Manual Relé Allen Bradley SI 440r-Um013 - En-P PDF

Guardmaster Safety Relays
Catalog Numbers 440R-S13R2, 440R-S12R2, 440R-D22R2,

440R-D22S2, 440R-EM4R2, 440R-EM4R2D
User Manual Original Instructions

Guardmaster Safety Relays User Manual
Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before
you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to
requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably
trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this
equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with
any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
These labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
The following icon may appear in the text of this document.
Identifies information that is useful and can help to make a process easier to do or easier to understand.
2 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022

Table of Contents
Who Should Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Overview Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removable Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Multi-position Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Optical Communication Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CI Safety Relay (Cat. No. 440R-S13R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DI Safety Relay (Cat. No. 440R-D22R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIS Safety Relay (Cat. No. 440R-D22S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EM Safety Relay (Cat. No. 440R-EM4R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EMD Safety Relay (Cat. No. 440R-EM4R2D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SI Safety Relay (Cat. No. 440R-S12R2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 2
Installation Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIN Rail Mounting and Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removable Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Enclosure Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Help Prevent Excessive Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 3
Power, Ground, and Wire Wiring Requirements and Recommendation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Terminal Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ground the Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Connect a Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Devices with Mechanical Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Devices with OSSD Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safety Mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safedge Safety Edges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electromechanical Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OSSD Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Single Wire Safety Input and Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Auxiliary Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 3

Table of Contents
Reset and Monitor Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Automatic/Manual Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Monitored Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Monitor with Expansion Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Retriggerable Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Jog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 4
Configuration Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DI and DIS Safety Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
EMD Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Configuration Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Five Steps to Configure Your GSR Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chapter 5
Status Indicators Status Indicators During Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Status Indicators During Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Status Indicators During Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chapter 6
Pulse Testing Functions Pulse Testing for Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CI Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DI, DIS, and SI Safety Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pulse Testing for OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Chapter 7
EMD Safety Relay Timing Off Delay, Non-retriggerable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Functions Case 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Case 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Case 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Off Delay, Retriggerable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Case 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Case 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
On Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Case 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Case 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Case 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Case 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Case 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chapter 8
Internal Circuit Block Diagrams CI Safety Relay (Cat. No. 440R-S13R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DI Safety Relay (Cat. No. 440R-D22R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Table of Contents

Chapter 9
Application and Wiring CI Safety Relay (Cat. No. 440R-S13R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Examples DI Safety Relay (Cat. No. 440R-D22R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chapter 10
Ethernet Communication Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Studio 5000 Logix Designer Add-on Profile (AOP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 11
Troubleshooting Tools Needed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Optional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
View the PWR/Fault Status Indicator (Step 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Check the Power Supply (Step 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Check Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Verify Grounding at the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Check Safety Device Inputs (Step 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Check Voltage-free Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Examine Pulse Test Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Effect of OSSD Test Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Detect Off Pulses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Capacitance Effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Long Wire - Resistance Effect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Channel Simultaneity (Discrepancy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Multiple-channel Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Recovery Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Check the Single Wire Safety Circuit (Step 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SWS Connections L11 and L12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check the Reset/Monitoring Circuit (Step 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Two-handed Reset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Applications with OSSD Outputs and Test Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Check the Safety Outputs (Step 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Electromechanical Output Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
OSSD Output Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Auxiliary Output Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
EMD Expansion Safety Relay B1/B2 Inputs (Step 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Terminal Block Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Terminal Block Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Terminal Block Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Series, Version, and Manufacturing Date Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Table of Contents
Current Product Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Old Product Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Appendix A
Specifications General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Environmental. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Safety Inputs IN, IN1, and IN2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Reset Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
B1 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Auxiliary Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Single Wire Safety (SWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Appendix B
Regulatory Approvals Agency Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
UKCA Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Machine Safety Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SIL Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Performance Level/Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Preface
This publication is a reference guide for the family of Guardmaster® Safety Relays (GSR). This
publication describes the procedures to install, wire, and troubleshoot your relay. This
publication also gives an overview of the operation of safety relays.
Who Should Use This Use this manual if your responsibilities include design, installation, programming, or
troubleshooting of control systems that use safety relays, including catalog numbers:
Manual
• 440R-S13R2 (CI safety relay)
• 440R-D22R2 (DI safety relay)
• 440R-D22S2 (DIS safety relay)
• 440R-EM4R2 (EM safety relay)
• 440R-EM4R2D (EMD safety relay)
• 440R-S12R2 (SI safety relay)
You must have a basic understanding of electrical circuitry and familiarity with safety-related
control systems. If you do not have this knowledge, obtain the proper training before you use
this product.
Summary of Changes This publication contains the following new or updated information. This list includes
substantive updates only and is not intended to reflect all changes.
Topic Page
Updated Table 2. 18
Updated Safety Mats section. 21
Updated Single Wire Safety Input and Output section. 26
Updated Auxiliary Output section. 26
Updated Introduction section. 31
Updated Figure 27. 32
Updated Table 8. 33
Updated Pulse Testing for Inputs section. 37
Updated EMD Safety Relay (Cat. No. 440R-EM4R2D) section. 48
Updated View the PWR/Fault Status Indicator (Step 1) section. 54
Updated Recovery Time section. 64
Added Figure 74. 65
Updated Applications with OSSD Outputs and Test Pulses section. 67
Updated General table. 77
Updated Safety Inputs IN, IN1, and IN2 table. 78
Updated Reset Input table. 78
Updated Safety Outputs table. 79
Updated Single Wire Safety (SWS) table. 80
Updated Regulatory Approvals 81
Updated Table 20 82
Updated Table 21 82
Download Firmware, AOP, Download firmware, associated files (such as AOP, EDS, and DTM), and access product release
notes from the Product Compatibility and Download Center at rok.auto/pcdc.
EDS, and Other Files

Preface
Definitions Publication AG-7.1 contains a glossary of terms and abbreviations that Rockwell Automation
uses to describe industrial automation systems. The following is a list of specific terms and
abbreviations that are used in this manual.
Table 1 - Definitions
Term Definition
N.C. Normally Closed - An electrical contact whose normal state is in the closed position.
N.O. Normally Open - An electrical contact whose normal state is in the open position.
Output Signal Switching Device - Typically a pair of solid-state signals that are pulled
OSSD up to the DC source supply. The signals are tested for short circuits to the DC power
supply, short circuits to the DC common and shorts circuits between the two signals.
PLC A programmable logic controller or a programmable automation controller.
Reaction time The time between the true states of one input to the on state of the output.
The time that is required for the input to be in the LO state before returning to the HI
Recovery time state.
Safety relays offer two types of reset - Monitored manual and automatic/manual.
• Monitored Manual - The safety relay performs a reset function when the reset signal
goes from off to on and then back to off in a prescribed time-period. The reset
occurs on the trailing edge.
Reset • Automatic/Manual - The safety relay performs a reset function if the reset input is
on. If the reset input is connected directly to 24V, the reset function is executed
immediately when the inputs become closed or active. If a contact (push button or
equivalent device) is used in the reset input, the reset function is executed on the
leading edge of the reset signal (if the inputs are closed or active).
Describes the time between the trigger of one input to the off state of the output.
Response time Throughout this manual, the safety outputs are described as turning off immediately,
which means that the safety outputs turn off within the response time.
Single Wire Safety - A unique, safety-rated signal that is sent over one wire to indicate
a safety status. The SWS can be used in safety systems that require Category 4,
SWS Performance Level e, per ISO 13849-1 and safety integrity level (SIL) 3, per IEC 62061
and IEC 61508. When an SWS signal is present, this publication describes this state as
ACTIVE or on. This signal is also referred to as the logic link signal.
Additional Resources These documents contain additional information concerning related products from Rockwell
Automation.
Resource Description
Describes the procedures that you use to install, wire,
Guardmaster EtherNet/IP Network Interface User Manual, configure, troubleshoot, and use EtherNet/IP™
publication 440R-UM009 modules.
Industrial Automation Wiring and Grounding Guidelines, Provides general guidelines for installing a Rockwell
publication 1770-4.1 Automation® industrial system.
Product Certifications website, Provides declarations of conformity, certificates, and
rok.auto/certifications. other certification details.
You can view or download publications at rok.auto/literature.

Chapter 1
Overview
The Guardmaster® safety relay (GSR) family is a group of advanced general-purpose and
special-purpose safety relays. This user manual addresses the CI, DI, DIS, EM, EMD, and SI
safety relays from this family of relays.
Hardware Features Figure 1 - Safety Relays
Removable Terminal Blocks
Status Indicators
Multi-position Switches to set

functionality
Optical Communication Bus on page 10
Removable Terminal Blocks

Each safety relay module is only 22.5 mm (0.9 in.) wide with four removable terminal blocks
(two on top and two on bottom). The terminal blocks are keyed to confirm that they are
installed in their proper slots. See Terminal Block Removal and Replacement on page 75.
Status Indicators
Multiple status indicators provide status and diagnostics. Under fault conditions, the PWR/
Fault status indicator flashes in specific patterns to help diagnose the fault. See
Status Indicators on page 9 and View the PWR/Fault Status Indicator (Step 1) on page 54 for
more information.
Multi-position Switches
Most safety relays are configured by adjusting multi-position switches to set their
functionality (a). The switches are on the front face of the safety relay so you can see the set
position during, and after, configuration. During the configuration process, status indicators
on the front face of the safety relay confirm the switch settings. See Switch Adjustment on
page 31 for more information.
(a) The EM safety relay does not require configuration.

Chapter 1 Overview
Optical Communication Bus

The DI, DIS, EM, EMD, and SI safety relays have an optical communications bus that delivers
status and diagnostics to the catalog number 440R-ENETR EtherNet/IP™ module (not shown in
Figure 1 on page 9) without additional wiring. See Ethernet Communication on page 51 for more
information.
Safety relays use single wire safety (SWS) signals that allow multiple safety relays to work in
coordination with one another in small to medium size safety systems. The SWS feature allows
safety relays to communicate the highest safety-rated control signal from one safety system
to another over one wire (plus a common ground connection). The wire must be less than 30 m
(98.4 ft) long.
CI Safety Relay The CI safety relay has one dual-channel input with three electromechanical relay outputs. The
CI safety relay can be configured for automatic or monitored manual reset by adjusting the
(Cat. No. 440R-S13R2) switch on the front. The CI safety relay has an SWS output, but does not support SWS input.
The CI safety relay is compatible to the MSR127 monitoring safety relay. The CI safety relay has
the same number of inputs and outputs, the same width, and the same terminal locations as
the MSR127 safety relay.
DI Safety Relay The DI safety relay has two dual-channel inputs and two electromechanical relay outputs. In
addition, the DI safety relay has an SWS input and output. The DI safety relay can be set for
(Cat. No. 440R-D22R2) automatic or monitored manual reset by adjusting the switch on the front panel. The
configuration switch also sets the AND/OR logic that is applied to the inputs.
DIS Safety Relay The DIS safety relay has two dual-channel inputs and four solid-state outputs. Two of the four
solid-state outputs are designed to operate with high-capacitance loads. In addition, the DIS
(Cat. No. 440R-D22S2) safety relay has an SWS input and output. The DIS safety relay can be set for automatic or
monitored manual reset by adjusting the switch on the front panel. The configuration switch
also sets the AND/OR logic that is applied to the inputs.
EM Safety Relay The EM safety relay is an expansion module with four immediately operated electromechanical
relay outputs. The only input to the EM safety relay is an SWS input. The EM safety relay is
(Cat. No. 440R-EM4R2) designed to expand the outputs of the GSR family of host relays. The EM safety relay also has
an SWS output for further expansion.
EMD Safety Relay The EMD safety relay is an expansion module with delayed electromechanical relay outputs.
The EMD safety relay can be configured for one of the following functions:
(Cat. No. 440R-EM4R2D)
• On delay
• Off delay
• Jog
The settings of the two switches on the front face of the safety relay configure the
functionality and duration of the delay and jog.
The main input to the EMD safety relay is the single wire safety input. With the SWS signal, the
EMD safety relay is designed to expand the outputs of the GSR family of host relays. The EMD
safety relay also has an SWS output for further expansion.
An additional input is used with the jog function or to set the off delay as retriggerable. See
EMD Safety Relay Timing Functions on page 39 for detailed descriptions on the EMD safety
relay timing functions.

Chapter 1 Overview
SI Safety Relay The SI safety relay has one dual-channel input with two electromechanical relay outputs. The
SI safety relay can be configured for automatic or monitored manual reset by adjusting the
(Cat. No. 440R-S12R2) switch on the front. The SI safety relay also has an SWS output.
The SI safety relay is similar in functionality to the MSR126 monitoring safety relay.

Chapter 1 Overview
Notes:

Chapter 2
Installation
All safety relays in this manual have the same dimensions (see Figure 2).
Mounting Dimensions Figure 2 - Dimensions [mm (in.)]

22.5
(0.88) 113.6 (4.47)
119.14
(4.69)
DIN Rail Mounting and Safety relays mount onto 35 mm (1.38 in.) DIN rails: 35 x 7.5 x 1 mm (1.38 x 0.3 x 0.04 in.)
(EN 50022-35x7.5).
Removal
1. Hold the top at an angle (see Figure 3).
2. Slide down until the housing catches the rail.
3. Swing the bottom down and push until the latch clips onto the rail.
Figure 3 - DIN Rail Mounting
DIN Rail Latch

DIN Rail
Removal
To remove a safety relay, use a screwdriver to pry the DIN rail latch downwards until it is in the
unlatched position. Then, swing the module up.

Chapter 2 Installation
Spacing
You can mount safety relays directly next to other safety relays. When using the EtherNet/IP™
module, you must mount the safety relay within 10 mm (0.4 in.) of the neighboring module to
maintain effective communication.
Maintain a space of 50.8 mm (2 in.) above, below, and in front of the safety relay for adequate
ventilation.
Removable Terminals Safety relays have removable terminals to ease wiring and replacement.
Figure 4 - Removable Terminals
1
2
1. Insert the tip of a small screwdriver into the slot near the terminal screws.
2. To unlock the terminal block, rotate the screwdriver.
You can now remove the terminal block from the housing.
Enclosure Considerations Most applications require installation in an industrial enclosure to reduce the effects of
electrical interference and environmental exposure. Pollution Degree 2 is an environment
where normally only non-conductive pollution occurs with the expectation that condensation
causes occasional temporary conductivity. Overvoltage Category II is the load level section of
the electrical distribution system. At this level, transient voltages are controlled and do not
exceed the impulse voltage capability of the product insulation.
This equipment is intended for use in a Pollution Degree 2 industrial environment, in

overvoltage Category II applications (as defined in IEC 60664-1), at altitudes up to 2000 m
(6562 ft) without derating. This equipment is considered Group 1, Class A industrial equipment
according to IEC/CISPR 11. Without appropriate precautions, there can be difficulties with
electromagnetic compatibility in residential and other environments due to conducted and
radiated disturbances.
This equipment is supplied as open-type equipment. The safety relays must be mounted
within an enclosure that is suitably designed for those specific environmental conditions that
are present and appropriately designed to help prevent personal injury as a result of
accessibility to live parts. The enclosure must have suitable flame-retardant properties to help
prevent or minimize the spread of flame, in compliance with a flame spread rating of 5VA, V2,
V1, V0 (or equivalent) if non-metallic. The interior of the enclosure must be accessible only by
the use of a tool. Subsequent sections of this publication contain additional information
regarding specific enclosure-type ratings that are required to comply with certain product
safety certifications.
For more information, see publications:

• 1770-4.1, for additional installation requirements.
• NEMA Standard 250 and IEC 60529, as applicable, for explanations of the degrees of
protection provided by different types of enclosure.

Help Prevent Excessive For most applications, normal convective cooling keeps the safety relay within the specified
operating range. Verify that the specified temperature range is maintained. Proper spacing of
Heat components within an enclosure is sufficient for heat dissipation.
In some applications, other equipment inside or outside the enclosure can produce a
substantial amount of heat. In this case, place blower fans inside the enclosure to help with air
circulation and to reduce “hot spots” near the controller.
Additional provisions for cooling are necessary when high ambient temperatures are
encountered. Do not bring in unfiltered outside air. Place the controller in an enclosure to help
protect it from a corrosive atmosphere. Harmful contaminants or dirt could cause improper
operation or damage to components. In extreme cases, you must use air conditioning to help
protect against heat buildup within the enclosure.

