Bul.

440R — Guardmaster® Safety

Relays (DI, DIS, SI, CI, GLP, EM, and EMD)
Selection Guide
Bulletin 440R
Next Generation Guardmaster® Safety Relays
DI, DIS, SI, CI, GLP, EM, and EMD

Specifications
Safety Ratings
IEC 60204-1, EN ISO 13849-1, EN ISO 12100,
Standards
IEC 61508
DI/DIS/CI/SI/EM/EMD: Suitable up to PLe and
CAT4 per EN ISO 13849-1:2006, SIL CL3 per
IEC 61508:2010/IEC62061:2006 depending on
architecture and application characteristics
Safety Classification
GLP: Suitable up to PLd and CAT3 per EN ISO
Description 13849-1:2006, SIL CL2 per IEC 61508:2010
The new generation of Guardmaster® safety relays addresses the /IEC62061:2006 depending on architecture and
application characteristics
broad scope of applications in the intricate safety world with a
range of devices. Designed to meet new functional safety CE Marked for all applicable directives, cULus
Certifications
standards, such as EN ISO 13849-1 and EN 62061, the new family Listed and TÜV
offers key functions to simplify installation and system complexity. A Functional Safety Data See next page
broad range of safety devices such as safety interlock switches, Power Supply
emergency stop devices, pressure sensitive safety mats, and OSSD Input Power Entry 24V DC (-15…+10%)
devices such as safety light curtains are all compatible with the
same relay without additional configuration.The functionality of two DI/SI: 2.5 W
DIS: 2 W
standard safety relays can be achieved in one Dual Input (DI) device, Power Consumption
CI/EM/EMD: 3.5 W
allowing connection of two dual-channel input devices into one GLP: 2.5 W
safety relay.
Inputs
A TÜV-approved single rotary switch sets the required function of DI/DIS: 2 dual N.C., 2 dual OSSD, or safety
the safety relay and eliminates the typical redundant switch setting mats and 1 single-wire safety input
process. Selectable functions include simple logic, reset, timing, and SI/CI: 1 dual N.C., 1 dual OSSD, or safety mats
Safety Inputs
diagnostics. GLP: 1 dual N.C. or 1 dual OSSD and 1
single/wire safety
The single-wire safety connection simplifies cascading and EM/EMD: 1 single-wire safety input
expanding safety functions by linking relays with a single-wire
Input Simultaneity Infinite
connection. A dynamic signal from device to device provides a
linkage in accordance with SIL 3, PLe, allowing easy addition of Input Resistance, Max. 900 Ω
extra I/O, which can be configured with simple logic combinations. Reset
Configured automatic/manual or monitored
Flexible AND/OR logic can be configured simply in a single relay or manual
through a combination of relays via single-wire connection. Reset Pulse Duration 250 ms…3 s
The family includes a module designed specifically for guardlocking DI/DIS/SI/CI/EM/EMD: 5.5 s
Power ON Delay Time
applications. The GLP uses two proximity sensors to monitor GLP: 11 s
machine motion, and unlocks the gate when safe speed is attained. Recovery Time
DI/DIS/SI/CI: 100 ms
EM/EMD: 150 ms
Expansion modules are available with four immediate or time-
DI: 35 ms (40 ms with mat input)
delayed outputs. The time delay module can be configured for on
DIS: 25 ms (30 ms with mat input)
delay, off delay, or jog. Response Time (Safety SI/CI: 35 ms (45 ms with mat input)
Outputs) GLP: overspeed detection time = 3/(speed limit
[Hz])
EM/EMD: 35 ms
Features
DI/DIS: 25 ms (30 ms with mat input)
 Suitable for applications up to PLe, SIL 3 Per ISO13849-1 Response Time (Single-
SI/CI: 25 ms (35 ms with mat input)
 Stop Category 0 and Stop Category 1 Wire Safety Outputs)
GLP/EM/EMD: 25 ms
 One or two dual-channel inputs Outputs
 Two or three safety contacts DI/SI: 2 N.O.
 One auxiliary contact CI: 3 N.O.
 Cross-fault monitoring DIS: 2 PNP (14, 24); 2 Decoupled (34, 44)
Safety Outputs
EM: 4 N.O.
 Rotary switch configures auto/manual or monitored manual reset EMD: 4 N.O. delayed
 Same rotary switch configures AND/OR logic of input to device DIS/GLP: 2 PNP safety, 2 PNP Lock
 Removable terminals DIS: 2 x 1.5 A; 2 x 0.5 A; Total: max. 4 A
Solid State Output Rating
 Can be used with interlocks, light curtains, safety mats, E-stops, GLP: 2 x 0.5 A; 2 x 0.3 A; Total: max 1.5 A
and SensaGuard™ switches DI: AgNi + 0.2μ Au
Contact Material
 Single-wire safety output connects to single-wire safety input SI/CI/EM/EMD: AgNi
relays while maintaining SIL 3, PLe DI/DIS/SI/GLP/EM/EMD: 1 PNP; 50 mA max
Auxiliary Contacts
 Guardlocking with proximity sensors CI: 1 N.C.
 Timed ON delay, OFF delay, and Jog outputs on EMD Thermal CurrentIlth 1x6A
Rated Impulse withstand
2500V
Voltage
Switching Current @
DI/SI/CI/EM/EMD: 10 mA/10V
Voltage, Min.
Relay Outputs: 6 A low blow or 10 A quick
blow
Fuses, Output
Power Supply GLP: 4A gG, tripping
characteristic B or C
Mechanical Life DI/SI/CI/EM/EMD: 10,000,000 operations

