NHP SAFETY REFERENCE GUIDE
WIRING DIAGRAMS
Guardmaster Safety Relays
(GSR)
Safeguarding Applications and Wiring Diagrams
Next Generation ‘GSR” Safety Monitoring Relays
Table of Contents
Page
Safety Relay
Modules
Input Devices
Output Devices
SIL
CL
PL
Cat.
No.
Stop
Cat
5
SI
E-Stop
6
SI
Trojan T15
Powerflex 525
2
d
3
0
Flex IO
2
d
3
0
7
SI, EM, EMD
8
SI, EMD
4 E-Stops
100S-C, 700S-DCP
2
d
3
0
E-Stop
Kinetix 6000 Guardmotion w/RBM
3
e
4
1
9
SI, EMD
GuardShield Safe 4
100S, 700S-C
3
e
4
0
10
SI, DI, DIS
3 E-Stops, Trojan T15, Safety Mat
100S, 700S-C
3
e
4
0
11
SI, MSR35H
GuardShield, 800Z
100S-C
3
e
4
0
12
SI, DIS
3 SensaGuards with Integrated Latch, 2 E-Stops
Powerflex 525
3
e
4
0
13
CI
Trojan T15, Elf, E-Stop, PLC on Ch 2
100S-C
2
d
3
0
14
CI
3 SensaGuards
100S-C
3
e
4
0
15
DI
GuardShield
100S-C
3
e
4
0
16
DI
2 GuardShields
100S-C
3
e
4
0
17
DI
2 Lifeline 4
100S-C
3
e
4
0
18
DI
5 SensaGuards, Distribution Block, E-Stop
Kinetix K350
2
d
3
0
19
DI
GuardShield, E-Stop
Pneumatic Safety Valve
3
e
4
0
20
DI
SensaGuard with Integrated Latch, E-Stop
Powerflex 525
2
d
3
0
21
DI, EMD
MT-GD2, GripSwitch
Powerflex 70
2
d
3
0
22
DI, EMD
TLS1-GD2, Trojan T15, E-Stop
700S-CF
3
e
4
0
23
DI, EMD
440G-MT, MT-GD2, GripSwitch
100S-D
2
d
3
0
24
DI, DI, DI
2 E-Stops, 2 GuardShueld Safe 4, Mat, SensaGuard
100S-C
2,3
d,e
3,4
0
25
DI
E-Stop
Powerflex 755
3
e
3
0
26
DI
SafeZone Mini, E-Stop
Kinetix 350
2
d
3
0
27
DI
SafeZone Multizone, E-Stop
Kinetix 350
2
d
3
0
28
DI
SC300 Safety Sensor, E-Stop
Kinetix 350
2
d
3
0
29
DIS
Galvanic Isolator 897H, Trojan T15, E-Stop
Powerflex 525
2
d
3
0
30
DIS
Galvanic Isolator 897H, Safedge, MatGuard, E-Stop
Powerflex 525
2
c,d
1,3
0
31
DIS
Trojan 5, MT-GD2
Powerflex 70
2
d
3
0
32
DIS
Trojan 5
2 Powerflex 70
2
d
3
0
33
DIS, MSR41
Micro 400 GuardShield, E-Stop
100S-C
3
e
4
0
34
DIS, MSR42
Micro 400 GuardShield, SensaGuard, E-Stop
100S-C
3
e
4
0
35
GLP
871TM, TLS53-GD2
Powerflex 70
2
d
3
1
36
GLP
872C, TLS-ZR
Powerflex 525
2
d
3
1
37
GLP
871TM, TLS-ZR
Powerflex 70
2
d
3
SLS
38
GLP
872C
Powerflex 525
2
d
3
0
39
GLP, DIS
872C, TLS3-GD2, E-Stops
Powerflex 70
2
d
3
1
40
GLP, DI
872C, TLS3-GD2, E-Stops
Powerflex 525
2
d
3
SLS
41
GLP, DI
872C, TLS3-GD2, E-Stops
100S
2
d
3
0
42
GLP, DI
872C, TLS3-GD2, E-Stops
Kinetix K300
2
d
3
SLS
43
GLP, DI, EMD
872C, TLS-ZR, E-Stops
Powerflex 525
2
d
3
0
NHP Safety Reference Guide > GSR Wiring Diagrams
3-2
Safeguarding Applications and Wiring Diagrams
Next Generation ‘GSR” Safety Monitoring Relays
Notes for Example Wiring Diagrams:
Note 1
In the following circuits the type of Allen-Bradley/Guardmaster
device is shown as an example to illustrate the circuit principle.
For specific applications the choice of device type should be
based on the suitability of its characteristics for its intended use.
Note 2
In most of the following examples showing dual channel
applications, one interlock switch is shown switching both
channels (one contact set per channel). If it is foreseeable that
damage to the guard (e.g., at the actuator mounting point) could
allow it to be opened without operating the switch then two
separate switches may be required. The electrical principle of the
circuit will remain the same.
Note 3
In most cases the circuits are shown with the guard door closed
and ready for motor starting by operating the normal start
control.
It must be possible to start the machine only by voluntary
actuation of the control provided for the purpose (see ISO
12100-2 4.11.8). For the purposes of these examples the use of a
conventional contactor latching circuit has been assumed. If this
is not the case, then a restart interlock will be required to prevent
an automatic or unintended starting of the motor when the guard
is closed. For example, a Minotaur safety relay with a momentary
action push button installed in the output monitoring circuit can
be used to achieve this.
•If the guard is designated as a Control Guard (see ISO 12100-2
5.3.2.5) these requirements do not apply but the use of control
guards is only allowed under certain conditions including:
•A control guard can only be used where there is no possibility
of an operator or part of his body staying in or reaching into
the danger zone whilst the guard is closed.
• The control guard must be the only access to the hazard area.
•The interlocking system must have the highest possible
reliability. It is often advisable to use a solenoid locking switch
such as the Guardmaster Atlas or TLS-GD2.
Note 4
Safety monitoring relay units used in dual channel circuits with
infrequent operation or with more than one switching device
connected. This note applies to all monitoring devices which use
the technique of comparing the signal at the change of state of
dual channels.
Certain faults are only detected at a change of state of the input
switching device (interlock switch or E-Stop switch). If the re are
long periods (e.g. months as opposed to days) between switching
actions, it may be possible for multiple faults to accumulate which
could lead to a dangerous situation. Therefore a regular check
should be performed on the system in order to detect single
faults before an accumulation occurs. This check may be manual
or initiated by part of the machines control system.
If, for example, 3 interlock switches are connected to the
monitoring unit, certain faults will only be detected at the switch
on the rst guard to be opened and the switch on the last guard to
be closed. This is because any switching between the rst opening/
last closing will not change the state of the monitoring unit input
circuits. Therefore in some applications it may be necessary to use
one monitoring device per switch.
Most of the following examples show an interlock switch and
an emergency stop switch combined in the circuit. When a
monitoring safety relay (e.g. Guardmaster Minotaur) is used for
fault detection it is important to note the following:
•All safety critical single faults, except for certain faults over
the contact sets at the E-Stop, will be detected at the next
opening of the guard.
•All safety critical single faults, except for certain faults over
the contact sets at the interlock switch, will be detected at the
next operation of the E-Stop.
•Because the E-Stop device is not likely to be operated
frequently, it is recommended that its function is checked
(with the gua rd closed) on a regular basis (start of shift or
daily) to enable the Minotaur to detect single faults. If the
guard is rarely opened, the interlock switch should be checked
in a similar manner.
Note 5
This symbol indicates that the associated component or
device features direct opening (positive opening) operation.
In the event of a fault, welded contacts will be forced open
by the motion of the safety guard.
This symbol denotes mechanically linked contacts; if
one contact welds closed, all other dependent (auxiliary)
contacts remain in position, i.e. they cannot change state.
NHP Safety Reference Guide > GSR Wiring Diagrams
3-3
Safeguarding Applications and Wiring Diagrams
Next Generation ‘GSR” Safety Monitoring Relays
General Safety Information:
IMPORTANT
This application example is for advanced users and assumes that you are trained
and experienced in safety system requirements.
Contact NHP to find out more about our safety risk assessment services.
ATTENTION
A risk assessment should be performed to make sure all tasks and hazard
combinations have been identied and addressed. The risk assessment may require
additional circuitry to reduce the risk to a tolerable level. Safety circuits must take
into consideration safety distance calculations which are not part of the scope of
this document.
NHP Safety Reference Guide > GSR Wiring Diagrams
3-4
Safeguarding Applications and Wiring Diagrams
SI with E-stop to 525 Drive
Safeguarding Applications and Wiring Diagrams
SI with E-stop to 525 Drive
E-Stop, SI, and PowerFlex 525:
E-Stop, SI, and PowerFlex 525
24V DC
L1 L2 L3
Reset
PowerFlex R S T
525
11 +24V DC
1 Stop
E-Stop
800FM-MT44
800F-MX02S
S11 S21 S34
RESET
A1 13
23
0
Gate control
power supply
AM
SI
440R-S12R2
2 Start
MM
S22 S12 Y32 L11 A2
14
24
Gate control
circuit
S1
S2
Status
To PLC
UV W
M
24V DC Com
Circuit Status
Detection
Circuit
Status
The SI Logic
is set to MM, monitored manual reset. The e-stop is released. TheFault
SI safety
outputs (13/14 and 23/24) are off. The PowerFlex 525
drive
powered
The motor
is off. reset. The e-stop
Upon successful completion of internal checks by the SI and
The
SI isLogic
is setbut
todisabled.
MM, monitored
manual
PowerFlex 525 drive, the drive awaits the closure of the safety
is released. The SI safety outputs (13/14 and 23/24) are o. The
Operating
Principle
outputs. If the SI fails, the drive will not energize the motor, and
PowerFlex
525
drive is powered but disabled. The motor is off.
STARTING: Press the Reset button to turn on the SI safety outputs. This enables
the
drive
andbe
also
applies power
to the Start and
buttons.The sI
the
fault
will
detected
by non-operation
ofStop
the motor.
Operating
Principle
Press the Start
buttons to start the motor.
generates test pulses through the E-stop circuits to detect cross
STOPPING: Press
Press the
button
to stop
the motor
stops. Press the e-stop to initiate a safety stop; the motor coasts to a stop.
STARTING:
theStop
Reset
button
to turn
on thefor
SI production
safety outputs.
channel shorts and shorts to power and ground. A fault in the
This enables the drive and also applies power to the Start and
safe-circuit of the drive will be detected by the drive and the drive
Fault
Detection
Stop
buttons.
Press the Start buttons to start the motor.
will execute a safe torque off stop.
Upon successful completion of internal checks by the SI and PowerFlex 525 drive, the drive awaits the closure of the safety outputs. If the SI fails,
the drive will
not energize
motor,toand
thethe
fault
will befor
detected
by non-operation
STOPPING:
Press
the Stopthe
button
stop
motor
production
Ratingsof the motor. The sI generates test pulses through the
E-stopPress
circuits
toe-stop
detect cross
channel
shorts stop;
and shorts
to power
and ground. A fault in the safe-circuit of the drive will be detected by the drive
stops.
the
to initiate
a safety
the motor
coasts
The safety function initiated by the e-stop meets the safety
the drive will execute a safe torque off stop.
toand
a stop.
performance requirements of SIL CL2 per IEC 62061:2005 and
has a Category 3 structure that can be used in systems requiring
Ratings
Performance
PLd per ISO
2006.3The circuit
The safety function initiated by the e-stop meets the safety performance requirements
of SIL Levels
CL2 perup
IECto
62061:2005
and13849-1:
has a Category
structure that can be used in systems requiring Performance Levels up to PLdexecutes
per ISO 13849-1:
The
a Safe
Torque Off (i.e., a
a Safe 2006.
Torque
Offcircuit
(i.e., executes
a Category
0) stop.
Category 0) stop.
NHP Safety Reference Guide > GSR Wiring Diagrams
- 03 -
3-5
Safeguarding Applications and Wiring Diagrams
Safety Relay to Flex I/O
Safety Applications and Wiring Diagrams
Safety Relay to Flex I/O
Trojan T15 GD2, 800F, SI, Flex I/O:
Trojan T15 GD2, 800F, SI, Flex I/O
+24V DC
Start
800FMF3MX10
Reset
800FM-F6MX10
Brown
12
Black
S11 S21 A1
11 21
RESET
S34
13
23
16
35
17
36
18
37
19
38
.
.
.
50
20
.
.
.
32
51
33
AM
12 22
Trojan T15 GD2
440K-T11390
889D-F4AC-2
SI
440R-S12R2
MM
S12 S22 A2 L11 Y32 14
24
White
Blue
C
11
700-HLT2Z24
700-TBR24
Limited to
6 Amps
34
0
Stop
800FME4MX01
0
0
16
34
1
1
17
35
2
2
18
36
CR
3
3
19
37
CR
4.
.
.
14
4.
.
.
14
20
.
.
.
32
38
.
.
.
50
Machine 15
Actuators
A
15
33
51
A
B
C
CR1
B
1794-TB3 & 1794-OB16
FLEX Output Module
1794-TB3 & 1794-I16
FLEX Input Module
24V DC Com
Circuit Status
STOPPING: Press the Stop button to stop the machine. Then,
Circuit
Status
The safety
gate is closed. The outputs of the SI safety relay are open and the machine actuators are off. Control Relay CR1 is de-energized and its
open the gate to access the machine. While the gate is open, the
11/12
contact
is closed.
The
safety
gate
is closed. The outputs of the SI safety relay are
machine actuators cannot operate because power is removed
open and the machine actuators are o. Control Relay CR1 is defrom the output module. If the gate is inadvertently opened while
Operating
Principle
energized
and
its 11/12 contact is closed.
the
machine
is running,
will be
from
output
The SI is chosen for this application because its thermal (non-switching) current
carrying
capacity
is 6A inpower
one circuit.
Theremoved
Flex output
module
Operating
Principle
performs the
normal switching of the machine actuators during the manufacturing
process.
The machine
safety system
enableswill
the be
machine
functions by
module
and the
actuators
de-energized.
providing
power to
FLEX
Output Module.
One
the Flex (nonoutputs must drive an electro-mechanical device (CR1) whose normally closed
The
SI is chosen
forthe
this
application
because
itsofthermal
Fault Detection
contact
is
in
the
monitoring
loop
of
the
safety
relay.
The
machine
switching) current carrying capacity is 6A in one circuit. The logic
Flex must energize this output while the machine is running, as it is used by the
SI to confirm that power is removed from the output module, before restarting.Upon successful completion of internal checks on power up, the
output module performs the normal switching of the machine
SI checks the input circuits. With the gates closed, the SI checks
actuators
the
manufacturing
process.
The safety
system
STARTING:during
Press the
reset
button to energize
the output
contacts
13/14 of the SI. This connects the 24V supply to terminal C34 of Flex 1974-OB16
the dual circuits and then waits for the reset signal. A single fault,
enables
the machine
by providing
power to
FLEX
output module
and alsofunctions
sends a signal
to the A3 terminal
of the
the 1794-IB16.
The logic system is informed that the gate is closed and the machine is
a short from 24V to terminal 14 of the SI, may lead to the loss
Output
One
thebutton
Flex outputs
must
driveprocess.
an electroready toModule.
run. Press
the of
Start
to start the
machine
the the
safety
function.
With
STOPPING: Press
the(CR1)
Stop button
stop the machine.
Then, open
access
machine.
While
the the
gateSIis and
open,Flex
the system
machinemounted
actuators in
mechanical
device
whosetonormally
closed contact
is inthe gate to of
same cabinet
and with
validation,
this fault
cannot
operate because
is removed
the outputlogic
module.
is inadvertently
opened
whileproper
the machine
is running,
powermay
will be
the
monitoring
loop ofpower
the safety
relay. from
The machine
mustIf the gatethe
be
removed
from
output
module
and
the
machine
actuators
will
be
de-energized.
excluded.
If
not
mounted
in
the
same
cabinet,
a
signal
from
the
energize this output while the machine is running, as it is used by
output
(A0)
should
be
fed
back
into
the
input
module
(A2).
The
the SI to conrm that power is removed from the output module,
Fault Detection
logic can perform a comparison of input A2 and A3, and turn the
before
restarting.
Upon successful completion of internal checks on power up, the SI checks the input
circuits.
gates closed,
checks the dual
circuits
machine
o if With
thesethe
signals
are notthe
in SI
agreement.
If CR1
is not deand then waits
forthe
thereset
reset signal.
single
fault, athe
short
from 24V
to terminal 14 of the SI, may lead to the loss of the safety function. With the SI
STARTING:
Press
buttonAto
energize
output
contacts
energized when the gate is closed, the SI will not close its outputs.
and Flex
mounted
in the the
same
cabinet
andto
with
properC34
validation,
this fault may be excluded. If not mounted in the same cabinet, a signal
13/14
of system
the SI. This
connects
24V
supply
terminal
of
from the output (A0) should be fed back into the input module (A2). The logic Ratings
can perform a comparison of input A2 and A3, and turn the
Flex 1974-OB16 output module and also sends a signal to the A3
machine off if these signals are not in agreement. If CR1 is not de-energized when the gate is closed, the SI will not close its outputs.
The safety function initiated by the Trojan T15-GD2 gate interlock
terminal of the 1794-IB16. The logic system is informed that the
meets the safety performance requirements of SIL CL 2 per IEC
gate is closed and the machine is ready to run. Press the Start
Ratings
62061:2005
and requirements
has a Category
3 structure
that
can be used
button
to
start
the
machine
process.
The safety function initiated by the Trojan T15-GD2 gate interlock meets the safety
performance
of SIL
CL 2 per IEC
62061:2005
and in
systems
Performance Levels
to PLd
per ISO13849has a Category 3 structure that can be used in systems requiring Performance Levels
up requiring
to PLd per ISO13849-1:2006.
Thisup
circuit
executes
a
1:2006. This circuit executes a Category 0 stop.
Category 0 stop.
NHP Safety Reference Guide > GSR Wiring Diagrams
- 04 -
3-6
Safeguarding Applications and Wiring Diagrams
Expansion Modules with Immediate and
Delayed Outputs
Safeguarding
Applications and Wiring Diagrams
800F, SI, EM , EMD, 100S, 700S:Expansion Modules with Immediate and Delayed Outputs
800F, SI, EM , EMD, 100S, 700S
+24V DC
Reset
800FM-F6MX10
S11 S21
E-Stops
800FM-MT44MX02L
S34
RESET
K6
K7
K8
K9
K10
K1
K2
K3
K4
K5
A1 13
X32 A1 13 23 33 43
23
0
AM
SI
440R-S12R2
S12 S22 Y32 L11
B1 B2 X32 A1 17 27 37 47
0
RANGE
9
8
A2 14
K1
24
L12 L11 A2 14 24 34 44
100SC43EJ14BC
K2
6 5
1
2
3
4
TIME
10
9
8
7 6
1
2
3
4
5
EMD
440R-EM4R2D
EM
440R-EM4R2
MM
7
100SC09EJ14BC
K5
K3
K4
L12 L11 A2 18 28 38 48
K6
K7
K9
K8
700SDCP310DZ24
with
199-FSMZ-1
K10
24VC DC Com
Circuit Status
Circuit
Status
The
e-stops
are reset. The safety outputs of the SI, EM and EMD
Fault Detection
Upon power-up, the SI, EM and EMD perform internal checks. The
The e-stops are reset. The safety outputs of the SI, EM and EMD are de-energized. All of the contactors are off. The EMD Range setting is 2 (10s
SI then looks for dual signals from the e-stop circuit. A crossfault
are
de-energized. All of the contactors are o. The EMD Range
OFF Delay) and the Time setting is 2 (20%), therefore the time delay is 2 seconds. The reset and monitoring circuit are connected to S34 for
on the e-stop circuit will be detected by the SI. With the E-stop
setting
is
2
(10s
OFF
Delay)
and
the
Time
setting
is
2
(20%),
monitored manual reaset.
signals made, closing the reset button places a voltage to the
therefore the time delay is 2 seconds. The reset and monitoring
S34 terminal. The external devices (K1 through K10) are checked
circuit
are connected
Operating
Principleto S34 for monitored manual reaset.
toModule
conrmwith
theyimmediate
are o. A fault
in K1and
through
K10
will cause their
Additional outputs are added to the SI (CI, DI, or DIS) relay by the EM (Expansion
outputs)
the EMD
(Expansion
Operating Principle
Module with Delayed outputs). A single wire, safety-rated signal from terminalnormally
L11 of theclosed
SI communicates
theremain
output open,
status to
L12this
of the
EMwill
andbe
contacts to
and
fault
Additional
EMD relays.outputs are added to the SI (CI, DI, or DIS) relay by the
detected by the SI.
STARTING:
Press Module
and release
theimmediate
reset buttonoutputs)
to energize
the
outputs
EM
(Expansion
with
and
the
EMD of the SI, EM and EMD. K1-K10 safety contactors or safety control relays
Ratings
energize to control
hazardous
portion
of theAmachine.
(Expansion
Modulethe
with
Delayed
outputs).
single wire, safetySTOPPING:
e-stop isL11
pressed,
theSIsafety
outputs of the
and EM turnThe
off immediately
and de-energize
- K6.
Four connection
seconds later,ofthe
safety function
initiated byK1the
series
the 800F
rated
signalWhen
fromanterminal
of the
communicates
theSIoutput
safety outputs of the EMD turn off and de-energize K7 through K10.
e-stop buttons meets the safety performance requirements of SIL
status to L12 of the EM and EMD relays.
CL 2 per IEC 62061:2005 and has a Category 3 structure that can
Fault Detection
STARTING:
Press and release the reset button to energize the
be used in systems requiring Performance Levels up to PLd per
Upon power-up,
SI,and
EM and
EMD
perform
internal
checks. The
SI then looks for dual signals from the e-stop circuit. A crossfault on the e-stop
outputs
of the SI,the
EM
EMD.
K1-K10
safety
contactors
or safety
ISO13849-1:2006.
The Category
rating requires
the redundant
circuit
will
be
detected
by
the
SI.
With
the
E-stop
signals
made,
closing
the
reset
button places a voltage
to the S343terminal.
The external
devices
control relays energize to control the hazardous portion of the
usage
of K1-K10
to de-energize
the machine
actuators,
(K1 through K10) are checked to confirm they are off. A fault in K1 through K10
will cause
their normally
closed contacts
to remain
open, andand
thisthe
machine.
fault will be detected by the SI.
contactors must be monitored by the safety system. This circuit
executes a Category 0 stop (coast to stop).
STOPPING: When an e-stop is pressed, the safety outputs of the SI
Ratings
and
EM turn o immediately and de-energize K1 - K6. Four seconds
The safety
function
initiated
series
connection
of the 800F e-stop
later,
the safety
outputs
of by
thethe
EMD
turn
o and de-energize
K7 buttons meets the safety performance requirements of SIL CL 2 per IEC
62061:2005
and has a Category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO13849-1:2006. The
through
K10.
Category 3 rating requires the redundant usage of K1-K10 to de-energize the machine actuators, and the contactors must be monitored by the
safety system. This circuit executes a Category 0 stop (coast to stop).
NHP Safety Reference Guide > GSR Wiring Diagrams
- 05 -
3-7
Safeguarding Applications and Wiring Diagrams
Safety Motion - Delayed Braking
Safety Applications and Wiring Diagrams
Safety Motion - Delayed Braking
800F, SI, EMD, Kinetix GuardMotion, RBM:
800F, SI, EMD, Kinetix GuardMotion, RBM
+24 VDC
E-Stop
800FM-MT44
800F-MX02S
S11 S21
S34
RESET
A1 13
L1 L2 L3
Reset
800FM-F6MX10
23
B1 B2 X32 A1 17
RANGE 0 1 TIME
0
9
8
AM
SI
440R-S12R2
S12 S22 Y32 L11
Kinetix 6000
with GuardMotion
2099-BMxx-s
MM
A2 14 24
7 6 54
2 10
3 9
8
7 6
1
27 37 47
R2
EN1+
R1
EN1-
2
3
4
5
EN2-
EMD
440R-EM4R2D
L12 L11
A2 18
Gate
Control
Power
Supply
R2
Safety
Monitor
Gate
Control
Circuit
EN2+
28 38 48
FBK1
FBK1
To PLC
FBK2
FBK2
R1
R1
R2
Gate
Control
Enable
Resistor Braking Module
COIL A1
U V W
CONSTAT41
K1
CONSTAT42
COIL A2
T1
100S-C
Contactor
U V W
M
24V DC Com
CircuitStatus
Status
Circuit
Fault Detection
The e-stop is reset. The outputs of the safety relay are open, and the motor is off. The EMD Range switch is set to 1 (1s OFF Delay) and the Time is
The
e-stop
is
reset.
The
outputs
of
the
safety
relay
are
open,
and
set to 10 (100%), therefore the off delay time is 1s.
Upon power-up, the Kinetix drive and SI and EMD perform
the motor is o. The EMD Range switch is set to 1 (1s OFF Delay)
internal checks. The SI then looks for dual signals from the e-stop.
and
the TimePrinciple
is set to 10 (100%), therefore the o delay time is 1s.
Operating
The e-stop has a self-monitoring contact, which opens if the
STARTING: Press
and release the reset button to energize the outputs of the SI.contact
This action
energizes
relays inWith
the Kinetix.
The signals
L11
block
falls o the
thefeedback
control panel.
the e-stop
Operating
Principle
signal from the SI to the EMD instructs the EMD to close its safety outputs, which
energizes
100S contactor
in the resistor
braking
module.
The
made,
the SIthe
checks
the S34 monitoring
circuit
when
the reset
STARTING:
Press
and release
reset
button
to energize
motor is now
connected
to thethe
drive.
When
the Kinetix
drive is the
enabled, an internal
signal
is sent back
to itschecks
controller
to inform
it
button
is pressed.
If these
are(not
OK,shown)
the output
energizes.
If
outputs
theisSI.
This action
energizes
feedback
relays
in the
that the of
drive
enabled.
The motor
is thenthe
controlled
by its
controller.
the delayed outputs of the SI fault to the ON state, the motor is
Kinetix.
TheWhen
L11 signal
fromis the
SI tothe
theimmediate
EMD instructs
theofEMD
STOPPING:
the e-stop
pressed,
outputs
the SI open and disable the drive. The motor begins to execute a stop. The L11
stopped by the SI immediate outputs. The fault will be detected
the SI to
the EMDwhich
turns off
and the EMD
beginscontactor
its timing cycle. After the time delay of the EMD expires, the delayed outputs open
tosignal
closefrom
its safety
outputs,
energizes
the 100S
by the S34 monitoring circuit on the next attempt to re-start
out the
100S contactor
themotor
Resistor
Module. This
inand
thedrop
resistor
braking
module.in
The
is Braking
now connected
to disconnects the motor from the drive and engages the braking resistors,
because K1 will remain energized. If the drive faults to an ON
which
rapidly
stop
the
motor.
the drive. When the Kinetix drive is enabled, an internal signal is
state, the motor will stop because it will be disconnected by K1.
sent back to its controller (not shown) to inform it that the drive is
This fault will be detected by the S34 monitoring circuit on the
Fault Detection
enabled.
The motor is then controlled by its controller.
next
attempt
to re-start
because
thee-stop.
Kinetix
feedback
circuit
will
Upon power-up, the Kinetix drive and SI and EMD perform internal checks. The
SI then
looks for
dual signals
from the
The
e-stop has
a
remain
o. Ifthe
K1e-stop
gets stuck
welded
closed,
STOPPING:
When
the e-stop
pressed,
the
immediate
outputs
self-monitoring
contact,
whichisopens
if the
contact
block falls
off theofcontrol panel.
With
signalsormade,
the SI
checksthe
themotor
S34 will stop
byoutput
the drive
and the
fault
will be
detected
monitoring
the
SI open and
disable
thereset
drive.button
The motor
begins
to execute
monitoring
circuit
when the
is pressed.
If these
checks aare OK, the
energizes.
If the
delayed
outputs
of thebySIthe
faultS34
to the
ON
circuit
the
TDmonitoring
on the next
attempt
re-start.
state,The
theL11
motor
is stopped
by the
immediate
outputs.
The
fault
will be detected
byof
the
S34
circuit
on theto
next
attempt to re-start
stop.
signal
from the
SI toSI the
EMD turns
o and
the
EMD
because
will remain
If thedelay
drive faults
an ON
state, the motor will stop because it will be disconnected by K1. This fault will be
begins
itsK1
timing
cycle.energized.
After the time
of thetoEMD
expires,
Ratings
detected
by outputs
the S34 monitoring
on the
to re-start
the
delayed
open and circuit
drop out
thenext
100Sattempt
contactor
in thebecause the Kinetix feedback circuit will remain off. If K1 gets stuck or
welded
closed,
the
motor
will
stop
by
the
drive
and
the
fault
will
be
detected
by
thesafety
S34 monitoring
circuit of the
TD on
the next
attempt
The
function initiated
by the
800F
e-stop
meetstothe safety
Resistor Braking Module. This disconnects the motor from the drive
re-start.
performance
requirements
of
SIL
CL3
per
IEC
62061:2005
and
and engages the braking resistors, which rapidly stop the motor.
has a Category 4 structure that can be used in systems requiring
Ratings
Performance Levels up to PLe per ISO13849-1:2006. This circuit
The safety function initiated by the 800F e-stop meets the safety performanceexecutes
requirements
of SIL CL31 per
IEC 62061:2005 and has a Category 4
a Category
stop.
structure that can be used in systems requiring Performance Levels up to PLe per ISO13849-1:2006. This circuit executes a Category 1 stop.