Notes:

Chapter 3
Power, Ground, and Wire
Wiring Requirements and

Recommendation
ATTENTION: Before you install and wire any device, disconnect power to the
system.
ATTENTION: Calculate the maximum possible current in each power and

common wire. Observe all electrical codes that dictate the maximum
current allowable for each wire size. Current above the maximum rating
causes the wiring to overheat, which can cause damage.
• Allow adequate space between the I/O wire ducts and the top and bottom of the safety
relays and front face to maintain an ambient temperature below the rated operating
temperature of the safety relays.
• Route incoming power to the safety relay by a path separate from the device wiring.
Where paths must cross, their intersection must be perpendicular.
• Do not run signal or communications wiring and power wiring in the same conduit.
Route wires with different signal characteristics by separate paths.
• Separate wiring by signal type. Bundle wiring with similar electrical characteristics
together.
• Separate input wiring from output wiring.
• Label wiring to all devices in the system. Use tape, shrink-tubing, or other more
dependable means to label wire. Use colored insulation as well to identify wiring by
signal characteristics. For example, use blue for DC wiring and red for AC wiring.
Wire Size
Each terminal accommodates copper wire with size from 0.2…2.5 mm² (24…14 AWG). Use
copper that withstands 60…75 °C (140…167 °F).
Terminal Torque
Torque terminals to 0.4 N•m (4 lb•in).
Terminal Assignments
Safety relays have four terminals: two on the top and two on the bottom. As shown in Figure 5
on page 18, the X2 and X4 terminal markings apply to the rear terminals. The X1 and X3
terminals apply to the front terminals.

Chapter 3 Power, Ground, and Wire
Figure 5 - Terminal Identification

S12 S22 AP S54 X2
A1 A2 P12 P22 X1
X1 X2
PWR/Fault
IN1
51/L61
Logic IN
X14/X24 L11
X3 X4
L12 L11 Y32 S44 X3
X14 X24 51 L61 X4
Figure 6 shows the markings on the front face of each safety relay, including the terminal and
status indicator identifications.
Figure 6 - Safety Relay Face Markings
Table 2 lists the terminal functions. Many of the terminals perform common functions on
multiple safety relays.
Table 2 - Terminal Assignments and Functions
Terminal Function Applies To
A1 +24V supply (+10%, -15%) All
A2 24V common All
S11 Pulse test output for Channel 1 CI, DI, DIS, and SI
S21 Pulse test output for Channel 2 CI, DI, DIS, and SI
S12 Safety input for IN1 Channel 1 CI, DI, DIS, and SI
S22 Safety input for IN1 Channel 2 CI, DI, DIS, and SI
S32 Safety input for IN2 Channel 1 DI and DIS
S34 Reset input CI, DI, DIS, and SI
S42 Safety input for IN2 Channel 2 DI and DIS
Y32 Auxiliary non-safety output DI, DIS, and SI
X32 Auxiliary non-safety output EM and EMD
B1 Jog input EMD
B2 Retrigger input EMD
L11 Single wire safety output All
L12 Single wire safety input DI, DIS, EM, and EMD
13/14, 23/24 Safety outputs - electromechanical relay CI, DI, EM, and SI
33/34 Safety outputs - electromechanical relay CI and EM
43/44 Safety outputs - electromechanical relay EM
14, 24 Safety Outputs - OSSD DIS
34, 44 Safety Outputs - OSSD for capacitive loads DIS
41/42 Auxiliary non-safety output CI
17/18, 27/28, 37/38, 47/48 Safety Outputs, Delayed - electromechanical relay EMD

Ground the Safety Relay There are no special grounding requirements. Terminal A2 must connect to the common of a
24V supply.
Connect a Power Supply An external 24V DC power supply source must provide power for safety relays.
To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with
safety extra low voltage (SELV) or protected extra low voltage (PELV) must power the safety
relays. Bulletin 1606 power supplies are SELV and PELV-compliant.
Figure 7 shows the power supply connections. The DI, DIS, EM, EMD, and SI safety relays have
the power supply connections at the top. The CI safety relay, which is backward compatible
with the MSR127 monitoring safety relay, has A1 at the top and A2 at the bottom.
Figure 7 - Power Supply Connections
Connect +24V DC Connect 24V Connect +24V DC
to Terminal A1 Common to to Terminal A1
Terminal A2
Connect 24V
Common to
Terminal A2
DI, DIS, EM, CI
EMD, and SI
Safety Inputs GSR safety relays can connect to the following devices:
• Devices with mechanical contacts
• Devices with OSSD output
• Safety mats
• Safedge™ safety edges
Devices with Mechanical Contacts

The GSR family of safety relays can connect to safety devices that have mechanical contacts.
The safety relays can accommodate either 1 N.C. or 2 N.C. circuits. Table 3 shows some of the
devices that can connect to safety relays.
Table 3 - Safety Devices with Mechanical Contacts
Rockwell Automation
Safety Device Contact Availability
Product Example s
E-stop push buttons 800F, 800T 1 N.C., 2 N.C., self-monitoring
Tongue-operated interlock switches Trojan™, MT-GD2, Cadet™, Elf™ 1 N.C., 2 N.C.
Guard locking interlock switches 440G-LZ, TLS-Z, TLS-GD2, Atlas™ 1 N.C., 2 N.C.
Non-contact switches with reed relays Ferrogard™, Sipha™, magnetically coded 1 N.C., 2 N.C.
Hinge-operated interlock switches Rotacam™, Ensign, Sprite 1 N.C., 2 N.C.
Limit switches 440P, 802T 1 N.C., 2 N.C.
Trapped key interlocks with electrical 440T 1 N.C., 2 N.C.
contacts
Cable pull switches Lifeline™ 1 N.C., 2 N.C.
Enabling devices GripSwitch 1 N.C., 2 N.C.
Interposing relays 700-HPS 1 N.C., 2 N.C.

Figure 8 shows the typical connections for devices with 2 N.C. mechanical contacts. One side
of each contact is connected to a pulse-testing outputs S11 and S21. The other side is
connected to an input terminal. The CI and SI safety relays have one set of input terminals. The
DI and DIS safety relays have two sets of input terminals. The DI and DIS safety relays can
operate with only one device that is connected to either input or with devices that are
connected to both inputs.
Figure 8 - Example Connections to 2 N.C. Mechanical Contacts
Device 1 Device 1 Device 2
S11 S21 S12 S22 S11 S21 S12 S22 S32 S42
Pulse Pulse
Testing Input 1 Testing Input 1 Input 2
Outputs Outputs
CI and SI DI and DIS
Figure 9 shows the typical connections for devices with 1 N.C. mechanical contact. One side of
the contact is connected to a pulse-testing output S11. The other side is connected to two input
terminals. The CI and SI safety relays only have one set of input terminals. The DI and DIS
safety relays have two sets of input terminals. The DI and DIS safety relays can operate with
only one device that is connected or with devices that are connected to both inputs.
Figure 9 - Example Connections to 1 N.C. Mechanical Contact
S11 S21 S12 S22 S11 S21 S12 S22 S32 S42
Pulse Pulse
Testing Input 1 Testing Input 1 Input 2
Outputs Outputs
Devices with OSSD Output

Devices, such as the GuardShield™ safety light curtains, SafeZone™ laser scanners,
SensaGuard™ interlock switch, TLS-Z and 440G-LZ guard locking switches, and Bulletin 442G
Multifunction Access Box (MAB), have current-sourcing PNP semiconductor outputs (OSSD).
Devices with OSSD send their own pulse-tested safety signals through their outputs. These
devices do not need to connect to the safety relay pulse-testing outputs. These devices must
have a common power supply reference (24V Com).
Figure 10 shows a typical example of the connections for devices, like safety light curtains or
laser scanners, with non-cascadable OSSD outputs.
Figure 10 - Example Connections to Devices with Non-cascadable OSSD Outputs
+24V DC

A1 A1 A1
A2 A2 A2
A1 S12 S22 A1 S12 S22 S32 S42

Input 1 Input 1 Input 2
A2 A2

24V Com

• OSSD1 can connect to either S12 or S22 and OSSD2 can connect to either S12 or S22.
• The safeguarding devices must have the same voltage supply reference (24V Com)
as the safety relay.
Figure 11 shows an example of a wiring configuration that includes non-cascadable and
cascadable devices. The non-cascadable devices (Devices 1 and 2) must always start the
cascade. Many cascadable devices (Devices 3…6 or more) can be included in the input circuit.
All devices must have the same voltage supply reference (for instance, 24V Com) as the safety
relay.
Examples of non-cascadable devices include GuardShield safety light curtains, SafeZone laser
scanners, and safety sensors. Examples of cascadable devices include SensaGuard interlock
switches, and the TLS-ZR and 440G-LZ guard locking interlock switches.
ATTENTION: You must consider the cumulative response time of all

cascaded devices, the safety relay, and output devices to verify that the
safety function is fulfilled within the required time that the risk assessment
determines.
Place devices with electromechanical (EM) outputs after the non-cascadable device. You can
place the EM safety relay devices anywhere in the chain after the first OSSD device.
From the perspective of the GSR safety relay, only the OSSD device closest to the safety relay
(Device 3 in Figure 11) is of concern. The other devices with OSSD outputs do not affect the
performance of the safety relay. The EM safety relay devices can suffer from masked faults,
their safety rating is limited to Category 3 per ISO13849-1.
Figure 11 - Example Connections to Device with Cascaded and Non-cascaded OSSD Devices
+24V DC

A1 A1 A1
A2 A2 A2

A1 A1 A1
A2 A2 A2

A1 A1 A1
A2 A2 A2
A1 S12 S22 A1 S12 S22 S32 S42

Input 1 Input 1 Input 2
A2 A2

24V Com
GSR safety relays cannot detect short circuits of the OSSD device outputs. The PWR/Fault
status indicator of your GSR safety relay remains steady green. The device with the OSSD
outputs must detect short circuits of its own OSSD outputs. When detected, the device must
shut off both OSSD outputs and go to a faulted state. A status indicator must inform you that
the OSSD is faulted.
Safety Mats
Guardmaster® (and similar) safety mats can connect to safety relays. These safety mats use
parallel metal-plate technology. Stepping on the safety mat shorts the top metal plate to the
bottom metal plate. With the proper connections, safety relays detect the presence of an
object on the safety mat and turn off their outputs. With no presence on the safety mat, safety
relays turn on their outputs.

When changing the function from mechanical switches or OSSDs to safety mats, GSR safety
relays must go through the complete configuration process.
Figure 12 shows the typical connections for safety mats. You notice the reverse of the wiring
between a device with 2 N.C. contacts and the safety mat.
When a safety mat is used, safety relays cannot detect short circuits between the inputs or
between the inputs and 24V DC. Test these conditions during validation.
IMPORTANT For fault detection purposes, configure GSR safety relays for monitored
manual reset when connected to safety mats.
IMPORTANT When using safety mats, set the DI and DIS safety relays for AND logic. If
you use only one safety mat, connect the second input with jumpers or to
another safety device. If another safety device connects to the second
input, the outputs of the safety device must be on during configuration
and during power-up.
Figure 12 - Example One Connection to Safety Mats
Mat 1 Mat 1 Mat 2 Mat 1 EM Device
S11 S21 S22 S12 S11 S21 S22 S12 S42 S32 S11 S21 S22 S12 S42 S32
Pulse Pulse Pulse
Testing Input 1 Testing Input 1 Input 2 Testing Input 1 Input 2
Outputs Outputs Outputs
CI and SI DI and DIS DI and DIS
Because the safety mats are parallel plates, they have a significant capacitive effect. The
larger the safety mat, the more capacitance. If the capacitance is too large, the safety relay
does not function properly. See Capacitance Effect on page 61 for further information.
Allen-Bradley® Guardmaster MSR safety relays can be tickled by tapping on the
safety mat, which generated fast cycles. This activity caused the safety relay to
fault because the fast cycles violated the recovery time specification. GSR safety
relays have a faster recovery time (30 ms). However, there is a small window of
actuation times (around 20 ms) that can cause a GSR relay to enter a faulted state
(steady red PWR/Fault indicator); a power cycle is required to clear the fault.
Figure 13 on page 23 shows an example where the safety mat and a device with pulse-testing
OSSD outputs are connected to the DI or DIS safety relay. In this example, performance is
independent of the input connection (IN1 or IN2). The devices must be connected and circuits
closed during the configuration process and upon normal power-up. Upon normal power-up,
the DI and DIS safety relay attempts to determine whether a safety mat is connected. During
the power-up test, the DI and DIS safety relay may detect the pulse test of the OSSD device at
the same time it is trying to determine if a safety mat is connected and determine that a
configuration is incorrect. If this situation occurs, another power-up cycle is required.
When you combine mats with devices with OSSD outputs, the duration and period
of the OSSD pulses affects the potential of a power-up fault. OSSD outputs with
shorter pulse widths and longer periods contribute to fewer power-up faults.

Figure 13 - Example Combining Safety Mats with Devices with OSSD Outputs
Mat
Mat Pulse
PulseTesting
Testing Pulse
Pulse Testing
Testing Mat
Mat
OSSD Device
Device OSSD Device
Device
S11 S21 S22 S12 S42 S32 S11 S21 S22 S12 S42 S32
Pulse
Pulse Pulse
Pulse
Testing
Testing Input11
Input Input
Input 22 Testing
Testing Input11
Input Input
Input 2
Outputs
Outputs Outputs
Outputs
DIDIand
andDIS
DIS DIDIand
andDIS
DIS
Safedge Safety Edges

Some of the Allen-Bradley Guardmaster Safedge pressure sensitive safety edges (only profiles
0110N, 0110R, and 1610N) can connect to CI, DI, DIS, and SI safety relays. Figure 14 shows how
Safedge edges are constructed of conductive rubber with two embedded wires that run the
length the edge. Each wire forms a channel for the GSR safety relay. When the edge is
compressed, a low resistance is created between the two channels. The Safedge edge must be
constructed with four wires (two wires exit each end). See publication 440F-UM002 for more
information on the Safedge edges.
Figure 14 - Safedge Operating Principle
Flexible Wire Wires on

Conductive
Cores Both Ends
Rubber
(Ch1 and Ch2) Compression
Creates a Low
Resistance from
Ch1 to Ch2
Non-conductive Rubber
Figure 15 on page 24 shows the typical wire connections. With the proper connection, GSR
safety relays detect the compression of the edge and turn off their outputs. With no pressure
on the edge, the GSR outputs can turn back on with a reset signal.
IMPORTANT Only use Safedge profiles 0110N, 0110R, and 1610N with the GSR safety
relays.
IMPORTANT For fault detection purposes, configure GSR safety relays for monitored
manual reset when connected to Safedge safety edges.
IMPORTANT When using safety edges, set the DI and DIS safety relays for AND logic. If
only one edge is used, the second input must either connect with
jumpers or to another safety device. If another safety device is
connected to the second input, the outputs of the safety device must be
on during configuration and during power-up.

Figure 15 - Example Connections to Safety Edges

Edge 1 Edge 1 Edge 2 Edge 1
EM Device
S11 S21 S22 S12 S11 S21 S22 S12 S42 S32 S11 S21 S22 S12 S42 S32
Pulse Pulse Pulse
Testing Input 1 Testing Input 1 Input 2 Testing Input 1 Input 2
Outputs Outputs Outputs
CI and SI DI and DIS DI and DIS
Safety Outputs GSR safety relays have two types of outputs:

• Electromechanical (CI, DI, EM, EMD, and SI safety relays)
• OSSD (DIS safety relay)
To extend the operating life of the safety relays, surge suppression is required.
Electromechanical Outputs
Internally, the CI, DI, EM, EMD, and SI safety relays have two positive-guided safety relays that
are connected in series to form the safety outputs. One side of the contact must connect to a
voltage supply (see Specifications on page 77 for appropriate ratings). The other side of the
contact must connect to a load.
Figure 16 - Electromechanical Output Connections
V supply V supply V supply V supply V supply
13 23 33 13 23 13 23 33 43 17 27 37 47 13 23
14 24 34 14 24 14 24 34 44 18 28 38 48 14 24
K1 K2 K3 K1 K2 K1 K2 K3 K4 K1 K2 K3 K4 K1 K2
V common V common V common V common V common

CI DI EM EMD SI
OSSD Outputs
The DIS safety relay has OSSD safety outputs on terminals 14, 24, 34 and 44. Output terminals
14 and 24 are pulse tested and can switch loads up to 1.5 A. They can only tolerate a load
capacitance up to 1.6 µF. Terminals 34 and 44 have a series diode and can switch loads up to
0.5 A. They can tolerate a load capacitance up to 9 µF. Terminals 34 and 44 are also pulse
tested, but these pulse tests are ignored as they are not used for short-circuit detection.
These terminals are intended for devices with high capacitance. For example, use terminals
34 and 44 when connecting to the Enable input of the PowerFlex® 70 drive and the Safe Torque
Off inputs of the PowerFlex and Kinetix® drives.