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2 Publication 440R-SG001B-EN-P
 Bulletin 440R
Next Generation ®
Guardmaster Safety Relays
DI, DIS, SI, CI, GLP, EM, and EMD

Specifications, continued Functional Safety Data 

Utilization Category Note: Subject to change. For up-to-date information, visit
http://www.ab.com/safety/
DI: 3 A/250V AC
Inductive: AC-15 SI/CI: 1.5 A/250V AC MTTFd PFHD
EM/EMD: 1.5 A/250V AC
DI 355 yr 4.35 x 10-9
DI: 4 A/24V DC (0.1 Hz)
Inductive: DC-13 SI/CI: 2 A/24V DC (0.1 Hz) DIS 484 yr 4.39 x 10-9
EM/EMD: 2 A/24V DC SI 262 yr 3.98 x 10-9
DIS: 14, 24: 1.5 A each
34, 44: 0.5 A each
CI 164 yr 4.26 x 10-9
Output Rating
GLP: X14, X24: 0.5 A each GLP 395 yr 7.18 x 10-9
51, L61: 0.3 A each
EM 190 yr 1.81 x 10-9
Environmental and Physical Characteristics
Enclosure Type Rating/ EMD 165 yr 4.4 x 10-9
IP40 (NEMA 1)/IP20
Terminal Protection
 Usable for ISO 13849-1: 2006 and IEC 62061. Data is based on the
Operating Temperature following assumptions:
-5…+55 ° (23…131 °)
[C (F)] - Mission time/proof test interval of 20 yr
Vibration 10…55 Hz, 0.35 mm - Functional test at least once within six-month period
-The PFHD given is the sum of the PFHD of the electronic aspects and the
Shock 10 g, 16 ms 100 shocks PFHD resulting from the B10d values of the two output relays based on 1
Mounting 35 mm DIN Rail operation/hour, 365 days a year, 24 hours a day (8760 operations/year) at
AC15 1 A 230V AC or at DC13 1.5 A 24V DC.
DI: 180 (0.40)
DIS: 150 (0.33)
SI: 150 (0.33)
Weight [g (lb)] CI: 225 (0.5)
GLP: 150 (0.33)
EM: 225 (0.50)
EMD: 220 (0.49)
Terminals Removable (Screw)
Conductor Size, Max. 0.2…4 mm2 (24…12 AWG)

