S32 S12 A1 Y31 Y40 Y41 Y42 13 23 31 Y3 Y4 Y5 Y6 17 18 35 U V W

A2 11 21 33 S62 S42 S52 A2 Y30 Y32 Y33 S34 Y1 Y2 14 24 32 Y3 Y4 Y7 Y8 18 28 36

To PLC (Inputs Closed/Ready)

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Group 1 Output Active

Group 3 Output Active

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S21 S11 S52 A1 13 23 33 41 Gate Control

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E-Stop Machine control system

GuardPLC, Enable Control

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Resistor Braking Module U V W

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S11 S52 S21 A1 S33 S34 13 23 37 47 55 EN1+ R2

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Kinetix 6000 and 7000 Gate

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ISO 13849-1:2006. This circuit executes a Category 0 stop.

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Fault Reset Zone 2

High Speed Counter Input Terminals Output Terminals

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MatGuard Safety Mat