The pulse-tested outputs check for short circuits between the following:
• Each terminal.
• Each terminal and the 24V supply.
• Each terminal and 24V common. The load must connect to the same voltage reference
as terminal A2.
The load must connect to the same voltage reference as terminal A2. All four OSSD outputs are
short-circuit protected.
Figure 17 - OSSD Output Connections
24V DC supply
A1
A2 34 44 14 24
K1 K2 K3 K4
24V common
DIS
Surge Suppressors
Because of the potentially high current surges that occur when switching inductive load
devices, such as motor starters and solenoids, the use of surge suppression to help protect
and extend the operating life of the safety relays is required. By adding a suppression device
directly across the coil of an inductive device, you prolong the life of the outputs. You also
reduce the effects of voltage transients and electrical noise from radiating into adjacent
systems.
Figure 18 shows an output with a suppression device. We recommend that you locate the
suppression device as close as possible to the load device.
For outputs that use 24V DC, we recommend 1N4001 (50V reverse voltage) to 1N4007 (1000V
reverse voltage) diodes for surge suppression for the OSSD safety outputs (see Figure 18). The
diode must connect as close as possible to the load coil.
For outputs that use 120V AC or 240V AC, we recommend metal oxide varistors.
Figure 18 - Surge Suppressors
Metal Oxide Varistors Diodes for
for VAC Supply VDC Supplies
K1 K2 K1 K2
V common V common
Example surge suppressors include the following catalog numbers:

• 100-FSD250 for Bulletin 100S contactors
• 1492-LD4DF terminal block with built-in 1N4007 diode
• 1492-JD3SS terminal block with built-in varistor

Single Wire Safety Input and The Single Wire Safety (SWS) feature allows a safety relay to expand the safety function to
additional safety relays using one wire, provided all safety relays have the same voltage supply
Output reference.
The CI and SI safety relays only have SWS outputs (terminal L11). The DI, DIS, EM, and EMD safety
relays have both SWS inputs (terminal L12) and SWS outputs (terminal L11).
There are many variations and combinations of series and parallel connections of the SWS.
Each L11 terminal (except the EM safety relay) can connect to up to ten L12 terminals. The EM
safety relay simply passes the input SWS signal at L12 directly to its L11 terminal, therefore, it
has no additional fanout capability.
IMPORTANT Do not connect two or more L11 terminals together.
Figure 19 shows an example wiring diagram with SWS input from a DI safety relay and SWS
output connection to an EM safety relay in parallel with a DIS safety relay. The safety relays
must have a common power reference (24V common). In this example, the safety function that
is started by the CI or SI safety relay is expanded to the DI safety relay. The safety functions
monitored by the DI safety relay are expanded to the EM and DIS safety relays. The safety
functions monitored by the DIS safety relay are expanded to the EMD safety relay.
ATTENTION: You must consider the additional response time of each SWS
connection when calculating the safety distance. See Specifications on
page 77 for the response time for each safety relay.
Figure 19 - Example SWS Connections
+24V DC +24V DC +24V DC +24V DC +24V DC
A1 A1 A1 A1 A1
CI or SI DI EM DIS EMD
A2 L11 A2 L12 L11 A2 L12 L11 A2 L12 L11 A2 L12 L11
SWS SWS SWS
24V DC Com (must have common reference)
Figure 20 shows the characteristics of the SWS signal when it is active. It starts with a 1 ms
pulse, followed 700 µs later by a 500 µs pulse. This waveform is repeated every 4 ms. When
inactive, the SWS is 0V.
Figure 20 - SWS Waveform
24V
Terminals
L11 and L12
0V
0 1 1.7 2.2 4ms
Auxiliary Output Each safety relay has an auxiliary output. The auxiliary output is not a safety rated output; it is
a low current output that is designed to indicate that the safety output status is off. The
auxiliary output is in the opposite state of the safety outputs. When the safety outputs are on,
the auxiliary output is off. When the safety outputs are off, the auxiliary output is on.
When the EM and EMD safety relays are in a nonrecoverable faulted state, the auxiliary outputs
are in an off state because the auxiliary outputs are often used as the source of the
monitoring circuit. If the EM or EMD safety relays are faulted, the safety system must not reset
until the nonrecoverable fault is corrected.
The DI, DIS, EM, EMD, and SI safety relays have a solid-state transistor auxiliary output. The CI
safety relay has an electromechanical output. Table 4 on page 27 summarizes the terminal
connections of the auxiliary output.

Table 4 - Auxiliary Outputs

Safety Relay Type of Output Terminal Connections
CI Electromechanical 41/42
DI, DIS, SI Transistor Y32
EM, EMD Transistor X32
Reset and Monitor Input The CI, DI, DIS, and SI safety relays have a reset/monitoring input (terminal S34). The
expansion safety relays (EM and EMD) do not have a reset input.
You can configure the reset action for either automatic or manual reset. When the safety relay
is configured for automatic reset, the safety relay outputs turn on as soon as the safety inputs
are closed if terminal 34 is connected to 24V. If a normally open switch is placed in the circuit,
the reset function occurs on the leading edge (when the switch is pressed).
When the safety relay is configured for manual reset, the safety relay outputs turn on after the
inputs are closed and then the reset input is cycled from off to on and then back off again.
Monitor external devices, like safety control relays and safety contactors, by adding N.C.
contacts in series with the reset signal. Figure 21 shows typical reset/monitoring circuits.
Figure 21 - Typical Reset/Monitoring Circuits
+24V DC
PLC
+
1
2
3
A1 S34 A1 S34 A1 S34 A1 S34 A1 S34 A1 A1 S34

EM or
A2 A2 A2 A2 A2 A2 EMD A2
24V DC Com
Circuit Circuit Circuit Circuit Circuit Circuit
1 2 3 4 5 6
Circuit Description
1 In automatic/manual reset, you can make a direct connection to 24V DC.
Output devices are monitored with their normally closed contacts. Only use this circuit in automatic/
2 manual reset.
An N.O push button is used. You can configure the safety relay for automatic/manual reset or monitored
3 manual reset.
Output devices are monitored along with an N.O. push button. You can configure the safety relay for
4 automatic/manual reset or monitored manual reset.
An EM or EMD expansion safety relay is used to supply the voltage to terminal S34. This circuit can also
5 contain feedback contacts and a Reset push button, similar to circuits 2, 3, and 4.
A PLC is used to generate the reset signal. You can configure the GSR safety relay for either automatic/
6 manual or monitored manual reset.
Automatic/Manual Reset
Use automatic reset when the risk assessment does not require additional manual
intervention to reset the safety system. Automatic reset is often used with partial body access
or where an additional control is implemented in the machine control system to start the
hazardous portion of the machine after the safety inputs are closed.

When automatic reset is desired, the S34 input must connect to 24V DC. Figure 22 shows three
possibilities:
a. A direct connection
b. A connection through some monitoring contacts
c. A connection through an N.O. push button.
You can combine the connection through a monitoring contact and push button. When a push
button is used, the reset occurs when the circuit is closed (not when it is released).
Figure 22 - Automatic/Manual Reset Connections
+24V DC
Momentary Push
Contactor Button (N.O.)
Monitoring
A1 S34 A1 S34 A1 S34

CI, DI, DIS, CI, DI, DIS, CI, DI, DIS,
or SI or SI or SI
A2 A2 A2
24V DC Com
(a) (b) (c)
Monitored Reset
Monitored reset requires a specific signal to turn on the safety outputs. The safety inputs and
single wire safety input (if used) must close before the reset. The reset signal must cycle from
0V to 24V and back to 0V within a duration of 250…3000 ms, as shown in Figure 23. The reset
occurs on the trailing edge. If the reset signal is too short or too long, the reset function is not
executed and you can try again.
Use the monitored reset in applications that have full-body access to the hazard. You can also
use the monitored reset in applications that require partial body access.
Figure 23 - Monitored Reset Signal Duration
24V
250…3000 ms
0V
You can create the signal with a momentary push button or programmatically create the signal
with a logic controller. Figure 24 shows example wire connections for the reset. The schematic
also shows an example monitoring the mechanically linked, normally closed contacts of two
contactors.
When using a PLC to generate the reset signal, set the duration to 260…2990 ms
for a more reliable reset.
Figure 24 - Monitored Reset Connections
+24V DC
Momentary Push
Button (N.O.) + PLC Output PLC
1 Processor
2 1756-OB16
3 1769-OB8
Contactor 1746-OB4
1734-OB2
Monitoring 1793-OB4
A1 S34 A1 S34
CI, DI, DIS, CI, DI, DIS,
or SI or SI
A2 A2
24V DC Com

Monitor with Expansion Relays

Monitoring of the expansion relays is recommended. This feature is especially useful when the
expansion relay is turning on loads (for example, solenoid-operated valves) that do not have
monitoring contacts. The auxiliary output of the expansion relay must be the 24V DC source of
the reset and monitoring input. Figure 25 shows an example of the connections for a
monitored reset with additional contactor monitoring. You can also use this type of connection
for automatic reset applications.
Figure 25 - Monitor Expansion Relay
+24V DC
Momentary Push
Button (N.O.)
Contactor
Monitoring
A1 S34 X32 A1
CI, DI, DIS, or SI EM or EMD
A2 A2
24V DC Com
Retriggerable Input The B1 and B2 inputs determine the type of timing function.
• B1 and B2 open: Off-delay non-retriggerable or on-delay
• B1 connected to B2: Off-delay retriggerable
• B1 connected to 24V DC: Jog
The EMD safety relay has a retriggerable input. Retriggerable operation only works in off-delay
applications. Retriggerable operation is accomplished by connecting a jumper from terminal
B1 to B2. Table 5 describes the off-delay operation.
Table 5 - Retriggerable Operation
Configuration Jumper Action
If the safety input is triggered and cleared within the duration of the time delay,
Retriggerable B1-B2 then the timing request is ignored and the safety output contacts remain closed.
The B1 status indicator is on.
The full-time delay lapses and the safety output contacts open before the safety
Non-retriggerable None relay can reset.
The B1 status indicator is off.
Jog Input When the EMD safety relay is configured for the Jog functions, terminal B1 must connect to
+24V DC.

Notes:

Chapter 4
Configuration
Introduction The multi-position, rotary switches on the front face of a GSR safety relay determine its
functionality. The configuration method of a GSR safety relay must provide means to help
protect against manipulation and maintain the integrity of the configuration.
The rotary switches accommodate a small screwdriver to turn the switch to the desired switch
position. The configuration procedure implies a willing action by the person who configures
the safety function to prove that the person is conscious and able to perform this task.
Therefore, GSR safety relays require a procedure of turning a switch to position [0] to start the
Configuration mode and then turn to the position desired.
The status indicators on the front panel provide continuous feedback by flashing the switch
positions. Power cycling the device completes the Configuration mode and the device enters
operation.
Switch Adjustment These safety relays have multi-position switches on their front face. Use a small screwdriver
to set the switches to the desired setting.
Make note of the mechanical stop location.
Figure 26 - Configuration Switch Adjustment

Mechanical
Stops
Screwdriver 0
Slot
IMPORTANT Adjust the switches gently and do not turn past the mechanical stops.
CI and SI safety relays have a three-position Reset switch. This switch determines whether the
safety relay uses a monitored manual reset or an automatic/manual switch (see Definitions on
page 8).
Table 6 - CI and SI Safety Relay Logic Switch
Position Function
0 Start configuration
MM Monitored manual reset
AM Automatic/manual reset

Chapter 4 Configuration
DI and DIS Safety Relays

The DI and DIS safety relays have a 10-position switch and use only the first nine positions. As
shown in Table 7, this switch configures the safety relay for its reset and logic functionality.
Table 7 - DI and DIS Safety Relay Logic Switch
Position Reset Function
0 Not applicable Start configuration
1 (IN1 OR IN2) OR L12
2 (IN1 AND IN2) OR L12
Monitored manual
3 (IN1 OR IN2) AND L12
4 (IN1 AND IN2) AND L12
5 (IN1 OR IN2) OR L12
6 (IN1 AND IN2) OR L12
Automatic/manual
7 (IN1 OR IN2) AND L12
8 (IN1 AND IN2) AND L12
Example 1: Logic setting 1 or 5: If any of the inputs (IN1, IN2, or L12) are on, then the safety relay
refers to the reset logic.
Example 2: Logic setting 4 or 8: If all three of the inputs (IN1, IN2, and L12) are on, then the
safety relay refers to the reset logic.
EMD Safety Relay

The EMD safety relay has two switches. The combination of the switch settings determines the
functionality and the duration. During configuration, the Time switch determines the duration
of the Range switch. Figure 27 and Table 8 on page 33 show the setting options for the Range
and Time switch.
With the Time switch set to 1 at the start of the configuration process, the duration of the
Range switch is the shorter range.
With the Time switch set to 10 at the start of the configuration process, the duration of the
Range switch is the longer range.
Figure 27 - EMD Safety Relay Range and Time
Start Configuration with Time Set to: x 10% or max 1: 10%
1 10 2: 20%
0 1: 0.1...1 s 10...100 s 3: 30%
RANGE TIME 1
1
Off 2: 1...10 s
3: 3...30 s
100...1000 s
300...3000 s
Off-Delay 2 4: 40%
9 2 — 3 5: 50%
4: 30...300 s 10
Jog 3 5: 0.3...3 s 30...300 s 4 6: 60%
8 9
6: 3...30 s 300...3000 s On-Delay 8 5 7: 70%
7 4 7: 30...300 s — 7 6 8: 80%
6 5 8: 1...10 s 100...1000 s
On Jog TIME 9: 90%
9: 3...30 s 300...3000 s
10: 100%

Table 8 - EMD Safety Relay Range and Time Settings

Range
Position Time
Function Range (Time 1) [s] Range (Time 10) [s]
0 Start configuration — — —
1 0.1…1 10…100 10
2 1…10 100…1000 20
Off delay
3 3…30 300…3000 30
4 30…300 — 40
5 0.3…3 30…300 50
6 On delay 3…30 300…3000 60
7 30…300 — 70
8 1…10 100…1000 80
Jogging
9 3…30 300…3000 90
10 — — — 100
Example 1: The range setting is 3 (starting with the Time set to 1), and the Time setting is 5.
Then the off-delay is: 30 s * 50% = 15 seconds
Example 2: The range setting is 6 (starting with the Time set to 10), and the Time setting is 1.
Then the on-delay is: 3000 s * 10% = 300 seconds
Configuration Process Configuration is a five-step process. The process requires the wiring to be completed and the
inputs closed. During the configuration process, GSR safety relays send out test pulses to
determine how it is wired and then configures the internal parameters to match the
application.
Five Steps to Configure Your GSR Safety Relay

1. With the power off, prepare the switches.
Safety Relay Action
DI/DIS Set the Logic switch to position 0.
CI/SI Set the Reset switch to position 0
EMD expansion safety Set the Range switch to position 0 and set the Time switch to 1 (short timing range) or 10
relay (long timing range).
EM expansion safety No switches. No action necessary.
relay
2. Apply power.
After a short wait, the PWR/Fault status indicator flashes red continuously at a 1 Hz rate
(0.5 s on, 0.5 s off). The prior configuration in the EEPROM is erased, and the device is
now prepared for a new configuration.
3. Adjust the Logic, Reset, Time, and Range switch settings as needed for your application.
You can change (or readjust) the switch settings during step 3 and step 4. The
power status indicator momentarily flashes red again.
4. Verify the settings by counting the flash rates of the status indicators.
Table 9 on page 34 shows the status indicator that flashes for the corresponding switch
setting for each safety relay.

Table 9 - Configuration Confirmation

Safety Relay Status Indicator Switch Setting
CI IN Reset
DI IN 1 Logic
DIS IN 1 Logic
B1 Range
EMD
Logic IN Time
SI IN Reset
Figure 28 shows an example of the flashing patterns for the EMD expansion safety relay.
The status indicators flash for 0.5 seconds to indicate the switch settings. The number
of flashes is equal to the switch setting. The flashing pattern repeats after a 2 second
pause.
Figure 28 - EMD Expansion Safety Relay Status Indicators Flashing in Configuration Mode
B1 - Indicates that the RANGE Switch is set to 3.
0.5 s 2s
Flash Pause
Logic IN - Indicates that the TIME Switch is set to 4
5. Cycle the power to store the settings.

After power-up, the current switch settings are compared to the values in the EEPROM
(makes sure that the switches were not changed while power was off), and the input
and output circuits are checked. Upon successful completion of the internal checks,
the safety relays are ready for operation.
IMPORTANT To keep your GSR safety relay from permanently faulting, complete the
configuration process by cycling the safety relay power within 5 minutes
of rotary switch configuration.