Product Selection
Safety Relays
Immediate Delayed Immediate
Safety Safety Auxiliary Power
Relay Type No. of Inputs Inputs Outputs Outputs Time Delay Outputs Supply Cat. No.
Dual Input (DI) 1 N.C., 2 2 N.O. 440R-D22R2
2 dual-
N.C., OSSD, — — 1 S.S. 24V
Dual Input Solid-State Output (DIS) channel 2 S.S. 440R-D22S2
Safety Mat
Single Input (SI) 1 N.C., 2 2 N.O. 440R-S12R2
1 dual-
N.C., OSSD, — — 1 S.S. 24V
Compatible Input (CI) channel 3 N.O. 440R-S13R2
Safety Mat
1 dual-
2 N.C.,
Guardlocking Proximity (GLP) channel 2 S.S. — — 1 S.S. 24V 440R-GL2S2P
OSSD
2 PNP
Expansion Module (EM) 4 N.O. — — 440R-EM4R2

1 single-wire 100 ms ... 300 s

Expansion Module Time Delayed — on or off delay 1 S.S. 24V
safety — — 440R-EM4R2D
(EMD) 100 ms ... 20 s
jog

Accessories LED Indicators

Description Cat. No. Indicator on
Bag of four, 4-pin screw terminals 440R-ATP4 Housing Function LED Color(s)
PWR/FAULT Status and diagnostics Green/Red
IN1 Status of safety output IN1 Green
IN2 Status of safety output IN2 Green
LOGIC IN Status of single wire safety input Green
OUT Status of safety output Green
LOCK‡ Status of the lock command Green
B1 Status and diagnostics Green

‡ GLP only
 B1 on EMD only

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Publication 440R-SG001B-EN-P 3
Bulletin 440R
Next Generation Guardmaster® Safety Relays
DI, DIS, SI, CI, GLP, EM, and EMD

Approximate Dimensions
Dimensions are shown in mm. Dimensions are not intended to be used for installation purposes.

S12 S22 S32 S42 S12 S22 S32 S42 S12 S22 13 23 33 41 S12 S22 AP S44 33 34 43 44 37 38 47 48
A1 A2 S11 S21 A1 A2 S11 S21 A1 A2 S11 S21 A1 S11 S12 L11 A1 A2 P12 P22 A1 A2 A1 A2 B1 B2
PWR/Fault PWR/Fault PWR/Fault PWR/Fault PWR/Fault PWR/Fault
PWR/Fault
IN 1 IN 1 IN IN IN 1 B1
IN 2 IN 2
LOCK
LOGIC IN LOGIC IN LOGIC IN LOGIC IN
LOGIC IN
OUT OUT OUT OUT OUT OUT
0 0 OUT
0 0 RESET RESET 0 0
1 1 LOGIC 1 33 34 43 44 RANGE 1
LOGIC AM AM
LOGIC 2 2 9 2 9 2
3 8 3 3 8 3
8 MM MM 8
7 4 7 4
7 6 54 7 6 5 4
6 5 119.4 6 5
119.4 119.4 13 23 33 41
119.4 0
119.4 119.4 1 119.4
SL1 1 TIME 2
A1 9 2 10 3
8 3 9 4
13 14 23 24 13 14 23 24
14 24 34 42 7 6 54 13 14 23 24
8 7 6 5
0
DI DIS 34 44 14 24 SI CI SL2 1 EM EMD
9 2
8 3
7 6 54
L12 L11 Y32 S34 L12 L11 Y32 S34 L11 Y32 S34 S21 S22 S34 A2 GLP L12 L11 Y32 L12 L11 X32
13 14 23 24 34 44 14 24 34 14 23 24 14 24 34 42 L12 L11 Y32 S54 13 14 23 24 17 18 27 28
X14 X24 51 L61

22.5 22.5 22.5 22.5 22.5 22.5

22.5
Dual Input Dual Input Single Input Single Input Guardlocking Expansion Expansion
Relay Output Solid-State Relay Output Legacy Prox Module Module Module Delayed
(DI) Output (SI) Compatible (GLP) (EM) (EMD)
(DIS) (CI)

Safety Relay
Model: GuardMaster
Cat No.: 440R-D22S2
Series: A
Supply: 24VDC Lot No.: 006 0
Output: 2 SS 24VDC
1 SS 24VDC
1042
105.7
10885630102211

Made in Germany
Rockwell Automation Germany
Westring 222 42329 Wuppertal XXXXX

113.6
Side View
(All Versions)

Block Diagrams
Dual Input Relay (DI) Dual Input Solid State Output Relay (DIS)
Safety Outputs (N.O.): 13-14, 23-24 Safety Outputs (PNP N.O.): 14 & 24 (1.5 A each max), 34 & 44 (0.5 A
A1 A2 S11 S21 S12 S22 S32 S42
each max, for high capacitive loads)
IN1 IN2 A1 A2 S11 S21 S12 S22 S32 S42
PWR mon. IN1 IN2

AND/OR PWR mon.