NHP Safety Reference Guide > GSR Wiring Diagrams
- 06 -
3-8
Safeguarding Applications and Wiring Diagrams
Light Curtain with Immediate and Delayed
Outputs
Safeguarding
Applications and Wiring Diagrams
Light Curtain with Immediate and Delayed Outputs
Safe 4, SI, EMD, 100S, 700S:
Safe 4, SI, EMD, 100S, 700S
+24V DC
Reset
800FM-F6MX10
Transmitter
Brown
1
2
4
Blue
Grey
Receiver
1
K1
Black
4
White
2
3
3
5
5
K2
K3
K4
K6
K5
Brown
Blue
Grey
POC Type 4 Safe 4
445L-P4S1200YD
Patchcord: 2 x 889D-F5AC-2
S11 S21
S34
RESET
A1 13
23
0
AM
SI
440R-S12R2
9
8
7
0
6 5
1
2
3
4
TIME
10
9
8
7 6
1
2
3
4
5
EMD
440R-EM4R2D
MM
S12 S22 Y32 L11
B1 B2 X32 A1 17 27 37 47
RANGE
A2 14
K1
24
100SC43EJ14BC
K2
L12 L11 A2 18 28 38 48
K5
K3
K4
700SCFB440EJC
K6
24VC DC Com
Circuit Status
Circuit
The
lightStatus
curtain is clear. The safety outputs of the SI and EMD are
Fault Detection
Upon power-up, the SI and EMD perform internal checks. The SI
The light curtain is clear. The safety outputs of the SI and EMD are de-energized. All of the contactors are off. The EMD Range setting is 2 (10s OFF
then looks for dual signals from the light curtain. A crossfault on
The reset and monitoring circuit are connected to S34 for monitored
de-energized.
All of the contactors are off. The EMD Range setting
Delay) and the Time setting is 2 (20%), therefore the time delay is 2 seconds.
ismanual
2 (10s reaset.
OFF Delay) and the Time setting is 2 (20%), therefore
the time delay is 2 seconds. The reset and monitoring circuit are
connected
S34 for monitored manual reaset.
OperatingtoPrinciple
the light curtain
will be detected by the light curtain. With the light curtain
signals made, closing the reset button places a voltage to the
Additional outputs are added to the SI relay by the EMD (Expansion Module with Delayed outputs). A single wire, safety-rated signal from terminal
S34 terminal. The external devices (K1 through K6) are checked
Operating Principle
L11 of the SI communicates the output status to L12 of the EMD relay.
to confirm
theysafety
are off.
A fault in
through
willenergize
cause their
Additional
outputs
added
to the
SI relay
by the EMD
STARTING: Press
and are
release
the reset
button
to energize
the outputs of the SI and
EMD. K1-K6
contactors
or K1
safety
controlK6
relays
normally
closed
contacts
to
remain
open,
and
this
fault
will be
to control the
hazardous
of the
machine.A single wire, safety(Expansion
Module
withportion
Delayed
outputs).
detected
by
the
SI.
STOPPING:
When
the
light
curtain
is
interrupted,
the
safety
outputs
of
the
SI
turn
off
immediately
and
de-energize
K1
K2.
Two
seconds
later,
the
rated signal from terminal L11 of the SI communicates the output
safety to
outputs
the EMD
EMD turn
off and de-energize K3 through K6.
status
L12 ofofthe
relay.
Ratings
The safety function initiated by the slight curtain meets the safety
STARTING:
Press and release the reset button to energize the
Fault Detection
Upon power-up,
SI and
EMD
perform
internal
checks.orThe
SI then looks forperformance
dual signals from
the light curtain.
crossfault
on the
light curtain
requirements
of SILA CL
3 per IEC
62061:2005
and
outputs
of the SIthe
and
EMD.
K1-K6
safety
contactors
safety
will be detected
by the light
curtain. the
Withhazardous
the light curtain
signals
made, closing
reset button
places a voltage
to the
terminal.
The requiring
hasthe
a Category
4 structure
that can
beS34
used
in systems
control
relays energize
to control
portion
of the
external devices (K1 through K6) are checked to confirm they are off. A fault inPerformance
K1 through K6Levels
will cause
their
normally
closed contacts toThe
remain
up to
PLe
per ISO13849-1:2006.
Category
machine.
open, and this fault will be detected by the SI.
4 rating requires the redundant usage of K1-K6 to de-energize
STOPPING: When the light curtain is interrupted, the safety
the machine actuators, and the contactors must be monitored by
outputs
Ratingsof the SI turn o immediately and de-energize K1 - K2.
the safety system. This circuit executes a Category 0 stop (coast to
The safety
function
by the
slight of
curtain
meetsturn
the safety
requirements of SIL CL 3 per IEC 62061:2005 and has a Category 4
Two
seconds
later, initiated
the safety
outputs
the EMD
o andperformance
destop).
structure K3
thatthrough
can be used
energize
K6. in systems requiring Performance Levels up to PLe per ISO13849-1:2006. The Category 4 rating requires the redundant
usage of K1-K6 to de-energize the machine actuators, and the contactors must be monitored by the safety system. This circuit executes a Category
0 stop (coast to stop).
NHP Safety Reference Guide > GSR Wiring Diagrams
- 07 -
3-9
Safeguarding Applications and Wiring Diagrams
Global E-Stop, Cascaded Safety Functions
Safeguarding Applications and Wiring Diagrams
Global E-Stop, Cascaded Safety Functions
800F, Trojan T15, MatGuard, SI, DI, DIS, 100S, 700S
800F, Trojan T15, MatGuard, SI, DI, DIS, 100S, 700S
+24V DC
Trojan T15-GD2
440K-T11287
K1
K2
E-Stop
800FM-MT44
800F-MX02S
Reset
800FMF6MX10
S11 S12 A1
RESET
Start
Start
Stop
S34 13
23
K3
K4
11
12
11
12
21
22
21
22
MatGuard
Safety Mat & Trim
440F-M2030BYNN
440F-T2030
Reset
800FMF6MX10
23 S34
AM
SI
MM
440R-S12R2
S21 S22 A2 L11 Y32 14
S11 S21 S12 S22 A1 A2 Y32 S34
8
24
7
0
1
2
3
4
LOGIC
8
6 5
DI
440R-D22R2
S32 S42 L11 L12 A2 14
24 Y32
7
E-Stop
800FM-MT44
800F-MX02S
K1
K2
100SC09EJ14BC
E-Stop
800FM-MT44
800F-MX02S
K3
K4
700SCFB440EJC
1
2
3
4
6 5
DIS
440R-D22S2
S32 S42 L11 L12 34 44 14
Aux.
to PLC
Aux.
to PLC
24 DC Com
Aux. to PLC
0
LOGIC
K6
Stop
S11 S12 S21 S22 A1 13
0
K5
24
K5
K5
K6 Start
K6
Stop
100SK5
C43EJ14BC
K6
Circuit
Status
Circuit
Status
the DI turns off the outputs of both the DI and DIS, while the SI is
The E-Stops are reset. The safety gate is closed. The safety mat is unoccupied. The
outputs of all
three controls
are off.or
K1-K6
are ready
be safety mat of
unaffected.
Pressing
the E-Stop
stepping
ontothe
Theenergized.
E-Stops are
reset.
The
safety
gate
is
closed.
The
safety
mat
is
The SI is set for monitored manual reset. The DI has logic set to 4 [(IN1 AND IN2) AND L12] with monitored manual reset because the
the
DIS
turns
o
the
outputs
of
the
DIS
only.
unoccupied.
The outputs
of access.
all three
are off.
K1-K6
are IN2) AND L12] with automatic reset as operators cannot get between the
safet gate provides
full body
Thecontrols
DIS has logic
set to
8 [(IN1AND
safety
matenergized.
and the hazard.
ready
to be
The SI is set for monitored manual reset.
Fault Detection
The DI has logic set to 4 [(IN1 AND IN2) AND L12] with monitored
Upon successful completion of internal checks on power up,
Operating
Principle
manual
reset because
the safet gate provides full body access.
The SI is connected to provide a Global E-Stop function. The DI and DIS safety relays
cascaded
from
the SIcheck
relay. their input circuits. Shorts from
the are
SI, DI
and DIS
relays
The DIS has logic set to 8 [(IN1AND IN2) AND L12] with automatic
the
inputs
to
power,
ground
or other inputs will be detected
reset
as operators
cannot
get between
safety mat
and the
STARTING:
Press the
reset button
for the SIthe
to energize
its outputs.
Then press the Start button energize K1 and K2 and send the L11 link signal to
immediately
and
will
prevent
energization
will
de-energize
the
hazard.
the DI Relay. This enables the DI relay. Press the reset button to energize to energize the DI relay. This sends a L11 link
signal to theorDIS
relay.
The
one
(K1 - K6) is stuck in an
outputs of the DIS energize automatically. Press the respective Start buttons to respective
energize the outputs.
contactorsIfK3,
K4,of
K5the
and contactors
K6.
Operating
Principle
STOPPING:
Pressing the E-Stop of the SI shuts down all three relays. Opening theactuated
interlocked
gate or
pressing
the E-Stop
of the
DI prevent
turns off the
state,
the
respective
control
will
startup because
outputs
of
both theto
DI provide
and DIS, while
the SIE-Stop
is unaffected.
Pressing
stepping
on the safety
matwill
of the
DIS turns
off the outputs of the
S34 feedback
loop
remain
open.
The SI is connected
a Global
function.
Thethe
DI E-Stop orthe
andDIS
DISonly.
safety relays are cascaded from the SI relay.
Ratings
Fault Detection
STARTING:
Press the reset button for the SI to energize its outputs.
The safety functions initiated by the e-stop devices and the two
Upon
successful
completion
internal checks
power
thethe
SI, DI and DIS relays check their input circuits. Shorts from the inputs to power,
Then
press
the Start
button of
energize
K1 andonK2
andup,
send
Trojan interlocks meet the safety performance requirements of
ground or other inputs will be detected immediately and will prevent energization or will de-energize the respective outputs. If one of the
L11 link signal to the DI Relay. This enables the DI relay. Press the
SIL startup
CL3 per
IEC 62061:2005
and have
Category
4 structures that
contactors (K1 - K6) is stuck in an actuated state, the respective control will prevent
because
the S34 feedback
loop will
remain open.
reset button to energize to energize the DI relay. This sends a
can be used in systems requiring Performance Levels up to PLe
L11Ratings
link signal to the DIS relay. The outputs of the DIS energize
per ISO13849-1:2006. The safety function initiated by the safety
automatically.
Press the
respective
Start devices
buttons
tothe
energize
theinterlocksmat
The safety functions
initiated
by the e-stop
and
two Trojan
meetmeets
the safety
requirements
of SIL CL3 perof
IECSIL CL2 per
theperformance
safety performance
requirements
62061:2005
Category
Performance
Levels
to PLe
per ISO13849-1:2006.
safety
contactors
K3,and
K4,have
K5 and
K6. 4 structures that can be used in systems requiring
IEC
62061:2005
anduphas
a Category
3 structureThe
that
can be used
function initiated by the safety mat meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that
in systems
requiring
Performance
Levels up to PLd per ISO13849STOPPING:
Pressing
therequiring
E-Stop of
the SI shuts
down
three
can be used
in systems
Performance
Levels
up toall
PLd
per ISO13849-1:2006.
This circuit
executes
a Category 0 stop.
1:2006. This circuit executes a Category 0 stop.
relays. Opening the interlocked gate or pressing the E-Stop of
- 08 R
NHP Safety Reference Guide > GSR Wiring Diagrams
3-10
Safeguarding Applications and Wiring Diagrams
Safety Applications and Wiring Diagrams
GuardShield, 800Z
GuardShield, 800Z
GuardShield, 800Z, MSR35H, SI,100S:
+24V DC
Receiver
2 Brown
6 Pink
5 Grey
Blue
Blue 3
7
GuardShield
440L-P4J0640YD
889D-F4AC-2 889D-F8AC-2
Brown
White
Black
Transmitter
Brown 1
800Z-GL3Q5 S1
889N-F5AE-6F
L1 L2 L3
S11 S12 A1
RESET
AM
Grey
Blue
24VDC
Reset
800FM-F6MX10
To PLC
S21 S11 S34 Y41 A1 Y2
Brown
White
Black
Two-Hand
Control
GuardShield, 800Z, MSR35H, SI,100S
SI
440R-S12R2
MSR35H
440R-D23202
S12 S22 A2 14 24 32
S34 13
0
K1
MM
K2
S21 S22 A2 L11 Y32 14
800Z-GL3Q5 S2
889N-F5AE-6F
23
24
M
Grey
Blue
To PLC
K1
24V DC Com
K2
100S-C09EJ14BC
Fault Detection
Circuit Status
Circuit Status
Upon
power
GuardShield,
MSR35H
andfactory
SI perform
The
handsare
arenot
not
buttons.
Theoperator’s
operator's hands
onon
thethe
twotwo
800Z800Z
palmpalm
buttons.
The outputs of the
MSR35H
are up,
off. the
The800Z,
light curtain
is configured
with the
default
settings
(Guard
only mode)
unobstructed.
outputs of the SIinternal
safety relay
are off.After
The passing
motor is off
and ready
to run.
checks.
internal
checks,
the MSR35H waits
The
outputs
of the
MSR35H
are o.and
Theislight
curtain isThe
congured
The light
curtain isdefault
protecting
one portion
the machine.
An is
operator, using for
two-hand
control
is accessing
a different
portion
of the
machine
a change
of state
of its inputs.
Faults
(opens
and
shorts) at the
with
the factory
settings
(Guardofonly
mode) and
and has full view
of his
or her of
area.
inputs will be detected by the MSR35H and prevent the outputs
unobstructed.
The
outputs
the SI safety relay are off. The motor
fro being energized. the GuardShield light curtain also performs
is off and ready to run.
Operating Principle
checks on its OSSD output signals for crossfaults, shorts and
STARTING:
Press the
Reset buttonone
to energize
output
of the SI.AnThe operator places both hands on the 800Z buttons simultaneously (within
The
light curtain
is protecting
portionthe
of the
machine.
opens. The
SI looks for dual signals at its inputs. It then checks
0.5s).
The
outputs
of
the
MSR35H
(terminals
14,
24)
and
energize
the
100S
contactors,
which start the motor.
operator, using two-hand control is accessing a dierent portion of
the
status
of
theMSR35H
contactors.
If one
contactors
failsK1
inand
theK2
actuated
STOPPING:
both
the 800Z palm buttons causes the outputs of the
to turn
off, which
drops out
the
machineRemoving
and has one
full or
view
ofhands
his orfrom
her area.
state, of
the
other
contactor
stop
motor.
Theturns
SI will
and stops the motor. Obstructing the light curtain de-energizes the safety outputs
the
SI, which
in turn will
drops
out the
K1 and
K2 and
thedetect
if onehas
of their
the contactors
are
stuck
in theThe
energized
position,
motor off. Clearing
the light curtain does not restart the motor, even if the operator
hands on the
palm
buttons.
reset button
must and
Operating
Principle
be pressed after the light curtain is cleared.
prevents restart.
STARTING: Press the Reset button to energize the output of
the SI. The operator places both hands on the 800Z buttons
Ratings
Fault Detection
simultaneously (within 0.5s). The outputs of the MSR35H
Upon power up, the 800Z, GuardShield, MSR35H and SI perform internal checks.
passing
internal
checks, the
MSR35H
waits for alight
change
of
TheAfter
safety
function
provided
by the
GuardShield
curtain
(terminals
14, 24) Faults
and energize
theshorts)
100S at
contactors,
which
start by the MSR35H and prevent the outputs fro being energized. the
state of its inputs.
(opens and
the inputs will
be detected
meets the safety performance requirements of SIL CL 3 per IEC
the
motor. light curtain also performs checks on its OSSD output signals for crossfaults, shorts and opens. The SI looks for dual signals at its
GuardShield
62061:2005 and has a Category 4 structure that can be used in
inputs. It then checks the status of the contactors. If one contactors fails in the actuated state, the other contactor will stop the motor. The SI will
systems requiring Performance Levels up to PLe per ISO13849STOPPING:
Removing one or both hands from the 800Z palm
detect if one of the contactors are stuck in the energized position, and prevents restart.
1:2006. This circuit executes a Category 0 stop.
buttons causes the outputs of the MSR35H to turn off, which
drops
out
K1
and
K2
and
stops
the
motor.
Obstructing
the
light
Ratings
curtain
de-energizes
the safety
outputs
of thelight
SI, which
turnthe safety performance requirements of SIL CL 3 per IEC 62061:2005 and has
The safety
function provided
by the
GuardShield
curtain in
meets
drops
out K1
and K2 and
motor
off. Clearing
light
a Category
4 structure
that turns
can bethe
used
in systems
requiringthe
Performance
Levels up to PLe per ISO13849-1:2006. This circuit executes a Category
0 stop. does not restart the motor, even if the operator has their
curtain
hands on the palm buttons. The reset button must be pressed
after the light curtain is cleared.
NHP Safety Reference Guide > GSR Wiring Diagrams
- 09 -
3-11
Safeguarding Applications and Wiring Diagrams
Interlock Switch - Multiple Gate Access
Safety Applications and Wiring Diagrams
Interlock Switch - Multiple Gate Access
Trojan T15, Elf-GD2, 800F, CI, 100S:
Trojan T15, Elf-GD2, 800F, CI, 100S
+24V DC
Trojan T15-GD2
440K-T11287
ELF-GD2
440K-E33046
11
12
11
12
21
22
21
22
Start
800FMF3MX10
E-stop
800FMMT44MX02L
Machine control system
can replace this circuit
arrangement.
K2
Stop
800FME4MX01
L1 L2 L3
S11 S12 A1
Output
PLC
Input
1756-IB16 Processor 1756-OW16I
1769-OW8
1769-IQ16
1746-OW4
1746-IB16
1734-OW2
1734-IB4
1793-OW4
1793-IB6
K1
RESET
S34
13
23
33
41
0
K2
AM
CI
440R-S13R2
K1
MM
S21 S22 A2 L11 Y32 14
K1
24
34
K2 100S-
42
M
C09EJ14BC
24V DC Com
Circuit
Status
Circuit
Status
STOPPING: Opening any one of the safety gates or pressing the
e-stop causes the motor to turn o. Closing the gate or releasing
the e-stop does not cause the motor to start due to the start-stop
interlocking circuit. To restart the motor, close the safety gate or
release
the
Thencontact
pressbeing
the start
button.
With 2NC + 1NO interlocks, a potential exists for the gate to be slightly open which
results
in e-stop.
the auxiliary
closed
and the safety
Operating
Principle
being open.
The machine cannot start and the PLC does not know which gate is open. By sending the second safety channel through the PLC,
Fault Detection
the2NC
machine
control
system knows
which door
is open,
when
With
+ 1NO
interlocks,
a potential
exists
for the
gatethe
tosafety
be system is off due to a gate that may be slightly open. The infinite
simultaneity feature of safety relays like the CI allow enough time for the PLC toIfprocess
all fails
the gates
close theclosed,
second channel
of the
safety
the PLC
withand
its output
the safety
relay
will detect
slightly open which results in the auxiliary contact being closed
relay without creating a lockout condition.
the
dierence
between
the
safety
gate
and
the
PLC
and
stop the
and the safety being open. The machine cannot start and the PLC
motor.
A
single
fault
(open
or
short)
across
one
of
the
interlocks
does
not
know
which
gate
is
open.
By
sending
the
second
safety
When a safety gate is opened, the interlock opens Ch1 directly to the safety relay and opens Ch2 which is connected to the input of a PLC. The
detected
byor
the
safety
relay
and
theare
motor
PLC must
then open
the machine
safety relay.
The logic
in the knows
PLC must open thewill
Ch2be
signal
if any one
more
of the
safety
gates
open will
and be turned
channel
through
the Ch2
PLC,ofthe
control
system
o.
The
motor
will
remain
off
until
the
fault
is
corrected
or power
must
only
close
the
Ch2
circuit
when
all
of
the
safety
gates
and
e-stop
are
closed.
The
PLC
can
also
use
the
information
on
the
inputs
on
which door is open, when the safety system is off due to a gate
similar open.
device.The
Theinnite
auxiliary
signal (Y32) from
the CIofmust
be an input
to the PLC.
This contactor
PLC program
only
closeON
its output
when will
is cycled.
If either
K1must
or K2
sticks
- the motor
thatPanelView
may be or
slightly
simultaneity
feature
safety
all the safety inputs are closed and the auxiliary signal from the CI is closed. Thisstop
allows
PLC to indirectly
that contactor,
its own output
onthe
command
due toconfirm
the other
butis the SI cannot
relays
like the CI allow enough time for the PLC to process all the
working properly.
be
reset
(thus
the
fault
is
revealed
to
the
operator).
A single
gates and close the second channel of the safety relay without
fault
detected
on
the
SI
input
circuits
will
result
in
the
lock-out
creating
a
lockout
condition.
STARTING: Channel 1 input (S11/S12) of the SI is satisfied. Using isolated relay contacts in its output module, the PLC closes the second safety
of the
system
to a safe state (OFF) at the next operation of the
channel (21/22 of the SI). The safety outputs of the SI close. Press the Start button
to start
the motor.
When
a safetyOpening
gate isany
opened,
interlock
Ch1 directly
tocauses the
safety
gate
or e-stop
device.
Contactors
K1 the
ande-stop
K2 are
controlled
STOPPING:
one of the
the safety
gatesopens
or pressing
the e-stop
motor
to turn
off. Closing
the gate
or releasing
does
thenot
safety
relay
and opens
is connected
to the circuit.
input of
cause
the motor
to startCh2
duewhich
to the start-stop
interlocking
To restartby
thethe
motor,
close
the safety
gate or release
e-stop. Then
pressthe
safety
system.
Contactor
K2 is the
controlled
by both
the The
start PLC
button.
a PLC.
must then open Ch2 of the safety relay. The logic
machine control system and the safety system. This increases the
in the PLC must open the Ch2 signal if any one or more of the
probability of performance of the safety function because K1 is
Fault
Detection
safety
gates
are open and must only close the Ch2 circuit when
signicantly less likely to weld at the same time as K2 due to the
If the
fails with
output
closed,
safetyThe
relayPLC
will can
detect
theuse
difference between the safety gate and the PLC and stop the motor. A single
all of
thePLC
safety
gatesitsand
e-stop
arethe
closed.
also
diversity of expected wear out times.
(open or short) across one of the interlocks will be detected by the safety relay and the motor will be turned off. The motor will remain off
thefault
information
on the inputs on PanelView or similar device. The
until the fault is corrected or power is cycled. If either contactor K1 or K2 sticks ON
- the motor will stop on command due to the other contactor,
Ratings
auxiliary
(Y32)
the CI
an input
PLC. This
but thesignal
SI cannot
be from
reset (thus
themust
fault be
is revealed
to to
thethe
operator).
A single fault detected on the SI input circuits will result in the lock-out of
PLCthe
program
must
only
all the
safety
inputs
The
safety
functionK1initiated
bycontrolled
the Trojan
and ELF-GD2 safety
system to
a safe
stateclose
(OFF)its
at output
the nextwhen
operation
of the
safety
gate or e-stop
device.
Contactors
and K2 are
by T15
the safety
aresystem.
closed Contactor
and the auxiliary
signalby
from
is closed.
Thissystem
allowsand thegate
and
the 800F
meets
the safety of
performance
K2 is controlled
boththe
theCI
machine
control
safetyinterlocks
system. This
increases
the e-stop
probability
of performance
safety
function because
is significantly
less likely
to weldproperly.
at the same time
as K2 due to the
expected
wear out times.
thethe
PLC
to indirectly
conrm K1
that
its own output
is working
requirements
ofdiversity
SIL CL2ofper
IEC 62061:2005
and has a Category
3 structure that can be used in systems requiring Performance
STARTING:
RatingsChannel 1 input (S11/S12) of the SI is satised. Using
Levels up to PLd per ISO13849-1:2006. This circuit executes a
isolated
relay
contacts
in itsby
output
module,
theELF-GD2
PLC closes
The safety
function
initiated
the Trojan
T15 and
safetythe
gate interlocks
and the 800F
e-stop meets the safety performance
Category
0 stop.
requirements
of SIL CL2(21/22
per IEC of
62061:2005
and safety
has a Category
structure
second
safety channel
the SI). The
outputs3 of
the that can be used in systems requiring Performance Levels up to PLd
per ISO13849-1:2006.
circuitto
executes
a Category
SI close.
Press the StartThis
button
start the
motor. 0 stop.
Circuit shown with the safety gates closed and e-stop released. The CI safety relay is de-energized. The motor is off. The monitoring circuit is
Circuit
showntowith
theautomatic
safety gates
e-stop released. The
connected
S34 for
reset closed
of the CIand
relay.
CI safety relay is de-energized. The motor is off. The monitoring
Operating
Principle
circuit
is connected
to S34 for automatic reset of the CI relay.
- 10 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-12
Safeguarding Applications and Wiring Diagrams
SI, DIS, SensaGuard, E-Stops, PF525 with Contactor
Safeguarding Applications and Wiring Diagrams
SensaGuard Integrated Latch, E-Stop, SI, DI, 100S and PowerFlex 525:
SI, DIS, SensaGuard, E-Stops, PF525 with Contactor
Grey Red
Pink
Yellow
K1
L1 L2 L3
Grey
Pink
PowerFlex R S T
525
Reset
White
Blue
White
Blue
Blue
White
Grey Red
Pink Yellow
E-Stops
800FM-MT44
800F-MX02S
Brown
Brown
Red
Yellow
SensaGuard
Integrated
Latches
440N-Z21SS3PA
Brown
SensaGuard Integrated Latch, E-Stop, SI, DI, 100S and PowerFlex 525
24V DC
1 Stop
2 Start
Gate
Open
4 Gnd
Gate
Open
S12 S22 A1
RESET
S34 13 23
0
LOGIC
AM
Gate
Open
S12 S22 S11 S21 S42 S32 A1 S34
SI
MM
440R-S12R2
S11 S21 A2 L11 Y32 14 24
8
DIS
440R-D22S2
7
6 5
0
1
2
3
Gate control
power supply
A1
4
Gate control
circuit
L11 L12 A2 34 44 14 24 Y32
S1
S2
Status
To PLC
K1
Status
To PLC
UV W
K1
100S-C09EJ14BC
24V DC Com
M
Circuit Status
The DIS
Logic is set to 4: [(IN1 AND IN2) AND L12] with monitored reset. The SI Fault
is set for
automatic reset. The SensaGuard Intgreated Latch
Detection
Circuit
Status
interlocks are connected in series to the SI. The two e-stops are connected to inputs 1 (S12 and S22) and 2 (S32 and S42) of the DIS. The three
Upon
completion
of internal
checks
the SI, DIS,
Thegates,
DIS Logic
is setbytothe
4:SensaGuard
[(IN1 AND Intergrated
IN2) AND L12]
monitored
monitored
Latch with
interlocks,
are closed and
safetysuccessful
outputs of the
SI (L11, 13/14
and 23/24)
are ON.byBoth
SensaGuard
and PowerFlex
525525
drive,
the
drive awaits
reset.
Theare
SI isreleased.
set for automatic
reset.
The(14,
SensaGuard
Intgreated
e-stops
The DIS safety
outputs
24, 34 and 44)
are off and waiting
for a reset signal.
The PowerFlex
drive
is powered
but the closure
disabled.
Contactor
K1 is de-energized.
Thetomotor
is off.
of the safety outputs. If the DIS fails, the drive will not energize
Latch
interlocks
are connected
in series
the SI.
The two
the motor, and the fault will be detected by non-operation of the
e-stops are connected to inputs 1 (S12 and S22) and 2 (S32 and
Operating
motor. The DIS generates test pulses through the e-stop circuits
S42)
of the DIS.Principle
The three gates, monitored by the SensaGuard
STARTING: Press the Reset button to turn on the DIS safety outputs. This energizes K1, enables the drive and also applies power to the Start and
to detect cross channel shorts and shorts to power and ground.
Intergrated
Latch interlocks, are closed and safety outputs of
Stop buttons. Press the Start buttons to start the motor.
SensaGuard
interlocks
test pulses
their
theSTOPPING:
SI (L11, 13/14
and
23/24)
are
ON.
Both
e-stops
are
released.
Press the Stop button to stop the motor for production stops. PressThe
either
e-stop or open
any safetygenerate
gate to initiate
a safety on
stop;
the outputs
to detect cross channel shorts and shorts to power and ground.
Themotor
DIS safety
outputs
coasts to
a stop. (14, 24, 34 and 44) are o and waiting for
A fault in the safe-circuit of the drive will be detected by the drive
a reset signal. The PowerFlex 525 drive is powered but disabled.
and issue a safety stop. The mechanically linked contacts of K1 are
Contactor
K1 is de-energized. The motor is off.
Fault Detection
Upon successful completion of internal checks by the SI, DIS, SensaGuard and PowerFlex
525by
drive,
awaits the
closure
of the safety
monitored
thethe
DISdrive
to ensure
that
the contactor
is de-energized
Operating
outputs. IfPrinciple
the DIS fails, the drive will not energize the motor, and the fault will be
detected
by non-operation
the motor. The DIS generates test
before
resetting
the safetyofsystem.
pulses through
to to
detect
channel
shorts and shorts to power and ground. The SensaGuard interlocks generate test pulses
STARTING:
Press the
thee-stop
Resetcircuits
button
turncross
on the
DIS safety
on their outputs to detect cross channel shorts and shorts to power and ground.
A fault in the safe-circuit of the drive will be detected by the
Ratings
outputs. This energizes K1, enables the drive and also applies
drive and issue a safety stop. The mechanically linked contacts of K1 are monitored by the DIS to ensure that the contactor is de-energized before
The safety functions initiated by the SensaGuard Integrated
power
to the
Stop buttons. Press the Start buttons to
resetting
theStart
safetyand
system.
Latch interlocks and the e-stop meets the safety performance
start the motor.
requirements of SIL CL3 per IEC 62061:2005 and a Category 4
Ratings
STOPPING: Press the Stop button to stop the motor for production
structure
can
usedperformance
in systemsrequirements
requiring Performance
The safety functions initiated by the SensaGuard Integrated Latch interlocks and
the e-stopthat
meets
thebe
safety
of SIL CL3
stops.
Press
either e-stop
or open4any
safetythat
gate
a
per IEC
62061:2005
and a Category
structure
canto
beinitiate
used in systems
requiring
Performance
up 13849-1:
to PLe per 2006.
ISO 13849-1:
2006. The
Levels
up to PLe Levels
per ISO
The circuit
executes a
safety
stop;
the motor
coasts
to a stop.
circuit
executes
a Category
0 stop.
Category 0 stop.