Chapter 5
Status Indicators
Status Indicators During The status indicators provide operating status and diagnostic information.
Power-up
Status Indicators During

Normal Operation Table 10 - Status Indicators (Normal Operation)
Status Indicator Models State Description
Steady green Normal operation.
Nonrecoverable fault. See Table 12 on page 55.
Flashing red Correct fault and cycle power
PWR/Fault All
Green with flashing Recoverable fault. See Table 13 on page 56.
red Correct fault and press Reset.
Steady red Internal fault. Cycle power.
On Input circuits at S12 and S22 are closed.
IN or IN 1 CI, DI, DIS, SI
Off Input circuits at S12 and S22 are open.
On Input circuits at S32 and S42 are closed.
IN 2 DI, DIS
Off Input circuits at S32 and S42 are open.
On Input circuit at B1 is closed.
B1 EMD
Off Input circuit at B1 is open.
On Logic IN signal (Single Wire Safety) at L12 is on.
DI, DIS, EM, EMD
LOGIC IN Off Logic IN signal at L12 is off.
EMD Flashing Timing cycle is in process.
On L11 is on.
All
Off L11 is off.
On 13/14, 23/24, 33/34 closed (41/42 open).
CI Off 13/14, 23/24, 33/34 open (41/42 closed).
Flashing Safety input is closed, waiting for the reset input.
On 13/14, 23/24 closed (Y32 Off).
DI Off 13/14, 23/24 open (Y32 On).
Flashing Safety inputs are closed, waiting for the reset input.
On 14, 24, 34, 44 On (Y32 Off).
OUT
DIS Off 14, 24, 34, 44 OF (Y32 On).
Flashing Safety inputs are closed, waiting for the reset input.
On 13/14, 23/24, 33/34, 43/44 closed (X32 Off).
EM
Off 13/14, 23/24, 33/34, 43/44 open (X32 On).
On 17/18, 27/28, 37/38, 47/48 closed (X32 Off).
EMD
Off 17/18, 27/28, 37/38, 47/48 open (X32 On).
On 13/14, 23/24 closed (Y32 Off).
SI Off 13/14, 23/24 open (Y32 On).
Flashing Safety input is closed, waiting for reset input.

Chapter 5 Status Indicators
Status Indicators During See the following tables:

Diagnostics Table Page
PWR/Fault Status Indicator Is Steady Red 55
PWR/Fault Status Indicator Is Flashing Red 55
PWR/Fault Status Indicator Is Green with Flashing Red 56

Chapter 6
Pulse Testing Functions
Safety relays use pulse testing of inputs and outputs to verify that the safety function is
performed when called upon. Pulse testing for the inputs must be used with devices with
mechanical contacts like E-stop push buttons, tongue operated interlock switches, and limit
switches. The pulse testing cannot be turned on or off and cannot be changed.
The test pulses are used to detect three short circuit conditions:
• Between the input terminals and +24V.
• Between the input terminals and 24V common.
• Between the two input terminals.
Pulse Testing for Inputs Pulse testing for the inputs is generated on terminals S11 and S21 of the CI, DI, DIS, and SI safety
relays. The EM and EMD safety relays do not use pulse testing.
IMPORTANT The pulse test sequences are provided for informational purposes. All
timing values are approximate.
CI Safety Relay
The pulse testing that is associated with the CI safety relay is shown in Figure 29. The pulse
widths are 2.5 ms wide. The pulse testing on S11 and S21 is offset by 1 ms. The pulses are
repeated every 14 ms.
Figure 29 - Pulse Test Sequence for CI Safety Relay
24V
S11
0V
24V
S21
0V
0 2.5 3.5 6 14
Time (ms)
When using a digital multimeter, S11 measures approximately 19V and S21
measures approximately 19V when the supply voltage to A1 is 24V DC and the input
circuits are open.
At the minimum-rated input on voltage (11V), a DC multimeter reads approximately
8.9V DC at S12 and S22.
DI, DIS, and SI Safety Relays

The pulse test sequence for the DI, DIS, and SI safety relays are shown in Figure 30 on page 38.
The sequence is repeated every 12.2 ms.

Chapter 6 Pulse Testing Functions
Figure 30 - Pulse Test Sequence for DI, DIS, and SI Safety Relays
24V
S11
0V
0 2.4 5.9 7.9 12.3 14.6 18.1 20.2

24V
S21
0V
0 3.8 5.9 16 18.1

4.9 7.2 17.1 19.4
Time(ms)
Time (ms)
When using a digital voltmeter, S11 measures approximately 14V DC and S21
measures approximately 18V DC when the supply voltage to A1 is 24V DC.
Pulse Testing for OSSD The DIS safety relay has OSSD transistor outputs. One main transistor supplies current to four
individual transistors (see Figure 31). When the main transistor is pulse tested, the pulse
Outputs appears on all outputs. When the individual transistors are tested, the pulse only appears on
that transistor.
Figure 31 - Output Transistor Arrangement
Main Transistor
Individual Transistors
33 44 14 24
The pulse test pattern is shown in Figure 32. The pulse widths vary from 50…150 µs. The pulse
pattern on terminal 14 is identical to terminal 34, and the pulse pattern on 24 is identical to 44.
The pattern is repeated every 3.371 seconds.
Figure 32 - OSSD Output Test Pulses on DIS Safety Relay
Main Transistor Test
Terminals
14 and 34 24V
0V
24V
24 and 44
0V
0 131 262 393 524 655 3371 (ms)
Individual Transistor Tests Repeats
Although pulse tests appear on terminals 34 and 44, the DIS safety relay does not detect faults
from A1 to 34, 44 or between 34 and 44 when the outputs are on.

Chapter 7
EMD Safety Relay Timing Functions
The EMD safety relay has three functions that use timing:
• Off delay
• On delay
• Jog
The off-delay timing depends on whether the function is retriggerable.
During the timing cycle, the Logic IN status indicator flashes.
Off Delay, Non- With input B1 open, the off-delay function is not retriggerable. The off-delay timer starts when
the logic link signal at terminal L12 turns off. Once started, the off-delay timer runs for its full
retriggerable duration. Figure 33 shows three cases of the timing sequences that can occur with this
configuration.
Figure 33 - Off-delay, Non-retriggerable Timing Diagram
Case 1 Case 2 Case 3
L12
Safety
Output
t t t
Fault
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Case 1
1. The logic link signal at terminal L12 turns on and the safety outputs turn on immediately
(that is, within the specified reaction time).
2. The logic link signal turns off and the off-delay timer starts.
3. The off-delay time has elapsed, and the safety outputs turn off.
Case 2
4. The logic link signal at terminal L12 turns on, and the safety outputs turn on within the
specified reaction time.
6. During off-delay time, the logic link signal turns off. A recoverable fault occurs. The
PWR/Fault status indicator is green and flashing red four times.
8. The logic link signal turns off.
9. Shortly after the logic link turns off, the fault is automatically cleared. The PWR/Fault
status indicator is steady green.

Chapter 7 EMD Safety Relay Timing Functions
Case 3
12. During off-delay time, the logic link signal turns off. A recoverable fault occurs. The
PWR/Fault status indicator is green and flashing red four times.
13. The logic link turns back off. The fault continues to exist.
14. The off-delay time has elapsed; the safety outputs turn off; and the fault is
automatically cleared.
Off Delay, Retriggerable To use the retriggerable off-delay function, input terminal B1 must connect to terminal B2
before the configuration process. The off-delay timer starts when the logic link signal at
terminal L12 turns off. During the timing cycle, the off-delay timer is automatically reset to
zero when the logic link turns back on. Figure 34 shows two cases of the timing sequences
that can occur with this configuration.
Figure 34 - Off-delay, Retriggerable Timing Diagram
Case 1 Case 2
L12
Safety
Output
t t t
1 2 3 4 5 6 7 8
Case 1
1. The logic link signal at terminal L12 turns on, and the safety outputs turn on
immediately (that is, within the specified reaction time).
2. The logic link signal turns off, and the off-delay timer starts.
Case 2
6. During off-delay time, the logic link signal turns on. The off-delay timer is set back to
zero, and the safety outputs remain on. No fault occurs.
On Delay To use the on-delay function, terminal B1 must be an open connection. The on-delay timer
starts when the logic link signal at terminal L12 turns on. The safety outputs turn on after the
delay time expires and remain on until the logic link signal turns off. If the logic link signal
turns off during the timing cycle, the safety outputs turn off immediately. Figure 35 shows two
cases of the timing sequences that can occur with this configuration.
Figure 35 - On-delay Timing Diagram
Case 1 Case 2
L12
Safety
Output
t t t
1 2 3 4 5 6 7 8

Case 1
1. The logic link signal at terminal L12 turns on, and the on-delay timer starts.
2. The on-delay timer elapses, and the safety outputs turn on.
3. When the logic link signal turns off, the safety outputs turn off.
Case 2
4. The logic link signal at terminal L12 turns on, and the on-delay timer starts.
5. The logic link signal turns off before the on-delay time elapses. The on-delay timer is
reset to zero. No fault occurs.
6. After a brief interruption (even as short as 100 ms), the logic link signal turns back on.
The on-delay timer starts from zero.
7. The on-delay timer elapses, and the safety outputs turn on.
8. When the logic link signal turns off, the safety outputs turn off.
Jog The jog function has two timers: an on-timer and an off-timer. The Range and Time switch
settings set the on-timer during configuration. The on-timer starts when both the B1 terminal
is connected to 24V DC and the logic link signal at terminal L12 is on. The order in which these
two signals turn on is not relevant. When both signals are on, the safety outputs turn on during
the on-timer. After the on-timer expires, the safety outputs turn off and the off-timer starts.
The off-timer is fixed at 500 ms. After the safety outputs turn off, they remain off until the off-
timer elapses. Then the jog can be restarted. Figure 36 shows three cases of timing
sequences.
During the on-timer cycle, the Logic IN status indicator flashes at a 1 Hz rate. During the off-
timer cycle, the Logic IN status indicator flashes at an 8 Hz rate.
Figure 36 - Jog Timing Diagram
Case 1 Case 2 Case 3
L12
B1
Safety
Output
t t t t
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Case 1
1. The logic link signal at terminal L12 turns on.
2. The B1 terminal turns on. The jog on-timer starts, and the safety outputs turn on.
3. The jog on-timer elapses, and the safety outputs turn off. The jog off-timer starts.
4. After 500 ms, the jog function is complete.
5. The B1 inputs turn off.
6. With the logic link input still on, the jog function is repeated when the B1 signal turns on.
7. The logic link signal turns off.
The L12 and B1 signals are interchangeable. The B1 signal can remain on and the
L12 turns on and off to execute the jog function.
Case 2
8. The B1 signal turns on before the logic link signal.
9. The logic link signal turns on. The jog on-timer starts, and the safety outputs turn on.

10. The B1 signal turns off before on-timer elapses. The safety outputs turn off immediately
and the off-timer starts.
11. The off-timer elapses. The logic link signal turns off to end Case 2.
The L12 and B1 signals are interchangeable. If the B1 signal remains on and the L12
turns off before the on-timer elapses, the safety outputs turn off immediately.
Case 3
12. The logic link signal at terminal L12 is on. The B1 signal turns on. The jog on-timer starts,
and the safety outputs turn on.
13. The on-timer elapses and the safety outputs turn off. The off-timer starts.
14. During the off-timer cycle, the B1 signal is turned off and then quickly back on. The
safety outputs remain off.
15. The B1 signal must turn off before a new jog cycle can begin.
The L12 and B1 signals are interchangeable. At least one of these two signals must
remain off throughout the off-timer cycle before a new jog cycle begins.

Chapter 8
Internal Circuit Block Diagrams
The figures in this chapter show the internal circuit block diagrams of each safety relay.
CI Safety Relay Figure 37 - CI Safety Relay Circuit Diagram

(Cat. No. 440R-S13R2)
Reset
DI Safety Relay Figure 38 - DI Safety Relay Circuit Diagram

(Cat. No. 440R-D22R2)
AND / OR
AND /
Reset
OR
DIS Safety Relay Figure 39 - DIS Safety Relay Circuit Diagram

(Cat. No. 440R-D22S2)
AND / OR
PWR
IN1 AND /
IN2
LOGIC IN OR
OUT
Logic
EM Safety Relay Figure 40 - EM Safety Relay Circuit Diagram

(Cat. No. 440R-EM4R2)
Logic

Chapter 8 Internal Circuit Block Diagrams
EMD Safety Relay Figure 41 - EMD Safety Relay Circuit Diagram

(Cat. No. 440R-EM4R2D)
on delay
off delay
Range Time jogging
SI Safety Relay Figure 42 - SI Safety Relay Circuit Diagram

(Cat. No. 440R-S12R2)
Reset

Chapter 9
Application and Wiring Examples
The application and wiring examples in this chapter show you how to put the inputs and
outputs together to create an operating safety system. These circuit diagrams are examples;
many features are interchangeable between safety relays.
Publication SAFETY-WD001 provides additional application and wiring diagrams.
CI Safety Relay In Figure 43, the CI safety relay is monitoring a device (an E-stop push button) with
mechanically operated contacts. The CI safety relay is configured for monitored manual (MM)
(Cat. No. 440R-S13R2) reset. The output turns on if the E-stop is released and the Reset push button is pressed and
released between 0.25…3 seconds. The CI safety relay monitors the status of the two output
contactors, K1 and K2. If either fails to close their N.C. contacts, the CI safety relay does not
reset. An auxiliary signal, terminals 41/42, is sent to the PLC when the E-stop is pressed.
Figure 43 - Mechanical Contacts with Monitored Manual Reset
24V DC
K1
K2
Reset
S11 S21 S34 A1 13 23 33 41

RESET 0
AM
MM
CI
440R-S13R2
S12 S22 A2 L11 14 24 34 42
To PLC
K1 K2
24V Com
Figure 44 on page 46 shows a CI safety relay monitoring a safety light curtain with two OSSD
outputs. The CI safety relay is set to automatic/manual reset (AM). The auxiliary signal
(terminals 41/41) informs the PLC that the safety system is off or on. The CI safety relay
outputs connect to AC voltage loads. When the CI safety relay is on, the PLC can then turn on
the K1 and K2 contactors.

Chapter 9 Application and Wiring Examples
Figure 44 - With Device Using OSSD Outputs, Automatic Reset, AC Load Voltage
L1
120/240V AC PLC
Input
Output
24V DC
K1
K2
S11 S21 S34 A1 13 23 33 41

RESET 0
AM
MM
CI
440R-S13R2
S12 S22 A2 L11 14 24 34 42
OSSD1
OSSD2
K1 K2
24V Com
N
DI Safety Relay The DI safety relay in Figure 45 monitors two devices having mechanical contacts and is set
for monitored manual reset. With the two devices closed, the operator presses the Reset
(Cat. No. 440R-D22R2) button to energize contactors K1 and K2. The DI safety relay verifies that contactors K1 and K2
are off by monitoring the mechanically linked normally closed contacts in the reset circuit.
When the DI safety relay is off, the auxiliary signal at terminal Y32 turns on and reports the
status to a PLC.
Figure 45 - With Two Devices with Mechanical Contacts and Monitored Manual Reset
24V DC
K1
K2
Reset
S11 S21 S22 S12 A1 13 23 S34

LOGIC 0
1
2
8 3
DI 7 4
6 5
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
To PLC
K1 K2
24V Com
In Figure 46 on page 47, a DI safety relay monitors a safety mat and non-contact interlock with
OSSD outputs. Make note of the specific wiring for the safety mat. Also, during configuration
and for each power-up, the safety mat must be clear and the interlock closed. The DI safety
relay must be configured for AND logic for the two inputs. The DI safety relay logic setting is 6:
(IN1 AND IN2) OR L12 with automatic reset. The DI safety relay verifies that contactors K1 and K2
are off by monitoring the mechanically linked normally closed contacts in the S34 circuit.
When the DI safety relay is off, the auxiliary signal at terminal Y32 turns on and reports the
status to a PLC. Per ISO 13856-1, safety mat applications require a manual reset function. For
fault detection purposes, all GSR safety relays used for safety mat control must be configured
for monitored manual reset.