PWR
IN1 K1 AND/OR
IN2 PWR
AND/OR IN1
LOGIC IN
OUT Logic K2 IN2 AND/OR
LOGIC IN
Logic
OUT
L12 L11 Y32 S34 13 14 23 24
L12 L11 Y32 S34 34 44 14 24

Single Input Relay (SI) Single Input Relay Compatible Layout (CI)
Safety Outputs (N.O.): 13-14, 23-24 Safety Outputs (N.O.): 13-14, 23-24, 33-34
A1 A2 S11 S21 S12 S22 A1 S11 S12 L11 13 23 33 41
IN1 IN1

PWR mon. PWR mon.

K1
PWR PWR
IN K1 IN
K2
Reset K2 Reset
OUT OUT

L11 Y32 S34 13 14 23 24 S21 S22 S34 A2 14 24 34 42

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4 Publication 440R-SG001B-EN-P
 Bulletin 440R
Next Generation ®
Guardmaster Safety Relays
DI, DIS, SI, CI, GLP, EM, and EMD

Block Diagrams, continued

Guardlocking with Proximity Sensors (GLP)
Safety Outputs (PNP N.O.): L11 (Single Wire Safety)
A1 A2 X14 X24 AP P12 P22 S12 S22 51 L61 S54
PROXES IN1 LOCK

PWR mon.

PWR
IN1
LOCK AND/OR
LOGIC IN Logic SL1 SL2
OUT

L12 S44 L11 Y32

Expansion Module Relay (EM) Expansion Module Delayed Output Relay (EMD)
Safety Outputs (N.O.): 13-14, 23-24, 33-34, 43-44 Delayed Safety Outputs (N.O.): 17-18, 27-28, 37-38,47-48
A1 A2 33 34 43 44 A1 A2 B1 B2 37 38 47 48

PWR mon. PWR mon.

on delay K1
K1 PWR off delay
PWR Logic
B1 jogging
Range Time K2
K2 LOGIC IN
LOGIC IN OUT
OUT
L12 L11 X32 17 18 27 28
L12 L11 X32 13 14 23 24

Common Terminals Auxiliary/Feedback Output Behavior

Terminals Relay Description DI, DIS, SI CI EM, EMD
A1, A2 All Power Unit Status Y32 41-42 X32
S12, S22 DI, DIS, SI, CI IN1: Safety input 1 Active & healthy Off Open Off
S32, S42 DI, DIS IN2: Safety input 2 Inactive & healthy 24V DC Closed 24V DC
S11, S21 DI, DIS, SI, CI Test outputs for safety inputs Fault 24V DC Closed Off
S34 DI, DIS, SI, CI Monitoring feedback loop for reset
S44 GLP Lock request and reset GLP

S54 GLP Unlock request Unit Status Y32

Cat 1 Stop Off upon unlock request 24V DC active & healthy
Y32 DI, DIS, SI, GLP Auxiliary PNP semiconductor output
24V DC upon unlock
41-42 CI Auxiliary N.C. relay output Safe Limited Speed Off active & healthy
request
X32 EM, EMD Feedback PNP semiconductor output
Fault Off Off
L12 DI, DIS, EM, EMD Single wire safety input
L11 All Single wire safety output
B1, B2 EMD Configuration for retriggering/jogging
51, L61 GLP Lock command to solenoid
X14, X24 GLP Multifunction safety outputs
AP, P12, P22 GLP Proximity sensor power and inputs
Note: Output terminals described by image.