- 11-
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-13
Safeguarding Applications and Wiring Diagrams
SensaGuard
Safeguarding Applications andWiring Diagrams
SensaGuard
SensaGuard, CI, 800F, 100S:
SensaGuard, CI, 800F, 100S
+24V DC
Shown Open
SensaGuard
2 3 7 1 4 8 56
SensaGuard
2 3 7 1 4 8 56
18mm Cylindrical
Plastic SensaGuard
440N-Z21S26H
Cordset
889D-F8AB-2
K1
Start
800FMF3MX10
Brown
Green
Blue
White (Aux)
Yellow
Red
Gray (OSSD1)
Pink (OSSD2)
2 3 7 1 4 8 5 6
K2
Stop
800FME4MX01
Machine Control
PLC Input
(1756-IB16
1769-IQ16
1746-IB16
1792-IB16 I0
1734-IB4 I1
1793-IB6 I2
or similar) I3
A1 S11 S12 L11 13
RESET
Auxiliary
Signals
to Machine
Control
System
RP
23
33
L1 L2 L3
41
K1
0
AM
CI
MM
440R-S13R2
S21 S22 S34 A2 14
24
44
42
K2
M
Com
K1
24V DC Com
K2 100S-C43EJ14BC
Fault Detection
Circuit Status
Upon successful completion of internal checks on power up, the
The
first and
third gates are closed. The second gate is open.
Circuit
Status
interlocks
check
at pins
4 and
If the actuator
The
CIfirst
safety
S12 and
S22 inputs
are open
to the
The
and relay
third gates
are closed.
The second
gate due
is open.
The open
CI safety relaySensaGuard
S12 and S22 inputs
are open
duefor
to24V
the open
gate,
and 8.
therefore,
is within
range,
the the
SensaGuard
will
activate
OSSD
outputs. The
gate,
therefore,
CI safety
outputscontrol
are open.
Thea machine
the and
CI safety
outputs the
are open.
The machine
PLC has
24V auxiliary signal
at terminal
I1 from
second gate
because
theits
gate
is open.
The first
and
third
auxiliary
signalssignal
are off,at
asterminal
their gatesI1are
closed.
has anoutputs
auxiliaryperform
signal from
the CI indicating
that for
the short
safety circuits to
continuous
checking
control
PLC
has
a 24V
auxiliary
from
the The PLC alsoOSSD
systemgate
is notbecause
ready. The
motor
24V, ground and crossfaults. Upon detection of a fault, the OSSD
second
the
gateisisoff.
open.
outputs turn off. The CI also performs internal checks on powerup.
The
first and third
auxiliary signals are off, as their gates are
Operating
Principle
It then checks for input signals. If OK, the CI checks the K1/K2/
closed.
The PLC
alsothe
has
an auxiliary
signal
CI CI.
indicating
STARTING:
Closing
second
gate satisfies
thefrom
inputthe
of the
The CI verifies that both K1 and K2 contactors are off and energizes its safety
S34 monitoring circuit to determine whether both contactors are
outptus.
Pressing
the start
button
energizes
the motor.
that
the safety
system
is not
ready.
The motor
is off.The Stop/Start circuit is not part of the safety system and can be replaced by the machine
off. If one of the contactors gets stuck on, the other contactor will
control system (e.g., a PLC).
de-energize
thesystem.
motor,Opening
and theany
CI will
detect
the next
Operating
STOPPING:Principle
Press the Stop button to turn the motor off, without affecting the status
of the safety
of the
gatesthe
willfault
causeatthe
safety system
to stop
thesecond
motor. gate satises the input of the CI.
attempt to start the motor. The contactors have mechanically linked
STARTING:
Closing
the
auxiliary contacts to help ensure fault detection of the contactors.
The CI veries that both K1 and K2 contactors are o and energizes
Fault Detection
itsUpon
safety
outputs. Pressing the start button energizes the motor.
Ratingscheck for 24V at pins 4 and 8. If the actuator is within
successful completion of internal checks on power up, the SensaGuard interlocks
The
Stop/Start
circuit iswill
not
part of
safety
system
and can
be perform continuous checking for short circuits to 24V, ground and
range,
the SensaGuard
activate
its the
OSSD
outputs.
The OSSD
outputs
This safety performance of this circuit meets the requirements
replaced
by the
machine
system
(e.g.,
a PLC).
crossfaults.
Upon
detectioncontrol
of a fault,
the OSSD
outputs
turn off. The CI also performs internal checks on powerup. It then checks for input
of SIL CL 3 per IEC 62061:2005 and has Category 4 structure and
signals. If OK, the CI checks the K1/K2/S34 monitoring circuit to determine whether both contactors are off. If one of the contactors gets stuck
can
be used
in systems
requiring
Performance
Levels
STOPPING:
Press
the Stop
to turn
the motor
o,CIwithout
on, the other
contactor
will button
de-energize
the motor,
and the
will detect the fault
at the
next attempt
to start
the motor.
The contactors
have up to PLe
per ISO 13849-1:2006. The SensaGuard interlocks are designed
aecting
the status
the safety
system.
Opening
anydetection
of the gates
mechanically
linkedofauxiliary
contacts
to help
ensure fault
of the contactors.
to meet Category 4 when connected in series. The CI is rated to
will cause the safety system to stop the motor.
Ratings
Category 4. The design and connection of the contactors meets
This safety performance of this circuit meets the requirements of SIL CL 3 per IECcategory
62061:2005
Category
4 structure
and can
be used
in
4. and
Thishas
example
circuit
performs
a Stop
Category
0
systems requiring Performance Levels up to PLe per ISO 13849-1:2006. The SensaGuard
interlocks
arestop).
designed to meet Category 4 when
function
(coast to
connected in series. The CI is rated to Category 4. The design and connection of the contactors meets category 4. This example circuit performs a
Stop Category 0 function (coast to stop).
- 12 NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-14
Safeguarding Applications and Wiring Diagrams
Light Curtain - Point of Operation Control
Safety Applications and Wiring Diagrams
Light Curtain - Point of Operation Control
GuardShield, 800F, DI, 100S:
GuardShield, 800F, DI, 100S
+24V DC
Transmitter
1
Brown
Blue
3
Receiver
2
8
4
6
5
1
7
3
Brown
Red
Yellow
Pink
Grey
White
Blue
Start
800FMF3MX10
Restart (not used)
EDM (not used)
Machine control system
can replace this circuit
arrangement.
K1
K2
Stop
800FME4MX01
Aux Signal
to PLC
Green
440L-P4KL0960YD
889D-F4AC-2
889D-F8AC-2
L1L2 L3
S11 S21 S12 S22
A1
13
23 S34
K1
0
LOGIC
1
2
3
4
8
DI
7
6 5
440R-D22R2
S32 S42 L11 L12 A2
K2
14
24 Y32
Aux Signal
to PLC
K1
M
K2 100S-C43EJ14BC
24V DC Com
Circuit
Status
Circuit
Status
The DI will detect the faulted contactor and will not allow the
The
lgihtcurtain
curtain isisclear
thethe
motor
is ready
to run.toThe
DIThe
RelayDIis set for Logic
5 (L12toorrestart
IN1 or IN2
with
Automatic
Reset).
motor
until
the
fault is corrected.
Contactors K1 and K2
The
light
clearand
and
motor
is ready
run.
are
controlled
by
the
safety
system.
Contactor
K2 is controlled by
Relay is set for Logic 5 (L12 or IN1 or IN2 with Automatic Reset).
both the machine control system and the safety system diversity
Operating Principle
Operating
STARTING:Principle
Press the Start button to energize contactors K2. The motor starts with
two normally
contacts of K1 and K2 holding circuit
of the
expected
wearopen
out times.
energized.
STARTING: Press the Start button to energize contactors K2. The
Ratings
STOPPING: Obstructing the light curtain de-energizes the safety outputs of the DI
which in turn drops out K1 and K2. The contactors disconnect
motor
starts with the two normally open contacts of K1 and K2
the motor from its power source, and the motor coasts to a stop. Clearing the obstruction in the light curtain does not cause the motor to
The
safety function initiated by the GuardShield light curtain
holding circuit energized.
meets the safety performance requirements of SIL CL 3 per IEC
Fault Detection
STOPPING:
Obstructing the light curtain de-energizes the
62061:2005
and has
a Category
4 structure
that can
Upon successful completion of internal checks on power up, the GuardShield light
curtain energizes
its outputs
with no
objects present.
Thebe used in
safety
outputs
of the DI which in turn drops out K1 and K2. The
upthe
toK1
PLe
per
successful completion of internal checks, the DI checks the signals from the lightsystems
curtain. Ifrequiring
OK, the DIPerformance
then checks theLevels
status of
and
K2ISO13849contactors
the
from
its power
and
1:2006. This
Category
0 stop.
contactors.disconnect
If either K1 or
K2motor
fails in the
actuated
state,source,
the other
contactor will disconnect
thecircuit
motor. executes
The DI willadetect
the faulted
contactor and
thewill
motor
coasts
to a stop.
Clearing
thefault
obstruction
in Contactors
the light K1 and K2 are controlled by the safety system. Contactor K2 is controlled
not allow
the motor
to restart
until the
is corrected.
by both
the machine
control
system and
the safety system. diversity of expected wear out times.
curtain
does
not cause
the motor
to restart.
Fault Detection
Ratings
Upon
successful
completion
checks
power
up,the
thesafety performance requirements of SIL CL 3 per IEC 62061:2005 and has a
The safety
function
initiated by of
theinternal
GuardShield
lighton
curtain
meets
Category 4 structure
that can
be used inits
systems
requiring
Performance
GuardShield
light curtain
energizes
outputs
with no
objects Levels up to PLe per ISO13849-1:2006. This circuit executes a Category 0
stop. The successful completion of internal checks, the DI
present.
checks the signals from the light curtain. If OK, the DI then checks
the status of the K1 and K2 contactors. If either K1 or K2 fails in
the actuated state, the other contactor will disconnect the motor.
- 13 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-15
Safeguarding Applications and Wiring Diagrams
Two Light Curtains - Point of Operation Control
Safety Applications and Wiring Diagrams
GuardShield, 800F, DI, 100S:
Two Light Curtains - Point of Operation Control
GuardShield, 800F, DI, 100S
+24V DC
Transmitter
Brown
1
Blue 3
Start
800FMF3MX10
Receiver
Brown
2
Pink
6
Grey
5
Blue
7
3 Green
Machine control system
can replace this circuit
arrangement.
K1
K2
Stop
800FME4MX01
440L-P4KL0960YD
889D-F4AC-2
889D-F8AC-2
S11 S21 S12 S22
A1
13
23 S34
L1L2 L3
0
LOGIC
Transmitter
Brown
1
Blue 3
Receiver
Brown
2
Pink
6
Grey
5
Blue
7
3 Green
1
2
3
4
8
DI
7
6 5
440R-D22R2
S32 S42 L11 L12 A2
K1
14
24 Y32
K2
Aux Signal
to PLC
440L-P4KL0960YD
889D-F4AC-2
889D-F8AC-2
K1
M
K2
100S-C43EJ14BC
24V DC Com
Circuit
Status
Circuit
Status
contactors. If either K1 or K2 fails in the actuated state, the other
The light curtains are configured with the factory default settings (Guard only mode)
and is unobstructed.
Thethe
outputs
of the
safety
relaydetect
are the faulted
contactor
will disconnect
motor.
The
DI will
The
light curtains are congured with the factory default settings
closed, and the motor is ready to run. The DI Relay is set for Logic 6: [(IN1 AND IN2)
OR L12] with
Automatic
Reset.the motor to restart until the fault is
contactor
and
will
not
allow
(Guard only mode) and is unobstructed. The outputs of the safety
corrected.
relay
are closed,
and the motor is ready to run. The DI Relay is set
Operating
Principle
forSTARTING:
Logic 6: [(IN1
AND
IN2)
OR
L12]
with
Automatic
Reset.
Press the Start button to energize contactor K2. The motor starts with
the two normally
open
of K1 andby
K2the
holding
thesystem.
circuit
Contactors
K1 and
K2 contacts
are controlled
safety
energized.
Contactor K2 is controlled by both the machine control
Operating
STOPPING:Principle
Obstructing either light curtain deenergizes the safety outputs of the DI which in turn drops out K1 and K2. The contactors disconnect
system and the safety system. This increases the probability of
the motorPress
from its
power
and
motor coasts
to a stop.
STARTING:
the
Startsource,
button
tothe
energize
contactor
K2.Clearing
The the obstruction in either light curtain does not cause the motor to
performance
of the
safety function because K1 is signicantly
energize
(the
Start
button
must
be
pressed).
The
motor
can
also
be
turned
off
by
pressing the stop
button.
motor starts with the two normally open contacts of K1 and K2
less likely to weld at the same time as K2 due to the diversity of
holding the circuit energized.
expected wear out times.
Fault Detection
Upon successful
completion
of internal
checks on
power up, the
GuardShield light curtains energize their outputs with no objects present. If a
STOPPING:
Obstructing
either
light curtain
deenergizes
the
Ratings
crossfault
is detected,
thewhich
GuardShield
light
curtain
a lockout
safety
outputs
of the DI
in turn
drops
outgoes
K1 to
and
K2. Thestate with its outputs off. After successful completion of internal checks, the
DI checks the signals from the light curtains. If OK, the DI then checks the statusThe
of the
K1 and
K2 contactors.
If either
K1 or
K2 fails in thelight
actuated
safety
function
initiated
by the
GuardShield
curtains
contactors disconnect the motor from its power source, and the
state, the other contactor will disconnect the motor. The DI will detect the faulted
contactor
and willperformance
not allow the motor
to restart until
theCL
fault
meets
the
safety
requirements
of
SIL
3 per IEC
motor
coasts to a stop. Clearing the obstruction in either light
is corrected.
62061:2005
and
has
a
Category
4
structure
that
can
be
curtain
doesK1
not
cause
motor by
to the
energize
(the Start
buttonK2 is controlled by both the machine control system and the safety system. used in
Contactors
and
K2 arethe
controlled
safety system.
Contactor
systems
requiring
Performance
up to
pertoISO13849Thisbe
increases
the probability
performance
of the safety
because
significantly
less likely
to weld at theLevels
same time
asPLe
K2 due
the
must
pressed).
The motorofcan
also be turned
o byfunction
pressing
the K1 is
1:2006. This circuit executes a Category 0 stop.
diversity
of expected wear out times.
stop
button.
Fault Detection
Ratings
Upon
successful completion of internal checks on power up,
safety function initiated by the GuardShield light curtains meets the safety performance requirements of SIL CL 3 per IEC 62061:2005 and has
theThe
GuardShield
light curtains energize their outputs with no
a Category 4 structure that can be used in systems requiring Performance Levels up to PLe per ISO13849-1:2006. This circuit executes a Category
objects
0 stop.present. If a crossfault is detected, the GuardShield light
curtain goes to a lockout state with its outputs o. After successful
completion of internal checks, the DI checks the signals from the
light curtains. If OK, the DI then checks the status of the K1 and K2
- 14 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-16
Safeguarding Applications and Wiring Diagrams
Lifeline
Safeguarding Applications and Wiring Diagrams
Lifeline
Lifeline, 800F, DI, 100S:
Lifeline, 800F, DI, 100S
+24V DC
Start
800FMF3MX10
43 31 21 11
44 32 22 12
LifeLine
440E-L13042
(M20)
LifeLine
440E-L13043
(1/2in NPT)
Cable
K1
K2
Stop
800FME4MX01
11 21 31 43
12 22 32 44
L1 L2 L3
S11 S21 S12 S22 A1 13 23 S34
0
LOGIC
DI
440R-D22R2
8
7
6 5
1
2
3
4
K1
K2
S32 S42 L11 L12 A2 14 24 Y32
440A-A17173
800E-N157R
M
Aux Signal
To PLC
855D-T10SC20B24Y4
K1
K2 100S-C09EJ413BC
24V DC Com
Circuit Status
Then press the Start button to start the motor. As an alternative,
the motor can be stopped by pressing the Stop pushbutton. It
Both
Lifeline
cable pull switches are taut and reset; their contacts
Circuit
Status
can
thensetting
be restarted
pressing
pushbutton.
Both
Lifeline
cable
pull
switches
are
taut
and
reset;
their
contacts
are
closed.
The
DI Logic
is 6: [(IN1by
AND
IN2) OR the
L12]Start
with automatic
reset.
are closed. The DI Logic setting is 6: [(IN1 AND IN2) OR L12] with
The DI safety
relay is energized, as its inputs and monitoring circuits are satisfied. The motor is off and ready to run.
automatic
reset.
Fault Detection
Upon successful completion of internal checks on power up, the
The DI safety relay is energized, as its inputs and monitoring
Operating Principle
DI checks
its input
With
switches
circuits
are
satised.
The
motor
is
o
and
ready
to
run.
Two cable pull switches are used to protect an area from 10m to 70m in length. Auxiliary
lights
providecurcuits.
indication
as toboth
whichLifeline
switch has
been reset, the
DI checks
contactors
through the K1/K2/S34 circuit.
actuated to stop the motor. The difference between the two switches is the conduit
thread the
and output
shown for
examples purposes.
Operating Principle
If theand
contactors
are o, the
energizes
outputs
STARTING: Press the Start button to energize contactors K1 and K2. The motor starts
the two normally
openDI
contacts
of K1its
and
K2 closeand
to turns on
Two
cable
pull switches
used
protect
hold
the circuit
energized are
across
the to
Start
button.an area from 10m
the contactors which turn on the motor. A short or open circuit
Pull theAuxiliary
Lifeline cable
or press
the e-stop
buttonas
ontothe
Lifeline switchfault
to de-energize
the outputs
theswitches
DI and turn
offbe
thedetected
motor. To by the DI.
toSTOPPING:
70m in length.
lights
provide
indication
which
in the Lifeline
cable of
pull
will
restarthas
the been
motor,actuated
make sureto
thestop
area the
is clear
of hazards,
pull out the e-stop button (if pressed) and rotate the reset knob to the Run position.
switch
motor.
The dierence
If either the K1 or K2 faults in the energized state, the motor will
Then press the Start button to start the motor. As an alternative, the motor can be stopped by pressing the Stop pushbutton. It can then be
between the two switches is the conduit thread and shown for
be stopped by the other contactor and the fault will be detected
restarted by pressing the Start pushbutton.
examples purposes.
by the DI on the next attempt to restart. An internal fault in the
DI will be detected by itself. Depending on the type of fault,
STARTING:
Press the Start button to energize contactors K1 and
Fault Detection
thecurcuits.
result wil
beboth
de-energization
the K1
K2 contactors
or
K2.Upon
Thesuccessful
motor starts
and the
two normally
open
contacts
ofchecks
K1 its input
completion
of internal
checks on
power
up, the DI
With
Lifeline switchesofreset,
the and
DI checks
the
prevention
of
re-start.
output
contactors
through
the
K1/K2/S34
circuit.
If
the
contactors
are
off,
the
DI
energizes
its
outputs
and
turns
on
the
contactors
which
turn
on
and K2 close to hold the circuit energized across the Start button.
the motor. A short or open circuit fault in the Lifeline cable pull switches will be detected by the DI. If either the K1 or K2 faults in the energized
Ratings
STOPPING:
Pull the
cable
or other
presscontactor
the e-stop
state, the motor
will Lifeline
be stopped
by the
andbutton
the faulton
will be detected
by the DI on the next attempt to restart. An internal fault in
theLifeline
DI will be
detected
by itself. Depending
on the type
of fault,
theturn
result wil beThe
de-energization
of theinitiated
K1 and K2by
contactors
or prevention
of switches
safety function
the Lifeline
cable pull
the
switch
to de-energize
the outputs
of the
DI and
re-start.
meets the safety performance requirements of SIL CL3 per IEC
o the
motor. To restart the motor, make sure the area is clear of
62061:2005 and has Category 4 structure that can be used in
hazards, pull out the e-stop button (if pressed) and rotate the
systems requiring Performance Levels up to PLe per ISO 13849-1:
reset
knob to the Run position.
Ratings
The safety function initiated by the Lifeline cable pull switches meets the safety performance
requirements
of SIL
CL3 per IEC062061:2005
and has
2006. The circuit
executes
a Category
stop.
Category 4 structure that can be used in systems requiring Performance Levels up to PLe per ISO 13849-1: 2006. The circuit executes a Category 0
stop.
- 15 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-17
Safeguarding Applications and Wiring Diagrams
Safety Distribution Block and DI with Kinextix
350
Safeguarding Applications and Wiring Diagrams
Safety
Distribution
Block and DI with Kinextix 350
SensaGuard, Safety Distribution Block,
E-stops,
DI, Kinetix 350:
24V DC
SensaGuard
440N-Z21S17H
SensaGuard
440N-Z21SS2HN
Brown
Red
Yellow
SensaGuard, Safety Distribution Block, E-stops, DI, Kinetix 350
Status Signals
Grey/Pink
Red/Blue
White/Green
Brown/Green
White/Yellow
Yellow/Brown
White/Grey
Grey/Brown
Input
1756-IB16
1769-IQ16
1746-IB16
1734-IB4
1793-IB6
Input
Output
1756-IV16
1756-OB16
1769-IV16
1769-OB8
PLC
1746-IV16 Processor 1746-OB4
1734-IV4
1734-OB2
1793-IV16
1793-OB4
+
E-Stop
800FM-MT44
800F-MX02S
Reset
889D-P88RT-M19
S11 S21 S22 S12 A1 13
LOGIC
2
3
8
DI
4
7
6 5
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
Shorting Plugs
889D-81RU-DM
Homerun Patchcord
889M-R19RMMU-2
Bulk Head
use with bulkhead
Receptacle
or
888M-F19AE-1
Homerun Cordset
889M-R19RM-2
1
23 S34
Pink
Grey
Blue
Device Patchcord
889D-F8ABDM-2
0
L1 L2 L3
Kinetix 350 Drive
1 +24V DC
2 Com
3 Status
4 Safety Input 1
5 Safety Common
6 Safety Input 2
M
24V DC Com
Circuit
Status
Circuit
Status
Fault Detection
The Logic setting of the DI is set to 2 - monitored manual reset with [(Input 1 AND Input 2) OR L12]. The two E-Stops are in the released position
successful
of internal
checks Block
on power
up,
The
Logic
setting ofinthe
DItoisInput
set to1 (S12
2 - monitored
manual
reset are closedUpon
and
are connected
series
and S22). The
SensaGuards
and are
connectedcompletion
in series through
the Distribution
to
Input
2 (S321and
S42).
The status
eachThe
SensaGuard
is monitored
by the PLC. The
outputs
and
24) are OFF.components
The Kinetix 350are
Drive
is
theDI
DI,safety
Kinetix
350(14
and
SensaGuard
prepared
with
[(Input
AND
Input
2) OR of
L12].
two E-Stops
are in the
poweredposition
but the safety
inputs
are off; therefore
theto
motor
is OFF.
The
Y32 Aux Signal
and 3 Status
signal
are OFF and
inform thegenerate
PLC that the
for operation.
The
SensaGuard
interlocks
test pulses
released
and are
connected
in series
Input
1 (S12
and
safety system is ready to run. The PLC turns ON an output that enables the Reset of the safety system.
to check for short circuit faults to power and ground. The DI
S22). The SensaGuards are closed and are connected in series
generates test pulses through the e-stop
through the Distribution Block to Input 2 (S32 and S42). The
Operating
status
of eachPrinciple
SensaGuard is monitored by the PLC. The DI safety
STARTING: Press the Reset button to energize the safety outputs of the DI. The Y32
andto
3 Status
turn OFF.
The
Kinetix
driveand
is ground.
circuit
checksignals
for short
circuit
faults
to350
power
outputs
(14The
and
Kinetix
enabled.
PLC24)
canare
notOFF.
turn The
the motor
ON350
(thisDrive
circuitisis powered
not shown).but
the safety inputs are o; therefore the motor is OFF. The Y32 Aux
Ratings
Signal
and 3Openting
Status signal
areorOFF
and any
inform
the
PLC
that thethe safety The
STOPPING:
any gate
pressing
e-stop
will
de-energize
outputs
of the
DI, whichinitiated
in turn cause
the output
of the Kinetix
safety
functions
by the
SensaGuard
interlocks
drivesystem
to turn OFF
. The motor
coast
a stop.ON an output that
safety
is ready
to run.will
The
PLCtoturns
and the E-Stop buttons can meet the safety performance
enables the Reset of the safety system.
requirements of SIL CL 2 per IEC 62061:2005 and Performance
Fault Detection
Level
PLd per ISO13849-1:2008.
This application
a
Operating
Principle
Upon successful
completion of internal checks on power up, the DI, Kinetix 350 and
SensaGuard
components are prepared
for operation.executes
The
Category
0 stop.
SensaGuard interlocks generate test pulses to check for short circuit faults to power
and ground.
The DI generates test pulses through the e-stop
STARTING: Press the Reset button to energize the safety outputs
circuit to check for short circuit faults to power and ground.
of the DI. The Y32 and 3 Status signals turn OFF. The Kinetix 350
drive is enabled. The PLC can not turn the motor ON (this circuit is
Ratings
not
shown).
The safety functions initiated by the SensaGuard interlocks and the E-Stop buttons can meet the safety performance requirements of SIL CL 2 per
IEC 62061:2005
and Performance
Level
PLd perany
ISO13849-1:2008.
This application executes a Category 0 stop.
STOPPING:
Openting
any gate or
pressing
e-stop will deenergize the safety outputs of the DI, which in turn cause the
output of the Kinetix drive to turn OFF . The motor will coast to a
stop.
-16 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-18
Safeguarding Applications and Wiring Diagrams
Safety Valve - Air Supply Release
Safeguarding Applications and Wiring Diagrams
GuardShield, 800F, DI, Pneumatic Safety Valve:
Safety Valve - Air Supply Release
GuardShield, 800F, DI, Pneumatic Safety Valve
+24V DC
E-Stop
800FM-MT44
800F-MX02S
Reset
800FMF6MX10
Reset
800FMF6MX10
2TM
DM
CrossflowTM
SERPAR®
Safety Rated Valve
Air
Supply
Air Exhaust
S11 S12 S21 S22 A1 13 23
LOGIC
8
S34
0
1
2
3
4
DI
7
6 5
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
Transmitter
Brown 1
Blue
3
Receiver
Brown
2
Pink
6
Grey
5
Blue
7
3 Green
Ch1
Status
Ch2
Aux Signal
to PLC
Air Outlet to other
pneumatic valves
440L-P4K0960YD
889D-F4AC-2
889D-F8AC-2
24V DC Com
Circuit
Status
Circuit
Status
circuit is detected, the DI will not energize its outputs. If both
inputare
circuits
thevalve
DI checks
theThe
status
of the safety
Thelight
lightcurtain
curtain isisclear
and
thethe
e-stop
button
is released.
The DI safety
off andare
theclosed,
pneumatic
is closed.
DI safety
The
clear
and
e-stop
button
is released.
The relay outputs
valve. If one or both solenoids of the safety valve are energized,
Logic
is set
to 2: [(IN1
IN2)the
OR L12]
with monitored
reset.
DIrelay
safety
relay
outputs
areAND
o and
pneumatic
valve ismanual
closed.
the Status contact will be open, and the DI will not energize its
outputs. If both solenoids are de-energized, the Status contact
STARTING: Press the reset button to energize the output contacts of the safety relay.
Theclosed
two solenoids
in DI
theReset
valve energize
and allow air
to flow
will be
and the
button energizes
the
DI safety
from the AirPrinciple
Supply to the Air Outlet.
Operating
outputs
and
opens
the
safety
valve.
STOPPING: Pressing the e-stop button or blocking the light curtain de-energizes the safety outputs of the DI, which in turn drops out the solenoids
STARTING:
Press
the
reset
to energize
contacts
of the safety
valve.
The
valvebutton
closes the
Air Supply the
and output
releases the
air pressure to
thesafety
Air Exhaust.
button orchecks.
clearing the
The
valve Releasing
performsthe
itse-stop
own internal
If one of the
oflight
the curtain
safety does
relay.not
The
twothe
solenoids
in the
valve
cause
valve to turn
back
on. energize and
valves remains actuated, gets stuck or moves too slowly, the Air
allow air to flow from the Air Supply to the Air Outlet.
Outlet ow will be re-directed to the exhaust. To clear the fault
Fault Detection
condition,
both
valves
must
deenergized
andis the valve reset
STOPPING:
Pressing
the
e-stop
button
or
blocking
the
light
Upon successful completion of internal checks on power up, the DI checks the e-stop
and light
curtain
status.
If anbe
open
or short circuit
pressed.
curtain
de-energizes
the
safetyitsoutputs
which
in turn
detected,
the DI will not
energize
outputs.ofIf the
bothDI,
input
circuits
are closed, thebutton
DI checks
the status of the safety valve. If one or both solenoids
of theout
safety
are energized,
Status
contact
be open,
and the DI will not energize its outputs. If both solenoids are de-energized, the
drops
thevalve
solenoids
of the the
safety
valve.
Thewill
valve
closes
Ratings
Status
contact will
closed and
Reset button
energizes
the DI safety outputs
and opens the safety valve.
the
Air Supply
andbereleases
thethe
airDIpressure
to the
Air Exhaust.
This safety function initiated by the 800F e-stop and the
Releasing the e-stop button or clearing the light curtain does not
The safety valve performs its own internal checks. If one of the valves remains actuated,
gets stuck
or curtain
moves too
slowly,
thesafety
Air Outlet
flow will be
GuardShield
light
meets
the
performance
cause
the valve
toexhaust.
turn back
on. the fault condition, both valves must be deenergized
re-directed
to the
To clear
and the valve reset button pressed.
requirements of SIL CL 3 per IEC 62061:2005 and has a Category
Fault Detection
4 structure that can be used in systems requiring Performance
Ratings
Levels
PLeperformance
per ISO13849-1:2006.
example
circuit
Upon
successful
completion
checks
on GuardShield
power up, the
This safety
function
initiated by of
theinternal
800F e-stop
and the
light curtain
meetsup
theto
safety
requirementsThis
of SIL
CL 3 per IEC
a Stop
function
(coast toThis
stop).
DI62061:2005
checks theand
e-stop
and light4 curtain
anused
open
or shortrequiringperforms
has a Category
structurestatus.
that canIfbe
in systems
Performance
LevelsCategory
up to PLe 0
per
ISO13849-1:2006.
The DI safety relay Logic is set to 2: [(IN1 AND IN2) OR L12] with
Operating
Principle
monitored
manual
reset.
example circuit performs a Stop Category 0 function (coast to stop).