Figure 46 - With a Safety Mat and Device with OSSD Outputs, Monitored Manual Reset, AC Loads
L1
120/230V AC
24V DC
K1
K2
Reset
S11 S21 S22 S12 A1 13 23 S34

LOGIC 0
1
2
8 3
DI 7 4
6 5
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
OSSD1
To PLC
OSSD2 K1 K2
24V Com
N
DIS Safety Relay Figure 47 shows the DIS safety relay with only one device. The DIS and DI safety relays can
monitor one device by configuring the safety relay for OR logic. The DIS safety relay logic
(Cat. No. 440R-D22S2) setting is 1: (IN1 OR IN2) OR L12 with monitored manual reset. The second input (terminals S32
and S42) requires no connection. With solid-state outputs, the contactors K1 and K2 must be
24V DC powered coils. The DIS safety relay verifies that contactors K1 and K2 are off by
monitoring the mechanically linked normally closed contacts in the S34 circuit. When the DIS
safety relay is off, the auxiliary signal at terminal Y32 turns on and reports the status to a PLC.
Figure 47 - Single Input, Monitored Reset
24V DC
K1
K2
Reset
S11 S21 S22 S12 S32 S42 A1 S34

LOGIC 0
1
2
8 3
7 4
6 5
DIS
440R-D22S2
L12 L11 Y32 A2 34 44 14 24
To PLC
K1 K2
24V Com
The DIS safety relay monitors two devices with OSSD outputs in Figure 48. The DIS safety relay
logic setting is 6: (IN1 AND IN2) OR L12 with automatic reset. The output terminals 34 and 44 are
designed to tolerate higher capacitance loads (but lower resistive load) as compared to
terminals 14 and 24.
Figure 48 - High Capacitive Load
24V DC
+
OSSD1
OSSD2
-
+
OSSD1
OSSD2
-
S11 S21 S12 S22 S32 S42 A1 S34
0
LOGIC 1
2
8 3
7 4
6 5
DIS
440R-D22S2
L12 L11 Y32 A2 34 44 14 24
To PLC
24V Com

EM Safety Relay The EM safety relay in Figure 49 expands the number of outputs of the DI safety relay. The
single wire safety signal from terminal L11 to L12 instructs the EM safety relay to turn on and
(Cat. No. 440R-EM4R2) off. The EM safety relay outputs mimic the DI safety relay outputs. The DI safety relay monitors
contactors K1…K6 and the status of the EM safety relay by sourcing the reset signal from the
X32 terminal on the EM safety relay.
Figure 49 - Expansion of Immediate Safety Outputs
24V DC
K2 K3 K4 K5
K1 K6
Reset
S11 S21 S22 S12 A1 13 23 S34 X32 A1 13 23 33 43

LOGIC 0
1
2
8 3
DI 7 4 EM
6 5
440R-D22R2 440R-EM4R2
S32 S42 L11 L12 A2 14 24 Y32 L12 L11 A2 14 24 34 44
To PLC
K1 K2 K3 K4 K5 K6
24V Com
EMD Safety Relay The EMD safety relay in Figure 50 is configured for a 5 second off-delay. The single wire safety
signal from terminals L11 to L12 instructs the EMD safety relay to turn on and off. When the
(Cat. No. 440R-EM4R2D) E-stop is pressed, the CI safety relay turns off immediately and the EMD safety relay turns off
5 seconds later. The CI safety relay monitors contactors K1…K6 and the status of the EMD
safety relay by sourcing the reset signal from the X32 terminal on the EMD safety relay.
In this example, the jumper from B1 to B2 makes the EMD safety relay retriggerable. If the
E-stop is released and the reset is pressed within the 5 second delay time, the outputs of the
EMD safety relay do not turn off because the internal timer is retriggered.
Figure 50 - EMD Safety Relay - Off Delay
24V DC
K2 K3 K4 K5
K1 K6
Reset
S11 S21 A1 S34 13 23 33 41 B1 B2 X32 A1 17 27 37 47

RANGE 0 TIME 1
RESET 0 1 2
9 2 10 3
AM 8 3 9 4
7 6 5 4 8 5
MM 7 6
CI EMD
440R-S13R2 440R-EM4R2D
S12 S22 A2 L11 14 24 34 42 L12 L11 A2 18 28 38 48
To PLC
K1 K2 K3 K4 K5 K6
24V Com
Figure 51 on page 49 shows the EMD safety relay that is configured for a 2.1 second on-delay.
The single wire safety signal from terminals L11 to L12 instructs the EMD safety relay to turn on
and off. When the Reset button is pressed, the DIS safety relay outputs turn on immediately.
After a 2.1 second delay, the EMD safety relay outputs turn on.
The DIS safety relay monitors contactors K1…K4 and the status of the EMD safety relay by
sourcing the reset signal from the X32 terminal on the EMD safety relay.

Figure 51 - EMD Safety Relay - On Delay

24V DC
K1 K3
K2 K4
Reset
S11 S21 S12 S22 S32 S42 A1 S34 B1 B2 X32 A1 17 27 37 47

LOGIC 0
1
RANGE 0 1 TIME 1
2
2 9 2 10 3
8 3 8 3 9 4
7 4 7 6 5 4 8 5
6 5 7 6
DIS
EMD
440R-D22S2 440R-EM4R2D
L12 L11 Y32 A2 34 44 14 24 L12 L11 A2 18 28 38 48
To PLC K1 K2 K3 K4
24V Com
The EMD safety relay in Figure 52 is configured for a maximum of a 100 second jog. The single
wire safety signal from terminals L11 to L12 enables the EMD safety relay when the safety gate
is closed and the SI safety relay is reset. When enabled, press and hold closed the Jog switch
to turn on the EMD safety relay outputs. If the Jog button is released before the 100 second
time, the EMD safety relay outputs turn off. If the Jog button is held longer than 100 seconds,
the EMD safety relay outputs only turn on for 100 seconds.
For most applications, the jog switch can be connected directly to 24V through a normally
open switch or contact. A Form C contact can be used for improved noise immunity; connect
the normally closed contact to 0V.
Figure 52 - EMD Safety Relay - Jog
24V DC
K2 K3 K4 K5
K1 K6
Jog
Jog Jog
Jog
Reset
Reset
S11 S21 S34 A1 13 23 B1 B2 X32 A1 17 27 37 47 B1 B2

RANGE 0 TIME 1 RANGE 0
1 2 1
RESET 0 9 2 10 3 2
9
8 3 9 4 3
8
AM 7 6 5 4 8
7 6
5
7 6 5 4
SI MM EMD EMD
440R-S12R2 440R-EM4R2D 440R-EM4R2D
S12 S22 Y32 L11 A2 14 24 L12 L11 A2 18 28 38 48 L12 L11
To
To PLC
PLC
K1 K2 K3 K4 K5 K6
24V Com

SI Safety Relay The SI safety relay monitors a gate interlock with mechanical contacts in Figure 53. The SI
safety relay is configured for automatic reset. When the gate is closed, the SI safety relay
(Cat. No. 440R-S12R2) outputs turn on if contactors K1 and K2 are already off. Press the Start button to turn on
contactors K1 and K2.
Figure 53 - SI Safety Relay Example
24V DC
K1
Start
K2
Stop
S11 S21 A1 S34 13 23
RESET 0
AM
SI MM
440R-S12R2
S12 S22 Y32 L11 A2 14 24
To PLC K1 K2
24V Com

Chapter 10
Ethernet Communication
The DI, DIS, EM, EMD, and SI safety relays are equipped with optical communication via an
optical link. With an optical link, diagnostic data can be read from these safety relays and
transferred to other devices over EtherNet/IP™ with the catalog number 440R-ENETR
EtherNet/IP module. The CI safety relay does not have an optical link.
The catalog number 440R-ENETR EtherNet/IP module must be in the leftmost position (see
Figure 54). See publication 440R-UM009 for more details on the EtherNet/IP module. The
safety relays must be Series A 200 or later.
Figure 54 - Arrangement of EtherNet/IP Module and Safety Relays
EtherNet/IP Module Up to Six Safety Relays

(in any order)
Webpage The catalog number 440R-ENETR EtherNet/IP module maintains its own webpage (see
Figure 55 on page 52). To access the webpage, connect an Ethernet cable to your computer,
open a web browser, and type in the IP address of the ENETR module.
The webpage is only available with the 440R-ENETR Series A. The webpage is not available in
Series B or later.

Chapter 10 Ethernet Communication
Figure 55 - ENETR Webpage
Type the IP address of the ENETR module
Click to browse
the safety relays
Studio 5000 Logix Designer The catalog number 440R-ENETR EtherNet/IP module includes the Studio 5000 Logix
Designer® AOP for the DI, DIS, EM, EMD, and SI safety relays. The AOP allows you to view the
Add-on Profile (AOP) status of the safety relays, including open and closed inputs, outputs on and off, waiting for
reset, and fault information. Figure 56 shows an example of the AOP for the DI safety relay.
See publication 440R-UM009 for further details on the EtherNet/IP module.

Figure 56 - AOP for the DI Safety Relay

Chapter 11
Troubleshooting
This chapter explains a systematic approach to determine the likely cause of the GSR safety
relay being in a faulted state or not operating properly. It describes the procedures to use to
troubleshoot your safety relay.
Tools Needed To troubleshoot your GSR safety relay, you need the following tools.
Required Tools
• Medium-sized screwdriver: For terminal screws, to remove terminal blocks, and to
configure the switches on the front face of the safety relays.
Figure 57 - Screwdriver [mm (in.)]
0.5 (0.02)
3 (0.12)
• Digital multimeter: To measure signal levels and contact resistance.
Optional Tools
• Oscilloscope: Dual or four-channel storage scope to view input and output signals and
to capture noise transients.
• Metal paper clips: To insert into the terminals and allow connection of scope probes to
terminals.
Follow These Steps To diagnose the condition of the GSR safety relay, follow the steps in Figure 58 on page 54.

Chapter 11 Troubleshooting
Figure 58 - Troubleshooting Flowchart

Start
Flashing OUT indicator Yes Go to Step 5

Go to Step 1 flashing green? (page 66)
PWR/Fault indicator No (page 54)
steady green? Off
Go to Step 2 No
(page 56)
Yes
OUT status indicator is steady green
IN indicator steady No Go to Step 3
green? (page 58)
Output devices No Go to Step 6
energized? (page 67)
Yes
Yes
LOGIC IN indicator No Go to Step 4
steady green? (page 64) B1/B2 inputs of EMD Yes Go to Step 7
relay used? (page 74)
Yes No
The safety relay is functioning properly
View the PWR/Fault Status The first troubleshooting step is to examine the PWR/Fault status indicator on the front of your
GSR safety relay module. See Figure 59 for status indicator location.
Indicator (Step 1)
The PWR/Fault status indicator is in the same position on all GSR safety relay
modules.
Figure 59 - PWR/Fault Status Indicator
PWR/Fault status indicator
The PWR/Fault status indicator has five possible states.

Status Description Action
Off No power to the safety relay Apply power
Steady green The safety relay is in the run state None
Steady red The safety relay is in a nonrecoverable faulted state See Table 11 on page 55
Flashing red A nonrecoverable/recoverable faulted state See Table 12 on page 55
Green and flashing red A recoverable faulted state See Table 13 on page 56
IMPORTANT For accurate diagnostics, always start counting the flashes after the
first pause. The first cycle can be inaccurate.

Table 11 - PWR/Fault Status Indicator Is Steady Red

Status Description Model Possible Causes Corrective Action
Indicator
• A momentary power interruption.
All
• Noise on the power or signal wires.
Short circuit has occurred, or is present, from
Faults that are not CI, DI, DIS, and SI +24V DC (A1) to S11 or S21 or from 24V Common • Cycle power to clear the fault and return the GSR safety
described in Table 12 (A2) to S11 or S21. relay to an operational state.
Steady red and Table 13 on page 56 • Reconfigure the safety relay (see Configuration on page 31).
result in a steady red DIS Short circuit has occurred, or is present, from • See additional information in Verify Grounding at the Power
status indicator. +24V DC (A1) to 14 or 24. Supply on page 57.
Excessive capacitance from input wiring to
SI ground, but not enough to cause flashing red four
times.
Table 12 - PWR/Fault Status Indicator Is Flashing Red

Status Indicator Description Model Possible Causes Corrective Action
• The safety relay is shipped from the factory
The GSR safety relay is All with no configuration. Continue with the configuration process. Rotate the switches
Flashing red 1 Hz in Configuration mode. • The configuration process was not completed to the desired positions and cycle power.
successfully.
• Return the switches/wiring to their proper settings/
terminals and cycle power. (1)
• Reconfigure the safety relay.
• Upon power-up, one or more of the rotary
switch settings do not agree with the value
Flashing red 2 that is stored in the EEPROM. Record the switch setting on the front
Invalid configuration. All
times face. For example, the logic setting is set
• Connections at S11 and S21 were swapped after
configuration. to 3, but it must be set to 4.
• During configuration, the Logic switch is set

for IN1 OR IN2 (position 1, 3, 5, or 7), but the
inputs are wired for safety mats.
DI, DIS • If the inputs are not closed during • Reconfigure the safety relays for IN1 AND IN2 (position 2, 4,
Flashing red 3 configuration, the DI and DIS safety relays 6, or 8). See Configuration on page 31
Invalid configuration.
times show this fault on the next power cycle if the • See additional information in Safety Mats on page 21.
inputs are closed.
A jumper was added from B1 to B2 after
EMD configuration and power was later cycled.
• You modified the wiring after configuration.
All • You wired up one or more input connections as
a safety mat. When you stepped on the safety • Check the wiring.
mat, the GSR safety relay went to Fault mode. • Remove the short circuit and cycle the input device, or
Flashing red 4 Cross fault. • A short circuit occurred (and is no longer cycle the power.
times
present) or is present from S11 to S21. • See additional information in Check Voltage-free Contacts
CI, DI, DIS, on page 58.
and SI • Excessive capacitance is detected on input
wiring to ground. The pulse tests waveform is
distorted.

Table 12 - PWR/Fault Status Indicator Is Flashing Red (Continued)

• A short circuit has occurred, or is present,
from +24V DC (A1) or S11 to L11.
CI and SI
• A short circuit has occurred, or is present,
from 24V Common (A2) to L11when L11 is on.
• Short circuit from L11 to L12
• Short circuit from L11 to A1 on the next
downstream safety relay.
• The 24V common connection to the • Correct the fault and cycle power to the GSR safety relays.
Flashing red 5 Output test has failed
times on L11. downstream safety relay has temporarily • See additional information in Check the Single Wire Safety
disconnected. Circuit (Step 4) on page 64.
DI and DIS • One of the downstream safety relays exhibited
a momentary power interruption.
• For long SWS runs, L11 can pick up noise.
Consider running the SWS signal in shielded
cable.
• Short circuit occurred from S21 to A1 while the
safety relay was operational.
• Check wiring.
Output test has failed • Remove fault or move high capacitance output connections
Flashing red 6 • External cross fault
DIS to 34, 44.
times on 14, 24 (2) • High capacitance load • Cycle power to clear the fault.
• See additional information in OSSD Outputs on page 24.
(1) If you do not know the correct setting, you can rotate the switch to a new setting and cycle power. If the new setting does not agree with the EEPROM, the PWR/Fault status indicator
continues to flash 2X red; make a new selection and cycle power again. If the new setting agrees with the EEPROM, the PWR/Fault status indicator is steady green, the GSR safety relay
functions properly.
(2) DIS safety relays only.
Table 13 - PWR/Fault Status Indicator Is Green with Flashing Red

One or more of the rotary switches have changed The safety relay continues to operate, and the
All switches can return to their original position,
during operation.
Green with flashing The configuration does not agree while powered.
red 2 times with the EEPROM. On Version 200, B1 was jumpered to B2 after
configuration. In Version 203, this condition is Remove the jumper and the EMD safety relay
EMD functions properly.
ignored.
B2 is connected to B1, after configuration. The • Remove connection and fault is cleared
fault indication occurs when the EMD output is automatically.
Green with flashing B1-B2 connection. All energized. If the output is already energized, this
red 3 times • See additional information in EMD Expansion
fault will be detected on the next energization of
the EMD. Safety Relay B1/B2 Inputs (Step 7) on page 74.
Set for non-retriggerable and Logic IN input has
Cycle the Logic In input signal to clear the fault
turned off and then back on before the time or let the timer expire and the fault clears
expired. automatically.
Green with flashing Retriggerable input. EMD Repeat the configuration process; the B1-B2
red 4 times
A connection was made from terminals B1 to B2, connection must be made before configuration.
after configuration. See additional information in EMD Expansion
Safety Relay B1/B2 Inputs (Step 7) on page 74.
Check the Power Supply The second troubleshooting step is to check the supply of power to your safety relay.
(Step 2)
Check Voltage
If the PWR/Fault status indicator is off, check the voltage by placing a digital multimeter on
terminals A1 and A2 as shown in Figure 60 on page 57.