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Publication 440R-SG001B-EN-P 5
Bulletin 440R
Next Generation Guardmaster® Safety Relays
DI, DIS, SI, CI, GLP, EM, and EMD

Logic
The logic between the two safety inputs IN1 (S12, S22) and IN2 (S32, S42) and the single-wire safety input (L12) can be configured to the four
options shown below, in either manual monitored or automatic/manual reset configurations (yielding eight settings total). L12 will only
recognize a valid test pattern from the L11 output of a Guardmaster device. Any other signal to that port will be detected as a fault. (A high
signal is considered to be true in this logic. So if an input is to be ignored or muted, OR logic should be used).
Note: In case only one safety input is used the second one can be left open if it is configured for OR. An AND conjunction requires this input
to be wired to S11 and S21. In case L12 is not in use, this input needs to be configured for OR.
Manual Monitored Reset Automatic / Manual Reset IN1 = S12, S22
IN1
1 (IN1 OR IN2) OR L12 5 (IN1 OR IN2) OR L12 AND/ IN2 = S32, S42
2 (IN1 AND IN2) OR L12 6 (IN1 AND IN2) OR L12 OR
IN2
3 (IN1 OR IN2) AND L12 7 (IN1 OR IN2) AND L12 AND/
4 (IN1 AND IN2) AND L12 8 (IN1 AND IN2) AND L12 L12 OR

Configuration
Setting the Logic Function/Reset Mode — DI, DIS, SI, and CI
1. Start configuration/overwrite: with power off, turn rotary switch to position 0 and unit is powered up. After power-up test, PWR LED will
flash red.
2. Set configuration: turn rotary switch to desired position. IN1 LED blinks new setting.
Note: Position is not stored until PWR LED is solid green.
3. Lock in configuration by cycling unit power.
4. Configuration must be confirmed before operation. A white rectangle on face of device is provided to record unit setting.
1 Enable program mode 2 Set operation mode Cycle power to store 4 Record setting

Setting the Time Delay — EMD

1. Start configuration/overwrite: with power off , turn rotary switch RANGE to position 0 and power unit up. After power-up test, PWR LED
will flash red.
2. Set configuration: turn rotary switch to desired position, both RANGE and TIME. LED B1 indicates position of RANGE and Logic IN of
TIME.
Note: Position is set when “PWR“ LED is solid green.
3. Lock in configuration by cycling unit power.
4. Configuration must be confirmed before operation. A white space on face of device is provided to record unit setting.

Note: When in off-delay mode, terminals B1 and B2 are used to modify the settings of retriggering. The terminals are not used in on-delay
mode. Terminal B1 is used for the pulse source when the relay is in single pulse jogging mode.
OFF-DELAY (RANGE 1, 2, 3, 4): Time delay starts when single-wire safety input L12 changes from HIGH to LOW. Delayed safety outputs
remain active until the set time has lapsed. The unit is safe against time extension. Restart the unit by cycling the safety input L12, LOW to
HIGH.
• RETRIGGERABLE (JUMPER B1-B2): In off-delay mode, the device can be set to retriggerable setting. In retrigger mode, if the safety
input is triggered and cleared within the duration of the time delay then the timing request is ignored and the safety output contacts will
remain closed. Retrigger setting can only be done in off-delay mode and can be set by running a jumper wire from terminal B1 to B2
(corresponds with MSR178 and MSR132ED delayed outputs).
• NON-RETRIGGERABLE (NO JUMPER): In off-delay mode, if retriggerable setting is not configured (terminals B1 and B2 are left vacant)
the full time delay will lapse and the safety output contacts will open before the relay can be reset (corresponds with MSR178 and
MSR132ED delayed outputs).
ON-DELAY (RANGE 5, 6, 7): Time delay starts when the single-wire safety input changes from LOW to HIGH. Safety outputs are activated
after time has lapsed and L12 is still HIGH.
SINGLE-PULSE JOGGING: The safety outputs are activated when both, the single-wire safety input L12 and B1 are HIGH. It remains active
until the set time has lapsed. When one of the inputs changes to LOW, the safety outputs are deactivated immediately. B1 acts as an
automatic/manual start to trigger the Jog function while L12 monitors the safety device through a base unit. If there is any malfunction, the
JOG switch should be replaced.
x10% of max.
On
Off-Delay On-Delay
1: 0.1…1 s 5: 0.3…3 s 1: 10% 6: 60%
2: 0.3…3 s 6: 3…30 s 2: 20% 7: 70%
Off