- 17 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-19
Safeguarding Applications and Wiring Diagrams
DI with SensaGuard Integrated Latch and 525 Drive
Safeguarding Applications and Wiring Diagrams
SensaGuard Integrated Latch, E-Stop,DI
DI,with
and SensaGuard
PowerFlex 525:Integrated Latch and 525 Drive
Red
Yellow
24V DC
Brown
SensaGuard Integrated Latch, E-Stop, DI, and PowerFlex 525
Reset
PowerFlex R S T
525
Pink
E-Stop
800FM-MT44
800F-MX02S
Grey
White
SensaGuard Integrated Latch
440N-Z21SS3PA
Blue
L1 L2 L3
11 +24V DC
S11 S21 S12 S22 A1 13
LOGIC
8
23 S34
0
7
1
2
3
4
6 5
DI
440R-D22R2
S42 S32 L11 L12 A2 14 24 Y32
1 Stop
2 Start
Gate control
power supply
Gate control
circuit
S1
S2
Gate
Open
UV W
M
24V DC Com
Circuit Status
The DI Logic is set to 2: [(IN1 AND IN2) OR L12] with monitored reset. The SensaGuard Light Latch interlock is connected to input 1 of the DI (S12
and S22).
The e-stop is connected to input 2 of the DI (S32 and S42). The gate, monitored
by the SensaGuard Light Latch, is closed and the e-stop
Fault Detection
Circuit
Status
is released. The DI safety outputs are off. The PowerFlex 525 drive is powered but disabled. The motor is off.
Upon successful completion of internal checks by the DI,
The DI Logic is set to 2: [(IN1 AND IN2) OR L12] with monitored
SensaGuard and PowerFlex 525 drive, the drive awaits the closure
reset.
The SensaGuard
Operating
PrincipleLight Latch interlock is connected to input
the
safety
1 ofSTARTING:
the DI (S12
and
S22).
The
e-stop
is
connected
to
input
2
of
the
Press the Reset button to turn on the DI safety outputs. This enablesofthe
drive
and outputs.
also applies power to the Start and Stop buttons.
DI (S32
S42).
The gate,
monitored
Press and
the Start
buttons
to start
the motor.by the SensaGuard Light
If
the
DI
fails,
the drive will not energize the motor, and the
STOPPING:
Press
thethe
Stope-stop
buttonistoreleased.
stop the motor
forsafety
production
stops. Press the e-stop or open the safety gate to initiate a safety stop; the
Latch,
is closed
and
The DI
outputs
fault
will
be
detected
by non-operation of the motor. The DI
coasts
to a stop.525 drive is powered but disabled. The
aremotor
off. The
PowerFlex
generates test pulses through the E-stop circuits to detect cross
motor is off.
channel shorts and shorts to power and ground. The SensaGuard
Fault Detection
Upon successful
completion of internal checks by the DI, SensaGuard and PowerFlex
525 drive,
drive on
awaits
the closure
the safety
outputs.
generates
testthe
pulses
its outputs
toofdetect
cross
channel shorts
Operating
Principle
If the DI fails, the drive will not energize the motor, and the fault will be detected
by non-operation
of the
motor.
The DI
generates
testsafe-circuit
pulses
and
shorts
to
power
and
ground.
A
fault
in
the
of the
STARTING:
Press the Reset button to turn on the DI safety outputs.
through the E-stop circuits to detect cross channel shorts and shorts to power and ground. The SensaGuard generates test pulses on its outputs
drive will be detected by the drive and issue a safety stop.
This enables the drive and also applies power to the Start and
to detect cross channel shorts and shorts to power and ground. A fault in the safe-circuit of the drive will be detected by the drive and issue a
Stop
buttons.
safety
stop. Press the Start buttons to start the motor.
Ratings
The safety functions initiated by the SensaGuard Integrated Latch
STOPPING: Press the Stop button to stop the motor for production
Ratings
the e-stop
meets
the safety
performance
requirements
of SIL
stops.
Press
the
e-stop
or
open
the
safety
gate
to
initiate
a
safety
The safety functions initiated by the SensaGuard Integrated Latch and and
the e-stop
meets
the safety
performance
requirements
of
CL2
per
IEC
62061:2005
and
category
3
structure
that
can
be
used
stop;
the
motor
coasts
to
a
stop.
SIL CL2 per IEC 62061:2005 and category 3 structure that can be used in systems requiring Performance Levels up to PLd per ISO
in systems requiring Performance Levels up to PLd per ISO 1384913849-1: 2006. The circuit executes a Category 0 stop.
1: 2006. The circuit executes a Category 0 stop.
- 18 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-20
Safeguarding Applications and Wiring Diagrams
DI and EMD with Enabling Jog System Safeguarding Applications and Wiring Diagrams
DI and EMD with Enabling Jog System
440G-MT, Enabling GripSwitch, DI, EMD, PowerFlex DriveGuard:
440G-MT, Enabling GripSwitch, DI, EMD, PowerFlex DriveGuard
24V DC
GripSwitch
440J N21TMPM-NP
Jog Button
5
Machine
Controlled
Jog Enable 1
3
6
2
L1 L2 L3
Grip
Lever
PowerFlex 70 R S T
w/ DriveGuard
9 +24V DC
7 DC Comm
4
8 Dig Comm
S11 S21 S12 S22 A1 13
11
12
21
22
33
43
11
12
21
22
34
33
34
44
43
44
To PLC Input
for Jog Enable
LOGIC
8
23 S34 B1 B2 X32 A1 17 27 37 47
9
8
1
2
3
4
0
1
1 TIME
2
2
3
10
3
4
9
4
5
7
8
6 5
7 6
RANGE
0
EMD
DI
7
6 5
440R-EM4R2D
440R-D22R2
L11 L12 A2 18 28
S32 S42 L11 L12 A2 14 24 Y32
2 Start
Safe Off Option
1
3
38 48
4
2
5 Jog
6 Enable
MT-GD2
440K-MT55050
440K-MT55026
440J-A04N
Gate Control
1 Stop Power Supply
Gate
Control
Circuit
Remove Jumper U V W
M
24V DC Com
Circuit Status
The 440J Enabling Switch is held by two MT-GD2 interlocks. The DI safety outputs are closed. The PowerFlex Enable and Safe-off option are
STOPPING:
The
jogwith
function
stops
after
timeswitch
expires. To
Circuit
StatusThe EMD safety outputs are de-energized. The DI Logic is set to 5: [(IN1
energized.
OR IN2) OR
L12]
automatic
reset.
Thethe
EMDset
Range
restart,
momentarily
release
the
jog
button
and
then
re-close it to
is
set
to
8
(Jog
10s)
and
the
Time
is
set
to
2
(20%),
therefore
the
Jog
will
occur
for
2s.
The
motor
is
ready
to
run.
The 440J Enabling Switch is held by two MT-GD2 interlocks. The
repeat the jog.
DI safety outputs are closed. The PowerFlex Enable and Safe-o
Operating
Principle
option
are energized.
The EMD safety outputs are de-energized.
Releasing or squeezing the 3-position GripSwitch opens the
The EMD is chosen for its ability to perform timing functions. In this case, the EMD is set up to jog the PowerFlex drive with a single pulse having a
The DI Logic is set to 5: [(IN1 OR IN2) OR L12] with automatic reset.
outputs
of the
the PowerFlex
drive executes
duration set between 0.5 to 10 s by adjustments made by potentiometers on the
EMD. While
in DI
theand
MT-GD2
holder, the Enabling
switch isa coast to stop.
Thedisabled,
EMD Range
switch
set
8 (Jog 10s)
and
the Time
is setsystem.
to 2 The Jog switch is disabled by the machine control system.
and the
drive is
can
beto
controlled
by the
machine
control
Fault Detection
(20%),
therefore
the Jog
occur for
2s.isThe
motor
is ready
to Start
run. button.
STARTING:
As shown,
thewill
PowerFlex
drive
ready
to run.
Press the
JOGGING: Close the 3-position GripSwitch to close the outputs of the DI and enable
drive. Remove
the enabling
switch from
the MT-GD2
Uponthe
successful
completion
of internal
checks
by the DI, EMD
Operating
Principle
holder. The
machine control system is notified that the GripSwitch has been removed
and
enables the
jog switch.
Pressawaits
the Jogthe
button
on the
and the
PowerFlex
drive,
the drive
closure
of the EMD
to initiate
the EMD.timing
The EMD
closes its safety outputs for the set duration. The Jog button must be held closed for
TheGripSwitch
EMD is chosen
forthe
itsoperation
ability toofperform
functions.
safety outputs. If the DI fails, the drive will not energize the motor
the duration
ofEMD
the jog
In this
case, the
is time.
set up to jog the PowerFlex drive with
and the
fault
detected
byre-close
non-operation
the
motor.
STOPPING: The jog function stops after the set time expires. To restart, momentarily
release
thewill
jogbe
button
and then
it to repeatofthe
jog.
a single
pulse
having
a duration set between 0.5 to 10 s by
Thethe
DIPowerFlex
uses dualdrive
channel
to detect
faults
Releasing or squeezing the 3-position GripSwitch opens the outputs of the DI and
executes
a coast to
stop.to power, ground and
adjustments made by potentiometers on the EMD. While in the
cross channel faults on the Enabling switch or the MT-GD2. A
MT-GD2
the Enabling switch is disabled, and the drive can
short across the jog switch will be detected and a subsequent
Fault holder,
Detection
be Upon
controlled
by the
machine
controlchecks
system.
Jog
switch
is PowerFlex
successful
completion
of internal
by The
the DI,
EMD
and the
the drive
the closureby
of the
the EMD
outputs.
jogdrive,
attempt
willawaits
be prevented
EMD.safety
A fault
in theIf Safe-O
the DI fails,
the machine
drive will not
energize
the motor and the fault will be detected by
non-operation
of the
motor.
The DI uses
to detect
disabled
by the
control
system.
option
of the drive
will
be detected
bydual
thechannel
DI on the
next attempt
faults to power, ground and cross channel faults on the Enabling switch or the MT-GD2. A short across the jog switch will be detected and a
to
restart
the
drive.
Internal
faults
in
the
DI
will
result
in nonSTARTING:
As jog
shown,
thewill
PowerFlex
drive
ready
run. in
Press
the option of the drive will be detected by the DI on the next attempt
subsequent
attempt
be prevented
by is
the
EMD. to
A fault
the Safe-Off
to
opeation
theofmotor.
Internal
faults
of the DI of
will
restart
the drive. Internal faults in the DI will result in non-opeation of the motor.
Internal of
faults
the DI will
result in
non-operation
theresult
jog in nonStart
button.
operation of the jog function.
function.
JOGGING: Close the 3-position GripSwitch to close the outputs
Ratings
of the DI and enable the drive. Remove the enabling switch from
Ratings
safety function
by the GripSwitch
meets is
the
safety performance
of SIL CL2 per
IEC 62061:2005
and has Category
3 the safety
The safety function
initiated
by the GripSwitch
meets
theThe
MT-GD2
holder. initiated
The machine
control system
notied
that the requirements
structure that
be removed
used in systems
requiring the
Performance
Levels
up to PLd per
ISO 13849-1: requirements
2006. The circuitof
executes
a Category
0 stop.
performance
SIL CL2
per IEC 62061:2005
and
GripSwitch
has can
been
and enables
jog switch.
Press
has Category 3 structure that can be used in systems requiring
the Jog button on the GripSwitch to initiate the operation of the
Performance Levels up to PLd per ISO 13849-1: 2006. The circuit
EMD. The EMD closes its safety outputs for the set duration. The
executes a Category 0 stop.
Jog button must be held closed for the duration of the jog time.
- 19 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-21
Safeguarding Applications and Wiring Diagrams
Guardlocking with DI and EMD
Safeguarding Applications and Wiring Diagrams
Guardlocking with DI and EMD
800F, TLS1-GD2, Trojan T15-GD2, DI, EMD, 700S:
800F, TLS1-GD2, Trojan T15-GD2, DI, EMD, 700S
+24V DC
Reset
800FM-F6MX10
CR1
K1
800FM-MT44
800F-X02S
Gate
Release
L1 L2 L3
K2
Power to
Release
TLS1 GD2
440G-T27171
Remove internal
jumper from
12 to 41
M1
L1 L2 L3
33
11 21
A1
A2
12 22 41 53
34
DI
440R-D22R2
8
7
RANGE
0
0
LOGIC
42 54
B1 B2 X32 A1 17 27 37 47
S11 S21 S12 S22 A1 13 23 S34
6 5
1
2
3
4
9
8
7
6 5
TIME
1
2
3
4
10
9
8
7 6
1
K3
2
3
4
5
EMD
440R-EM4R2D
L11 L12 A2 18 28
S32 S42 L11 L12 A2 14 24 Y32
K4
38 48
M2
11 21
12 22
Trojan T15-GD2
440K-T11397
700-HPS2Z24
K1
CR1
K2
700S-CFB440EJC
K3
K4
700S-CFB440EJC
24V DC Com
Circuit Status
T15. The e-stop has a self-monitoring contacts, which open if the
block
o the
panel.
WithThe
the
e-stop signals
The The
e-stop
is reset
and
closed
and
locked.
e-stop
is reset
andthe
thesafety
safety gate
gate isisclosed
and
locked.
TheThe
outputs of thecontact
safety relays
arefalls
open,
andcontrol
the motors
are off.
rotary
theOFF
DI delay”,
checksTime
the6:K1,
K2,ofK3,
K4 and
TLS1
switches
of the
EMDrelays
deviceare
have
the delay
set to 18are
seconds
seconds
“60%
range”).
The
EMDmonitoring
will open circuit
outputs
of the
safety
open,
and time
the motors
o. The(Range 3: “30made,
its switches
contacts 18ofseconds
after
the signal
DI L11
output
turns
when the reset button is pressed. If these checks are OK, the output
rotary
the EMD
device
havefrom
thethe
delay
time
set to
18 off.
energizes. The Reset Button is linked to the delayed Y32 output in
seconds (Range 3: “30 seconds OFF delay”, Time 6: “60% of range”).
Operating
Principle
order to supply +24V for reset only when delay time has lapsed. If
The EMD will open its contacts 18 seconds after the signal from the
STARTING: Press the Reset button to energize the outputs of the DI. The outputs
the
DI DI
energize
the K1
and to
K2 the
control
M1is stopped
anyofof
the
contacts
faults
ONrelays
state,and
themotor
motor
DI L11
output
turns
off.
starts. At the same time, the DI sends a signal via L11 to the EMD. The outputs of the EMD energize the K3 and K4 control relays and motor M2
by the redundant outputs. The fault will be detected by the Y32,
starts.
Operating
Principle
K1,coasts
K2, K3,toK4
andAfter
TLS1
onexpires,
the next
attempt to
STOPPING: When the e-stop is pressed, the outputs of the DI open and motor M1
stop.
themonitoring
time delay ofcircuit
the EMD
motor
re-start.
If the
GateRelease
is not interlocked
solenoid
STARTING:
Press
button
to energize
theThe
outputs
of be
theunlocked by
M2 coasts
to athe
stopReset
and the
Y32 output
energizes.
gate can
pressing
the Gate
button. Press by
thethe
GateTLS1
Release
buttonor one of
to power
the of
solenoid
open the
Gate.
Closing
the Gaterelays
or resetting
does not
re-energise
700S
the 700S
control
relays the
faults
tocontrol
the ONrelays.
state, the DI will detect the
DI. The
outputs
the DIand
energize
the
K1 and
K2 control
and the e-stop
fault
in
the
Y32,
K1,
K2,
K3,
K4
and
TLS1 monitoring circuit on the
motor M1 starts. At the same time, the DI sends a signal via L11 to
FaultThe
Detection
next attempt to reset. An additional interlock (Trojan T15) is added
the EMD.
outputs of the EMD energize the K3 and K4 control
Upon power-up, the DI and EMD perform internal checks. The DI then looks for signals from the e-stop and the TLS1 GD2 and Trojan T15. The
to the gate to to prevent potential single point failures related to
relays
and
motor
M2
starts.
e-stop has a self-monitoring contacts, which open if the contact block falls off the control panel. With the e-stop signals made, the DI checks the
styleare
interlocks.
K1, K2, K3,
K4 and
monitoring
circuit
when
the reset
button
is pressed. Iftongue
these checks
OK, the output energizes. The Reset Button is
STOPPING:
When
theTLS1
e-stop
is pressed,
the
outputs
of the
DI open
linked to the delayed Y32 output in order to supply +24V for reset only when delay time has lapsed. If any of the DI contacts faults to the ON
Ratings
and state,
motor
M1
coasts
to
stop.
After
the
time
delay
of
the
EMD
the motor is stopped by the redundant outputs. The fault will be detected by the Y32, K1, K2, K3, K4 and TLS1 monitoring circuit on the
expires,
coasts to
a stop
the
Y32 output
energizes.
safety
function
by the
gate
nextmotor
attemptM2
to re-start.
If the
Gateand
is not
interlocked
by the
TLS1 solenoid or The
one of
the 700S
controlinitiated
relays faults
to the
ON interlocks
state, the DIand
will the e-stop
The detect
gate can
unlocked
button.
the be
fault
in the Y32,by
K1,pressing
K2, K3, K4the
andGate
TLS1Release
monitoring
circuit on the next
attempt
reset.performance
An additional interlock
(Trojanof
T15)
added
meets
the to
safety
requirements
SILisCL3
per IEC
the Gate
gate to
to prevent
potential
single the
point
failures related
to tongue
interlocks. and has a Category 4 structure that can be used in
Presstothe
Release
button
to power
solenoid
and open
the style62061:2005
Gate. Closing the Gate or resetting the e-stop does not re-energise
systems requiring Performance Levels up to PLe per ISO13849Ratings
the 700S
control relays.
1:2006. This circuit executes Category 0 stops.performance
The safety function initiated by the gate interlocks and the e-stop meets the safety performance requirements of SIL CL3 per IEC 62061:2005 and
CL2 per IEC 62061:2005
and has Category
a Category 4 structure that can be used in systems requiring Performance requirements
Levels up to PLeof
perSIL
ISO13849-1:2006.
This circuit executes
Faulthas
Detection
3 structure that can be used in systems requiring Performance
Category 0 stops.
Upon power-up, the DI and EMD perform internal checks. The DI
Levels up to PLd per ISO 13849-1: 2006. The circuit executes a
then looks for signals from the e-stop and the TLS1 GD2 and Trojan
Category 0 stop.
Circuit Status
- 20 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-22
Safeguarding Applications and Wiring Diagrams
Interlock Switch with Enabling Device – Guard Locking
with Time Delay
Safety Applications and Wiring Diagrams
Interlock Switch with Enabling Device—Guard Locking with Time Delay
GripSwitch, MT-GD2, 400G-MT, 800F, DI, EMD, 100S:
GripSwitch, MT-GD2, 400G-MT, 800F, DI, EMD, 100S
24V DC
Guardlocking Interlock
440G-MT47045
Primary
Safeguard
11
12
11
12
21
22
21
22
33
34
43
44
E-Stop
800FM-MT64
800F-X02S
GripSwitch
440J-N21TNPM-NP
440J-A04N
MT-GD2
Latch Release
A
K1
MT-GD2
440T-MT55076
33
34
43
44
3
2
4
Start
800FM-F3MX10
B
Reset
800FM-F6MX10
1
K2
11
12
21
22
33
34
43
44
Stop
800FM-E4MX01
Machine control system
can replace this circuit
arrangement.
GripSwitch
Jog Button
L1 L2 L3
S11 S21 S22 S12 A1 13 23 S34
LOGIC
0
1
2
3
Lock Release
8
4
7
6 5
DI
800FM440R-D22R2
F2MX10
S32 S42 L11 L12 A2 14 24 Y32
B1 B2 X32 A1 17
RANGE 0 1 TIME
9
8
7 6 54
2 10
3 9
8
7 6
1
27 37 47
K1
2
3
4
5
EMD
440R-EM4R2D
L12 L11
A2 18
Mirror
Contacts
K2
28 38 48
M
24V Com
Circuit Status
Circuit Status
K1 K2 100S-D1405ZJ33LC
and closes its safety outputs and the motor is ready to run. Press the
The 440J GripSwitch is held by two MT-GD2 tongue interlocks by its mounting plate accessories. The safety gate is closed and the 440G-MT guard
button
the GripSwitch
to momentarily
turn
the motor.
The 440Jlocking
GripSwitch
isisheld
byThe
twoDIMT-GD2
tongue
interlocks
interlock
locked.
and EMD safety
outputs
are open. Contactorsjog
K1 and
K2 areon
de-energized.
The EMD
Range switch is set
to 8on
(Jog
10s) and the
Time
is set to 2 (20%),
Jogiswill
occur and
for 2s. The motor is off and the application ready to run.
by its mounting
plate
accessories.
Thetherefore
safety the
gate
closed
STOPPING DURING ENABLING: Release the jog switch to stop the
the 440G-MT guard locking interlock is locked. The DI and EMD
motor. Releasing or applying further pressure to the trigger switch
Operating
Principle
safety outputs
are open.
Contactors K1 and K2 are de-energized.
on theis running.
GripSwitch
will stop
thefull
motor.
The GripSwitch enabling device is used to access the hazardous area while the motor
The access
is of the
body type. With the safety
The EMDgate
Range
switch
set to 8
(Joginto
10s)
the Time
is set
2
unlocked,
theisoperator
walks
theand
hazardous
area with
thetoGripSwitch.
Before accessing the hazard area, the motor must be stopped.
Fault
Detection
(20%), therefore
the the
Joghazard
will occur
formotor
2s. The
is offwith
and
After entering
area, the
can motor
be restarted
thethe
GripSwitch. One MT-GD2 interlock is used to bypass the gate interlock safety
circuit.
The other
MT-GD2 is used to reset the safety system and prevent the starting
the motor from
outside the of
cell,internal
when thechecks
GripSwitch
application
ready
to run.
Uponofsuccessful
completion
on ispower-up, DI
used.
checks
the
e-stop,
gate
and
GripSwitch
circuit.
If
the circuits are
STOPPING:
Press the Safety Stop. The immediate outputs of the DI open and the motor initiates a coast to stop. After the time expires on the EMD,
Operating
Principle
closed,
the DIPress
checks
therelease
reset circuit.
closure of the reset
the delayed outputs change state. The EMD outputs close and the safety gate can
be unlocked.
the lock
button toUpon
momentarily
The GripSwitch
enabling
device
is used
toopen
access
the hazardous
power the
solenoid of
the 440G-MT
and
the gate.
button, the DI checks the status of the contactors. Due to the size
area while
the motor
is running.
Theswitch
access
is of
full body
STARTING:
Remove
the enabling
from
thethe
MT-GD2
holders. Squeeze theof
GripSwitch
trigger
to the middle
position. The
DI resets
andeither
closes side of
the 100S-D
contactors,
mirrored
contacts
(on
its the
safety
outputs
andunlocked,
the motor is the
readyoperator
to run. Press
the jog
button
to momentarily turn on the motor.
type. With
safety
gate
walks
into
the on the GripSwitch
the
unit)
are
used
to
safely
reect
the
staus
of
the
armature.
If all
STOPPING DURING ENABLING: Release the jog switch to stop the motor. Releasing or applying further pressure to the trigger switch on the
hazardous
area with the GripSwitch. Before accessing the hazard
mirrored contacts are closed, then the DI energizes its outputs. If
GripSwitch will stop the motor.
area, the motor must be stopped.
one contactor welds in the closed state, the second contactor will
Fault
Detection
shut o the motor and the fault will be detected by the DI, upon the
After entering the hazard area, the motor can be restarted with
Upon successful completion of internal checks on power-up, DI checks the e-stop,
gate
and GripSwitch
If the circuits
are channel
closed, thefaults
DI
next
attempt
to startcircuit.
the motor.
Single
on the input
the GripSwitch.
One
MT-GD2
interlock
is
used
to
bypass
the
gate
checks the reset circuit. Upon closure of the reset button, the DI checks the status of the contactors. Due to the size of the 100S-D contactors,
devices
(GripSwitch,
Interlocks
and
Stop
switch)
interlockmirrored
safety circuit.
otherside
MT-GD2
is used
to reset
the
safety
contactsThe
(on either
of the unit)
are used
to safely
reflect
the staus of the armature. If all mirrored contacts are closed, then the will
DI be detected by
the DIwill
either
onthe
or motor
before
a the
demand
placed
onbythe
energizes
its outputs.
If one contactor
welds infrom
the closed
state,the
the cell,
second contactor
shut off
and
fault willisbe
detected
thesafety system
system and
prevent
the starting
of the motor
outside
upon the next attempt to start the motor. Single channel faults on the input(depending
devices (GripSwitch,
Interlocks
Stop fault).
switch) will be detected
on the
natureand
of the
when theDI,GripSwitch
is used.
by the DI either on or before a demand is placed on the safety system (depending on the nature of the fault).
Ratings
STOPPING: Press the Safety Stop. The immediate outputs of the DI
open andRatings
the motor initiates a coast to stop. After the time expires
The safety function initiated by the MT-GD2 guard locking
The safety function initiated by the MT-GD2 guard locking interlock and the GripSwitch button meets the safety performance requirements of SIL
on the EMD,
theIEC62061:2005
delayed outputs
The that
EMDcan
outputs
interlock
the GripSwitch
button
the safety
CL 2 per
and haschange
Categorystate.
3 structure
be used in systems
requiringand
Performance
Levels up to
PLd permeets
ISO 13849-1:
2006. performance
close andThis
theexample
safetycircuit
gate performs
can be unlocked.
Press
the lock release
requirements of SIL CL 2 per IEC62061:2005 and has Category 3
a Stop Category
0 function.
button to momentarily power the solenoid of the 440G-MT and
structure that can be used in systems requiring Performance Levels
- 21 - up to PLd per ISO 13849-1: 2006. This example circuit performs a
open the gate.
Stop Category 0 function.Levels up to PLd per ISO 13849-1: 2006.
STARTING: Remove the enabling switch from the MT-GD2 holders.
The circuit executes a Category 0 stop.
Squeeze the GripSwitch trigger to the middle position. The DI resets
R
NHP Safety Reference Guide > GSR Wiring Diagrams
3-23
Safeguarding Applications and Wiring Diagrams
Global E-Stop and Zone Control
Safeguarding Applications and Wiring Diagrams
GuardShield, SensaGuard, MatGuard, 800F, DI,100S:
+24VDC
MatGuard
Safety Mat & Trim
440F-M2030BYNN
440F-T2030
K1
E-Stop
800FM-MT44
800F-MX02L
Global E-Stop and Zone Control
GuardShield, SensaGuard, MatGuard, 800F, DI,100S
SensaGuard
440N-Z21S26H
K3
K2
K4
Reset
800FMF6MX10
Reset
800FMF6MX10
S11 S21 S12 S22 A1 13 23 S34
S11 S21 S12 S22 A1 13 23 S34
1
2
0
LOGIC
1
2
3
4
8
DI
7
440R-D22R2 6 5
S32 S42 L11 L12 A2 14 24 Y32
Aux Signal
to PLC
E-Stop
800FM-MT44
800F-MX02L
100S-C09
EJ14BC
LOGIC
2
1
4
3
1
2
3
4
A
2 4
Aux
Signal
to PLC
3
5
3
5
GuardShield Safe 4
Light Curtain
445L-P4L1920YD
24V DC Com
K3 K4
100S-C09
EJ14BC
K5
K6
Reset
800FMF6MX10
S11 S21 S12 S22 A1 13 23 S34
0
8
DI
7
6 5
440R-D22R2
S42
S32
L11 L12 A2 14 24 Y32
1
K1 K2
Brown
Red
Yellow
Blue
Green
White (Aux)
To PLC
Pink (OSSD2)
6 Gray (OSSD1)
5
2
8
4
7
3
1
0
LOGIC
8
1
2
3
4
DI
7
6 5
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
2
1
1
4
B
2 4
Aux
Signal
to PLC
3
5
3
5
GuardShield Safe 4
Light Curtain
445L-P4L0240YD
K5 K6
100S-C09
EJ14BC
Circuit Status
prevent
will de-energize
the respective
Circuit
The Status
light curtains are unobstructed. The safety gate is closed. The e-stops are reset,
andenergization
the safety mator
is unoccupied.
The outputs
of all threeoutputs.
DI
relays are off. K1-K6 are ready to be energized.
If
one
of
the
100S
or
700S
output
devices
(K1-K6)
is
stuck
in an
The light curtains are unobstructed. The safety gate is closed. The
actuated state, the respective DI will prevent startup because the
e-stops are reset, and the safety mat is unoccupied. The outputs of
Operating Principle
S34 feedback loop will remain open.
all three DI relays are off. K1-K6 are ready to be energized.
The DI is chosen as the safety relay for its zoning capability. The two e-stops operate globally - turning off relays 1, 2 and 3.
STARTING:
Press the reset button for relay 1 to energize its outputs. Then pressRatings
the reset button for relays 2 and 3 to energize their respective
Operating
Principle
outputs.
The
safety functions initiated by the input devices, except the
The STOPPING:
DI is chosen
as the safety
relay
for its
zoning
capability.
The two
Obstructing
the light
curtain
A or
stepping
on the safety
mat turns off the outputs of relay 2 while leaving the outputs of relay 1 and
safety
mat,
meet the
safetyturns
performance
requirements
of SIL
relay
3
energized.
Obstructing
the
light
curtain
B
or
opening
the
safety
gate
with
the
SensaGuard
interlock
off the outputs
to relay 3 while
e-stops operate globally - turning o relays 1, 2 and 3.
CL3 per
IEC
leaving the outptus of relay 1 and relay 2 energized. . Pressing either e-stop shuts
down
all62061:2005
three relays. and have Category 4 structures that can
STARTING: Press the reset button for relay 1 to energize its outputs.
be used in systems requiring Performance Levels up to PLe per
Then
pressDetection
the reset button for relays 2 and 3 to energize their
Fault
ISO13849-1:2006. The safety function initiated by the safety mat
Upon successful
their input
circuits.
Shorts from the
inputs to power,
ground
or IEC
respective
outputs.completion of internal checks on power up, the DI relays check
meets
the safety
performance
requirements
of SIL
CL2 per
other inputs will be detected immediately and will prevent energization or will de-energize the respective outputs. If one of the 100S or 700S
62061:2005 and has a Category 3 structure that can be used in
STOPPING:
Obstructing
light
A orstate,
stepping
on the safety
output devices
(K1-K6) the
is stuck
in curtain
an actuated
the respective
DI will prevent startup because the S34 feedback loop will remain open.
systems requiring Performance Levels up to PLd per ISO13849mat turns o the outputs of relay 2 while leaving the outputs of relay
1:2006. This circuit executes a Category 0 stop.