Figure 60 - Measure Power Supply Voltage
A2
A1 Acceptable Range
A1
20.4…26.4V DC
13 23 33 41
A1 S11 S12 L11 S12 S22
PWR/Fault A1 A2 S11 S21
DMM IN DMM PWR/Fault
IN
24 OUT
24
0 OUT
RESET
Volts Volts
AM 0
RESET
AM
MM
13 23 33 41
MM
14 24 34 42
CI 13 14 23 24
SI
S21 S22 S34 A2

14 24 34 42 L11 Y32 S34
34 14 23 24
A2
SI, DI, DIS, EM,
and EMD
CI
If the voltage is not within the acceptable range, verify that the power supply, wiring, circuit
breakers, and/or fuses are functioning properly.
Verify Grounding at the Power Supply

IEC 60204-1 and NFPA79 require that the 24V is supplied by a PELV-rated power supply. The
24V common must be connected to protective earth, as shown in Figure 61. The protective
ground connection must only be in one location and is often best when closest to the power
supply.
Ground loops and noise transients on the ground can cause the GSR safety relays to go into a
fault state. This state is hard to capture. One method is to remove the protective grounding
connection between machine ground and the 24V common temporarily. Then, wait to see if the
fault does not occur (wait time varies). If the fault occurs, then the grounding scheme must be
investigated further.
Figure 61 - 24V Common to Protective Earth Connection
+24V DC
++ -- A1 S11 S12
24V DC
PELV
Power GSR Safety Relay
Supply
L N A2 13
AC
Power +24V Common
Supply Temporarily remove the protective ground
connection for troubleshooting. Reconnect
ground after completing.
IEC 60204-1 edition 5.1 (Section 6.1) allows a SELV supply to be used when a PELV is not
practicable due to physical or operational conditions. NFPA79 does not allow the use of a SELV
supply. If you are meeting only IEC 60204-1, you can install a separate SELV supply for your
safety system and leave it ungrounded (no protective ground).

Check Safety Device Inputs This step only applies to CI, DI, DIS, and SI safety relays. Each safety relay has a status
indicator for its inputs.
(Step 3)
Table 14 - Input Status Indicator
IN, IN1, and IN2 Status Indicator Status Action
Go to Check the Single Wire Safety
Green Both channels are closed Circuit (Step 4) on page 64.
Off One or both input channels are open Continue with this section.
IMPORTANT The following factors affect the value that is measured at the safety
relay inputs:
• Voltage-free contacts
• Pulse testing waveforms
• Capacitance
• Length of wire
• Contact resistance
• Channel sequence
Table 15 shows the voltage levels that are viewed on an oscilloscope versus a digital
multimeter.
Table 15 - On/Off Voltage
Measurement Device Turn On Voltage Turn Off Voltage
Oscilloscope 11V 5V
Digital Multimeter 6…8V 3…4V
Check Voltage-free Contacts

Safety devices (for example; interlock switches, E-stops, or cable pull switches) with voltage-
free contacts must be connected to the pulse testing outputs. You can use a digital multimeter
to measure the input levels.
Check CI Safety Relay

1. With the device contacts open, measure the voltage at the pulse testing outputs with a
digital multimeter, as shown in Figure 62. The voltage must be 18…19V on both pulse
testing outputs of the CI safety relay.
Figure 62 - Typical Voltage Measurements of the CI Safety Relay
DMM
19
DMM Volts
19 S12 S11 S21 S22
Volts
Pulse Testing
Outputs A2
2. Check the voltage at each of the inputs with the device contacts closed, as shown in
Figure 63 on page 59. The values must be very close to the values measured at
terminals S11 and S21.
a. If both channels are closed, a voltmeter must read about 19V and the IN status
indicator is green. The voltage levels are approximately the same on Channel 1 (S12)
and Channel 2 (S22) because the pulse testing waveforms are similar on both
channels.

b. If only one input is above the turn on voltage level, then the IN status indicator is red.
c. Try cycling the input device.
d. If the contacts of the safety device do not operate consistently, the safety device
must be replaced.
Figure 63 - Check the CI Safety Inputs with the Device Contacts Closed
DMM
19
DMM Volts
19 S12 S11 S21 S22
Volts
Pulse Testing
A2
Outputs
3. If a significant difference in voltage levels exists, see Capacitance Effect on page 61

and Long Wire - Resistance Effect on page 62.
To find where the voltage drop is occurring, you have to trace the wiring of the circuit
that is not achieving at least 11V as measured by an oscilloscope.
Check DI, DIS, and SI Safety Relays
DI, DIS, and SI safety relays can also be checked in a similar fashion. The voltage of Channel 1
is lower (about 14V) than Channel 2 (about 18V). The reason for the difference in voltage levels
is due to the difference in the pulse test wave forms (see Figure 67 on page 61). S11 is
effectively off longer than S21.
1. Check the safety inputs with the device contacts open, as shown in Figure 64.
The SI safety relay does not have terminals S32 and S42.
Figure 64 - Typical Voltage Measurements of the DI, DIS, and SI Safety Relays with Contacts Open
Device 1 Device 2
DMM
DMM S11 S21 S12 S22 S32 S42
14 Pulse
18 Testing Input 1 Input 2
Volts Outputs
Volts
A2
2. Check the voltage at each of the inputs with the device contacts closed. The values
must be very close to the values measured at terminals S11 and S21.

Figure 65 - Typical Voltage Measurements of the DI, DIS, and SI Safety Relays with Contacts Closed
Device 1 Device 2
DMM
DMM S11 S21 S12 S22 S32 S42
14 Pulse
18 Testing Input 1 Input 2
Volts Outputs
Volts
A2
3. If a significant difference in voltage levels exists, see Capacitance Effect on page 61

and Long Wire - Resistance Effect on page 62.
Examine Pulse Test Waveforms

If you have an oscilloscope, you can examine the pulse tests. The test pulses are used to check
for short-circuit conditions; the test pulses are not used to turn the inputs on and off. If they
are clean and square, then they are OK.
The test pulses are generated on terminals S11 and S21. The waveforms, which are shown in
Figure 66 and Figure 67 on page 61, must always be present on their respective safety relays;
the test pulses cannot be turned off or adjusted.
Figure 66 - CI Safety Relay Pulse Test Waveforms
Terminal
S11
Terminal
S21

Figure 67 - DI, DIS, and SI Safety Relay Pulse Test Waveforms
Terminal S11
Terminal S21
Effect of OSSD Test Pulses

GSR safety relays cannot detect short circuits of OSSD outputs. The PWR/Fault status indicator
of your GSR safety relay remains steady green. The device with the OSSD outputs must detect
short circuits of its own OSSD outputs. When detected, the device must shut off both OSSD
outputs and go to a faulted state. A status indicator must inform you that the OSSD is faulted.
See Devices with OSSD Output on page 20 for more information.
Detect Off Pulses

When configured for monitored manual (or manual) reset, the GSR safety relay detects off
pulses as described in Table 16.
Table 16 - Off Pulses
Time Description
GSR safety relays always detect when the input device turns off. GSR safety relays also
Off time ≥25 ms detect that the input device has turned back on.
7 ms < Off time < 25 ms When the off pulse is between 7…25 ms, GSR safety relays turn off their output, but the
input does not turn back on. The input must be cycled again.
Off time < 7 ms GSR safety relays cannot detect inputs that turn off for 7 ms or less.
Test pulses on OSSD outputs are less than 1 ms; therefore the GSR safety relay ignores the test
pulses.
Capacitance Effect
Capacitance leakage of the input wiring to ground causes a deformation of the leading edge of
the pulses. Figure 68 on page 62 shows the deformation with 1 µF on each signal to ground.
With this high capacitance, the CI safety relay still operates.
Capacitance from Ch1 to Ch2 looks the same as Ch1 to ground and Ch2 ground.

Figure 68 - Capacitive Effect on Pulse Tests
Capacitance causes
deformation of leading edge
Long Wire - Resistance Effect

Long input wiring adds resistance and decreases the input signal voltage. Figure 69 shows the
effects on the pulse tests. Notice that the shape of the pulses has not changed, only the
amplitude. If the wiring is too long, the safety relay does not turn on.
Figure 69 - Resistance Effect on Input Signal
Long Wiring adds resistance and

decreases the input signal voltage
GSR safety relays have a maximum input resistance of 900 ohms.
Table 17 on page 63 shows the resistance of wire sizes that are typically used to connect to
safety devices. For example, if you used 200 m (656.2 ft) of a 4-wire cable that contains
0.33 mm² (22 AWG) wire, the wire resistance from the safety relay pulse test outputs to the
safety device and back to the safety relay inputs, would be:
200 m x 52.94 Ω / 1000 m x 2 directions = 21 Ω

As the example shows, long wires are not a likely cause of safety input issues.
Table 17 - Wire Resistance
ISO Cross Section [mm²] AWG Ω Per 1000 m Ω Per 1000 ft
0.33 22 52.94 16.14
0.5 20 33.30 10.15
0.75 18 20.95 6.386
1.5 16 13.18 4.016
2.5 14 8.28 2.525
4 12 5.21 1.588
Channel Simultaneity (Discrepancy)

GSR safety relays have infinite simultaneity (sometimes referred to as discrepancy). One
channel can close (at T1) and the other channel can close much later (at T2), and the input
circuit is satisfied. The order in which the channels close is not significant; either channel can
close before the other (see Figure 70).
Figure 70 - GSR Safety Relays Have Infinite Simultaneity (Discrepancy)
Closed
Channel 1
Open
Closed
Channel 2
Open
T1 T2 T1 T2
Time Time

Multiple-channel Cycling
GSR safety relay inputs are not satisfied if one channel turns on and off multiple times,
followed by the closure of the second channel (see Figure 71). The input status indicator
remains red. This condition is not shown as a fault condition by the PWR/Fault status
indicator. To clear this condition, open both channels and then reclose them.
Figure 71 - Multiple Cycles on One Channel Are Not Allowed
Closed
Channel 1
Open
Closed
Channel 2
Open
T1 T2 T1 T2
Time Time


Recovery Time
Recovery time is a delay time that is required, measured from when the safety relay inputs
turned off until they can turn back on again. GSR safety relays have a 30 ms recovery time
specification (see Figure 72).
The GSR family of safety relays has conservative recovery time specifications. Actual
measurements show the recovery time to be as fast as 20 ms. As a result, recovery time is
unlikely to cause spurious trips.
Figure 72 - Recovery Time
Closed
Closed
Channel11
Channel
Open
Open
Closed
Closed
Channel22
Channel
Open
Open
0 30 0 15
Time(ms)
Time [ms] Time
Time[ms]
(ms)
Fast input cycling, where both input channels are cycled simultaneously, has three outcomes:
• Cycles shorter than 7 ms are ignored.
• Cycles of 7...30 ms: An input cycle causes the output to turn off. The IN1 or IN2 status
indicator is off and the output is off (even with automatic reset).
Repeated cycles of the input at less than 30 ms cause the output to be off or on, but a
true state is always present. An example in automatic reset: If the inputs are green, the
outputs are green, and if one of the inputs is off, the output is off.
• Cycles longer than 30 ms are processed properly.
Check the Single Wire The Logic IN status indicator represents the single-wire safety (SWS) signal at terminal L12.
The SWS output is terminal L11.
Safety Circuit (Step 4)
Check the Logic IN status indicator.
Table 18 - Logic IN Status Indicator
Logic IN Status Indicator Status Action
Green L12 input is active (closed) See Check the Reset/Monitoring Circuit (Step 5) on page 66
Off L12 input is inactive (open) See SWS Connections L11 and L12
SWS Connections L11 and L12

CI and SI safety relays only have SWS outputs (terminal L11); they do not have SWS inputs.
DI and DIS safety relays have both SWS input and output signals. If you have a DI or DIS safety
relay and the SWS input signal is not used, then the Logic IN status indicator is always off. If no
wire is connected to terminal L12, then make sure that the LOGIC switch is set is to either 1, 2,
5, or 6 (switch positions with OR logic).
EM or EMD expansion safety relays have both SWS input and output signals. You must connect
a wire to L12. Your application requirements determine whether L11 is used.

Figure 73 shows an example of an SWS connection. Note the L11 terminal (which is the SWS
output) can be connected to multiple L12 terminals (SWS input), but the L12 terminal cannot be
connected to multiple L11 terminals.
Figure 73 - Example SWS Connections
+24V DC +24V DC +24V DC +24V DC +24V DC
A1 A1 A1 A1 A1
CI or SI DI EM DIS EMD
A2 L11 A2 L12 L11 A2 L12 L11 A2 L12 L11 A2 L12 L11
SWS SWS SWS
24V DC Com (must have common reference)
For long wire runs of the SWS signal, a shielded cable can be necessary to help
prevent nuisance faults from electromagnetic and motor noise.
Figure 74 - SWS with Shielded Cable
+24V DC
24V Com (0V)
+ + S12 S22 S32 S42 A1 13 23 S34 A1 X32 B1 B2 17 27 37 47

DC ok 0 RANGE 0 TIME 1
LOGIC 1 1 2
24- 9 2 10 3
28V 2 8 3 9 4
3 76 54 87 65
8
1606-XLP95E DI 7 6 54 EMD
440R-D22R2 440R-EM4R2D
N L S11 S21 L11 L12 A2 14 24 Y32 Shielded cable A2 L12 L11 18 28 38 48
Connect unused conductors to 0V
120…240V AC SWS signal
N
Connect Shield to PE
L
SWS wiring distances between 10…30 m
Protective Earth Ground
PE
Figure 75 shows the characteristics of SWS signal when it is active. It starts with a 1 ms pulse,
followed 700 µs later by a 500 µs pulse. This waveform is repeated every 4 ms. When inactive,
the SWS is 0V.
Figure 75 - SWS Waveform
Terminals 24V
L11 and L12
0V
0 1 1.7 2.2 4 ms
When the signal is active, use a digital multimeter to measure the voltage. The digital
multimeter shows 8…9V.
If a fault occurs with either an SWS input or SWS output, then that circuit is held high. If a
digital multimeter reads a voltage measurement of approximately 21V, the signal is high. The
PWR/Fault status indicator flashes red five times.
Figure 76 on page 66 shows an example timing of a momentary interruption of the SWS input.
If a momentary interruption of the SWS signals occurs, the downstream unit ignores
interruptions less than 5.7 ms. The downstream unit automatically turns off and then back on
when the interruption is greater than 5.7 ms.
The momentary interruption does not cause a 'recovery' type fault, where the output turns off
and stays off and requires a further cycling of the SWS signal.

Figure 76 - Momentary Interruption of SWS Input
Command to open SWS
SWS opens SW closes in 5.7 ms
The Downstream unit

turns off its Output
The Downstream unit

turns its Output back on
auto-reset
Check the Reset/Monitoring The OUT status indicator flashes green when the inputs to the GSR safety relay are satisfied
and the GSR safety relay is ready to turn on its outputs. The OUT status indicator flashes green
Circuit (Step 5) at a 1 Hz rate. The GSR safety relay is waiting for the appropriate reset signal at terminal S34.
If the OUT status indicator is flashing green, but the safety relay does not turn on its outputs
when the Reset button is pressed, measure the voltage at terminal S34 (point 1) as shown in
Figure 77. If 24V is not present when the Reset button is pushed, then check the other
connections (points 2...7) in the circuit. If 24V is present at terminal S34, then you must
consider the reset configuration.
• Automatic/manual: The GSR safety relay must be replaced as the output status
indicator must turn steady green as soon as the voltage was present at terminal S34.
• Monitored/manual: If the output status indicator does not turn steady green when
voltage at S34 is present between 0.25…3 seconds, then the GSR safety relay must be
replaced.
Figure 77 - Measure Reset/Monitoring Circuit Voltage
+24V DC
7
6
5
4 DMM
(
3 24
2 Volts
1
A1 S34
OUT
A2
24V DC Com

Two-handed Reset Operation

Reset signals for GSR safety relays can be pressed 10 ms after the safety relay inputs are
satisfied. Therefore, GSR safety relays are useful for application scenarios such as:
• The application has an E-stop mounted close to the Reset button, which allows you to
release the E-stop with one hand and press the Reset button with the other.
• The application allows you to close a safety gate with one hand and press the Reset
button with the other hand.
Applications with OSSD Outputs and Test Pulses

If your application uses an OSSD output with test pulses as the source of the reset signal, the
GSR safety relays execute the reset function properly as shown in Figure 78.
Test pulses are much less than 1 ms long. GSR safety relays ignore test pulses up to 6 ms in
duration. Test pulses between 7…13 ms are sometimes ignored and sometimes cause the
execution of the Reset function. Figure 78 shows a reset signal that is 2500 ms long. During
this time, a 6 ms test pulse occurs. This test pulse is ignored. A test pulse of 14 ms causes the
GSR safety relay to execute the reset function, provided the test pulse occurs after 250 ms.
Figure 78 - Reset Input Ignores Test Pulses Up to 6 ms
Reset occurs on the trailing edge
24V
Ignores Test
Pulse up to
6 ms
0V
0V 2500 ms
Check the Safety Outputs The GSR family of safety relays has two types of outputs.
(Step 6) • Electromechanical outputs: CI, DI, EM, EMD, and SI safety relays
• OSSD outputs: DIS safety relay
Electromechanical Output Issues

If the OUT status indicator is steady green, but the output device does not energize, begin
troubleshooting by measuring the terminal voltage.
Measure the Terminal Voltage
Confirm that voltage is present at the safety relay terminals and the load. Figure 79 on page 68
shows an example of the measurement points for one output channel (13/14). Since most
safety circuits consist of two channels, repeat the checking on the second channel (23/24).