3: 3…30 s 7: 30…300 s 3: 30% 8: 80%

4: 30…300 s 4: 40% 9: 90%
5: 50% 10: 100%
Jogg

Jogging
ing

8: 0.3…3 s Time
Range
9: 3…30 s
0: Configuration Mode

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6 Publication 440R-SG001B-EN-P
 Bulletin 440R
Next Generation ®
Guardmaster Safety Relays
DI, DIS, SI, CI, GLP, EM, and EMD

Configuration, continued
Setting the Guardlocking Prox Logic Function — GLP
Logic Setting Lock Command Application Logic
0 Start-up Configuration Mode (X14 and X24 - safety outputs)
1 Logic In Off
Category 1 Stop
2 Logic In AND
Power To Release
3 Logic In Off
Safe Limited Speed
4 Logic In AND
5
6
Reserved for Future Use
7
8
9 Alternate Start-up Configuration Mode (X14 and X24 - test outputs)

The GLP supports a power to release locking command:

 During normal operation, the lock command signal (51/L61) to the guardlocking device is unpowered to maintain the gate in a locked state.
Press the Unlock request to start the timer. After the configured time delay expires, the lock command is powered to allow the safety gate
to be opened.

The GLP is designed for two types of applications:

 Category 1 Stop: When the Unlock request is made, the Y32 output turns off to allow the stopping function to begin. When the GLP
detects that the speed is below the stopped speed, the lock command changes state (depending on whether Power-To-Release or Power-
To-Lock was configured).
 Safe Limited Speed: When the Unlock request is made, the Y32 output turns ON to allow slow speed operation. When the GLP detects
that the speed is below the SL1 speed, the unlock command is turned ON.

Setting the configuration:

1. Start configuration/overwrite: With power off, turn rotary switch LOGIC to position 0 to configure X14 and X24 as saftey outputs, or
position 9 to configure X14 and X24 as pulse test outputs for safety inputs. Power unit up. After power-up test, PWR LED will flash red.
2. Set configuration: Turn all three rotary switches to desired position, LOGIC, SLS, and MAX. IN1 indicates position of LOGIC, and Logic IN
of SLS and Lock of MAX.
Note: Position is set when PWR LED is solid green.
3. Lock in configuration by cycling unit power.
4. Configuration must be confirmed before operation. A white rectangle on face of device is provided to record unit setting.
1 Enable configuration mode
Logic

2 Set operation mode (Logic, SLS and MAX)

Logic Safe Limited Speed (SLS) Safe Maximum Speed (MAX)
0: 0.5 Hz 4 5 6 5: 5 Hz 0: None 4 5 6 5: 200 Hz
1: 1 Hz 3 7 6: 6 Hz 1: 10 Hz 7 6: 500 Hz
9 2: 2 Hz 7: 7 Hz 3
2 8 2: 20 Hz 8 7: 1000 Hz
3: 3 Hz 8: 8 Hz 2
1 9 3: 50 Hz 8: 2000 Hz
4: 4 Hz 9: 10 Hz 4: 100 Hz 1 9 9: 3000 Hz
0 0

3 Cycle power to store

4 Record setting

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Publication 440R-SG001B-EN-P 7
Bulletin 440R
Next Generation Guardmaster® Safety Relays
DI, DIS, SI, CI, GLP, EM, and EMD

Proximity Sensor Configuration

The GLP is designed to operate with two PNP sensors.
1. The proximity sensors can detect a geartooth arrangement where the ratio of the space to mark is 2:4.
2. The space must be at least twice the diameter of the sensor. The mark must be at least twice the width of the space.
3. The proximity sensors must be set back from the mark no further than 80% of their rated sensing distance, Sn.
Note: The distance of 0.5 Sn is required to achieve maximum speed.
4. The depth of the space must be at least 3 times the rated sensing distance.
5. The distance between the sensors must ensure that both sensors are not off at the same time.