1 and
relay 3 energized. Obstructing the light curtain B or opening
Ratings
The safety
functions
initiated
by the input
devices,
except
theoutputs
safety mat, meet the safety performance requirements of SIL CL3 per IEC 62061:2005
the safety
gate
with the
SensaGuard
interlock
turns
o the
and have
Category
4 structures
that can
be used
in systems
Performance Levels up to PLe per ISO13849-1:2006. The safety function
to relay
3 while
leaving
the outptus
of relay
1 and
relay 2requiring
energized.
initiated by the safety mat meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that can be
Pressing
either
e-stop
shuts
down
all
three
relays.
used in systems requiring Performance Levels up to PLd per ISO13849-1:2006. This circuit executes a Category 0 stop.
Fault Detection
Upon successful completion of internal checks on power up, the DI
relays check their input circuits. Shorts from the inputs to power,
ground or other inputs will be detected immediately and will
- 22 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-24
Safeguarding Applications and Wiring Diagrams
E-Stops for a PowerFlex 755 Drive
Safeguarding Applications and Wiring Diagrams
E-Stops for a PowerFlex 755 Drive
800F, DI, PowerFlex 755:
800F, DI, PowerFlex 755
+24V DC
L1 L2 L3
E-Stop
800FM-MT44
800F-MX02S
PowerFlex
755 Series
S11 S12 S21 S22 A1 13 23 S34
LOGIC
8
0
1
4
2
3
7
6 5
DI
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
Stop
Status
to PLC
Start
Start/Stop Common
24V DC Com
Gate Control
Power Supply
SP+
SE+
Gate
Control
Circuit
SPSE-
Motor
24V DC Com
Circuit Status
The E-Stop
755 isDetection
powered and its safety circuit is enabled. The motor is off.
Fault
Circuit
Statusis released. The safety outputs of the DI are energized. The PowerFlex
The DI has a Logic setting of 5: [(IN1 OR IN2) OR L12] with automatic reset. The connections to Input 2 (S32 and S42) are ignored.
Upon power-up the PowerFlex drive and DI perform internal
The E-Stop is released. The safety outputs of the DI are energized.
checks. The DI then looks for dual signals from the e-stop. A
The PowerFlex 755 is powered and its safety circuit is enabled. The
Operating Principle
crossfault
(channel
to channel
2) of
E-Stop
be detected
motor
is off. The
has
a Logic
5: [(IN1 OR
IN2) OR
L12]system (not
STARTING:
PressDIthe
start
buttonsetting
or otherofequivalent
machine
control
shown) to
start the1motor.
Although
thethe
DI is
set forwill
automatic
immediately. The DI is rated for Category 4 and will not lose the
with
automatic
The connections
to Input
S42) are
reset,
releasingreset.
the E-stop
will not cause the
motor2to(S32
startand
rotating.
STOPPING: Normal production is stopped by the Stop switch or other equivalent
machine
controldue
system
(not
shown). The E-stop
button
safety
function
to an
accumulation
of faults.
Thewill
PowerFlex 755
ignored.
initiate a safety stop. The DI removes power to the Start/Stop circuit as well as the
Gate
The motor
a Safe Torque
OFF function in
Drive
is Control
rated atCircuit.
Category
3, as itexecutes
will perform
the safety
Operating
Principle
function and
the motor coasts to a stop.
the presence of a single internal fault.
STARTING: Press the start button or other equivalent machine
Ratings
Faultsystem
Detection
control
(not shown) to start the motor. Although the DI
Upon
the
PowerFlex
drive the
and E-stop
DI perform
checks.
looks
for dual
signalsinitiated
from the e-stop.
crossfault
(channel
1 to
The
safety
function
by the A
e-stop
meets
the safety
is set
for power-up
automatic
reset,
releasing
willinternal
not cause
theThe DI then
channel 2) of the E-Stop will be detected immediately. The DI is rated for Category 4 and will not lose the safety function due to an accumulation of
performance requirements of SIL CL3 per IEC 62061:2005 and
motor
to start rotating.
faults. The PowerFlex 755 Drive is rated at Category 3, as it will perform the safety function in the presence of a single internal fault.
has a Category 3 structure that can be used in systems requiring
STOPPING: Normal production is stopped by the Stop switch or
Performance Levels up to PLe per ISO13849-1:2006. This circuit
other
equivalent machine control system (not shown). The E-stop
Ratings
executes
a Safe Torque OFF (Category 0) stop.
The
safety
function
initiated
by
the
e-stop
meets
the
safety
performance
requirements
of SIL CL3 per IEC 62061:2005 and has a Category 3 structure
button will initiate a safety stop. The DI removes power to the Start/
that
can be
requiring
Performance
Levels
up to
PLe per ISO13849-1:2006.
This circuit executes a Safe Torque OFF (Category 0) stop.
Stop
circuit
asused
wellinassystems
the Gate
Control
Circuit. The
motor
executes
a
Safe Torque OFF function and the motor coasts to a stop.
- 23 NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-25
Safeguarding Applications and Wiring Diagrams
SafeZone Mini, E-stop and DI with Kinetix
350
Safeguarding
Applications and Wiring Diagrams
SafeZone Mini, E-stop and DI with Kinetix 350
SafeZone Mini, E-stop, DI, Kinetix 350:
Brown
24V DC
SafeZone Mini, E-stop, DI, Kinetix 350
Grey
Pink
Shield
White (Warning Field)
Blue
SafeZone Mini
442L-SFZNMN
442L-ACABL210 (Cable)
Input
1756-IB16
1769-IQ16
1746-IB16
1734-IB4
1793-IB6
Reset
S11 S21 S22 S12 A1 13 23 S34
LOGIC
8
E-Stop
800FM-MT44
800F-MX02S
7
0
1
4
Input
Output
+
1756-IV16
1756-OB16
1769-IV16
1769-OB8
PLC
1746-IV16 Processor 1746-OB4
1734-IV4
1734-OB2
1793-IV16
1793-OB4
+
L1 L2 L3
Kinetix 350 Drive
2
3
6 5
DI
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
1 +24V DC
2 Com
3 Status
4 Safety Input 1
5 Safety Common
6 Safety Input 2
Warning
Field
M
24V DC Com
Circuit Status
The Logic
setting of the DI is set to 2 - monitored manual reset with [(Input 1 AND
Input
2) OR L12]. The E-Stop is in the released position and is
Fault
Detection
Circuit
Status
connected to Input 2 (S32 and S42) of the DI. The area scanned by the SafeZone Mini is clear and the signals to Input 1 of the DI (S12 and S22) are
Upon
completion
of internal
on power
up, the
The
Logic
ofField
the DI
is set
to 2 - monitored
reseton an indicator
high.
Thesetting
Warning
signal
is connected
to a PLC,manual
which turns
andsuccessful
may also perform
other logic.
The DI checks
safety outputs
(14 and
SafeSone
Mini, DI,
and The
Kinetix
350Signal
are prepared
for operation.
with
1 AND
Input350
2) OR
L12].
The E-Stop
is insafety
the released
24)[(Input
are OFF.
The Kinetix
Drive
is powered
but the
inputs are off; therefore
the motor
is OFF.
Y32 Aux
is high, which
informs
the PLCand
thatisthe
safety system
is ready
to run.
The safety outputs of the SafeZone Mini generates test pulses to
position
connected
to Input
2 (S32
and S42) of the DI. The
check for cross channel shorts and short circuit faults to power and
area scanned by the SafeZone Mini is clear and the signals to
ground . The DI generates test pulses through the e-stop circuit to
Input
1 of the DI
(S12 and S22) are high. The Warning Field signal
Operating
Principle
STARTING: Press
button
toon
energize
the safety
outputs
of the DI. Thecheck
Y32 status
signalchannel
turns OFF.
The Kinetix
350 drive
is enabled.
for cross
shorts
and short
circuit
faults to The
power and
is connected
to a the
PLC,Reset
which
turns
an indicator
and
may also
PLC canother
not turn
theThe
motor
(thisoutputs
circuitry (14
is not
shown).
ground.
perform
logic.
DI ON
safety
and
24) are OFF. The
Kinetix 350 Drive is powered but the safety inputs are o; therefore
STOPPING: Entering the warning field of the SafeZone Mini scanner does not cause
system to
turn
butthe
theDIS
PLCas
turns
an checking
NOTE:the
Dosafety
not replace
the
DIoff;
with
theon
pulse
theindicator.
motor isEntering
OFF. The
Y32
Aux Signal
which informs
the PLC
the
protective
field is
ofhigh,
the SafeZone
Mini scanner
or pressing
E-Stop
causes
safety
relayan
toF059
turn OFF,
disables
onthe
the
outputs
of the
theDI
DIS
causes
faultwhich
on the
K350 safety
that
safety
system
ready
tocoasts
run. to a stop.
thethe
Kinetixt
350
drive. is
The
motor
inputs.
Operating Principle
Ratings
Fault Detection
STARTING:
Press the
Reset button
to energize
safety
Upon successful
completion
of internal
checks onthe
power
up,outputs
the SafeSone Mini,The
DI, and
Kinetix
350 areinitiated
preparedby
forthe
operation.
TheMini
safetyand
outputs
safety
functions
SafeZone
the E-Stop
of of
thethe
DI.SafeZone
The Y32Mini
status
signal test
turns
OFF.to
The
Kinetix
350channel
drive isshorts and short circuit faults to power and ground . The DI generates test
generates
pulses
check
for cross
buttons
can
meet
the
safety
performance
requirements
of SIL CL 2
pulses
through
the
e-stop
circuit
to
check
for
cross
channel
shorts
and
short
circuit
faults
to
power
and
ground.
enabled. The PLC can not turn the motor ON (this circuitry is not
per
IEC
62061:2005
and
has
a
Category
3
structure
that
can
be used
NOTE: Do not replace the DI with the DIS as the pulse checking on the outputs of the DIS causes an F059 fault on the K350 safety inputs.
shown).
in systems requiring Performance Level up to PLd per ISO138491:2006. This application executes a Category 0 stop
STOPPING:
Ratings Entering the warning eld of the SafeZone Mini scanner
does
cause
the safety
system
turn o; but
turns on
an can meet the safety performance requirements of SIL CL 2 per IEC
Thenot
safety
functions
initiated
by thetoSafeZone
Minithe
andPLC
the E-Stop
buttons
62061:2005 and has a Category 3 structure that can be used in systems requiring Performance Level up to PLd per ISO13849-1:2006. This
indicator.
Entering the protective eld of the SafeZone Mini scanner
application executes a Category 0 stop.
or pressing the E-Stop causes the DI safety relay to turn OFF, which
disables the Kinetixt 350 drive. The motor coasts to a stop.
- 24 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-26
Safeguarding Applications and Wiring Diagrams
Multizone Scanner, E-Stop and DI with Safeguarding
Kinetix 350Applications and Wiring Diagrams
Multizone Scanner, E-Stop and DI with Kinetix 350
SafeZone Multizone, 800F, DI, Kinetix 350:
Select Zone A (White/Red & White/Orange)
A1 (Brown)
24V DC
SafeZone Multizone, 800F, DI, Kinetix 350
Select Zone B (White/Yellow & White/Green)
Warning Field (White/Brown)
A2 (Blue)
OSSD2 (Pink)
OSSD1 (Grey)
SafeZone
Multizone
Reset
Input
1756-IB16
1769-IQ16
1746-IB16
1734-IB4
1793-IB6
Input
Output
1756-IV16
1756-OB16
1769-IV16
1769-OB8 +
PLC
1746-IV16 Processor 1746-OB4
1734-IV4
1734-OB2
1793-IV16
1793-OB4
+
S11 S21 S22 S12 A1 13 23 S34
442L-SFZNMZ
Cable & Mem Module
442L-CSFZNMZ-10
LOGIC
8
E-Stop
800FM-MT44
800F-MX02S
0
1
4
L1 L2 L3
2
3
7
6 5
DI
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
Kinetix 350 Drive
1 +24V DC
2 Com
3 Status
4 Safety Input 1
5 Safety Common
6 Safety Input 2
Warning
Field
M
24V DC Com
Circuit Status
The Logic
setting of the DI is set to 2 - monitored manual reset with [(Input 1 AND
Input
2) OR L12]. The E-Stop is in the released position and are
Fault
Detection
Circuit
Status
connected to Input 2 (S32 and S42) of the DI. The area scanned by the SafeZone Multizone is clear and the signals to Input 1 of the DIS (S12 and
Upon
successful
completion
internal
power
up,
The
Logic
setting
ofWarning
the DI isField
set signal
to 2 - is
monitored
S22)
are high.
The
connectedmanual
to a PLC,reset
which turns on an
indicator
and may
also performofother
logic.checks
The DIon
safety
outputs
Multizone,
DIS, and
Kinetix
areis prepared
with
AND
Input
OR L12].
The E-Stop
is inbut
thethe
released
(14[(Input
and 24)1are
OFF.
The 2)
Kinetix
350 Drive
is powered
safety inputs arethe
off;SafeSone
therefore the
motor is OFF.
The Y32
Aux 350
Signal
high, whichfor
informsand
the are
PLC connected
that the safety
system2is(S32
readyand
to run.
operation. The safety outputs of the SafeZone Multizone generates
position
to Input
S42) of the DI. The
test pulses to check for cross channel shorts and short circuit faults
area scanned by the SafeZone Multizone is clear and the signals to
to power and ground . The DI generates test pulses through the
Input
1 of the DIS
(S12 and S22) are high. The Warning Field signal
Operating
Principle
The PLC sends
signalsturns
(a NCon
andan
a NO)
to the SafeZone
to switch
thecircuit
activeto
zones
between
Zones
A and B.
The OSSD
outputs
e-stop
check
for cross
channel
shorts
and short
circuit
is connected
to aa pair
PLC,ofwhich
indicator
and mayMultizone
also
respond
to either
zone.
faults to power and ground.
perform
other
logic.
The DI safety outputs (14 and 24) are OFF. The
Kinetix 350 Drive is powered but the safety inputs are o; therefore
STARTING: Press the Reset button to energize the safety outputs of the DI. TheNOTE:
Y32 status
signal
turns OFF.
The
Kinetix
is enabled.
The
Do not
replace
the DI
with
the350
DISdrive
as the
pulse checking
thePLC
motor
is OFF.
Y32 Aux
is high,
which
informs the PLC
can not
turn The
the motor
ON Signal
(this circuitry
is not
shown).
on the outputs of the DIS causes an F059 fault on the K350 safety
that the safety system is ready to run.
inputs.
STOPPING: Entering the warning field of the SafeZone Multizone scanner does not cause the safety system to turn off; but the PLC turns on an
Operating
Principle
indicator. Entering the protective field of the SafeZone Multizone scanner or pressing
Ratingsthe E-Stop causes the DI safety relay to turn OFF, which
disables
the Kinetixt
drive. The
motor
stop.SafeZone
The
PLC sends
a pair 350
of signals
(a NC
andcoasts
a NO)totoa the
The safety functions initiated by the SafeZone Multizone and the
Multizone to switch the active zones between Zones A and B. The
E-Stop buttons can meet the safety performance requirements of
Fault
Detection
OSSD outputs respond to either zone.
SIL CL DIS,
2 per
IECKinetix
62061:2005
and has aforCategory
structure
Upon successful completion of internal checks on power up, the SafeSone Multizone,
and
350 are prepared
operation.3 The
safety that
can be
used
inshort
systems
requiring
Performance
Levels
upDIto PLd per
STARTING:
the Reset
button generates
to energize
safety
outputs
outputs ofPress
the SafeZone
Multizone
testthe
pulses
to check
for cross channel
shorts
and
circuit
faults to power
and ground
. The
test
pulses
through
e-stop
circuit
check 350
for cross
channel
shorts
and short circuit faults
to power andexecutes
ground. a Category 0 stop.
ISO13849-1:2006.
This application
of generates
the DI. The
Y32
status
signalthe
turns
OFF.
Theto
Kinetix
drive
is
NOTE: Do
not
replace
the DI
with
themotor
DIS as ON
the pulse
checking is
onnot
the outputs of the DIS causes an F059 fault on the K350 safety inputs.
enabled.
The
PLC
can not
turn
the
(this circuitry
shown).
Ratings
STOPPING:
warning
eld
of the SafeZone
Multizone
The safetyEntering
functionsthe
initiated
by the
SafeZone
Multizone and
the E-Stop buttons can meet the safety performance requirements of SIL CL 2 per IEC
scanner
doesand
nothas
cause
the safety
systemthat
to turn
o; used
but the
PLC requiring Performance Levels up to PLd per ISO13849-1:2006. This
62061:2005
a Category
3 structure
can be
in systems
application
executes aEntering
Categorythe
0 stop.
turns
on an indicator.
protective eld of the SafeZone
Multizone scanner or pressing the E-Stop causes the DI safety relay
to turn OFF, which disables the Kinetixt 350 drive. The motor coasts
to a stop.
- 25 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-27
Safeguarding Applications and Wiring Diagrams
Safety Sensor, E-Stop and DI with Kinetix
350
Safeguarding
Applications and Wiring Diagrams
Safety Sensor, E-Stop and DI with Kinetix 350
SC300, 800F, DI, Kinetix 350:
SC300, 800F, DI, Kinetix 350
Blue
Yellow
Green
White
Brown
24V DC
Red
SC300
442L-SAFCAM1
Cable
889D-F8FB-5
Teach
Pink
Grey
Reset
Input
1756-IB16
1769-IQ16
1746-IB16
1734-IB4
1793-IB6
Input
Output
+
1756-IV16
1756-OB16
1769-IV16
1769-OB8
PLC
1746-IV16 Processor 1746-OB4
1734-IV4
1734-OB2
1793-IV16
1793-OB4
+
S11 S21 S22 S12 A1 13 23 S34
LOGIC
8
E-Stop
800FM-MT44
800F-MX02S
7
0
1
4
L1 L2 L3
2
3
6 5
DI
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
Kinetix 350 Drive
1 +24V DC
2 Com
3 Status
4 Safety Input 1
5 Safety Common
6 Safety Input 2
M
Warning
Field
24V DC Com
Circuit Status
The Logic setting of the DI is set to 2 - monitored manual reset with [(Input 1 AND Input 2) OR L12]. The E-Stop is in the released position and is
Fault Detection
Circuit
Status
connected to Input 2 (S32 and S42) of the DI. The area scanned by the SC300 safety sensor is clear and the signals to Input 1 of the DI (S12 and
Upon
successful
completion
internal
power
up, the
The
Logic
setting
the DI is
setsignal
to 2 - ismonitored
S22)
are high.
TheofWarning
Field
connected manual
to a PLC, reset
which turns on an
indicator
and may
also performofother
logic.checks
The DI on
safety
outputs
(14[(Input
and 24) 1are
OFF.Input
The Kinetix
350 Drive
powered
safety inputs areSC300
off; therefore
motor
OFF. Kinetix
The Y32350
Auxare
Signal
is high, for
which
safetythe
sensor,
DI,is and
prepared
operation.
with
AND
2) OR L12].
The is
E-Stop
is inbut
thethe
released
informsand
the PLC
that the safety
system
is ready
run. of the DI. The
The safety outputs of the SC300 safety sensor generates test pulses
position
is connected
to Input
2 (S32
andtoS42)
to check for cross channel shorts and short circuit faults to power
area scanned by the SC300 safety sensor is clear and the signals to
Operating
Principle
and ground . The DI generates test pulses through the e-stop circuit
Input
1 of the DI
(S12 and S22) are high. The Warning Field signal
STARTING: Press
Reset
button
to on
energize
the safety
outputs
of the DI. Theto
Y32
statusfor
signal
turns
OFF. The
Kinetix
drive
is enabled.
check
cross
channel
shorts
and350
short
circuit
faultsThe
to power
is connected
to athe
PLC,
which
turns
an indicator
and
may also
PLC can not turn the motor ON (this circuitry is not shown).
and ground.
perform other logic. The DI safety outputs (14 and 24) are OFF. The
Kinetix
350 Drive
is powered
butfield
theof
safety
inputssafety
are o;
therefore
STOPPING:
Entering
the warning
the SC300
sensor
does not cause
the safety
system
to turn
the
PLC
turns
on an
indicator.
NOTE:
Do not
replace
theoff;
DI but
with
the
DIS
as the
pulse
checking
theEntering
motor the
is OFF.
The Y32
Aux
Signal
is high,
thethe
PLC
protective
field
of the
SC300
safetywhich
sensor informs
or pressing
E-Stop causes the DI safety relay to turn OFF, which disables the Kinetixt
on
the
outputs
of
the
DIS
causes
an
F059
fault
on
the K350 safety
350
drive.
The
motor
coasts
to
a
stop.
that the safety system is ready to run.
inputs.
Operating
Principle
Fault Detection
Ratings
Upon successful
completion
of internal
checks onthe
power
up, outputs
the SC300 safety sensor, DI, and Kinetix 350 are prepared for operation. The safety
STARTING:
Press the
Reset button
to energize
safety
The shorts
safetyand
functions
initiated
SC300
safety sensor
of the
SC300
safety
sensor
generates
testKinetix
pulses to
check
foriscross channel
short circuit
faultsby
to the
power
and ground
. The DIand the
of outputs
the DI. The
Y32
status
signal
turns
OFF. The
350
drive
E-Stop
buttons
meet
the safety
performance requirements of
generates test pulses through the e-stop circuit to check for cross channel shorts
and short
circuitcan
faults
to power
and ground.
enabled. The PLC can not turn the motor ON (this circuitry is not
NOTE: Do not replace the DI with the DIS as the pulse checking on the outputs of
causes
F059 fault on
thehas
K350
safety inputs.
SILthe
CLDIS
2 per
IEC an
62061:2005
and
a Category
3 structure that
shown).
can be used in systems requiring Performance Levels uo to PLd per
ISO13849-1:2006. This application executes a Category 0 stop.
STOPPING:
Ratings Entering the warning eld of the SC300 safety sensor
Thenot
safety
functions
initiated
by theto
SC300
andturns
the E-Stop
does
cause
the safety
system
turn safety
o; butsensor
the PLC
on anbuttons can meet the safety performance requirements of SIL CL 2 per IEC
62061:2005
and hasthe
a Category
3 structure
thatSC300
can besafety
used insensor
systemsorrequiring Performance Levels uo to PLd per ISO13849-1:2006. This
indicator.
Entering
protective
eld of the
application executes a Category 0 stop.
pressing
the E-Stop causes the DI safety relay to turn OFF, which
disables the Kinetixt 350 drive. The motor coasts to a stop.
- 26 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-28
Safeguarding Applications and Wiring Diagrams
Hazardous Location
Safeguarding Applications and Wiring Diagrams
Hazardous Location
T15, 800F, 897H, DIS, PowerFlex 525:
T15, 800F, 897H, DIS, PowerFlex 525
+24V DC
Wiring intrinsically safe systems must be identified as such through the use of
light blue jacketing or appropriate labels. Such labels are required by NEC
Article 504 and ANSI/ISA RP-12.6 to be placed at no more than 25 foot intervals.
When installing intrinsically safe equipment, the user should refer to all relevant
national standards and those standards set forth by the authority under
jurisdiction at the installation site.
Hazardous Location
U.S.
Class I,II,III, Div 1,2
European
Zone 0,1,2, EExia IIB
See Entity Parameters
for 897H for Groups
15
14
10
DIP Switch 1 2 3 4
Settings 1 0 1 0
1492-LD4RB223 (22K)
15
21
22
14
11
12
11
L1 L2 L3
PowerFlex R S T
525
1 Stop
2 Start
4
5
6
S12 S22 S11 S21 S42 S32 A1 S34
3
1
2
DIS
440R-D22S2
L11 L12 A2 34 44 14 24 Y32
7
8
9
LOGIC
8
7
6 5
0
1
2
3
4
4 Gnd
A1
Line
Fault
Gate control
power supply
Gate control
circuit
S1
S2
Status
To PLC
4
5
6
UV W
M
3
1
2
10
Trojan T15
440K-T11395
Reset
Non-hazardous Location
Galvanic Isolator
897H-G231
11
1492-LD4RB272 (2.7K)
E-Stop
800FM-MT44
800F-MX02S
DIP Switch 1 2 3 4
Settings 1 0 1 0
7
8
9
Line
Fault
24V DC Com
Circuit
Status
Circuit
Status
well as opening the gate. The tongue interlock switch should be
The DIS Logic is set to 2: [(IN1 AND IN2) OR L12] with monitored reset. The Trojan T15 is connected to input 1 of the DIS (S12 and S22) through
wired to both inputs (terminals 7 and 8) of the galvanic isolator to
The the
DISGalvanic
Logic isIsolator.
set to 2:
[(IN1
AND
IN2) OR L12]
with
The
e-stop
is connected
to input
2 ofmonitored
the DI (S32 and S42). The gate is closed and the e-stop is released. The DIS safety
reset.
The Trojan
connected
input
1 of the
(S12 and
outputs
are off.T15
TheisPowerFlex
525 to
drive
is powered
butDIS
disabled.
The motor isdrive
off. both outputs (1/5 and 2/3) of the galvanic isolator. A single
fault will not cause a loss of safety function. If one output of the
S22) through the Galvanic Isolator. The e-stop is connected to
galvanic isolator fails in the closed state, the DIS safety relay will
Operating
input
2 of the DIPrinciple
(S32 and S42). The gate is closed and the e-stop
thehazardous
2nd output
and The
turnDIS
the
drive
and motor
The galvanic
limitsoutputs
energy toare
theo.
interlock
switch, which
considered adetect
simple opening
apparatus of
in the
location.
safety
relay
is released.
The isolator
DIS safety
The PowerFlex
525isdrive
checks the
outputs
of theThe
galvanic
isolator
is actuated.
o. The motor
will remain o until the fault is corrected or power
is powered
but
disabled.
motor
is off.upon power-up and each time the gate/e-stop
STARTING: Press the Reset button to turn the DIS safety outputs (14, 24, 34, 44 and
L11) ON.The
ThisIsolator
enables DIP
the PF525
drive.must
Pressbe
theset
Start
is cycled.
switches
forbutton
Line to
Fault
turn the Principle
motor ON.
Operating
Detection (1) and non inverted (0) output. The 1492 resistors are
requried to detect line faults. Two isolators must be used to avoid
The STOPPING:
galvanic isolator
limits energy to the interlock switch, which
Normal production stopping is performed by pressing the Stop button. Opening the gate or pressing the e-stop initiates a safety stop;
potential common cause failures.
is considered
a
simple
apparatus
in
the
hazardous
location.
The
the motor coasts to a stop.
DIS safety relay checks the outputs of the galvanic isolator upon
Ratings
power-up
and each time the gate/e-stop is actuated.
Fault Detection
safety
by theasTrojan
interlock
The DIP switch setting of the galvanic isolator allows for open and short circuit The
detection
of function
the tongueinitiated
interlock switch,
well asT15
opening
the meets
STARTING:
Press the Reset button to turn the DIS safety outputs
the8)safety
performance
of SIL(1/5
CL2and
per2/3)
IECof
gate. The tongue interlock switch should be wired to both inputs (terminals 7 and
of the galvanic
isolatorrequirements
to drive both outputs
(14, the
24, galvanic
34, 44 and
L11)AON.
This
enables
PF525
drive.
the If one62061:2005
has aisolator
Category
structure
thatthe
canDIS
be used in
isolator.
single
fault
will not the
cause
a loss of
safetyPress
function.
output of theand
galvanic
fails in1 the
closed state,
Startsafety
button
turn
theopening
motor ON.
relaytowill
detect
of the 2nd output and turn the drive and motorsystems
off. The motor
will remain
until the faultLevel
is corrected
or power
requiring
up tooff
Performance
PLc per
ISO13849is cycled. The Isolator DIP switches must be set for Line Fault Detection (1) and 1:2006.
non inverted
(0) output.
The
1492shows
resistors
are channel,
requried tothe
detect
Although
the
circuit
dual
very low
STOPPING:
Normal
production
is performed
by pressing
line faults.
Two isolators
must bestopping
used to avoid
potential common
cause failures.
diagnostic coverage of the Galvanic Isolator limits structure to
the Stop button. Opening the gate or pressing the e-stop initiates
Cat 1. The safety function initiated by the E-stop meets the safety
a safety
stop; the motor coasts to a stop.
Ratings
performance requirements of SIL CL2 per IEC 62061:2005 and has
The safety function initiated by the Trojan T15 interlock meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a
FaultCategory
Detection
a Category
3 structure thatAlthough
can be used
in systems
requiring up to
1 structure that can be used in systems requiring up to Performance Level
PLc per ISO13849-1:2006.
the circuit
shows dual
The channel,
DIP switch
setting
of the galvanic
isolator
allows for
open
the very
low diagnostic
coverage
of the Galvanic
Isolator
limits structure to Cat 1. The safety function initiated by the E-stop meets the
Performance Level PLd per ISO13849-1:2006. This circuit executes
requirements
SIL CL2 per
IEC 62061:2005
3 structure that can be used in systems requiring up to
and safety
shortperformance
circuit detection
of theoftongue
interlock
switch, and
as has a Category
a Category 0 stop.
Performance Level PLd per ISO13849-1:2006. This circuit executes a Category 0 stop.
- 27 R
NHP Safety Reference Guide > GSR Wiring Diagrams
3-29
Safeguarding Applications and Wiring Diagrams
Hazardous Location
Safeguarding Applications and Wiring Diagrams
Hazardous Location
SafedgeTM, MatGuardTM, 800F, 897H, DIS, PowerFlex
525: , MatGuard , 800F, 897H, DIS, PowerFlex 525
Safedge
TM
TM
+24V DC
Wiring intrinsically safe systems must be identified as such through the use of
light blue jacketing or appropriate labels. Such labels are required by NEC
Article 504 and ANSI/ISA RP-12.6 to be placed at no more than 25 foot intervals.
When installing intrinsically safe equipment, the user should refer to all relevant
national standards and those standards set forth by the authority under
jurisdiction at the installation site.
Hazardous Location
U.S.