Figure 79 - Measure the Terminal Voltage

+V supply
DMM 1
+Vs 13 23
Volts
OUT
14 24
2
3
A1 A1
K1 K2
A2 A2
4
0V
Step Description
The voltage at 13 must be the same as the supply voltage. If not, check for an open circuit (broken
1 wire), blown fuse, or tripped circuit breaker.
The voltage at 14 must be the same as the supply voltage. If not, the positive-guided safety relay inside
2 the GSR safety relay is not closing. Measure the contact resistance; see Figure 80 on page 69.
The voltage at A1 must be the same as the supply voltage. If not, check for an open circuit (broken
3 wire) between terminal 14 and A1.
The voltage at A2 must be zero. If not, check for an open circuit between A1 and the voltage supply
4 ground connection. If A2 measures zero volts and A1 measures the supply voltage, then K1 is not
operating properly and must be replaced.
Measure the Contact Resistance
If the voltage at terminal 13 is the same as the supply voltage but terminal 14 measures 0V,
measure the contact resistance.
SHOCK HAZARD: Turn off power before power connection is removed if +V

supply is greater than 50V.
Measure the contact resistance to confirm that the safety relay is not functioning properly. As
shown in Figure 80 on page 69, remove the power wires to terminal 13 and set the digital
multimeter to ohms. Be sure that the OUT status indicator is green.
The contact resistance must be less than 1 ohm. If it is not, then the internal positive-guided
safety relay is not functioning properly, and the GSR safety relay must be replaced.

Figure 80 - Measure the Contact Resistance

+V supply
SHOCK HAZARD: Remove the

DMM power connections to terminal
<1 23
13 before measuring the
13
contact resistance.
Ohms
OUT
14 24
A1 A1
K1 K2
A2 A2
0V
OSSD Output Issues

If the OUT status indicator is steady green, but the output device that is connected to terminal
14 or 24 does not energize, begin troubleshooting by checking the voltage at the output
connections. See Check the OSSD Connections.
If the OUT status indicator is steady green, but the PowerFlex® drive indicates that the safety
circuit is open, check the connections to the PowerFlex drive. See Check the PowerFlex Drive
Connections on page 70.
Check the OSSD Connections
Confirm that voltage is present at the safety relay terminals and the load. Figure 81 shows an
example of the measurement points for one output channel (terminal 14). Since most safety
circuits consist of two channels, repeat the checking on the second channel (terminal 24).
Figure 81 - OSSD Output Connections
24V DC supply
A1
DMM
OUT
23
Volts
A2 34 44 14 24
1
2
A1 A1
K1 K2
A2 A2
3
24V common
Step Description
The voltage at 14 must be slightly less than the supply voltage. If not, then the DIS safety relay must be
1 replaced.
The voltage at A1 must be slightly less than the supply voltage and must be the same voltage as
2 measured at terminal 14. If not, check for an open circuit (broken wire) between terminal 14 and A1.
The voltage at A2 must be zero. If not, check for an open circuit between A1 and the voltage supply
3 ground connection. If A2 measures zero volts and A1 measures the supply voltage, then K1 is not
operating properly, and must be replaced.

Check the PowerFlex Drive Connections
Confirm that voltage is present at the safety relay terminals and the safety input terminals of
the PowerFlex drive. Figure 82 shows an example of the measurement points for one output
channel (terminal 34). Repeat the checking on the second channel (terminal 44). The terminal
connections from 34 and 44 to S1 and S2 can be reversed.
Figure 82 - Typical Connections to PowerFlex Drive
24V DC supply
A1
DMM
OUT
23 PowerFlex 525
Volts AC Drive
A2 34 44 14 24
1
S1
S2
2
3 4
Motor
24V common
Step Description
The voltage at 34 must be slightly less than the supply voltage. If not, then the DIS safety relay must be
1 replaced.
The voltage at S2 must be slightly less than the supply voltage and must be the same as the voltage at
2 terminal 34. If not, check for an open circuit (broken wire) between terminal 34 and S2.
The voltage at terminal 4 must be zero. If not, check for an open circuit between terminal 4 and the
3 voltage supply ground connection. Figure 83 shows how to verify the continuity from terminal 4 of the
drive to terminal A2 of the DIS safety relay.
Figure 83 shows the test connections to verify the common reference between the DIS safety
relay and the AC Drive. Remove power from the application and set the digital multimeter to
ohms. If possible, measure directly at the terminals. The resistance must be less than 1 ohm.
SHOCK HAZARD: Turn the power off before continuity is tested.
Figure 83 - Continuity Test of the Voltage Supply Common Connection

24V DC supply
DMM
A1
<1
OUT
Ohms PowerFlex 525
AC Drive
A2 34 44 14 24
S1
S2
4
Motor
24V common

The OSSD test pulses of the DIS safety relay, as viewed by an oscilloscope, are shown in
Figure 84 and Figure 85. Most often, the main transistor triggers the scope; this test pulse
appears on all four terminals simultaneously. The main transistor pulses are about 110 µs wide.
Each channel is tested individually as shown in Figure 85. The individual pulses are about 50
µs wide. These pulse widths are provided for informational purposes; the pulses cannot be
turned off or adjusted.
Figure 84 - OSSD Main Transistor Test Pulses
110 µs
Figure 85 - OSSD Channel Transistor Test Pulse
Terminal 14, 34
50 µs
50 µs Terminal 24, 44
Auxiliary Output Issues

Table 19 - Auxiliary Output Issues
State Symptom Action
My PLC does not know that the safety relay is off or See Measure the Auxiliary Output Terminal
my auxiliary status indicator does not turn on. Voltage on page 72.
OUT status The voltage at terminal 41 is the same as the See Measure the Contact Resistance on
indicator is off supply voltage. However, terminal 42 measures 0V. page 72.
Terminal Y32 does not turn on. See Check the Y32 Output on page 73.
Terminal X32 does not turn on. See Check the X32 Output on page 73.
Safety outputs The Y32 output must be on. This condition is true See Check the Y32 Output on page 73.
are off for both faulted and running states.
For more information on auxiliary outputs, see Auxiliary Output on page 26.

Measure the Auxiliary Output Terminal Voltage
When the OUT status indicator is off, my PLC does not know that the safety relay is off or my
auxiliary status indicator does not turn on.
Confirm that voltage is present at the safety relay terminals and the load. Figure 86 shows an
example of the measurement points for one output channel (41/42).
Figure 86 - Measure Voltage Aux Output Terminals
+V supply
DMM 1
+Vs 41
Volts
OUT
PLC
42
Input
2
3
Com
5 4
6
0V
Step Description
The voltage at 41 must be the same as the supply voltage. If not, check for an open circuit (broken
1 wire), blown fuse, or tripped circuit breaker.
The voltage at 42 must be the same as the supply voltage. If not, the positive-guided safety relay
2 inside the GSR safety relay is not closing. Measure the contact resistance; see Figure 87 on page 73.
The voltage at the PLC input must be the same as the supply voltage. If not, check for an open circuit
3 (broken wire), a bad contact at a terminal connection), or go to step 4.
Place the black test probe on the PLC common terminal. Verify that the common of the PLC is
4 connected to the common of the voltage supply.
The aux output voltage at one side of the auxiliary status indicator must be the same as the supply
5 voltage. If not, check for an open circuit (broken wire) between terminal 14 and Aux status indicator.
Verify that the aux status indicator is connected to the voltage supply common. The aux status
6 indicator must be replaced.
Measure the Contact Resistance
The OUT status indicator is off, and the voltage at terminal 41 is the same as the supply
voltage. However, terminal 42 measures 0V.
SHOCK HAZARD: Turn off power before power connection is removed if +V

supply is greater than 50V.
Measure the contact resistance to confirm that the safety relay is not functioning properly. As
shown in Figure 87 on page 73, remove the power wires to terminal 41 and set the digital
multimeter to ohms. Be sure that the OUT status indicator is off.
The contact resistance must be less than 1 ohm. If it is not, then the internal positive-guided
safety relay is not functioning properly, and the GSR safety relay must be replaced.

Figure 87 - Measure Contact Resistance of Aux Output Terminals

+V supply
SHOCK HAZARD: Remove the

DMM power connections to terminal
<1 41 before measuring the
41
contact resistance.
Ohms
OUT
42
PLC
Input
Com
0V
Check the Y32 Output
When the OUT status indicator is off, terminal Y32 does not turn on, or when the safety outputs
are off, the Y32 output must be on. This condition is true for both faulted and running states.
Use a digital multimeter to measure the voltage at Y32 (point 1 in Figure 88). The voltage must
be around 23V DC. Figure 88 shows a typical schematic for the aux output; the aux signal can
go to a PLC input or to a status indicator on a control panel. If it is 23V, then check the
remaining points (2…5). If Y32 measures 0V, then the safety relay must be replaced.
Figure 88 - Measure Y32 Voltage
+24V DC
CI, DI, DIS, or SI

A1
DMM
23 PWR/Fault
OUT
Volts
PLC
A2 Y32
Input
1
2
Com
4 3
5
0V
Check the X32 Output
When the OUT status indicator is off, terminal X32 does not turn on.
This operation is proper for the EM and EMD safety relays if they are in a
nonrecoverable faulted state. If so, then the PWR/Fault status indicator is steady
red or flashing red.
Correct the fault and cycle power. The safety relay must be reconfigured to correct the fault.
If the PWR/Fault status indicator is green, then measure the voltage at terminal X32 with a
digital multimeter. Figure 89 on page 74 shows a typical usage of X32 (point 1) as the source
for the monitoring circuit. The voltage must be around 23V DC. If it is 23V, then follow the
circuit and check the voltage at each of the remaining points (2…6). If X32 measures 0V, then
the safety relay must be replaced.

Figure 89 - Measure X32 Voltage

+24V DC
EM or EMD CI, DI, DIS, or SI

A1 A1
DMM PWR/Fault PWR/Fault
23
OUT OUT
Volts
A2 X32 A2 S34
1 6
2 3 4 5
0V
EMD Expansion Safety Relay Figure 90 shows the waveform from B1 to B2. This waveform is the same as the single wire
safety waveform. The waveform is present only when the output of the EMD expansion safety
B1/B2 Inputs (Step 7) relay is on. With a digital multimeter, the voltage measures 8…9V DC.
If the B1 status indicator is on, but no voltage is read, the expansion safety relay must be
replaced.
For more information on retriggerable inputs, see Retriggerable Input on page 29.
Figure 90 - The B1-B2 Waveform When the EMD Safety Relay Output is On

Terminal Block Removal Terminal blocks can be replaced following these instructions.
and Replacement
Terminal Block Removal
GSR safety relays have removable terminal blocks. Use a screwdriver as a lever to remove the
blocks. As shown in Figure 91, insert the screwdriver into the slot and pry up.
Figure 91 - Terminal Block Removal
1. Insert 2. Pry Up
Terminal Block Replacement

The terminal blocks are keyed to help prevent a block from being inserted into an incorrect
location. The orange-colored insert provides the orientation of the key (see Figure 92).
Figure 92 - Orange Keyway
Orange inserts
match keys

Series, Version, and The product label differs slightly depending on when you purchased your safety relay.
Manufacturing Date Code
Current Product Label
The series, firmware revision number, and manufacturing date code are identified on the
safety relay label, as shown in Figure 93.
Figure 93 - Product Label - Series and Revision Identification
Manufactured during
the 18th week of 2015
Old Product Label

The initial production runs of GSR safety relays excluded a firmware revision number, as
shown in Figure 94.
Figure 94 - Early Version of Product Label
Manufactured during
the 34th week of 2012

Appendix A
Specifications
General
Attribute 440R-S13R2 440R-D22R2 440R-D22S2 440R-EM4R2 440R-EM4R2D 440R-S12R2
(CI) (DI) (DIS) (EM) (EMD) (SI)
Dimensions, HxWxD [mm (in)] 119.14 x 22.5 x 113.6 (0.88 x 4.69 x 4.47)
Shipping weight, approx. [g (lb)] 225 (0.5) 180 (0.4) 50 (0.33) 225 (0.5) 220 (0.49) 150 (0.33)
Wire size [mm² (AWG)] 0.2…2.5 (24…14)
Wiring category [°C (°F)] Copper that withstands 75 (167)
Terminal screw torque
[N•m (lb•in)] 0.4 (4)
Power supply voltage range 24V DC PELV/SELV, 0.85…1.1 x rated voltage
Power on delay, max [s] 7
Power consumption, typical [W] 4 3.3 2.5 2.8 2.9 2.5
Case material Polyamide PA 6.6
Terminal protection IP20
Enclosure protection IP40 (NEMA 1)
Mounting [mm (in)] 35 (1.38) DIN rail in enclosure that is rated to a minimum of IP54
Environmental
440R-S13R2 440R-D22R2 440R-D22S2 440R-EM4R2 440R-EM4R2D 440R-S12R2
Attribute (CI) (DI) (DIS) (EM) (EMD) (SI)
Temperature, operating [°C (°F)] -5…+55 (23…131)
Relative humidity 90%
Vibration 10…55 Hz, 0.35 mm (0.01 in.)
Shock 10 g, 16 ms
Pollution level 2
Installation group Overvoltage Category III, VDE 0110-1
Impulse withstand voltage [V] 2500

Appendix A Specifications
Safety Inputs IN, IN1, and

IN2 Attribute 440R-S13R2 440R-D22R2 440R-D22S2 440R-EM4R2 440R-EM4R2D 440R-S12R2
1 NC, 1 PNP 2 NC, 2 PNP 2 NC, 2 PNP 1 NC, 1 PNP
Inputs (OSSD) (OSSD) (OSSD) — — (OSSD)
S12, S22, and S12, S22, and
Wiring terminals S12, S22 — — S12, S22
S32, S42 S32, S42
Max [V] 26.4 — — 26.4
On voltage
Min [V] 11 — — 11
Off voltage, max [V] 5 — — 5
Off current, max [mA] 2 — — 2
On current, At 24V DC [mA] 11.0 — — 11.0
max At 26.4V DC [mA] 11.1 — — 11.1
Galvanic isolation: I/O from Logic No — — No
Overvoltage protection Yes — — Yes
Test out Duration [ms] 2.5 1.5, 3 — — 1.5, 3
pulse Period [ms] 14 13.6 — — 13.6
OSSD test pulse width, max [ms] 0.75 — — 0.75
Off pulse accepted for OSSD
setting without declaring the 3.1 2.2 — — 2.2
input as off, max [ms]
Recovery time, min [ms] 30 — — 30
Reverse voltage protection Yes — — Yes
Input capacitance [nF] 10 — — 10
Input simultaneity Infinite — — Infinite
Allowable input resistance, max
900 — — 900
[Ω]
Allowable S11 to S21 350 160 — — 160
cable
capacitance, S11 to ground 350 320 — — 320
max [nF] S21 to ground 350 320 — — 320
Safety mat, max size [m²] 23 35 — — 35
Reset Input
Attribute
Wiring terminal S34 — — S34
Max [V] 26.4 — — 26.4
On voltage
Min [V] 11 — — 11
Off voltage, max [V] 5 — — 5
Off current, max [mA] 2 — — 2
On current, At 24V DC [mA] 11.0 — — 11.0
max At 26.4V DC [mA] 11.1 — — 11.1
Galvanic isolation: I/O from Logic No — — No
Overvoltage protection Yes — — Yes
Input capacitance [nF] 10 — — 10
Duration [s] 0.25…3.0 — — 0.25…3.0

B1 Input
Wiring terminal — — — — B1 —
Max [V] — — — — 26.4 —
On voltage
Min [V] — — — — 11 —
Off voltage, max [V] — — — — 5 —
Off current, max [mA] — — — — 2 —
On current, At 24V DC [mA] — — — — 11.0 —
max At 26.4V DC [mA] — — — — 11.1 —
Galvanic isolation: I/O from Logic — — — — No —
Overvoltage protection — — — — Yes —
Input capacitance [nF] — — — — 10 —
Safety Outputs
13/14, 23/24, 13/14, 23/24, 17/18, 27/28,
Wiring terminal 33/34 13/14, 23/24 14, 24, 34, 44 33/34, 43/44 37/38, 47/48 13/14, 23/24
Output type 3 N.O. 2 N.O. 4 PNP 4 N.O. 4 N.O. delayed 2 N.O.