3d
d d
Prox 1 Prox 2

max. 0.8 x Sn
min. 3 x Sn mark space mark space mark

2d 4d

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8 Publication 440R-SG001B-EN-P
 Bulletin 440R
Next Generation ®
Guardmaster Safety Relays
DI, DIS, SI, CI, GLP, EM, and EMD

Typical Wiring Diagram

Light Curtain and Dual Channel E-stop, Manual Monitored Reset
Here the logic is set to 2, which will AND IN1 and IN2. The single wire safety input is set to OR with the standard safety inputs so the relay
ignores the fact that no input is coming to L12. This logic can be applied to the DI and DIS.
24V DC

E-Stop
OSSD Reset

A1 A2 S11 S21 S12 S22 S32 S42

+ - PULSE IN1 IN2
Power 24V DC
Logic 0 L1 L2 L3
In1 1
In2
DI 2 K1
3 K2
Out
8 4
Logic 7 6 5
L12 L11 Y32 S34 13 14 23 24

PLC
M

K1 K2

GND

Single Channel E-stop, Automatic Reset, Monitoring

Here the logic is set to 5, which will OR all inputs. The device will source its outputs if any input is high. Here S12 and S22 are jumpered to
allow a single-channel source for the one input used.
24V DC

E-Stop

A1 A2 S11 S21 S12 S22 S32 S42

+ - PULSE IN1 IN2
Power
24V DC 0 L1 L2 L3
In1 Logic 1
DIS 2 K1
In2
Out 3 K2
8 4
Logic 7 6 5 PULSED
L12 L11 Y32 S34 33 34 14 24

PLC
M

K1 K2

GND

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Publication 440R-SG001B-EN-P 9
Bulletin 440R
Next Generation Guardmaster® Safety Relays
DI, DIS, SI, CI, GLP, EM, and EMD

E-stop, Safety Mat, Light Curtain and Interlock Switch, Monitored Manual Reset
Here the DI to the left will AND the IN1 and IN2 inputs. The single-wire safety input is ignored. The DI on the right will AND IN1, IN2 and the
single-wire safety input (L12). For the safety mat input, S11 is wired to S22 and S21 is wired to S12 (opposite of N.C. safety switch wiring) so
the relay recognizes that a mat is wired to the input rather than a N.C. safety switch with a cross fault. If the E-stop or the OSSD devices are
tripped, all outputs on both relays will turn off. If the mat or interlock switch are tripped, only the outputs to K3 and K4 will turn off.
24V DC

Reset
E-Stop OSSD
K1
Safety Interlock
K2 Mat

A1 A2 S11 S21 S12 S22 S32 S42 K3 A1 A2 S11 S21 S12 S22 S32 S42
+ - PULSE IN1 IN2 + - PULSE IN1 IN2
Power 24V DC Power
Logic 0 24V DC Logic 0
In1 1 K4 In1 1
DI 2 DI
In2 In2 2
3 3
Out 4 Out
8 8 4
Logic 7 6 5 Logic 7 6 5
L12 L11 Y32 S34 13 14 23 24 L12 L11 Y32 S34 13 14 23 24

K1 K2 K3 K4
PLC

GND

Two Dual-Channel E-stops to DI Connected to EM via Single-Wire Safety Connection, Manual Monitored Reset
Here the DIS will AND IN1 and IN2 while ignoring the single-wire safety input. The single-wire safety output is driving the input of the
expansion module (EM) while not using any of the safety outputs of the base device.
24V DC

E-Stop E-Stop

Reset

A1 A2 S11 S21 S12 S22 S32 S42 A1 A2 33 34 43 44 L1 L2 L3

+ - Test Out IN1 IN2 + -
Power Power K1
24V DC A1 24V DC
In1 0
DIS 1 K2
In2 LOGIC 2 EM
Out 8 3 Logic IN K3
7 4
Logic 6 5 Out 1 K4
L12 L11 Y32 S34 33 44 14 24 L12 L11 X32 13 14 23 24

M
PLC
K1 K2 K3 K3

GND

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10 Publication 440R-SG001B-EN-P
 Bulletin 440R
Next Generation ®
Guardmaster Safety Relays
DI, DIS, SI, CI, GLP, EM, and EMD