Non-hazardous Location
Class I,II,III, Div 1,2
Galvanic Isolator
European
897H-G231 B
Zone 0,1,2, EExia IIB
See Entity Parameters
for 897H for Groups
4
15
5
1492-LD4RB223 (22K)
6
14
10
DIP Switch 1 2 3 4
Settings 1 0 1 0
7
8
9
Reset
L1 L2 L3
PowerFlex R S T
525
1 Stop
2 Start
S12 S22 S11 S21 S42 S32 A1 S34
LOGIC
8
7
6 5
0
1
2
3
4
4 Gnd
A1
DIS
440R-D22S2
L11 L12 A2 34 44 14 24 Y32
3
1
2
11
Safedge
with cable termination
e.g. 440F-EAAAA00300
or
MatGuard
e.g. 440F-M2030BYNN
E-Stop
800FM-MT44
800F-MX02S
Gate control
power supply
Gate control
circuit
S1
S2
Line
Fault
Status
To PLC
UV W
M
1492-LD4RB272 (2.7K)
24V DC Com
Circuit Status
FaultorDetection
Circuit
Status
The DIS
Logic is set to 2: [(IN1 AND IN2) OR L12] with monitored reset. The Safedge
MatGuard is connected to input 1 of the DIS (S12 and S22)
through
the Galvanic
e-stop
connected
to input
2 of the DI (S32The
and DIP
S42).switch
The gate
is closed
and galvanic
the e-stopisolator
is released.
The DIS
setting
of the
allows
for open
The
DIS Logic
is set toIsolator.
2: [(IN1The
AND
IN2)isOR
L12] with
monitored
safety outputs are off. The PowerFlex 525 drive is powered but disabled. The motor is off.
and short circuit detection of the Safedge or MatGuard. The
reset.
The Safedge or MatGuard is connected to input 1 of the
897H-G231 has a Hardware fault tolerance of zero. A single fault
DIS (S12 and S22) through the Galvanic Isolator. The e-stop is
Operating Principle
can lead to the loss of the safety function. The motor will remain
connected
to
input
2
of
the
DI
(S32
and
S42).
The
gate
is
closed
The galvanic isolator limits energy to the Safedge or MatGuard, which is considered a simple apparatus in the hazardous location. The DIS safety
until
the faultisisactuated.
corrected or power is cycled. The Isolator DIP
and
thechecks
e-stop
released.
Thegalvanic
DIS safety
outputs
are o. Theand each timeothe
relay
theisoutputs
of the
isolator
upon power-up
gate/e-stop
switches
must
set for
Fault
Detection
and
nontoinverted
PowerFlex
drive
is powered
but
disabled.
The motor
off.24, 34, 44 and
STARTING:525
Press
the Reset
button to
turn
the DIS safety
outputsis(14,
L11) ON.
Thisbe
enables
theLine
PF525
drive.
Press the (1)
Start
button
turn the motor ON.
(0) output. The 1492 resistors are requried to detect line faults.
Operating Principle
Ratings
STOPPING:
production
stopping
is performed
the Stop button.
Depressing the Safedge, stepping on the MatGuard or pressing
The
galvanicNormal
isolator
limits energy
to the
Safedgeby
orpressing
MatGuard,
the e-stop
initiates a a
safety
stop;
the motor in
coasts
a stop.
which
is considered
simple
apparatus
the to
hazardous
location.
The DIS safety relay checks the outputs of the galvanic isolator
Fault
Detection
upon
power-up
and each time the gate/e-stop is actuated.
The safety function initiated by the Safedge and MatGuard
meets the safety performance requirements of SIL CL2 per IEC
62061:2005 and has a Category 1 structure that can be used in
The DIP switch setting of the galvanic isolator allows for open and short circuit detection of the Safedge or MatGuard. The 897H-G231 has a
systems
Performance
Level
per ISOor13849Hardware
fault
tolerance
of
zero.
A
single
fault
can
lead
to
the
loss
of
the
safety
function.requiring
The motorup
willtoremain
off until the
faultPLc,
is corrected
STARTING: Press the Reset button to turn the DIS safety outputs
Theinverted
safety (0)
function
the e-stop
meetstothe
power is cycled. The Isolator DIP switches must be set for Line Fault Detection 1:2006.
(1) and non
output.initiated
The 1492by
resistors
are requried
(14, 24, 34, 44 and L11) ON. This enables the PF525 drive. Press the
detect line faults.
safety performance requirements of SIL CL2 per IEC 62061:2005
Start button to turn the motor ON.
and has a Category 3 structure that can be used in systems
Ratings Normal production stopping is performed by pressing
requiring up to Performance Level PLd, per ISO 13849-1:2006. This
STOPPING:
safety
function
initiated bythe
the Safedge,
Safedge and
MatGuard
requirements
of SIL CL2
per IEC 62061:2005 and has a
circuit executes
a Category
0 stop.
theThe
Stop
button.
Depressing
stepping
onmeets
the the safety performance
Category 1 structure that can be used in systems requiring up to Performance Level PLc, per ISO 13849-1:2006. The safety function initiated by the
MatGuard or pressing the e-stop initiates a safety stop; the motor
e-stop meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that can be used in systems
coasts
to a up
stop.
requiring
to Performance Level PLd, per ISO 13849-1:2006. This circuit executes a Category 0 stop.
- 28 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-30
Safeguarding Applications and Wiring Diagrams
PowerFlex Drive - Multiple Gate AccessSafeguarding Applications and Wiring Diagrams
PowerFlex Drive - Multiple Gate Access
Trojan 5 GD2, MT-GD2, DIS, PowerFlex 70:
Trojan 5 GD2, MT-GD2, DIS, PowerFlex 70
+24V DC
Guard Shown
Open
L1 L2 L3
11 21
12 22
33
1 Stop
34
PowerFlex 70
with DriveGuard
2 Start
440K-T11341
Trojan 5 GD2
7 DC Comm
8 Dig Comm
Gate Control
Power Supply
S11 S21 S12 S22 S32 S42 S34 A1
0
LOGIC
8
7
6 5
1
2
3
4
DIS
440R-D22S2
L12 L11 Y32 A2 34
11
12
21
22
33 43
1
3
44 14
24
Safe Off Option
4
2
6 Enable
Aux
Signal
to PLC
Gate
Control
Circuit
Remove Jumper
34 44
Motor
440K-MT55080
MT-GD2 Latch Release
24V DC Com
Fault Detection
Circuit Status
Circuit
Upon power-up the PowerFlex drive and DIS perform internal
One
of theStatus
gates is open. The safety outputs of the DIS are deOne of the gates is open. The safety outputs of the DIS are de-energized. The PowerFlex with DriveGuard is de-energized and not enabled. The
checks. The DIS then looks for dual signals from the gate
energized.
The
PowerFlex
with
DriveGuard
is
de-energized
and
motor is off. The DIS has a Logic setting of 6: [(IN1 AND IN2) OR L12] with automatic reset.
interlocks. With the gates closed, the DIS checks the wiring of the
not enabled. The motor is o. The DIS has a Logic setting of 6: [(IN1
drive Safe-O option. If closed, then the DIS energizes its outputs
AND
IN2) OR L12]
with automatic reset.
Operating
Principle
andpower
the motor
started.
A single
circuit
STARTING: When the last gate closes, the safety outputs of the DIS close and apply
to the can
Drivebe
Enable
circuit,
Safe-Offopen
option,
Start fault
and at the
Operating Principle
Stop buttons. Pressing the Start and Stop buttons turns the motor on and off. The
motor
is controlled
by detected
parametersimmediately,
set within the PowerFlex
gate
interlocks
will be
and the motor
STARTING:
When the last gate closes, the safety outputs of the DIS
drive.
will coast to a stop. A crossfault (channel 1 to channel 2) at the
STOPPING:
Opening
anyto
of the
the guard
causes
the Safe-O
DIS safety
outputs to de-energize.
This removes
to theimmediately.
PowerFlex Enable,
close
and apply
power
Drive doors
Enable
circuit,
option,
gate interlocks
will bepower
detected
TheSafe-Off,
DIS is rated
Start,
and
Stopbuttons.
circuits. The
motor performs
coastStop
to stop.
Start
and
Stop
Pressing
the Starta and
buttons turns
for Category 4 and will not lose the safety function due to an
the motor on and o. The motor is controlled by parameters set
accumulation of faults. The PowerFlex 70 DriveGuard is rated at
Faultthe
Detection
within
PowerFlex drive.
Category
3, dual
as it signals
will perform
safety
function
presence
Upon power-up the PowerFlex drive and DIS perform internal checks. The DIS then
looks for
from thethe
gate
interlocks.
With in
thethe
gates
a single
internal
fault.and the motor can be started. A single
closed, theOpening
DIS checksany
theof
wiring
of the drive
Safe-Off
option.
If closed,
energizes
its outputs
STOPPING:
the guard
doors
causes
the DIS
safetythen theofDIS
open circuit
fault at the gate
be detected
outputs
to de-energize.
Thisinterlocks
removeswill
power
to the immediately,
PowerFlex and the motor will coast to a stop. A crossfault (channel 1 to channel 2) at
the gate interlocks will be detected immediately. The DIS is rated for Category Ratings
4 and will not lose the safety function due to an accumulation of
Enable,
Safe-O, Start, and Stop circuits. The motor performs a
faults. The PowerFlex 70 DriveGuard is rated at Category 3, as it will perform theThe
safety
function
in the initiated
presence of
single
internal
fault. meets the
safety
function
byathe
gate
interlocks
coast to stop.
safety performance requirements of SIL CL2 per IEC 62061:2005
Ratings
and has a Category 3 structure that can be used in systems
The safety function initiated by the gate interlocks meets the safety performance
requirements
of SIL CL2 Levels
per IEC up
62061:2005
andISO138429-1:2006.
has a Category 3
requiring
Performance
to PLd per
structure that can be used in systems requiring Performance Levels up to PLd per ISO138429-1:2006. This circuit executes a Category 0 stop.
This circuit executes a Category 0 stop.
- 29 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-31
Safeguarding Applications and Wiring Diagrams
Multiple PowerFlex Drives
Safeguarding Applications and Wiring Diagrams
Multiple PowerFlex Drives
Trojan 5 GD2, DIS, PowerFlex 70 with DriveGuard:
Trojan 5 GD2, DIS, PowerFlex 70 with DriveGuard
+24V DC
Gate shown
open
11 21
12 22
Trojan5-GD2
440K-T11213
PowerFlex 70 R S T
with DriveGuard
34
DeviceNet
Dig. Comm
8
7
0
1
2
3
4
6 5
DIS
440R-D22S2
L12 L11 Y32 A2 34
44 14
24
Safe-Off Option
1
3
Safe-Off Option
1
3
4
2
4
2
Enable
Gate
Control
Circuit
Enable
U V W
Remove Jumper
Gate
Control
Circuit
U V W
Remove Jumper
Motor
PLC
DeviceNet
Processor 1756-DNB
1769-SDN
1747-SDN
1734-PDN
1794-ADN
PowerFle 70x R S T
with DriveGuard
DeviceNet
Dig. Comm
Gate Control
Power Supply
Gate Control
Power Supply
S11 S21 S12 S22 S32 S42 S34 A1
LOGIC
Input
1756-IB16
1769-IQ16
1746-IB16
1734-IB4
1793-IB6
L1 L2 L3
L1 L2 L3
33
Motor
24VC DC Com
Circuit Status
STOPPING:
Normal
stopping
performed
byare
theoff.PLC. If the gate is
Circuit
TheStatus
safety gate is open. The DIS safety outputs (14, 24, 34, and 44) are off The Enable
and Safe-Off
Option
on bothisPowerFlex
drives
Auxiliary
signals
from
the
Trojan
5
GD2
(33/34)
and
the
DIS
(Y32)
inform
the
PLC
that
the
safety
system
is
OFF.
The
motors
of
both
drives
are opens
off.
opened,
the
input
signals
to
the
DIS
open.
The
DIS
its safety
The safety gate is open. The DIS safety outputs (14, 24, 34, and 44)
The Logic setting of the DIS is set to 5: [(IN1 OR IN2) OR L12] with automatic reset.
outputs which disable all the drives connected to them via the
are off The Enable and Safe-O Option on both PowerFlex drives
Safe-O option. The drives perform an immediate coast to stop.
are off.
signals to
from
the
Trojan
5 GD2
and the DIS
ThisAuxiliary
circuit is intended
show
that
multiple
drives(33/34)
can be connected
in parallel. The number of drives that can be connected in parallel is
on:PLC
the load
plus
enable
of each drive),
de-rating to prevent early wearout of the DIS solid state
(Y32)dependent
inform the
that(the
thesafe-off
safetyoption
system
is the
OFF.
The motors
of appropriate
Fault Detection
the application
requirements
zoning)
assessment
bothoutputs,
drives are
off. The Logic
setting (e.g.,
of the
DIS isand
setthe
torisk
5: [(IN1
OR (e.g., some drives may require separate safety systems).
Upon power-up, the DIS performs internal checks. The DIS then
IN2) OR L12] with automatic reset.
looks for dual signals from the Trojan5-GD2. If only one signal is
Operating Principle
Upon closing
gate,
the multiple
Trojan 5 GD2
closescan
the safety inputs of the
DIS (S32or
and
S42) and opens
the the
signal
to the
PLC. The
safetyis present
present,
a crossfault
exists,
DIS
assumes
a fault
This STARTING:
circuit is intended
to the
show
that
drives
outputs of the
DIS close and
bothofPowerFlex
drives.
of thedoes
DIS opens.
The PLC compares
gate andWith
safetythe
relay
aux closed, the
not energize
its safetythe
outputs.
gate
be connected
in parallel.
Theenable
number
drives that
canThe
beauxiliary signaland
signals. When both signals are open, the PLC knows that the safety system is ready. The PLC can now start and control the drives over the
DIS
checks
the
S34
monitoring
circuit.
If
the
Safe-O
options
are
connected
in
parallel
is
dependent
on:
the
load
(the
safe-o
option
DeviceNet network. The PLC must ensure that the drives are not started upon the closing of the gate; a separate, intentional action must initiate
de-energized, the DIS assumes the drives are off and are ready to
plus the
themotor
enable
of each(this
drive),
appropriate
movement
is not
shown in the de-rating
diagram). to prevent
enabled.
The
itsopens
safety
If the monitoring
earlySTOPPING:
wearout Normal
of the stopping
DIS solidisstate
outputs,
performed
by thethe
PLC.application
If the gate is opened, thebe
input
signals to
theDIS
DIS energizes
open. The DIS
itsoutputs.
safety outputs
which disable
all the
drives and
connected
to them
via the Safe-Off
option. The drives
perform
an immediate
coast
to stop.
circuit
remains
open, the
DIS
assumes a fault is present and not
requirements
(e.g.,
zoning)
the risk
assessment
(e.g., some
allow its safety outputs to energize. Single point failures related
drives may require separate safety systems).
Fault Detection
to the tongue interlock are excluded if actuator speed, alignment
Upon power-up,
the DIS performs internal checks. The DIS then looks for dual signals from the Trojan5-GD2. If only one signal is present, or a
Operating
Principle
andoutputs.
mechanical
stops
instruction
requirements,
crossfault exists, the DIS assumes a fault is present and does not energize its safety
With the
gatemeet
closed,installation
the DIS checks
the S34
STARTING:
Upon
closing
the
gate,
the
Trojan
5
GD2
closes
the
and
a
periodic
proof
test
conrms
proper
operation.
monitoring circuit. If the Safe-Off options are de-energized, the DIS assumes the drives are off and are ready to be enabled. The DIS energizes its
safety
inputs
of the
DISmonitoring
(S32 andcircuit
S42) and
opens
the
to a fault is present and not allow its safety outputs to energize. Single point
safety
outputs.
If the
remains
open,
thesignal
DIS assumes
Ratings
the PLC.
The
safety
ofinterlock
the DISare
close
and enable
both
failures
related
to outputs
the tongue
excluded
if actuator
speed, alignment
and mechanical stops meet installation instruction requirements,
and
a
periodic
proof
test
confirms
proper
operation.
The safety function initiated by the Trojan 5-GD2 gate interlock
PowerFlex drives. The auxiliary signal of the DIS opens. The PLC
meets the safety performance requirements of SIL CL2 per IEC
compares the gate and safety relay aux signals. When both signals
Ratings
62061:2005 and has a Category 3 structure that can be used in
are open,
the PLC knows that the safety system is ready. The PLC
The safety function initiated by the Trojan 5-GD2 gate interlock meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has
systems
requiring
Performance
to PLd
per ISO 13849can now
start
and
control
the
drives
over
the
DeviceNet
network.
a Category 3 structure that can be used in systems requiring Performance Levels
up to PLd
per ISO 13849-1:2006.
ThisLevels
circuit up
executes
a Category
1:2006. This circuit executes a Category 0 stop.
The PLC
must ensure that the drives are not started upon the
0 stop.
closing of the gate; a separate, intentional action must initiate the
motor movement (this is not shown in the diagram).
- 30 R
NHP Safety Reference Guide > GSR Wiring Diagrams
3-32
Safeguarding Applications and Wiring Diagrams
Micro 400 Light Curtain
Safeguarding Applications and Wiring Diagrams
Micro 400 Light Curtain
Micro 400, 800F, MSR41, DIS, 100S:
Micro 400, 800F, MSR41, DIS, 100S
+24V DC
K1
E-Stop
800FM-MT44
800F-MX02S
Micro 400
445L-P4C0300FP
445L-AC8RJ5 (2x)
Transmitter Receiver
K2
Reset
800FMF6MX10
Status
to PLC
IN1 IN2 24V
LOGIC
Rcv
RJ45
Trans
RJ45
0V
L1L2 L3
S11 S12 S21 S22 L12 A1 Y32 S34
8
MSR41
440R-P221AGS
INFO1 INFO2 OSSD1 OSSD2
7
6 5
K1
0
1
2
3
4
K2
DIS
440R-D22S2
S32 S42 A2 34 44 14 24 L11
Start
Lockout Status
to PLC
M
K1
K2
Safety Output
Status to PLC
Stop
K1
K2 100S-C43EJ14BC
24V DC Com
Circuit
Status
Circuit
Status
Fault Detection
The light curtain is clear and the e-stop is released. The MSR41 outptus are energized. The safety outputs of the DIS are OFF. The motor is off. The
Upon
power-up,
the reset.
safety devices perform internal checks.
The light
clearThe
and
released.
TheAND
MSR41
DIS iscurtain
ready forisreset.
DISthe
hase-stop
a Logic is
setting
of 2: [(IN1
IN2) OR L12] with
monitored
manual
The OSSD outputs of the MSR41 are pulse tested to check for
outptus are energized. The safety outputs of the DIS are OFF. The
crossfaults. The e-stop signals are pulse tested to check for
motor
is off. The Principle
DIS is ready for reset. The DIS has a Logic setting
Operating
mechanically
contacts
of theoperates
100S ensure
of 2: STARTING:
[(IN1 ANDPress
IN2)the
ORreset
L12]button
with monitored
manual
reset. ON. Press thecrossfaults.
to turn the DIS
safety outputs
Start button The
to turn
the motor ON.linked
The Start
/Stop circuit
only K2, as a planned maintnenace feature. K1 does not switch motor currentthat
on, but
can switch the
current
off whenisaplaced
demandon
is placed
theitcontactors
aremotor
o after
a demand
the safety
Operating
Principle
on the safety
stystem.
system.
STOPPING:
Normal
production
stopping
performed
by pressing
the Stop button. A safety stop can be accomplished by obstructing the light
STARTING:
Press
the reset
button
to turnisthe
DIS safety
outputs
curtain or by pressing the e-stop. The motor performs a coast to stop.
Ratings
ON. Press the Start button to turn the motor ON. The Start /Stop
The safety function meets the safety performance requirements
circuit operates only K2, as a planned maintnenace feature. K1
Fault Detection
of of
SILthe
CL3
per are
IECpulse
62061:2005
CategoryThe
4 structure
that
doesUpon
not switch
motor
current
on,
but
it
can
switch
the
motor
power-up, the safety devices perform internal checks. The OSSD outputs
MSR41
tested to and
checkhas
for acrossfaults.
e-stop
can be
used
inensure
systems
Performance
up to
current
o when
a demand
placed
on the safety
signals
are pulse
tested toischeck
for crossfaults.
The stystem.
mechanically linked contacts
of the
100S
thatrequiring
the contactors
are off afterLevels
a demand
is PLe
per ISO13849-1:2006. This circuit executes a Category 0 stop.
placed on the safety system.
STOPPING: Normal production stopping is performed by
pressing
the Stop button. A safety stop can be accomplished by
Ratings
obstructing
the
light curtain
orsafety
by pressing
the e-stop.
The motor
The safety
function
meets the
performance
requirements
of SIL CL3 per IEC 62061:2005 and has a Category 4 structure that can be used in
performs
a coast
to stop.
systems
requiring
Performance Levels up to PLe per ISO13849-1:2006. This circuit executes a Category 0 stop.
- 31 R
NHP Safety Reference Guide > GSR Wiring Diagrams
3-33
Safeguarding Applications and Wiring Diagrams
Micro 400 Light Curtain
Safeguarding Applications and Wiring Diagrams
Micro 400, SensaGuard, 800F, MSR42, DIS, DI, 100S:
+24V DC
Micro 400 Light Curtain
Micro 400, SensaGuard, 800F, MSR42, DIS, DI, 100S
Mounted on Machine
to Indicate
Machine Position
Micro 400
445L-P4E0300FP
445L-AC8RJ5 (2x)
Transmitter Receiver
E-Stop
800FM-MT44
800F-MX02S
K1
K2
2 3 7 1 4 8 5 6
Stop
800FME4MX01
Brown
Green
Blue
White (Aux)
Yellow
Red
Gray (OSSD1)
Pink (OSSD2)
SensaGuard
440N-Z21S26H
889D-F8AB-2
Start
800FMF3MX10
Reset
800FMF6MX10
To PLC
IN1
IN2 +24V
GPIO1 GPIO2 GPIO3 GPIO4
S11 S21 S12 S22 L12 A1 Y32 S34
LOGIC
Rcv
RJ45
8
Trans
RJ45
MSR42
440R-P221AGS
LAMP
0V
INFO1 INFO2 OSSD1 OSSD2
7
LOGIC
0
6 5
1
2
3
4
8
DIS
440R-D22S2
S32 S42 A2 34 44 14 24 L11
L1L2 L3
S11 S12 S21 S22 A1 13 23 S34
7
6 5
K1
0
1
2
3
4
DI
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
K2
M
To PLC
K1
K2
100S-C43EJ14BC
24V DC Com
Circuit
Status
Circuit
Status
Fault Detection
The light curtain is clear; the SensaGuard is closed; and the e-stop is released. The MSR42 and DIS safety outptus are energized. The safety outputs
theIN2)
safety
devices
checks.
Theoflight
curtain
is The
clear;
the isSensaGuard
is closed;
andThe
theDIS
e-stop
the DI
are OFF.
motor
off. The DI is ready
for reset.
has a LogicUpon
settingpower-up,
of 6: [(IN1 AND
OR L12]
with perform
automaticinternal
reset. When
the
TheisOSSD
outputs
the
MSR42moves
are pulse
tested
check for
is released.
and
DIS safety
outptus
areSensaGuard,
energized.the
The
machine The
is in aMSR42
specified
postion,
as detected
by the
light curtain
bypassed.
Whenofthe
machine
away from
theto
specified
position,
the SensaGuard
turns
OFF
and
the Micro
curtain
The DI The
has aOSSD
logic setting
of 3:of[(IN1
IN2) AND L12]
crossfaults.
outputs
theOR
SensaGuard
arewith
pulse tested
safety
outputs
of the DI are
OFF.
The
motor
is o.400
Thelight
DI is
readybecomes active.
monitored
this makes
effective
(and the
or
curtain) atThe
all times.
toMicro
check400
forlight
crossfaults.
single wire safety signal (L11 to L12)
for reset.
The manual
DIS hasreset;
a Logic
settingtheofE-Stop
6: [(IN1
AND IN2)
OR SensaGuard
L12]
tests for faults to power and ground when active. The e-stop
with automatic reset. When the machine is in a specied postion,
Operating
signals are pulse tested to check for crossfaults. The mechanically
as detected
by Principle
the SensaGuard, the light curtain is bypassed.
STARTING:
Press the
reset button
turnthe
the specied
DI safety outputs
ON.the
Press the Start
button
to turn of
thethe
motor
ON.ensure
The Start
/Stop
operatesare o after
linked
contacts
100S
that
thecircuit
contactors
When
the machine
moves
away to
from
position,
only K2, as a planned maintnenace feature. K1 does not switch motor current on, but it can switch the motor current off when a demand is placed
a
demand
is
placed
on
the
safety
system.
SensaGuard
turns
OFF
and
the
Micro
400
light
curtain
becomes
on the safety stystem.
active.
The DINormal
has a logic
setting
of 3: [(IN1
OR IN2)by
AND
L12]the
with
STOPPING:
production
stopping
is performed
pressing
Stop button.
A safety stop can be accomplished by obstructing the light
Ratings
monitored
manual
reset; this
makes
thedetected
E-Stopby
eective
(and theor pressing the e-stop. The motor performs a coast to stop.
curtain when
the machine
postion
is not
the SensaGuard
The safety function meets the safety performance requirements
SensaGuard or Micro 400 light curtain) at all times.
of SIL CL3 per IEC 62061:2005 and has a Category 4 structure that
Fault Detection
Operating
Principle
Upon power-up,
the safety devices perform internal checks. The OSSD outputscan
of the
aresystems
pulse tested
to checkPerformance
for crossfaults.Levels
The OSSD
beMSR42
used in
requiring
up to PLe
outputs of
the SensaGuard
are pulse
to check
for crossfaults.
wireISO13849-1:2006.
safety signal (L11 toThis
L12) circuit
tests forexecutes
faults to power
and ground
a Category
0 stop.
STARTING:
Press
the reset button
totested
turn the
DI safety
outputs The
ON.singleper
when active. The e-stop signals are pulse tested to check for crossfaults. The mechanically linked contacts of the 100S ensure that the contactors
Press
the Start button to turn the motor ON. The Start /Stop circuit
are off after a demand is placed on the safety system.
operates only K2, as a planned maintnenace feature. K1 does not
switch
motor current on, but it can switch the motor current o
Ratings
when
a
demand
is placed
safety
stystem.
The safety
function
meets on
the the
safety
performance
requirements of SIL CL3 per IEC 62061:2005 and has a Category 4 structure that can be used in
systems requiring Performance Levels up to PLe per ISO13849-1:2006. This circuit executes a Category 0 stop.
STOPPING: Normal production stopping is performed by
pressing the Stop button. A safety stop can be accomplished by
obstructing the light curtain when the machine postion is not
detected by the SensaGuard or pressing the e-stop. The motor
performs a coast to stop.
- 32 R
NHP Safety Reference Guide > GSR Wiring Diagrams
3-34
Safeguarding Applications and Wiring Diagrams
Cat 1 Stop with Guardlocking Interlock Safeguarding
and Proximity
Sensors
Applications and Wiring Diagrams
Cat 1 Stop with Guardlocking Interlock and Proximity Sensors
TLS3-GD2, 871TM, GLP, PowerFlex 70:
TLS3-GD2, 871TM, GLP, PowerFlex 70
+24 VDC
L1 L2 L3
Reset &
Gate Lock
Request
Gate
Unlock
Request
PowerFlex 70 R
with DriveGuard
Start
ST
2 Start
Stop
Safety
Gate
A2
42 52
LOGIC
9
8
7
GLP
440R-GL2S2P
0
1 SLS1
1
2 9
2
3 8
3
4
4
7
6 5
6 5
0
TLS3 GD2
0
SLS2
1
2
9
3
8
7 6 5 4
7 DC Comm
8 Digital In Com
Gate Control
Power Supply
S12 S22 L61 A2 AP P12 P22 L11
1
3
Black
41 51
12 22
34
X14 X24 51 A1 S54 S44 Y32 L12
Brown
A1
33
Black
11 21
1 Stop
4
2
Gate
Open
Blue
Blue
6 Enable
24V DC Com
Proximity Sensors
871TM-N40NP30-D4
889D-F4AC-2
Gate
Control
Circuit
Remove Jumper U V W
M
Circuit Status
The gate is closed and locked. The motor is off. The GLP is ready for reset. The GLP has a Logic setting of 2: (Category 1 Stop with Logic IN OFF), an
OVERSPEED: If the proximity sensors detect a speed greater than
Circuit
Status
Safe Limited Speed (SLS) setting of 3 (3Hz) and a Maximum speed setting of 2 (20Hz). The safety outputs (S11 & S21), the single wire safety output
the maximum
(20Hz),
theS21
auxiliary
output
(Y32), the safety
the auxiliary
output (Y32)
OFF. is
NOTE:
Start
theisGLP
logic configuration
from “0” to speed
configure
S11 and
for use as
safety outputs.
The(L11)
gateand
is closed
and locked.
Theare
motor
o. The
GLP
ready
outputs
(S11
&
S21)
and
the
single
wire
safety
output
(L11) turn
for reset. The GLP has a Logic setting of 2: (Category 1 Stop with
off.
The
PWR/Fault
indicator
ashes
at
a
3X
rate.
When
the
speed
Operating
Principle
Logic IN OFF), a Safe Limited Speed (SLS) setting of 3 (3Hz) and
STARTING: speed
Press the
Reset button
to lock The
the gate
andoutputs
turn the GLP
ON.below
Press the
to limit,
turn the
motor
drops
theStart
maxbutton
speed
press
theON.
Reset button to clear
a Maximum
setting
of 2 (20Hz).
safety
(S11safety
& outputs
the fault and energize the safety outputs.
S21), the single wire safety output (L11) and the auxiliary output
STOPPING: Normal production stopping is performed by pressing the Stop button. Access through the safety gate is initiated by pressing the Gate
(Y32)
are OFF.
NOTE:
Start
the
GLP
logic
from
“0”initiates
to
Unlock
Request
button.
The
Y32
output
of conguration
the GLP turns OFF
and
a stop
command
to the drive. When the speed detected by the
Fault
Detection
congure
S11sensors
and S21
forbelow
use asthe
safety
outputs.
proximity
drops
safe limited
speed, the gate becomes unlocked and the safety outputs turn OFF. The PowerFlex drive goes to a
Upon power-up, the safety devices perform internal checks. The
safe off state. If the motor has not already stopped, the motor coasts to a stop.
TLS3 has dual channel signals but does not checks for crossfaults.
Operating Principle
GLP
safety
pulse
tested
to check
for(S11
faults.