Thermic current Ith [A] 1x6 — 1x6
Fuses output Slow blow 6 6
(external) [A] Quick blow —
10 10
Switched current, min [mA] 10 — 10
Switched voltage, min [V] 10 — 10
Mechanical life 10,000,000 cycles — 10,000,000 cycles
UL: C300
UL: C300 UL: B300 AC-15: 1.5 A/
Rating AC-15: 1.5 A / 250V AC 14, 24: 1.5 A each AC-15: 1.5 A / 250V AC 250V AC
34, 44: 0.5 A each
DC13: 2 A / 24V DC (0.1 Hz) DC13: 2 A / 24V DC (0.1 Hz) DC13: 2 A/
24V DC (0.1 Hz)
14, 24: 1.6 µF each
Capacitance — 34, 44: 9 µF each —
AgNi +
Contact material AgNi — AgNi
0.2 µ Au
Reaction time L12 — 45 40 100 45 —

safety output Inputs 35 25
[ms] 150 — — 150
Mat operation 40 30
Reaction time L12 — 40 45 0 45 —
single wire
safety output Inputs 25 25 25
— —
25
[ms] Mat operation 30 30 30 30
Reaction time
to jog, max B1 — — — — 35 —
[ms]
Response L12 45 45 45 45 45 45
time
safety output Inputs 35 35 25
— —
35
[ms] Mat operation 45 45 35 45
L12 45 45 45 45 45 45
Response
time Inputs 25 25 25 25
single wire — —
Mat operation 40 35 35 35
safety output
[ms] Single-wire 55 50 50 (1) 45 50
fault
Response
time to jog, B1 — — — — 35 —
max [ms]
(1) Response time of the single-wire source device.

Auxiliary Output
Wiring terminal — Y32 X32 Y32
Output type 1 N.C. 1 PNP, 50 mA max
Single Wire Safety (SWS)

Attribute
Output L11
Wiring terminal
Input L12
Continuous output current,
max [mA] 50
On state voltage drop (P/S to +),

0.2
max [V]
Surge output current, max [mA] 700
Surge output current duration, 5
max [ms]
Load capacitance, max [µF] 1
Off state leakage current, max
[mA] < 0.1
Short circuit detection No

Short circuit protection Yes
Galvanic isolation: I/O from Logic No
Fanout (max number of
10 10
connections to L11)
Repeater (1)
Cable length between L11 and 30 30
L12 [m]
(1) The EM safety relay has a direct connection from L12 to L11, so it cannot fan out to 10 additional devices. It repeats the signal.
The EM safety relay must be included as one of the fan-out units.

Appendix B
Regulatory Approvals
Agency Certifications • UL Listed Industrial Control Equipment, certified for US and Canada.
• CE Marked for all applicable EU directives
• UKCA Marked for all applicable regulations
• C-Tick Marked for all applicable acts
• CCC Mark
• S-Mark
Declaration of Conformity CE Conformity

This product is designed and tested to meet the 2014/30/EU EMC Directive and the European
Council Directive 2006/42/EC on machinery. These products also conform to:
• EN 61000-6-4: Generic Standards - Emission Standard for Industrial Environments
• EN 61000-6-2: Generic Standards - Immunity for Industrial Environments
• IEC/EN 61508 - Functional safety of electrical/electronic/programmable electronic
safety-related systems
• IEC/EN 62061 - Safety of machinery - Functional safety of safety-related electrical,
electronic, and programmable electronic control systems
• EN ISO 13849-1 - Safety of machinery -- Safety-related parts of control systems -- Part 1:
General principles for design
This product is intended for use in an industrial environment.
For a comprehensive CE certificate visit: rok.auto/certifications.
UKCA Conformity
This product is designed and tested to meet the 2016 No. 1091 Electromagnetic Compatibility
Regulations and the 2008 No. 1597 Supply of Machinery (Safety) Regulations on machinery.
These products also conform to:
• EN 61000-6-4: Generic Standards - Emission Standard for Industrial Environments
• EN 61000-6-2: Generic Standards - Immunity for Industrial Environments
• IEC/EN 61508 - Functional safety of electrical/electronic/programmable electronic
safety-related systems
• IEC/EN 62061 - Safety of machinery - Functional safety of safety-related electrical,
electronic, and programmable electronic control systems
• EN ISO 13849-1 - Safety of machinery -- Safety-related parts of control systems -- Part 1:
General principles for design
This product is intended for use in an industrial environment.
For a comprehensive UKCA certificate visit: rok.auto/certifications.

Appendix B Regulatory Approvals
Machine Safety Directive

The performance of the safety function is dependent on the structure of all devices that
comprise the safety function. Table 20 and Table 21 provide the data that must be used to
represent safety relays when calculating the safety integrity level (SIL) or the Performance
Level (PL).
Safety relays can be used in safety circuits according to DIN EN 60204-1/VDE 0113 part 1. The
following safety requirements are achievable in maximum based on the operation mode and
wiring.
Specifications are applicable only if the safety function is demanded at least once within 6
months. All diagnostic tests are conducted at least before next demand. At mission time (TM),
the proof test interval (PTI) is assumed. Components failure rates are according to SN29500.
SIL Rating
Safety relays meet the requirements in Table 20 in accordance with IEC/EN 61508 and can be
used in applications up to SIL 3 according to IEC 62061.
Table 20 - SIL Rating
PFH (1/h) 4.42 E-09 4.52 E-09 4.42 E-09 1.54 E-09 4.58 E-09 4.28 E-09
Safety integrity level 3
Mode of operation High demand
Hardware fault 1
tolerance
Safe failure fraction 99%
Performance Level/Category
Safety relays can be used in safety systems that meet up to Category 4 and Performance Level
PLe in accordance with ISO 13849-1.
Table 21 - Performance Level/Category
MTTFd 252 230 439 342 256 363
Category Up to 4
Performance Level Up to e
DC avg 98.8%
Mission time [year] 20
Days of operation 365
Hours of operation 24
T cycle 8 hr/8.28 s

Index
A contact
resistance 72
add-on profile voltage-free 58
Studio 5000 Logix Designer 52 cycling
adjustment
multiple-channel 63
switch 31
agency certifications 81
AOP D
Studio 5000 Logix Designer 52 date code
application
manufacturing 76
examples 45 detect
CI safety relay 45
off pulse 61
DI safety relay 46
devices
DIS safety relay 47
EM safety relay 48 mechanical contacts 19
EMD safety relay 48 safety, OSSD output 20
SI safety relay 50 DI safety relay
approvals overview 10
regulatory 81 safety mat 46
assignments switch adjustment 32
terminal 17 diagnostics
automatic indicators 36
diagram
reset 27
auxiliary output 26, 72 internal circuit block 43
CI safety relay 43
issues 71
DI safety relay 43
specifications 80
DIS safety relay 43
EM safety relay 43
B EMD safety relay 44
SI safety relay 44
B1 input dimensions
specifications 79 mounting 13
DIN rail 13
mounting 13
C removal 13
capacitance effect 61 directive
category 82 European Union 81
CE conformity 81 DIS safety relay
certifications overview 10
agency 81 switch adjustment 32
discrepancy 63
channel simultaneity 63
check
power supply 56 E
safety device input 58
safety output 67 effect
single wire safety circuit 64 OSSD test pulse 61
voltage 56 electromechanical
CI safety relay output 24
overview 10 electromechanical output
circuit block diagram 43, 44 issues 67
communication EM safety relay
Ethernet 51 overview 10
compliance EMD safety relay
European Union (EU) directives 81 overview 10
configuration 31 switch adjustment 32
process 33 timing functions 39
connect enclosure
power supply 19 considerations 14
considerations environmental
enclosure 14 specifications 77
Ethernet
communication 51
Index
European Union (EU) directives input

compliance 81 jog 29
examples monitor 27
application 45 pulse testing 37
CI safety relay 45 CI safety relay 37
DI safety relay 46 DI, DIS, and SI safety relay 37
DIS safety relay 47 reset 27
EM safety relay 48 retriggerable 29
EMD safety relay 48 safety 19
SI safety relay 50 single wire safety 26
wiring 45 SWS 26
CI safety relay 45 installation 13
DI safety relay 46 internal circuit block
DIS safety relay 47 diagram 43
EM safety relay 48 CI safety relay 43
EMD safety relay 48 DI safety relay 43
SI safety relay 50 DIS safety relay 43
excessive heat EM safety relay 43
prevent 15 EMD safety relay 44
expansion relays SI safety relay 44
monitor 29
J
F jog 41
features input 29
hardware 9
functions
pulse testing 37 L
label
product (current) 76
G product (old) 76
general long wire 62
specifications 77
ground 17, 57
relay 19 M
Guardmaster safety relay machine safety directive 82
CI 10, 43, 45 manual
DI 10, 32, 43, 46 reset 27
DIS 10, 32, 43, 47 manufacturing date code 76
EM 10, 43, 48 mats
EMD 10, 32, 39, 44, 48
SI 11, 44, 50 safety 21
mechanical contacts
devices 19
H monitor
hardware expansion relays 29
input 27
features 9 monitored reset 28
heat
mounting
prevent excessive 15
dimensions 13
DIN rail 13
I multiple-channel
cycling 63
indicator multi-position
PWR/fault 54 switch 9
flashing red 55
green with flashing red 56
solid red 55 N
indicators
diagnostics 36 non-retriggerable
normal operation 35 off delay 39
powerup 35 normal operation
status 35 indicators 35

Index
O recommendation
wiring 17
off delay
recovery time 63
non-retriggerable 39
retriggerable 40 regulatory approvals 81
off pulse relay
detect 61 ground 19
on delay 40 removable
optical communication bus 10 rerminals 14
terminal blocks 9
OSSD output 24
removal 13
issues 69
safety devices 20 terminal block 75
replacement
OSSD outputs
terminal block 75
pulse testing 38
requirements
OSSD test pulse
wiring 17
effect 61
rerminals
output
removable 14
auxiliary 26, 72
reset
issues 71
electromechanical 24 automatic 27
OSSD 24 input 27
safety 24 input, specifications 78
single wire safety 26 manual 27
SWS 26 monitored 28
X32 73 resistance
overview 9 contact 72
CI safety relay 10 resistance effect 62
DI safety relay 10 retriggerable
DIS safety relay 10 input 29
EM safety relay 10 off delay 40
EMD safety relay 10
SI safety relay 11
S
P safety
input 19
performance level 82 mats 21
power 17 output 24
power supply safety device input
check 56 check 58
connect 19 safety inputs IN, IN1, and IN2
ground 57 specifications 78
powerup safety mat
indicators 35 DI safety relay 46
prevent safety output
excessive heat 15 check 67
process electromechanical output
configuration 33 issues 67
product label OSSD output
current 76 issues 69
old 76 safety outputs
pulse testing specifications 79
functions 37 safety relay
input 37 CI 10, 43, 45
CI safety relay 37 DI 10, 32, 43, 46
DI, DIS, and SI safety relay 37 DIS 10, 32, 43, 47
OSSD outputs 38 EM 10, 43, 48
PWR/fault status indicator 54 EMD 10, 32, 39, 44, 48
flashing red 55 SI 11, 44, 50
green with flashing red 56 series 76
solid red 55 SI safety relay
overview 11
SIL
R rating 82
rating simultaneity
SIL 82 channel 63

Index
single wire safety U

input 26
UKCA conformity 81
output 26
specifications 80
single wire safety circuit
check 64
V
spacing 14 version 76
specifications 77 voltage
auxiliary output 80 check 56
B1 input 79 voltage-free contact 58
environmental 77
general 77
reset input 78 W
safety inputs IN, IN1, and IN2 78
web page 51
safety outputs 79
single wire safety 80 wire 17
SWS 80 size 17
status indicator wiring
PWR/fault 54 examples 45
flashing red 55 CI safety relay 45
green with flashing red 56 DI safety relay 46
solid red 55 DIS safety relay 47
status indicators 9, 35 EM safety relay 48
diagnostics 36 EMD safety relay 48
normal operation 35 SI safety relay 50
powerup 35 recommendation 17
steps requirements 17
troubleshooting 53
Studio 5000 Logix Designer X
add-on profile (AOP) 52
suppressors X32 output 73
surge 25
surge suppressors 25
switch
adjustment 31
DI safety relay 32
DIS safety relays 32
EMD safety relay 32
multi-position 9
SWS
input 26
output 26
specifications 80
SWS circuit
check 64
T
terminal
assignments 17
torque 17
terminal block
removal 75
replacement 75
terminal blocks
removable 9
time
recovery 63
timing functions
EMD safety relay 39
tools 53
torque
terminal 17
troubleshooting 35
steps 53

Guardmaster Safety Relays User Manual

Rockwell Automation Support
Use these resources to access support information.
Find help with how-to videos, FAQs, chat, user forums, Knowledgebase, and product
Technical Support Center rok.auto/support
notification updates.
Local Technical Support Phone Numbers Locate the telephone number for your country. rok.auto/phonesupport
Quickly access and download technical specifications, installation instructions, and user
Technical Documentation Center rok.auto/techdocs
manuals.
Literature Library Find installation instructions, manuals, brochures, and technical data publications. rok.auto/literature
Product Compatibility and Download Center Download firmware, associated files (such as AOP, EDS, and DTM), and access product rok.auto/pcdc
(PCDC) release notes.
Documentation Feedback
Your comments help us serve your documentation needs better. If you have any suggestions on how to improve our content, complete the
form at rok.auto/docfeedback.
Waste Electrical and Electronic Equipment (WEEE)
At the end of life, this equipment should be collected separately from any unsorted municipal waste.
Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec.
Allen-Bradley, Atlas, Cadet, Elf, expanding human possibility, Ferrogard, Guardmaster, GuardShield, Kinetix, Lifeline, PowerFlex, Rockwell Automation, Rotacam, Safedge, SafeZone, SensaGuard,
Sipha, Studio 5000 Logix Designer, and Trojan are trademarks of Rockwell Automation, Inc.
EtherNet/IP is a trademark of ODVA, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Rockwell Otomasyon Ticaret A.Ş. Kar Plaza İş Merkezi E Blok Kat:6 34752, İçerenköy, İstanbul, Tel: +90 (216) 5698400 EEE Yönetmeliğine Uygundur
Publication 440R-UM013G-EN-P - December 2022

Supersedes Publication 440R-UM013F-EN-P - July 2021 Copyright © 2022 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

Manual Relé Allen Bradley SI 440r-Um013 - En-P PDF

Uploaded by

Copyright:

Available Formats

Manual Relé Allen Bradley SI 440r-Um013 - En-P PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Relé Allen Bradley SI 440r-Um013 - En-P PDF

Uploaded by

Copyright:

Available Formats

Guardmaster Safety Relays

Catalog Numbers 440R-S13R2, 440R-S12R2, 440R-D22R2,

User Manual Original Instructions

Important User Information

The following icon may appear in the text of this document.

2 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 3

Reset and Monitor Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022

EMD Safety Relay (Cat. No. 440R-EM4R2D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 5

Current Product Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 7

You can view or download publications at rok.auto/literature.

8 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022

Hardware Features Figure 1 - Safety Relays

Removable Terminal Blocks

Multi-position Switches to set

Optical Communication Bus on page 10

Removable Terminal Blocks

(a) The EM safety relay does not require configuration.

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 9

Optical Communication Bus

10 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 11

12 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022

Mounting Dimensions Figure 2 - Dimensions [mm (in.)]

DIN Rail Latch

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 13

This equipment is intended for use in a Pollution Degree 2 industrial environment, in

For more information, see publications:

14 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 15

16 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022

Power, Ground, and Wire

Wiring Requirements and

ATTENTION: Calculate the maximum possible current in each power and

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 17

Figure 5 - Terminal Identification

18 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022

Devices with Mechanical Contacts

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 19

Device 1 Device 1 Device 2

CI and SI DI and DIS

Devices with OSSD Output

Device 1 Device 1 Device 2

A1 S12 S22 A1 S12 S22 S32 S42

CI and SI DI and DIS

20 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022

ATTENTION: You must consider the cumulative response time of all

Device 1 Device 1 Device 2

Device 3 Device 3 Device 4

Device 5 Device 5 Device 6

A1 S12 S22 A1 S12 S22 S32 S42

CI and SI DI and DIS

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 21

Mat 1 Mat 1 Mat 2 Mat 1 EM Device

CI and SI DI and DIS DI and DIS