Proximity Sensors, Guardlocking Interlock, E-Stops, Monitored Manual Reset

Two PNP output proximity sensors are used to monitor the speed of the motor. The GLP LOGIC switch is set to 3, which configures the GLP
for Safe Limited Speed and Logic IN OFF. The single-wire safety input is ignored. The DIS LOGIC switch is set to 4, which requires IN1and
IN2 and L12 to turn its safety outptus ON.
Press the Lock & Reset button to activate the single wire safety output of the GLP. Press the Reset button (for the DIS) to activate the safety
outputs of the DIS and enable the motor to start. When the Unlock Request is pressed, the Y32 output of the GLP turns ON. This signal is
intended to be used by the machine control system to run the motor at a safe limited speed of less than 3 Hz (SL1 switch setting = 3). When
the motor speed reduces below 3 Hz , the guardlocking switch is unlocked. If the motor exceeds the Safe Limited Speed, the single-wire
safety output turns OFF, which turns off the DIS and therefore turns the motor OFF. The Single Wire Safety output of the GLP will also turn
OFF, if the motor exceeds 20 Hz (SL2 switch setting = 3).
24V DC

Unlock
Request Reset
Lock &
Guardlocking Interlock Reset
L1 L2 L3
E-Stop E-Stop
Machine
Control
System
(with PLC)
A1 A2 X14 X24 S12 S22 51 L61 S54 S44 A1 A2 S11 S21 S12 S22 S32 S42
+ - PULSE IN1 LOCK + - PULSE IN1 IN2
Power 24V DC Power
0 0 24V DC A1
In1 LOGIC 0 SLS MAX In1 LOGIC 0 K1
1 1 1 1
Lock GLP 2 9 2 9 2 In2 DIS 2
9 3 3 3 3
Out 8 8 Out 8
8 7 4
Logic 7 6 54 7 6 5 4 7 6 5 4 Logic 5 6 K2
AP P12 P22 L12 L11 Y32 L12 L11 Y32 S34 34 44 14 24

M
PLC
Slow Speed Command
Proximity K1 K2
To PLC
Sensors

GND

Proximity Sensors, Guardlocking Interlock, Monitored Manual Reset

The GLP is configured starting from Logic setting 0. This changes the behavior of X14 and X24 to pulsed outputs, and the inputs S12 and
S22 are expecting OSSD signals from the safeguarding device.
Two PNP output proximity sensors are used to monitor the speed of the motor. The GLP LOGIC switch is set to 1, which configures the GLP
to Category 1 Stop with Logic IN OFF. The single-wire safety input is ignored.
Press the Lock & Reset button to activate the X14 and X24 pulse outputs. The contactors pull in and enable the motor to start.
When the Unlock Request is pressed, the Y32 output of the GLP turns OFF. This signal is intented to be used by the machine control system
to initiate a Stop command. When the motor speed reduces below 1Hz (SL1 switch setting = 1), the guardlocking switch is unlocked and the
X14 and X24 safety outputs turn OFF. The motor now coasts to a stop. The safety outputs of the GLP will also turn OFF if the motor exceeds
50Hz (SL2 switch setting = 5).
24V DC

TLSZR-GD2
Guardlocking
Interlock Unlock Lock &
Request Reset
L1 L2 L3

Machine
Control
System
A1 A2 S12 S22 51 L61 X14 X24 S54 S44 (with PLC)
+ - IN1 LOCK PULSE
Power 24V DC
In1 LOGIC 0 1 SLS 0 1 MAX 0 1 K1
Lock GLP 2 9 2 9 2
9 3
Out 3 3
8 8
8 54 4 4
Logic 7 6 7 6 5 7 6 5 K2

AP P12 P22 L12 L11 Y32

M
Proximity Stop Command
K1 K2
Sensors to PLC

GND

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Publication 440R-SG001B-EN-P 11
Trademark List
Guardmaster and SensaGuard are trademarks of Rockwell Automation, Inc.

Publication 440R-SG001C-EN-P – October 2012 Copyright ©2012 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
Supersedes Publication 440R-SG001B-EN-P – July 2011