OVERSPEED:
If the
sensorsto
detect
speed
greater
than the
speed
(20Hz),
theoutputs
auxiliary are
output
(Y32),
the safety
outputs
& The
STARTING:
Press
theproximity
Reset button
lock athe
gate
and turn
themaximumThe
S21) and the single wire safety output (L11) turn off. The PWR/Fault indicator flashes
at a 3Xsensors
rate. When
the
speed dropstested
below the
max
speed that
proximity
are
continuously
by
requiring
GLP safety outputs ON. Press the Start button to turn the motor
limit, press the Reset button to clear the fault and energize the safety outputs. both sensors cannot be OFF at the same time. The PowerFlex 70
ON.
requires two safety signals to enable the drive.
STOPPING:
Normal production stopping is performed by pressing
Fault Detection
the safety
devicesthe
perform
internal
The TLS3
channel signals but does not checks for crossfaults. The GLP safety
theUpon
Stoppower-up,
button. Access
through
safety
gate checks.
is initiated
by has dual Ratings
outputs
areGate
pulseUnlock
tested toRequest
check forbutton.
faults. The
proximity
sensors
tested by
requiringmeets
that both
be OFF atrequirements
the
The safety
function
thesensors
safety cannot
performance
pressing
the
The
Y32 output
ofare
thecontinuously
same time. The PowerFlex 70 requires two safety signals to enable the drive.
of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that
GLP turns OFF and initiates a stop command to the drive. When
can be used in systems requiring Performance Levels up to PLd
the speed detected by the proximity sensors drops below the safe
Ratings
per62061:2005
ISO13849-1:2006.
circuit
executes
Category
limited
speed,
the gate
becomes
unlocked
andrequirements
the safety outputs
The safety
function
meets
the safety
performance
of SIL CL2 per IEC
and has a This
Category
3 structure
thata can
be used1instop.
turnsystems
OFF. The
PowerFlex
drive goes
state.
If the motorThis circuit executes a Category 1 stop.
requiring
Performance
Levelsto
upatosafe
PLdoper
ISO13849-1:2006.
has not already stopped, the motor coasts to a stop.
- 33 NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-35
Safeguarding Applications and Wiring Diagrams
Cat 1 Stop with Guardlocking Interlock and
Proximity
Sensors
Safeguarding
Applications
and Wiring Diagrams
Cat 1 Stop with Guardlocking Interlock and Proximity Sensors
TLS3-GD2, 871TM, GLP, PowerFlex 70:
TLSZR-GD2, 872C, GLP, PowerFlex 525
+24 VDC
Gate
Unlock
Request
Reset &
Gate Lock
Request
L1 L2 L3
PowerFlex R S T
525
1 Stop
2 Start
LOGIC
9
8
7
0
1 SLS1
1
2 9
2
3
3
8
4
7 6 5 4
6 5
0
GLP
440R-GL2S2P
0
SLS2
1
2
9
3
8
7 6 5 4
S12 S22 L61 A2 AP P12 P22 L11
Gate control
power supply
Gate control
circuit
S1
S2
Black
TLS-ZR
440G-TZS21UPRH
889D-F8AC-2
Black
Green
Grey
Pink
White
Blue
4 Gnd
X14 X24 51 A1 S54 S44 Y32
UV W
M
Gate
Unlocked
Blue
Blue
Brown
Red
Yellow
Brown
Safety
Gate
Proximity Sensors
872C-D3NP12-D4
889D-F4AC-2
24V DC Com
Circuit Status
the proximity
sensors
detect
speed
greater
Circuit
The Status
gate is closed and locked. The motor is off. The GLP is ready for reset. The OVERSPEED:
GLP has a LogicIfsetting
of 2: (Category
1 Stop
with a
Logic
IN OFF),
an than
Safe
Limited
Speed
(SLS1)
setting
of
3
(3Hz)
and
a
Maximum
(SLS2)
speed
setting
of
2
(20Hz).
The
safety
outputs
(S11
&
S21),
the
single
wire
safety
the
maximum
speed
(20Hz),
the
auxiliary
output
(Y32),
the
safety
The gate is closed and locked. The motor is o. The GLP is ready
output (L11) and the auxiliary output (Y32) are OFF. NOTE: Start the GLP logic outputs
configuration
“0” to
configure
S11 and
for use
as safety
(S11from
& S21)
and
the single
wireS21
safety
output
(L11) turn
for reset.
The
GLP
has
a
Logic
setting
of
2:
(Category
1
Stop
with
outputs.
off. The PWR/Fault indicator ashes at a 3X rate. When the speed
Logic IN OFF), a Safe Limited Speed (SLS1) setting of 3 (3Hz) and
drops below the max speed limit, press the Reset button to clear
a Maximum
(SLS2)
speed setting of 2 (20Hz). The safety outputs
Operating
Principle
the fault.
(S11STARTING:
& S21), the
single
wirebutton
safetytooutput
andturn
thethe
auxiliary
Press
the reset
lock the(L11)
gate and
GLP safety outputs ON. Press the Start button to turn the motor ON.
output (Y32) are OFF. NOTE: Start the GLP logic conguration from
Fault Detection
STOPPING:
production
is performed
by pressing the Stop button. Access through the safety gate is initiated by pressing the Gate
“0” to
congureNormal
S11 and
S21 for stopping
use as safety
outputs.
Upon
power-up,
safety
perform
internal
Unlock Request button. The Y32 output of the GLP turns OFF and initiates a stop
command
to thethe
drive.
Whendevices
the speed
detected
by the checks. The
proximityPrinciple
sensors drops below the safe limited speed, the gate becomes unlocked
andhas
theOSSD
safety outputs
The PowerFlex
drive goes
a
TLSZR
outputsturn
andOFF.
checks
for crossfaults.
ThetoGLP
Operating
safe off state. If the motor has not already stopped, the motor coasts to a stop.safety outputs are pulse tested to check for faults. The proximity
STARTING: Press the reset button to lock the gate and turn the
sensors are continuously tested by requiring that both sensors
GLPOVERSPEED:
safety outputs
Presssensors
the Start
button
to greater
turn the
motor
If theON.
proximity
detect
a speed
than
the maximum speed (20Hz), the auxiliary output (Y32), the safety outputs (S11 &
cannotatbe
the same
time.
Thebelow
PowerFlex
45speed
performs its
ON. S21) and the single wire safety output (L11) turn off. The PWR/Fault indicator flashes
a 3XOFF
rate.atWhen
the speed
drops
the max
own
internal
safety
checks,
and
requires
two
safety
signals to
limit, press the Reset button to clear the fault.
STOPPING: Normal production stopping is performed by pressing
enable the drive.
the Stop button. Access through the safety gate is initiated by
Ratings
pressing
Gate Unlock Request button. The Y32 output of the
Faultthe
Detection
Theoutputs
safety and
function
the safety
requirements
GLPUpon
turnspower-up,
OFF andthe
initiates
a stop perform
command
to the
drive.
When
safety devices
internal
checks.
The
TLSZR has OSSD
checksmeets
for crossfaults.
The performance
GLP safety outputs
are
pulse tested
to check
The proximity
continuously
bySIL
requiring
thatIEC
both
sensors cannot
OFFa at
the same3time.
The that
CL2 per
62061:2005
andbehas
Category
structure
the speed
detected
byfor
thefaults.
proximity
sensorssensors
dropsare
below
the safetestedof
PowerFlex
performs
its own internal
safety and
checks,
requires
two safety signals
enable
drive. requiring Performance Levels up to PLd
can betoused
in the
systems
limited
speed,45the
gate becomes
unlocked
theand
safety
outputs
per ISO13849-1:2006. This circuit executes a Category 1 stop.
turn OFF. The PowerFlex drive goes to a safe o state. If the motor
has Ratings
not already stopped, the motor coasts to a stop.
The safety function meets the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that can be used in
systems requiring Performance Levels up to PLd per ISO13849-1:2006. This circuit executes a Category 1 stop.
- 34 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-36
Safeguarding Applications and Wiring Diagrams
Safe Limited Speed with Guardlocking Interlock
Proximity
Sensors
Safeguardingand
Applications
and Wiring
Diagrams
Safe Limited Speed with Guardlocking Interlock and Proximity Sensors
TLSZR-GD2, 871TM, GLP, PowerFlex 70:
TLSZR-GD2, 871TM, GLP, PowerFlex 70
+24 VDC
L1 L2 L3
Reset &
Gate Lock
Request
Gate
Unlock
Request
PowerFlex 70
with DriveGuard
R ST
9 24VDC
2 Start
1 Stop
3 Speed Select 1
7 DC Comm
Safety
Gate
8 Digital In Com
TLS-ZR
440G-TZS21UPRH
889D-F8AC-2
GLP
440R-GL2S2P
0
1 SLS1
1
2 9
2
3
3
8
4
7 6 5 4
6 5
0
0
SLS2
1
2
9
3
8
7 6 5 4
S12 S22 L61 A2 AP P12 P22 L11
Gate Control
Power Supply
1
3
4
2
6 Enable
Black
White
Blue
LOGIC
9
8
7
Black
Green
Grey
Pink
X14 X24 51 A1 S54 S44 Y32 L12
Brown
Brown
Red
Yellow
Gate
Control
Circuit
Remove Jumper U V W
Blue
Blue
M
24V DC Com
Proximity Sensors
871TM-N40NP30-D4
889D-F4AC-2
Circuit Status
Detection
Circuit
TheStatus
gate is closed and locked. The motor is off. The GLP is ready for reset. TheFault
GLP has
a Logic setting of 4: (Safe Limited Speed with Logic IN
OFF), a Safe Limited Speed (SLS) setting of 5 (5Hz) and a Maximum speed setting of 8 (2000Hz). The safety outputs (S11 & S21), the single wire
Upon power-up, the safety devices perform internal checks. The
The gate
is closed and locked. The motor is o. The GLP is ready for
safety output (L11) and the auxiliary output (Y32) are OFF. NOTE: Start the GLP logic configuration from “0” to configure S11 and S21 for use as
TLSZR has OSSD outputs and checks for crossfaults. The GLP
reset.safety
The GLP
has a Logic setting of 4: (Safe Limited Speed with
outputs.
safety outputs are pulse tested to check for faults. The proximity
Logic IN OFF), a Safe Limited Speed (SLS) setting of 5 (5Hz) and a
sensors are continuously tested by requiring that both sensors
Maximum
speedPrinciple
setting of 8 (2000Hz). The safety outputs (S11 &
Operating
cannot
OFFON.
at the
same
time.button to turn the motor ON.
S21),STARTING:
the single
wire
safety
andGLP
thesafety
auxiliary
output
Press
the
Reset output
button to(L11)
turn the
outputs
and single wire
safetybe
output
Press
the Start
(Y32) are OFF. NOTE: Start the GLP logic conguration from “0” to
The PowerFlex
70 requires
signals
to enable
STOPPING:
Normal
is performed by pressing the Stop button.
Access through
the safetytwo
gatesafety
is initiated
by pressing
the the drive.
congure
S11 and
S21production
for use as stopping
safety outputs.
If thethe
gate
is unlocked
the
motor
increases
beyond the
Gate Unlock Request button. The Y32 output of the GLP turns ON and commands
PowerFlex
drive toand
bring
the
motorspeed
to a safe
slow speed
(less than
5Hz). When the speed detected by the proximity sensors drops below
safe limited
speed
the gate
unlocked.
safethe
limited
speed,
the(5Hz),
GLP turns
itsbecomes
safety and
single The
wire safety
Operating
Principle
operator can enter the machine cell, as the motor continues to run at the safeoutputs
slow speed.
OFF.After leaving the cell and closing the gate, press the
STARTING: Press the Reset button to turn the GLP safety outputs
reset button to lock the gate and return the machine to production speeds.
and single wire safety output ON. Press the Start button to turn
the motor
ON.
Fault Detection
OVERSPEED: If the proximity sensors detect a speed greater than
the maximum speed (2000Hz), the safety and the single wire
Upon power-up, the safety devices perform internal checks. The TLSZR has OSSD
outputs
and checks
for crossfaults.
The GLP
safety outputs
outputs
turn OFF.
The PWR/Fault
indicator
ashesare
at a 3X
STOPPING:
Normal
production
is performed
pressing testedsafety
pulse tested
to check
for faults.stopping
The proximity
sensors are by
continuously
by requiring that both sensors cannot be OFF at the same time.
rate.
When
the
speed
drops
below
the
max
speed
limit,
press the
the Stop
button. Access
through
the safety
is initiated
The PowerFlex
70 requires
two safety
signals gate
to enable
the drive.byIf the gate is unlocked and the motor speed increases beyond the safe limited
Reset button to clear the fault.
pressing
the
Unlock
Request
The
Y32outputs
outputOFF.
of
speed,
theGate
GLP turns
its safety
and button.
single wire
safety
the GLP turns ON and commands the PowerFlex drive to bring
Ratings
OVERSPEED:
If theslow
proximity
sensors
detect5Hz).
a speed
greater
the maximum speed (2000Hz), the safety and the single wire safety outputs
the motor
to a safe
speed
(less than
When
thethan
speed
safety
function
meets
thethe
safety
turn OFF. The PWR/Fault indicator flashes at a 3X rate. When the speed dropsThe
below
the max
speed limit,
press
Resetperformance
button to clearrequirements
the fault.
detected by the proximity sensors drops below the safe limited
of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that
speed (5Hz), the gate becomes unlocked. The operator can enter
Ratings
can be used in systems requiring Performance Levels up to PLd
the machine
as the
motor
continues
to run requirements
at the safe slow
The safetycell,
function
meets
the safety
performance
of SIL CL2 perper
IECISO13849-1:2006.
62061:2005 and has This
a Category
structure that
can be
used inSpeed
circuit3 executes
a Safe
Limited
speed.
Afterrequiring
leaving Performance
the cell andLevels
closing
the
gate,
press the reset This circuit executes a Safe Limited Speed function.
systems
up to
PLd
per ISO13849-1:2006.
function.
button to lock the gate and return the machine to production
speeds.
- 35 NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-37
Safeguarding Applications and Wiring Diagrams
Overspeed Only Detection
Safeguarding Applications and Wiring Diagrams
Overspeed Only Detection
872C, GLP, PowerFlex 525:
872C, GLP, PowerFlex 525
+24 VDC
L1 L2 L3
Reset
PowerFlex R S T
525
1 Stop
2 Start
11 +24V DC
800F-POT6
X14 X24 51 A1 S44 S54 Y32 L12
LOGIC
9
8
7
0
0
1 SLS1
1
2 9
2
3
3
8
4
4
7
6 5
6 5
GLP
440R-GL2S2P
0
SLS2
1
2
9
3
8
4
7 6 5
4 Gnd
Gate control
power supply
Gate control
circuit
Black
Black
Blue
Blue
Brown
S12 S22 L61 A2 AP P12 P22 L11
24V DC Com
12 Analog
13 Speed
14 Control
S1
S2
Proximity Sensors
872C-D8NP18-D4 (2)
889D-F4AC-2
U V W
M
Circuit Status
The motor is off. The GLP is ready for reset. The GLP has a Logic setting of 1: (Cat 1Stop with Logic IN OFF), a Safe Limited Speed (SLS1) setting of 0
(0.5 Hz) and a maximum (SLS2) speed setting of 5 (200 Hz). Both E-Stops are closed. NOTE: Start the GLP logic configuration from “0” to configure
OVERSPEED: When the GLP detects overspeed, X14, X24 and L11
Circuit
X14Status
and X24 for use as safety outputs.
will turn OFF and the PWR/Fault indicator wiil show green with
The motor is off. The GLP is ready for reset. The GLP has a Logic
4 red ashes. To recover, reduce the speed below the SLS2 setting
Operating
setting
of 1: (CatPrinciple
1Stop with Logic IN OFF), a Safe Limited Speed
and press
the
Reset200Hz.
button to re-enable the PowerFlex 525 drive.
The
GLP
is
only
used
to
execute
a
safety
stop
if
the
speed
detected
by
the
proximity
sensors
exceeds
(SLS1) setting of 0 (0.5 Hz) and a maximum (SLS2) speed setting
of 5 (200 Hz). Both E-Stops are closed. NOTE: Start the GLP logic
Detection
STARTING: Press the Reset button to turn the GLP safety outputs (X14 and X24)Fault
ON. This
enables the PowerFlex 525 drive. Press the Start button to
conguration
fromON.
“0” Adjust
to congure
X14 andtoX24
for the
usespeed
as safety
turn the motor
the 800F-POT6
control
of the motor. Upon power-up, the GLP and PowerFlex 525 perform internal
outputs.
checks. If the checks are completed safely, the GLP will be ready
STOPPING: Normal production stopping is performed by manually reducing the speed of the motor by turning the 800F-POT6 or by pressing the
forGLP
reset.
At outputs
least one
sensors must
be ON.
Operating
Principle
Stop button. If the speed detected by the proximity sensors exceeds 200Hz, the
safety
turnproximity
OFF. The PowerFlex
525 drive
executes a
0 stop
andto
theexecute
motor coasts
to a stop
stop. if the speed
The Category
GLP is only
used
a safety
detected by the proximity sensors exceeds 200Hz.
Ratings
safety
functions
meetwiil
the
safety
performance
requirements
OVERSPEED: When the GLP detects overspeed, X14, X24 and L11 will turn OFFThe
and the
PWR/Fault
indicator
show
green
with 4 red flashes.
To
recover, Press
reducethe
the Reset
speed below
andsafety
press the
Reset button to
the PowerFlex
525 drive.
ofre-enable
SIL CL2 per
IEC 62061:2005
and has a Category 3 structure
STARTING:
buttonthetoSLS2
turnsetting
the GLP
outputs
that can be used in systems requiring Performance Levels up to
(X14 and X24) ON. This enables the PowerFlex 525 drive. Press
PLd per ISO13829-1:2008. This circuit executes a Category 0 stop
the Start button to turn the motor ON. Adjust the 800F-POT6 to
Fault Detection
when the spped exceeds 200Hz.
control the speed of the motor.
Upon power-up, the GLP and PowerFlex 525 perform internal checks. If the checks are completed safely, the GLP will be ready for reset. At least
one proximity
sensors
must be ON.
STOPPING:
Normal
production
stopping is performed by
manually reducing the speed of the motor by turning the
Ratingsor by pressing the Stop button. If the speed detected
800F-POT6
The safety functions meet the safety performance requirements of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that can be used in
by the
proximity
sensors
exceeds
200Hz,
safety outputs This circuit executes a Category 0 stop when the spped exceeds 200Hz.
systems
requiring
Performance
Levels
up tothe
PLdGLP
per ISO13829-1:2008.
turn OFF. The PowerFlex 525 drive executes a Category 0 stop and
the motor coasts to a stop.
- 36 NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-38
Safeguarding Applications and Wiring Diagrams
Category 1 Stop with Guardlocking Interlock
and Proximity
Sensors
Safeguarding
Applications and
Wiring Diagrams
Category 1 Stop with Guardlocking Interlock and Proximity Sensors
TLS3-GD2, 800F, 872C, GLP, DIS, PowerFlex 70:
TLS3-GD2, 800F, 872C, GLP, DIS, PowerFlex 70
+24 VDC
L1 L2 L3
Reset &
Gate Lock
Request
Gate
Unlock
Request
1 Stop
E-Stop
42 52
GLP
440R-GL2S2P
S12 S22 L61 A2 AP P12 P22 L11
TLS3 GD2
440G-T27183
S11 S21 S22 S12 S42 S32 A1 Y32
DIS
440R-D22S2
7
7 DC Comm
8 Digital In Com
Gate Control
Power Supply
0
LOGIC
8
Safety
Status
to PLC
6 5
1
2
3
4
A1
L11 L12 A2 34 44 14 24 S34
Reset
1
3
4
2
6 Enable
Gate
Control
Circuit
Remove Jumper U V W
Gate Status
to PLC
24V DC Com
Stop
Black
A2
41 51
34
0
SLS2
1
2
9
3
8
7 6 5 4
Black
12 22
0
1 SLS1
1
2 9
2
3
3
8
4
4
7
6 5
6 5
0
Blue
Blue
A1
LOGIC
9
8
7
Brown
33
11 21
X14 X24 51 A1 S54 S44 Y32 L12
R ST
2 Start
800FM-MT44MX02V
Safety
Gate
PowerFlex 70
with DriveGuard
Start
Proximity Sensors
872C-M8NP18-D4
889D-F4AC-2
M
Circuit Status
The Status
gate is closed and locked. The motor is off. The GLP is ready for reset. The The
GLP has
a Logic
settingcan
of 1:be
(Cat
1 Stop
Logica IN
OFF), a Safe
E-stop
buttons
used
towith
initiate
“coast-to-stop”.
Press
Circuit
Limited Speed (SLS) setting of 9 (10 Hz) and a maximum (MAX) speed setting of 7 (1000 Hz). Both E-Stops are closed. The DI is configured to
the
e-stop
and
the
DI
outputs
turn
o,
which
causes
the
PowerFlex
The setting
gate is4closed
and
TheINmotor
is off. Themanual
GLP isreset).
readyNOTE: Start the GLP logic configuration from “9” to configure X14 and X24 for
(IN1 AND
IN2locked.
AND LOGIC
with monitored
drive to execute a Safe-O function. The motor coasts to a stop.
use with
safety
for reset.
The
GLPinputs.
has a Logic setting of 1: (Cat 1 Stop with Logic
IN OFF), a Safe Limited Speed (SLS) setting of 9 (10 Hz) and a
Fault Detection
Operating
Principle
maximum
(MAX)
speed setting of 7 (1000 Hz). Both E-Stops are
safety
devices
perform
checks. The
STARTING: Press the Reset button to turn the GLP safety output (L11) ON. ThisUpon
enablespower-up,
the DI relay.the
Press
the Reset
button
to turn internal
the DI outputs
closed.
The DI is congured to setting 4 (IN1 AND IN2 AND LOGIC
ON and enable the Safe-Off Option of the PowerFlex Drive. Press the Start button
turnDI
the
motor
ON.
GLPtoand
send
out
test pulses on X14 and X24 to check for faults
IN with monitored manual reset). NOTE: Start the GLP logic
on the guardlocking switch and e-stops. The GLP checks to see
conguration
“9”production
to congure
X14 and
X24 for use
with safety
STOPPING:from
Normal
stopping
is performed
by pressing
the Stop button. Access through the safety gate is initiated by pressing the
that the proximiity sensors are connected, by requiring that both
inputs.
Unlock Request button. The Y32 output of the GLP turns OFF and initiates a stop command to the drive. When the motor speed drops below the
sensors
cannot the
be DI
OFF
at the
sameoutputs
time. The
L11/L12
safe limited speed, the GLP unlocks the gate and turns its L11 safety output OFF.
Subsequently
turns
its safety
off, and
the connection
is
Single
Wire
Safety
connection
tested
for
shorts
to power or
Operating
Principle
PowerFlex drive goes to a Safe-Off state. The motor, if not already stopped, coasts to a stop.
ground
when
active.
The
DIS
outputs
14
&
24
are
pulse
tested to
STARTING: Press the Reset button to turn the GLP safety output
The E-stop buttons can be used to initiate a “coast-to-stop”. Press the e-stop and
the DI
outputs
off, which
causes
the PowerFlex
to 34 & 44,
check
for
shortsturn
to power
and
ground.
The DIS drive
outputs
(L11) ON. This enables the DI relay. Press the Reset button to turn
execute a Safe-Off function. The motor coasts to a stop.
which are not pulse tested, should be used for compatibility with
the DI outputs ON and enable the Safe-O Option of the PowerFlex
devices that cannot tolerate the pulse testing.
Drive. Press the Start button to turn the motor ON.
Fault Detection
Upon power-up, the safety devices perform internal checks. The GLP and DI send
out test pulses on X14 and X24 to check for faults on the
Ratings
STOPPING:
Normal production stopping is performed by pressing
guardlocking switch and e-stops. The GLP checks to see that the proximiity sensors are connected, by requiring that both sensors cannot be OFF
Thefor
safety
functions
meet
thewhen
safety
performance
requirements
the Stop
Access
through
the safety
gate Wire
is initiated
by
at the button.
same time.
The L11/L12
connection
is Single
Safety connection
tested
shorts
to power or
ground
active.
The DIS outputs
14
of34SIL
CL2which
per IEC
62061:2005
and
has abeCategory
pressing
thepulse
Unlock
Request
Y32 output
of theThe
GLP
& 24 are
tested
to checkbutton.
for shortsThe
to power
and ground.
DIS outputs
& 44,
are not
pulse tested,
should
used for 3 structure
compatibility
with devices
thatcommand
cannot tolerate
thedrive.
pulse When
testing.the
that can be used in systems requiring Performance Levels up to
turns
OFF and initiates
a stop
to the
PLd per ISO13849-1:2006. This circuit executes a Category 1 stop
motor speed drops below the safe limited speed, the GLP unlocks
Ratings
when requesting gate access through the GLP, and a Category 0
the gate
and turns its L11 safety output OFF. Subsequently the
The safety
functions
meet o,
theand
safety
of SIL
IEC 62061:2005
and hasthe
a Category
when pressing
e-stops.3 structure that can be used in
DI turns
its safety
outputs
theperformance
PowerFlexrequirements
drive goes to
a CL2 perstop
systems requiring Performance Levels up to PLd per ISO13849-1:2006. This circuit executes a Category 1 stop when requesting gate access
Safe-O
state.
The
motor,
if
not
already
stopped,
coasts
to
a
stop.
through the GLP, and a Category 0 stop when pressing the e-stops.
- 37 NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-39
Safeguarding Applications and Wiring Diagrams
Safe Limited Speed with Guardlocking Interlock
and Proximity Sensors
Safeguarding Applications and Wiring Diagrams
with
Guardlocking Interlock and Proximity Sensors
TLS3-GD2, 800F,Safe
872C,Limited
GLP, DI, Speed
PowerFlex
525:
TLS3-GD2, 800F, 872C, GLP, DI, PowerFlex 525
+24 VDC
Reset &
Gate Lock
Request
Gate
Unlock
Request
L1 L2 L3
E-Stop
800FM-MT44
800F-MX02S
Reset
PowerFlex R S T
525
1 Stop
2 Start
5 Preset Freq
(SLS)
A2
42 52
0
1 SLS1
1
2 9
2
9
3
3
8
8
4
7
7 6 5 4
6
5
GLP
LOGIC
440R-GL2S2P
0
SLS2
9
8
7 6 5
1
2
3
4
S12 S22 L61 A2 AP P12 P22 L11
TLS3 GD2
440G-T27183
Gate
Open
24V DC Com
0
S11 S12 S21 S22 A1 13 23 S34
LOGIC 0
8
7
6
DI
440R-D22R2
1
2
3
5
4 DC Com
4
S32 S42 L11 L12 A2 14 24 Y32
Gate control
power supply
Gate control
circuit
Black
41 51
12 22
34
X14 X24 51 A1 S54 S44 Y32 L12
Black
A1
33
Blue
Blue
11 21
Brown
Safety
Gate
S1
S2
Proximity Sensors
872C-D8NP18-D4
889D-F4AC-2
Safety
Status
to PLC
UV W
M
Circuit Status
leaving
closing
gate,
the reset
Circuit
The Status
gate is closed and locked. The motor is off. The GLP is ready for reset. Thespeed.
GLP hasAfter
a Logic
setting the
of 3: cell
(Safeand
limited
Speedthe
with
Logicpress
IN OFF),
a Safe Limited Speed (SLS) setting of 9 (10 Hz) and a maximum (MAX) speed setting
of 7to(1000
Hz).
Both
E-Stops
are closed.
The DI is configured
to
button
lock
the
gate
and
return
the
machine
to
production
The gate is closed and locked. The motor is off. The GLP is ready
setting 4 (IN1 AND IN2 AND LOGIC IN with monitored manual reset). The single
wire safety output (L11) and the GLP auxiliary output (Y32) are
speeds.
for reset.
TheDIGLP
hasoutputs
a Logic
limited
Speed
OFF. The
safety
aresetting
off and of
the3:DI(Safe
auxiliary
output
(Y32) with
is ON . NOTE: Start the GLP logic configuration from “9” to configure X14 and
Logic
IN OFF),
a Safe
Limited
X24for
use with
safety
inputs.Speed (SLS) setting of 9 (10 Hz) and
The E-stop buttons can be used to initiate a “coast-to-stop”. Press
a maximum (MAX) speed setting of 7 (1000 Hz). Both E-Stops are
the e-stop and the DI outputs turn o, which commands the drive
closed.
The DI isPrinciple
congured to setting 4 (IN1 AND IN2 AND LOGIC
Operating
to a safe off state. The motor coasts to a stop.
STARTING:
Press the
Reset button
turn
the GLP
safety
outputs
(L11) ON. This enables the DI relay. Press the Reset button to turn the DI outputs
IN with
monitored
manual
reset).to
The
single
wire
safety
output
ON
and
enable
the
PowerFlex
Drive.
Press
the
Start
button
to
turn
the
motor
ON.
Fault Detection
(L11) and the GLP auxiliary output (Y32) are OFF. The DI safety
outputs
are o and the DI auxiliary output (Y32) is ON . NOTE: Start
UponAccess
power-up,
the
perform
internalthe
checks.
STOPPING: Normal production stopping is performed by pressing the Stop button.
through
thesafety
safety devices
gate is initiated
by pressing
Gate The
the GLP
logic
conguration
from
to congure
and
use
GLP
and DI send
out
testthe
pulses
to (less
check
for faults
Unlock
Request
button. The
Y32“9”
output
of the GLPX14
turns
ONX24for
and commands
the
PowerFlex
drive to
bring
motoron
to S11
a safeand
slowS21
speed
than
with10Hz).
safetyWhen
inputs.
onlimited
the guardlocking
switch
e-stops.
The GLP
the speed detected by the proximity sensors drops below the safe
speed (10Hz), the
gate and
becomes
unlocked.
The checks
operatorto see
can enter the machine cell, as the motor continues to run at the safe slow speed.
the cell
and closing
the gate, press
reset button
thatAfter
theleaving
proximiity
senors
are connected,
by the
requiring
that both
Operating
Principle
to lock the
gate and return the machine to production speeds.
sensors cannot be OFF at the same time. The L11/L12 connection
STARTING: Press the Reset button to turn the GLP safety outputs
is Single Wire Safety connection tested for shorts to power or
E-stop buttons can be used to initiate a “coast-to-stop”. Press the e-stop and the DI outputs turn off, which commands the drive to a safe off
(L11)The
ON.
This enables the DI relay. Press the Reset button to turn
ground when active.
state. The motor coasts to a stop.
the DI outputs ON and enable the PowerFlex Drive. Press the Start
Ratings
button to turn the motor ON.
Fault Detection
Theout
safety
functions
thetosafety
Upon power-up,
safety devices
performisinternal
checks.by
The
GLP and DI send
test pulses
on S11meet
and S21
check performance
for faults on therequirements
STOPPING:
Normalthe
production
stopping
performed
pressing
guardlocking switch and e-stops. The GLP checks to see that the proximiity senors
connected,
by requiring that
cannot3be
OFF
of SILare
CL2
per IEC 62061:2005
andboth
hassensors
a Category
structure
that
the Stop
Access
through
the safety
gate Wire
is initiated
by
at the button.
same time.
The L11/L12
connection
is Single
Safety connection
tested
or ground
whenPerformance
active.
can for
beshorts
used to
inpower
systems
requiring
Levels up to PLd
pressing the Gate Unlock Request button. The Y32 output of the
per ISO13849-1:2006. This circuit executes a Safe Limited Speed
GLPRatings
turns ON and commands the PowerFlex drive to bring the
function when requesting gate access through the GLP, and a
motor
a safe
slow speed
(less
than
10Hz). When
the speed
Theto
safety
functions
meet the
safety
performance
requirements
of SIL CL2 per IEC 62061:2005 and has a Category 3 structure that can be used in
Category 0 stop when pressing the e-stops.
systems
Performance
Levels
up tobelow
PLd perthe
ISO13849-1:2006.
detected
byrequiring
the proximity
sensors
drops
safe limited This circuit executes a Safe Limited Speed function when requesting gate
access
through
the
GLP,
and
a
Category
0
stop
when
pressing
the
e-stops.
speed (10Hz), the gate becomes unlocked. The operator can enter
the machine cell, as the motor continues to run at the safe slow
- 38 -
NHP Safety Reference Guide > GSR Wiring Diagrams
R
3-40
Safeguarding Applications and Wiring Diagrams
E-Stops with Speed Monitored Guardlocking
Interlock
andand
Contactors
Safeguarding
Applications
Wiring Diagrams
E-Stops with Speed Monitored Guardlocking Interlock and Contactors
TLS-GD2, 872C, GLP, DI and Contactors:
TLS-GD2, 872C, GLP, DI and Contactors
+ 24V DC
Reset &
Gate Lock
Request
Gate Unlock
Request
K1
K2
X14 X24 51 A1 S44 S54 Y32 L12
A1
41 51
A2
42
52
Gate
Open
9
8
76 5
0
1
2
3
4
SL1
GLP
440R-GL2S2P
9
8
0
7 6 5
1
2
3
4
0
SL2
9
8
7 6 5
1
2
3
4
S12 S22 L61 A2 AP P12 P22 L11
Brown
Black
12 22 34
LOGIC
Brown
872C-D8NP18-E5 (2)
S11 S12 S21 S22 A1 13
LOGIC
8
7
6 5
DI
440R-D22R2
23 S34
0
K1
1
2
3
4
K2
S32 S42 L12 L11 A2 14
24 Y32
Safety
Status
to PLC
Black
11 21 33
External
StartStop
Control
Reset
SLS Request
to PLC
TLS3-GD2
440G-T27260
Solenoid
E-Stops
800FM-MT44
800F-MX02S
Blue
M
100S-C09EJ14BC
Blue
K1
K2
24V DC COM
Circuit Status
Detection
Circuit Status
The gate is closed and locked. The motor is off. The GLP is ready for reset. TheFault
GLP has
a Logic setting of 3: (Safe Limited Speed with Logic in OFF),
Safe
Limitedand
Speed
(SL1) setting
of 1(1 Hz)
and
a maximum
(SL2) setting of 8Upon
(2000Hz).
The singlethe
wiresafety
safety output
(L11)DI
and
the auxiliary
power-up,
GLP and
perform
internal checks.
The gatea is
closed
locked.
The motor
is o.
The
GLP is ready
(Y32)has
are OFF.
NOTE:
Start the
configuration
from
“9” to configureThe
X14 and
as test
pulse outputs
for usedevices
with the electroGLPX24
and
DI check
their input
for faults. The proximity
for reset.output
The GLP
a Logic
setting
ofGLP
3: (Safe
Limited
Speed
mechanical TLS3-GD2 contacts. Both E-Stops are released. The DI is ready for reset.
sensors are constantly monitored by requiring that only one
with Logic in OFF), a Safe Limited Speed (SL1) setting of 1(1
sensor is OFF at any time. An auxiliary NC contact from each
Hz) and a maximum (SL2) setting of 8 (2000Hz). The single wire
Operating
contactor is connected in series with the DI reset contact so that
safety output
(L11)Principle
and the auxiliary output (Y32) are OFF. NOTE:
should a contactor become welded closed the DI cannot be reset;
Start theSTARTING:
GLP conguration
from
“9”
to
congure
X14
and
X24
as
Press and release the Reset button of the GLP. The gate locks, and the L11 output turns ON. Press and release the reset button of the
motor
cannot
be started.
test pulse
for contacts
use with
theand
electromechanical
TLS3-GD2
DI. outputs
The DI safety
close
energize the contactor
coils. The externalthe
start-stop
control
can now
start the motor.
contacts. Both E-Stops are released. The DI is ready for reset.
Ratings
STOPPING: Normal production start-stop is performed by an external start-stop control. When an E-Stop is pressed the DI immediately de-energizes
Operating
Principle
the two
contactors. The motor coasts to a stop. When the speed detected by theEmergency
proximity sensors
drops
below the
speed
the GLP
stop
initiated
bysafe
anlimited
E-Stop
(2):(1Hz)
These
safety
unlocks
thegate.
The operator
safely
enter the
area.
After
leaving the
area and closing
the operator
presses and
releases the GLPof SIL3 per
functions
meetthe
thegate
safety
performance
requirements
STARTING:
Press
and release
thecan
Reset
button
ofguarded
the GLP.
The
gate
reset button to lock the gate. The E-Stops must be released before the DI can be reset. Press and release the DI reset to energize the contactors. The
IEC 62061: 2005 and have a Category 4 structure, can be used in
locks, and
the L11 output turns ON. Press and release the reset
external circuit can nowstart the motor.
systems requiring Performance Levels up to PLe per ISO 13849button of the DI. The DI safety contacts close and energize the
1:2006
execute
category
stops.
contactor
coils. TheIf the
external
start-stop
canthe
now
start the
OVERSPEED:
GLP detects
a speedcontrol
greater than
maximum
speed (2000Hz),
the and
GLP single
wire asafety
output 0L11
turns OFF. The DI
motor. de-energizes the two contactors and the motor coasts to a stop. The gate can not be unlocked until speed is less than 1 Hz. Should the speed
Emergency
stop initiated by an an Overspeed: This safety
increase above safe limited speed while the gate is unlocked, the GLP turns OFF its safety
outputs..
function meets the safety performance requirements of SIL2 per
STOPPING: Normal production start-stop is performed by an
IEC 62061: 2005 and has a Category 3 structure, can be used in
externalFault
start-stop
control. When an E-Stop is pressed the DI
Detection
Levelssensors
up toarePLd
per ISO 13849immediately
de-energizes
theGLP
twoand
contactors.
The motor
coasts
Upon power-up,
the safety
DI perform internal
checks.
The GLP and DIsystems
check theirrequiring
input devicesPerformance
for faults. The proximity
constantly
contactor
is connected
in series0with
the DI reset contact so
monitored
by requiring
only one sensor
is OFF
at any time.sensors
An auxiliary NC contact
from each
1:2006
and
executes
a category
stop.
to a stop.
When the
speedthat
detected
by the
proximity
that should
contactor
become
welded
closed
theGLP
DI cannot
be reset; the motor cannot be started.
drops below
the asafe
limited
speed
(1Hz)
the
unlocks
Prevention of access while dangerous motion is present: This
thegate. The operator can safely enter the guarded area. After
safety function meets the safety performance requirements of
Ratings
leaving the area and closing the gate the operator presses and
Emergency stop initiated by an E-Stop (2): These safety functions meet the safety
performance
requirements
of SIL3
IEC 62061: 3
2005
and
SIL2 per
IEC 62061:
2005 and
has per
a Category
structure
and can
releaseshave
the aGLP
reset4button
lock
the in
gate.
Therequiring
E-StopsPerformance
must
Category
structure,to
can
be used
systems
Levels
up to PLe
per ISO 13849-1:2006
execute a category
stops.
be used
in systems
requiring and
Performance
Levels0 up
to PLd per
be released
beforestop
theinitiated
DI can be
reset.
Press andThis
release
DI meets the safety performance requirements of SIL2 per IEC 62061: 2005 and
Emergency
by an
an Overspeed:
safety the
function
ISO 13849-1:2006.
reset to has
energize
the3contactors.
external
circuit
can Performance
nowstart Levels up to PLd per ISO 13849-1:2006 and executes a category 0 stop.
a Category
structure, can The
be used
in systems
requiring
Prevention of access while dangerous motion is present: This safety function
meets the safety
performance requirements
of SIL2Monitoring):
per IEC 62061: This
the motor.
Prevention
of unexpected
start-up (Gate
2005 and has a Category 3 structure and can be used in systems requiring Performance Levels up to PLd per ISO 13849-1:2006.
safety function meets the safety performance requirements of
OVERSPEED:
If theofGLP
detectsstart-up
a speed(Gate
greater
than the
Prevention
unexpected
Monitoring):
This safety function meets the safety performance requirements of SIL2 per IEC
SIL2 per IEC
62061:2005
and
a Category
structure,
62061:2005
and has a Category
3 structure,
can be
used in
systemsL11
requiring Performance
Levels
up to PLd per
ISOhas
13849-1:2006.
The3system
can can be
maximum
speed (2000Hz),
the GLP
single wire
safety
output
used the
in systems
requiring
Performance Levels up to PLd per ISO
not
started
if
stopped
nor
put
into
production
speed
from
safe
limited
speed
unless
gate
is
closed
and
locked.
turns OFF. The DI de-energizes the two contactors and the motor
13849-1:2006. The system can not started if stopped nor put
coasts to a stop. The gate can not be unlocked until speed is less
into production speed from safe limited speed unless the gate is
than 1 Hz. Should the speed increase above safe limited speed - 39 closed and locked.
while the gate is unlocked, the GLP turns OFF its safety outputs.
R
NHP Safety Reference Guide > GSR Wiring Diagrams
3-41
Safeguarding Applications and Wiring Diagrams
Safe Limited Speed with Guardlocking, E-Stops
and
Servo Drive
Safeguarding
Applications
and Wiring Diagrams
Safe Limited Speed with Guardlocking, E-stops and Servo Drive
440G, 800F, 872C, GLP, DI, K300 Servo
440G, 800F, 872C, GLP, DI, K300 Servo
Red
LightLatch
440G-LZS21SPRA
Pink
Grey
Blue
White
X14 X24 51 A1 S44 S54 Y32 L12
9
8
76 54
2
3
GLP
440R-GL2S2P
Reset
SLS
Request
to PLC
Green
LOGIC 0 1
Drive Status
to PLC
Gate
Unlock
Request
Reset &
Gate Lock
Request
Yellow
Brown
+24V DC
SL1
9
8
0
1
2
3
7 6 54
SL2
9
8
0
1
2
3
7 6 54
S12 S22 L61 A2 AP P12 P22 L11
Brown
Brown
872C-D8NP18-E5 (2)
LOGIC
8
0
DI
6 5
440R-D22R2
7
23 S34
1
2
3
4
S32 S42 L12 L11 A2 14
24 Y32
K300
Safe Torque-off (STO)
Connector With
Wiring Header
Status
Safety Input 1
Safety Common
Safety Input 2
Black
Black
Gate Open
- Unlocked
S11 S12 S21 S22 A1 13
Safety
Status
to PLC
Stop/Start/SLS
Commands
from PLC
Blue
Blue
E-Stops
800FM-MT44
800F-MX02S
M
24V DC COM
Circuit Status
The gate is closed and locked. The motor is off. The E-Stops are released and the
DI iscontacts
ready for reset.The
GLP is
ready
forTorque
reset. The
a Logic the PLC
Circuit Status
safety
energizing
the
Safe
O GLP
andhas
allowing
setting of 3: Safe Limited Speed with Logic in OFF, a Safe Limited Speed (SL1)control
setting ofto0 return
(0.5 Hz) and
maximum
(SL2) settingspeed.
of 4 (100Hz).
The the speed
the adrive
to production
Should
The gate is single
closedwire
and
locked.
The
motor
is
o.
The
E-Stops
are
released
safety output (L11) and the auxiliary output (Y32) are OFF. NOTE: Start
the GLP
configuration
from “0”
to configure
the GLP
increase
above
safe limited
speed
while the
gatetoisaccept
unlocked the GLP
and the DI is
ready
for
reset.The
GLP
is
ready
for
reset.
The
GLP
has
OSSD inputs at S12 and S22.
turns OFF its single wire safety. The DI immediately opens its safety
a Logic setting of 3: Safe Limited Speed with Logic in OFF, a Safe
contacts controlling the Safe Torque O of the drive. The drive removes
Limited Speed
(SL1)
setting
of
0
(0.5
Hz)
and
a
maximum
(SL2)
setting
Operating Principle
theGLP.
motor
motor
coasts
to aofstop.
of 4 (100Hz).
The single
safety
outputbefore
(L11)the
and
STARTING:
The wire
GLP must
be started
DI.the
Pressauxiliary
and release the Resetpower
button to
of the
Pressand
and the
release
the reset
button
the DI to
close
safety
contacts
allow
the motor by the
PLC“0”
system.
output (Y32)
areitsOFF.
NOTE:
Start
thestart
GLPofconguration
from
to
Fault Detection
Normal OSSD
production
stopping
is performed
congure theSTOPPING:
GLP to accept
inputs
at S12
and S22. by the PLC control system. When an E-Stop is pressed the DI immediately opens its safety
power-up,
SI coasts
and GLP
perform internal checks. The SI and
contacts controlling the Safe Torque Off of the drive. The drive removes power Upon
to the motor
and thethe
motor
to a stop.
SAFE LIMITED SPEED (SLS): When the Unlock Request button is pressed and released
the GLPtheir
Y32 output
a SLSfor
request
to The
the PLC
control
Operating Principle
GLP check
input sends
devices
faults.
440G
checks its OSSD
system. The PLC system instructs the drive to go to speed less than 0.5Hz. When
the GLP senses
that the
motion
is at, or sensors
below, SLSare
theconstantly
GLP unlocks monitored by
outputs
for
faults.
The
prox-imity
STARTING: The
GLPThe
must
be started
before
the
DI.
Press
release
the gate.
operator
can open
the gate
and
enter
theand
guarded
area. After leaving the guarded area the operator closes the gate and presses and
requiring that only one sensor is OFF at any time. The K300 monitors
the Reset button
GLP.
andbutton
release
the the
reset
button
releasesof
thethe
Reset
andPress
gate Lock
to lock
gate
and endofthe SLS request. The Y32 signal turns off and the PLC control system is free to instruct
the status of its inputs and outputs performs internal checks.
the DI to close
its safety
contacts
allow start
the drive
to go back
to production
speed.of the motor by the PLC
OVERSPEED: When the GLP detects a speed greater than the maximum speed (100Hz), the GLP turns OFF its L11 single wire safety signal. The DI
system.
Ratings
immediately opens its safety contacts de-energizing the Safe Torque Off of the drive. The drive removes power to the motor and the motor coasts
STOPPING: to
Normal
stopping
is performed
byWhen
the the
PLCspeed drops Emergency
initiated
by anthe
E-Stop
(2): These
safety
a stop. production
The GLP PWR/Fault
LED flashes
at a 3X rate.
below 100(Hz) stop
pressing
and releasing
Reset/Gate
Lock button
willfunctions
reset When
the GLPan
andE-Stop
turn its is
L11
Single Wire
signal ON. Pressing
DIsafety
reset button
closes its safety
contacts energizing
control system.
pressed
theSafety
DI immediately
opensand releasing
meetthe
the
performance
requirements
of SIL2 the
perSafe
IEC 62061:
Torque Off
and allowing
theSafe
PLC Torque
control toOreturn
thedrive.
drive The
to production
the speed
increase above
safe limited
whileinthe
its safety contacts
controlling
the
of the
drive speed.
2005Should
and have
a Category
3 structure,
canspeed
be used
systems
gate is unlocked the GLP turns OFF its single wire safety. The DI immediately opens its safety contacts controlling the Safe Torque Off of the drive.
removes power
to the motor and the motor coasts to a stop.
requiring Performance Levels up to PLd per ISO 13849-1: 2006 and
The drive removes power to the motor and the motor coasts to a stop.
execute a category 0 stop.
SAFE LIMITED SPEED (SLS): When the Unlock Request button is
pressed andFault
released
the GLP Y32 output sends a SLS request to the
Emergency stop initiated by an an Overspeed: This safety function
Detection
power-up,
the system
SI and GLP
perform internal
checks.
The
and GLP checkmeets
their input
forperformance
faults. The 440G checks
its OSSD outputs
for faults.
PLC controlUpon
system.
The PLC
instructs
the drive
to go
toSIspeed
thedevices
safety
requirements
of SIL2
per IEC 62061:
The prox-imity
sensors
aresenses
constantly
monitored
by requiring
one sensor is2005
OFF at and
any time.
K300 monitors
the status ofcan
its inputs
and outputs
less than 0.5Hz.
When the
GLP
that
the motion
is at,that
oronly
below,
hasThe
a Category
3 structure,
be used
in systems requiring
internal checks.
SLS the GLPperforms
unlocks
the gate. The operator can open the gate and
Performance Levels up to PLd per ISO 13849-1: 2006 and executes a
enter the guarded area. After leaving the guarded area the operator
category 0 stop.
Ratings
closes the gate
and
presses
and
releases
the
Reset
and
gate
Lock
Emergency stop initiated by an E-Stop (2): These safety functions meet thePrevention
safety performance
requirements
of SIL2 per IEC
62061: 2005
and
of access
while dangerous
motion
is present:
This safety
button to lock
gate and
end thecan
SLS
The Y32
signalPerformance
turns
havethe
a Category
3 structure,
berequest.
used in systems
requiring
Levels
up to meets
PLd per the
ISO 13849-1:
2006 and execute
a category 0 stop.
function
safety
performance
requirements
of
SIL3
per IEC
o and the PLC
controlstop
system
is free
the drive
to gofunction
back tomeets the safety performance requirements of SIL2 per IEC 62061: 2005 and
Emergency
initiated
byto
aninstruct
an Overspeed:
This safety
62061: 2005 and has a Category 3 structure, can be used in systems
a Category 3 structure, can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006 and executes a category 0 stop.
productionhas
speed.
requiring
Performance
Levelsrequirements
up to PLd per
ISO
13849-1
: 2006
Prevention of access while dangerous motion is present: This safety function
meets the
safety performance
of SIL3
per
IEC 62061:
OVERSPEED:
When
detects
a speed
the requiring Performance Levels up to PLd per ISO 13849-1 : 2006
2005
and the
has aGLP
Category
3 structure,
cangreater
be usedthan
in systems
Prevention
of
unexpected
start-up
(Gate
Monitoring):
This
safety
Prevention
of unexpected
start-up
(Gate
This safety
maximum speed
(100Hz),
the GLP turns
OFF
its Monitoring):
L11 single wire
safetyfunction meets the safety performance requirements of SIL2 per IEC 62061:
function
meets
the
safety
performance
requirements
of
SIL2
per
2005,
has a Category
3 structure,
can be
used in systems
requiring Performance Levels up to PLd per ISO 13849-1: 2006. The system can not be
signal. The DI
immediately
opens
its safety
contacts
de-energizing
IEC 62061:
has
Category 3 structure, can be used in systems
started,
nor put
production
speed
fromto
safe
limited
speed unless
the gate 2005,
is closed
anda locked.
the Safe Torque
O ifofstopped,
the drive.
Theinto
drive
removes
power
the
motor
and the motor coasts to a stop. The GLP PWR/Fault LED ashes at a 3X- 40 - requiring Performance Levels up to PLd per ISO 13849-1: 2006. The
system can not be started, if stopped, nor put into production speed
rate. When the speed drops below 100(Hz) pressing and releasing the
from safe limited speed unless the gate is closed and locked.
Reset/Gate Lock button will reset the GLP and turn its L11 Single Wire
Safety signal ON. Pressing and releasing the DI reset button closes its
R
NHP Safety Reference Guide > GSR Wiring Diagrams
3-42
Safeguarding Applications and Wiring Diagrams
Speed Monitoring with Guardlocking, E-Stops
and
Drive and Wiring Diagrams
Safeguarding
Applications
Speed Monitoring with Guardlocking, E-Stops and Drive
TLS-ZR, GLP, DI, EMD and PF 525:
TLS-ZR, GLP, DI, EMD and PF 525
+24V DC
L1 L2 L3
Reset &
Gate Lock
Request
440GTSZ21UPRH
Gate
Unlock
Request
X14 X24 51 A1 S44 S54 Y32 L12
Yellow
Green
TLS-ZR
Brown
Red
LOGIC
9
8
0
1
2
3
4
GLP 7 6 5
440R-GL2S2P
0
SL1
9
8
7 6 5
1
2
3
4
0
SL2
9
8
7 6 5
1
2
3
4
S12 S22 L61 A2 AP P12 P22 L11
E-Stop
800FM-MT44
800F-MX02S
PowerFlex R S T
525
1 Stop
Reset
S11 S12 S21 S22 A1 13
0
LOGIC
1
8
7
6 5
DI
440R-D22R2
4
2 Start
23 S34
1
0
2
3
S32 S42 L12 L11 A2 14
24V DC COM
24 Y32
Brown
872C-D8NP18-E5 (2)
5 2
6 1
7
34 5
10
9
6
7
8
EMD
440R-EM4R2D
Gate control
power supply
L12 L11 A2 18 28
38 48
Gate control
circuit
S1
S2
Black
Black
Pink
White
Blue
Grey
Gate
Unlocked
2 3 4
9 8
889D-F8AC-5
Brown
B1 B2 X32 A1 17 27 37 47
Range Time
4 Gnd
Blue
Blue
E-Stop
800FM-MT44
800F-MX02S
Safety
Status
to PLC
UV W
M
and removes the signals to the safe o inputs fo the PF525. The
Circuit Status
Circuit Status
gate is closed and locked.The motor is off. The GLP is ready for reset. Themotor
GLP hasthen
a Logiccoasts
settingto
of a
3: stop
(Safe Limited
Speed
with Logic In OFF),
if it is still
running.
The gateThe
is closed
and locked.The motor is o. The GLP is ready for
a Safe Limited Speed (SL1) setting of 1(1 Hz) and a maximum speed (SL2) setting of 7 (1000Hz). The single wire safety output (L11) and the
reset. The
GLP has
a Logic
3: E-Stops
(Safe Limited
Speed
with
Fault
auxiliary
outputs
(Y32)setting
are OFF.ofThe
are released
and the
DI is ready for
reset.Detection
The EMD is configured to provide a 9 second (30% of the
Logic In 30s
OFF),
a Safe
Speed
(SL1)
setting
of 1(1 Hz)
and
Range)
OFFLimited
delay . NOTE:
Start
the GLP
configuration
from
“0”ato accept OSSD inputs at S12 and S22.
Upon power-up, the TLSZR, GLP, DI, EMD and PF 525 perform
maximum speed (SL2) setting of 7 (1000Hz). The single wire safety
internal checks. The GLP checks its prox, gate, reset and unlock
output (L11)
and the
auxiliary outputs (Y32) are OFF. The E-Stops
Operating
Principle
inputs and its L11 output. The DI generates test pulses to check
are released
and the
ready
reset.
Thethe
EMD
is congured
tothe Reset button of the GLP. The gate locks. The single wire safety (L11) of the
STARTING:
The DI
GLPismust
be for
started
before
DI. Press
and release
for faults at its inputs and also checks for shorts at the L11 output.
turns ON.(30%
Press and
release
reset button
of the .DI.
The DIStart
closes its safety contacts enabling the PF525 Start-Stop buttons and its L11 turns
provide aGLP
9 second
of the
30sthe
Range)
OFF delay
NOTE:
The button
440G checks
its motor.
OSSD outputs for faults.The proximity sensors
The EMD closes
safety
contactsOSSD
enabling
the PF525
Safeand
Off. S22.
Press the Start
to start the
the GLP ON.
conguration
fromits“0”
to accept
inputs
at S12
are constantly
byisrequiring
only one sensor is
STOPPING: Normal production stopping and starting is performed using the Start-Stop
buttons. monitored
When an E-Stop
pressed the that
DI immediately
turns
OFF its (L11) single wire safety signal. Simultaneously the DI safety contactsOFF
openatproviding
a stop
signal
to the
drive. The drive
controlsof
theits inputs and
any time.
The
PF525
monitors
the status
Operating
Principle
motor to a stop. After the 9 second OFF delay the EMD contacts open removing outputs
24V from the
PF252 Safe
Off inputs.
The PF525 removes power to
performs
internal
checks.
STARTING:
The GLP must be started before the DI. Press and
the motor. The motor, if still turning, coasts to a stop. When the speed detected by the proximity sensors drops below the Safe Limited Speed
release the
Reset
buttoncan
ofpress
the GLP.
The gate
locks.
Thethe
single
(1Hz),
the operator
the Unlock
button
and open
gate. At any time,
the operator can press the Unlock button to initiate a controlled
Ratings
wire safety
GLP
ON.
Press
andgoes
release
the
reset the resetting of the DI relay.
stop.(L11)
Afterof
thethe
EMD
timeturns
expires,
its X32
output
to 24V
to enable
Emergency
stop initiated by an E-Stop (2): These safety
OVERSPEED:
If the
detects
a speed contacts
greater thatenabling
1000Hz, the
GLP single wire safety output (L11) turns OFF. The DI safety contacts open
button of
the DI. The
DIGLP
closes
its safety
the
functions
meet
the
safetyopen
performance
providing
a
stop
command
to
the
drive.
The
drive
stops
the
motor.
After
9
seconds
the
EMD
safety
contacts
and removesrequirements
the signals to theof SIL2
PF525 Start-Stop buttons and its L11 turns ON. The EMD closes its
per IEC 62061: 2005, have a Category 3 structure, can be used in
safe off inputs fo the PF525. The motor then coasts to a stop if it is still running.
safety contacts
enabling the PF525 Safe O. Press the Start button
systems requiring Performance Levels up to PLd per ISO 13849-1 :
to start the motor.
Fault Detection
2006 and execute a category 1 stop.
Upon
power-up,
the TLSZR, GLP,
DI, EMDand
and PF
525 perform
internal checks. The GLP checks its prox, gate, reset and unlock inputs and its L11 output.
STOPPING:
Normal
production
stopping
starting
is performed
Emergency
initiated
byOSSD
an an
Overspeed:
The
DI generatesbuttons.
test pulses to
check for
at its is
inputs
and alsothe
checks for shorts at
the L11 output.stop
The 440G
checks its
outputs
for faults.TheThis safety
using the
Start-Stop
When
anfaults
E-Stop
pressed
proximity sensors are constantly monitored by requiring that only one sensor is OFF atfunction
any time. The
PF525the
monitors
the status
of its inputs and
outputs
meets
safety
performance
requirements
of SIL2
DI immediately
turns OFF its (L11) single wire safety signal.
performs internal checks.
per IEC 62061: 2005, has a Category 3 structure, can be used in
Simultaneously the DI safety contacts open providing a stop
systems requiring Performance Levels up to PLd per ISO 13849-1:
signal toRatings
the drive. The drive controls the motor to a stop. After
2006 and executes a category 1 stop.
the 9 second
OFF delay
the EMD
contacts
open
removing
24V meet the safety performance requirements of SIL2 per IEC 62061: 2005, have a
Emergency
stop initiated
by an
E-Stop (2):
These
safety functions
structure,
can beThe
usedPF525
in systems
requiring
Performance
to PLd per ISOof
13849-1
anddangerous
execute a category
1 stop.
from theCategory
PF252 3Safe
O inputs.
removes
power
to theLevels upPrevention
access: 2006
while
motion
is present: This safety
Emergency
initiated
by an
an Overspeed:
safetythe
function
meets the
safety performance
of SIL2 perrequirements
IEC 62061: 2005,of
hasSIL2 per
motor. The
motor, stop
if still
turning,
coasts
to a stop.This
When
speed
function
meets therequirements
safety performance
3 structure, sensors
can be used
in systems
requiring
Performance
to PLd per ISO 13849-1: 2006 and executes a category 1 stop.
detecteda Category
by the proximity
drops
below
the Safe
Limited Levels up
IEC
62061:
2005,has
a
Category
3
structure,
can
be
used
in systems
Prevention of access while dangerous motion is present: This safety function meets the safety performance requirements of SIL2 per IEC
Speed (1Hz),
the
operator
can
press
the
Unlock
button
and
open
requiring
Performance
Levels
up
to
PLd
per
ISO
13849-1:
2006.
62061: 2005,has a Category 3 structure, can be used in systems requiring Performance Levels up to PLd per ISO 13849-1: 2006.
the gate.Prevention
At any time,
the operator
can(Gate
pressMonitoring):
the Unlock
button
of unexpected
start-up
This
safety function meets the safety performance requirements of SIL2 per IEC 62061:
Prevention of unexpected start-up (Gate Monitoring): This
to initiate
a controlled
stop.
After the
time
expires,
its X32
2005,
has a Category
3 structure,
canEMD
be used
in systems
requiring
Performance Levels up to PLd per ISO 13849-1: 2006. The system cannot be
safety
function
meets
the safety performance requirements
startedtoif 24V
stopped,
nor put into
limited speed, unless
the gate
is closed
and locked.
output goes
to enable
theproduction
resettingspeed
of thefrom
DI safe
relay.
of SIL2 per IEC 62061: 2005, has a Category 3 structure, can be
OVERSPEED: If the GLP detects a speed greater that 1000Hz,
used in systems requiring Performance Levels up to PLd per ISO
the GLP single wire safety output (L11) turns OFF. The DI safety
13849-1: 2006. The system cannot be started if stopped, nor put
contacts open providing a stop command to the drive. The drive
- 41 - into production speed from safe limited speed, unless the gate is
stops the motor. After 9 seconds the EMD safety contacts open
closed and locked.
R
NHP Safety Reference Guide > GSR Wiring Diagrams
3-43