Guard-Locking Proximity Inputs Safety Relay User Manual
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Guard-Locking Proximity Inputs Safety Relay User Manual
guard-locking proximity inputs, guard locking, GLP, safety relay, 440R-GL2S2P, Allen-Bradley, Guardmaster
Purpose of This Manual This manual is a reference guide for the GLP safety controller, plug-in modules, and accessories. It describes the procedures that you use to install, wire, and troubleshoot your controller. This…
Rockwell Automation Publication 440R-UM012E-EN-P - November 2018. 3. Table of Contents. Preface. Who Should Use This Manual?
Original Instructions. Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and
Extracted Text
User Manual Original Instructions Guard-Locking Proximity Inputs Safety Relay Catalog Number 440R-GL2S2P Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards. Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice. If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited Throughout this manual, when necessary, we use notes to make you aware of safety considerations. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence. IMPORTANT Identifies information that is critical for successful application and understanding of the product. Labels may also be on or inside the equipment to provide specific precautions. SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE). Overview Installation Power, Ground, and Wire Table of Contents Preface Who Should Use This Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Firmware Revision History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Chapter 1 Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Logic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Logic Setting 1 - Cat 1 Stop, Logic IN Off . . . . . . . . . . . . . . . . . . . 10 Logic Setting 2 - Cat 1 Stop with Logic IN. . . . . . . . . . . . . . . . . . . 10 Logic Setting 3 - Safe Limited Slow Speed, Logic IN Off . . . . . . 11 Logic Setting 4 - Safe Limited Slow Speed with Logic IN . . . . . . 11 Logic Setting 5...8 - Guard Locking with Delayed Unlock and Automatic Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Logic Setting 8 -- Speed Status Only. . . . . . . . . . . . . . . . . . . . . . . . 12 Chapter 2 Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DIN Rail Mounting and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removable Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Enclosure Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Preventing Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Chapter 3 Wiring Requirements and Recommendation . . . . . . . . . . . . . . . . . . . . 17 Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Terminal Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Terminal Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Grounding the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Connecting a Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Proximity Sensor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Guard Locking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Devices with Mechanical Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Safety Devices with OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 21 Unlock Request Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Lock and Reset Request Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Lock and Unlock Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 3 Table of Contents Lock Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 TLS3-GD2 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 TLS-Z, 440G-LZ, and MAB Connections . . . . . . . . . . . . . . . . . . . 23 Multiple Guard Locking Devices and Power to Lock . . . . . . . . . 24 No Guard Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Safety Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Single Wire Safety (SWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Configuration Chapter 4 Logic Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SLS1 Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 SLS2/Time Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Configuration Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Diagnostic Status Indicators and Troubleshooting Chapter 5 Status Indicators During Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Status Indicators During Normal Operation. . . . . . . . . . . . . . . . . . . . . 31 Status Indicators During Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Pulse Testing Functions Chapter 6 Introduction to Pulse Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pulse Testing for Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Test of OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Ethernet Communication Chapter 7 Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Logix AOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Proximity Sensors and Targets Chapter 8 Proximity Sensor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Proximity Sensor Targets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Example Operational Sequence Diagrams Chapter 9 Stop Cat 1 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Example Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Sequence Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Sequence Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 SLS Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Example Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Sequence Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Sequence Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 4 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Specifications Regulatory Approvals Table of Contents Delayed Unlock with Auto Reset Example . . . . . . . . . . . . . . . . . . . . . . 49 Example Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Sequence Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Sequence Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Status Only Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Example Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Sequence Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Sequence Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Appendix A General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Input IN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Proximity Sensor Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Lock Unlock Request. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Lock Unlock Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Auxiliary Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Single Wire Safety Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Single Wire Safety Output Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Safety/Pulse Test Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Response Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Appendix B Agency Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Compliance to European Union Directives. . . . . . . . . . . . . . . . . . . . . . 59 Machine Safety Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 SIL Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Performance Level/Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 5 Table of Contents Notes: 6 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Preface Who Should Use This Manual? Use this manual if you are responsible for designing, installing, programming, or troubleshooting control systems that use the guard locking with proximity (GLP) safety controller. You must have a basic understanding of electrical circuitry and familiarity with safety-related control systems. If you do not, obtain the proper training before using this product. Purpose of This Manual This manual is a reference guide for the GLP safety controller, plug-in modules, and accessories. It describes the procedures that you use to install, wire, and troubleshoot your controller. This manual explains how to install and wire your controller. It also gives you an overview of the GLP controller system. Firmware Revision History Series A A A A A A Firmware 100 202 203 204 205 206 Description Initial release. Logic settings 1...4 functions only; 5...8 reserved for future use. Added logic settings 5...8 (CU2 functionality). New microprocessor technology (no change for user). CU2 functionality removed. Internal testing revealed an undetected proximity sensor fault. Affected manufacturing date codes from 1601...1707. CU2 functionality restored. Additional EMC filtering for proximity sensors. Summary of Changes This manual contains new and updated information as indicated in the following table. Topic Page Added Firmware Revision History section 7 Clarified power supply requirement for U.S.A. applications 19 Added correct connection of 100S contactors 24 Updated Webpage section 35 Updated Logix AOP section 36 Added statement that the GLP safety relay can operate with standard-rated proximity sensors 39 Added footnote about spacing of proximity sensors 40 Updated Stop Cat 1 Example (Sequence Diagram and Sequence Steps) 44 Updated SLS Example (Sequence Diagram and Sequence Steps) 47 Updated Delayed Unlock with Auto Reset Example (Sequence Diagram and Sequence Steps) 50 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 7 Preface Terminology Additional Resources Publication AG-7.1 contains a glossary of terms and abbreviations that are used by Rockwell Automation to describe industrial automation systems. Specific terms and abbreviations that are used in this manual include: � Normally Closed (N.C.) - An electrical contact whose normal state (for example, no pressure or electrical potential applied) is in the closed position. � Normally Open (N.O.) - An electrical contact whose normal state (for example, no pressure or electrical potential applied) is in the open position. � Reaction Time - Describes the time between the true states of one input to the ON state of the output. � Recovery Time - Describes the time that is required for the input to be in the LO state before returning to the HI state. � Response Time - Describes the time between the trigger of one input to the OFF state of the output. � Output Signal Switching Device (OSSD) - Typically a pair of solidstate signals that are pulled up to the DC source supply. The signals are tested for short circuits to the DC power supply, short circuits to the DC common and shorts circuits between the two signals. � Single Wire Safety (SWS) - A unique, safety-rated signal that is sent over one wire to indicate a safety status. The SWS can be used in Category 4, Performance Level e, per ISO 13849-1 and safety integrity level (SIL) 3, per IEC 62061 and IEC 61508. These documents contain additional information concerning related products from Rockwell Automation. Resource Next Generation Guardmaster Safety Relay (GSR) Wiring Diagram, publication SAFETY-WD001 Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Product Certifications website, rok.auto/certifications. Allen-Bradley� Industrial Automation Glossary, AG-7.1 Description Provides example wiring diagrams for applications using Guadmaster� safety relays. Provides general guidelines for installing a Rockwell Automation� industrial system. Provides declarations of conformity, certificates, and other certification details. A glossary of industrial automation terms and abbreviations. You can view or download publications at http://www.rockwellautomation.com/literature/. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. 8 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Overview 1 Chapter Hardware Features The Guard Locking Proximity (GLP) inputs special-purpose safety relay is designed to use proximity sensors to detect the safe speed of a machine. The GLP safety relay issues lock or unlock commands to a guard locking interlock based on the speed of the signals that are received from the proximity sensors. The GLP safety relay has three rotary switches that are used to set its configuration. A logic switch sets the functionality. Two other switches set speed limits and time delay: Switch SLS1 sets the safe limited slow speed. Switch SLS2 set the safe maximum speed limit or a percentage of the timing range. Figure 1 - GLP Safety Relay Removable terminal blocks Five status indicators for status and diagnostics Logic switch sets functionality SLS1 sets the safe limited slow speed SLS2/Time sets the maximum safe speed or percentage of time delay Optical communication bus Five status indicators provide status and diagnostic information. Table 1 - Status Indicator Information Indicator PWR/Fault IN1 51/L61 Logic IN X14/X24 L11 Description Indicates that power is applied or a fault condition Indicates that the safety gate is closed, input valid. Indicates that power is applied to unlock the guard locking interlock. Indicates the presence of the Single Wire Safety input signal. Indicates that the safety outputs are ON. The GLP safety relay has four removable terminal blocks; two on the top and two on the bottom. Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 9 Chapter 1 Overview Logic Functions 10 The optical communication bus is on the sides of the housing. The GLP safety relay operates with the catalog number 440R-ENETR EtherNet/IPTM network interface to transmit its status to the machine control system over an EtherNet/IP network. The GLP safety relay can be operated with other safety relays in the GSR family by use of the single wire safety (SWS) connection. When the GLP safety relay receives an SWS signal from other GSR relays, the GLP safety relay issues an Unlock command. When the GLP safety relay turns ON its safety output, it also turns ON its SWS output for use by other GSR safety relays. The GLP safety relay can be configured to operate in one of eight logic safety functions. Logic Setting 1 - Cat 1 Stop, Logic IN Off You initiate a stop command by pressing the unlock push button. The GLP safety relay issues an immediate stop command from the Y32 auxiliary output to the machine control system. When the GLP safety relay determines that the proximity sensor speed has dropped below the SLS1 setting, it starts the Frequency Measuring Timer that SLS1 specifies. If the proximity sensor speed remains below the SLS1 setting, the GLP safety relay turns OFF its safety outputs and powers the guard locking interlock through 51 and L61 to unlock the gate. TIP If the Reset button is pressed within the Frequency Measuring Time, the GLP safety relay turns the Y32 auxiliary output back ON. If the proximity sensor speed does not decrease below the SLS1 setting, the GLP safety relay continues to wait with the 51/L61 status indicator flashing, and the safety gate remains locked. Once the proximity sensor speed drops below SLS1 setting, the GLP safety relay begins the Frequency Measurement timer. The proximity sensor speed must remain below SLS1 during the Frequency Measurement timer. The SWS signal at wiring terminal L12 is ignored. Logic Setting 2 - Cat 1 Stop with Logic IN You initiate a stop command by either pressing the unlock push button or turning off the single-wire safety signal at wiring terminal L12. The GLP safety relay issues an immediate stop command from the Y32 auxiliary output to the machine control system. When the GLP safety relay determines that the proximity sensor speed has dropped below the SLS1 setting, it starts the Frequency Measuring Timer that SLS1 specifies. If the proximity sensor speed remains below the SLS1 setting, the GLP safety relay turns OFF its safety Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Overview Chapter 1 outputs and powers the guard locking interlock through 51 and L61 to unlock the gate. TIP If the SWS input turns back ON or if the Reset button is pressed within the Frequency Measuring Time, the GLP safety relay turns the Y32 auxiliary output back ON. If the proximity sensor speed does not decrease below the SLS1 setting, the GLP safety relay continues to wait with the 51/L61 status indicator flashing, and the safety gate remains locked. Once the proximity sensor speed drops below SLS1 setting, the GLP safety relay begins the Frequency Measurement timer. The proximity sensor speed must remain below SLS1 during the Frequency Measurement timer. Logic Setting 3 - Safe Limited Slow Speed, Logic IN Off You initiate a slow speed command by pressing a momentary push button. The GLP safety relay issues a slow speed command to the machine control system by turning terminal Y32 ON. When the GLP safety relay determines that the speed of the proximity signals is less than the SLS1 setting, the GLP safety relay issues an unlock command to the guard locking interlock, while keeping its safety outputs ON. If the speed of the machine exceeds the SLS1 setting, the GLP safety relay turns it safety outputs OFF. The single wire safety signal at wiring terminal L12 is ignored. Logic Setting 4 - Safe Limited Slow Speed with Logic IN The single wire safety signal at wiring terminal L12 must be active to turn on the GLP safety relay outputs. You initiate a slow speed command by pressing the unlock push button. The GLP safety relay issues a slow speed command to the machine control system by turning terminal Y32 ON. When the GLP safety relay determines that the speed of the proximity signals is less than the SLS1 setting, the GLP safety relay issues an unlock command to the guard locking interlock, while keeping its safety outputs ON. If the speed of the machine exceeds the SLS1 setting, the GLP safety relay turns it safety outputs OFF. When the single wire safety signal at terminal L12 becomes inactive, the GLP safety relay initiates a shutdown. If the machine is running at production speed, the GLP safety relay turns on Y32. When the proximity speed falls below the safely limited speed, the GLP safety relay turns OFF its outputs. If the machine is already running at safe limited slow speed, the GLP safety relay turns off its safety outputs and issues an unlock command to the guard locking interlock. Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 11 Chapter 1 Overview Logic Setting 5...8 - Guard Locking with Delayed Unlock and Automatic Reset The GLP safety relay uses two timers to delay the turning ON of the safety outputs and unlocking the gate. When the proximity sensor speed falls below SLS1, the GLP safety relay starts the Frequency Measurement timer. The timer duration is dependent on the SLS1 setting. The GLP safety relay waits to verify that the proximity sensor speed is maintained below SLS1. For slower SLS1 settings, the GLP safety relay waits longer. For higher SLS1 settings, the GLP safety relay responds a little faster. If the proximity sensor speed is maintained below SLS1, the GLP safety relay turns on the X14, X24, Y32, and L11 outputs. The GLP safety relay also starts the unlock timer. After the unlock timer expires, the GLP safety relay turns on the 51 and L61 outputs, which unlock the safety gate. A combination of the Logic switch and SLS2 sets the duration of the unlock timer. The Logic switch sets a range of delay and the SLS2 switch sets a percentage of that range. As the speed of the proximity sensors crosses (increasing or decreasing) the SLS1 setting, the outputs and locking functions are performed automatically. The frequency measurement and unlock timers only apply when the proximity sensor speed decreases below the SLS1 setting. The S12, S22, S44, and S54 inputs do not have any functionality and do not need any connections. Logic Setting 8 -- Speed Status Only This logic setting does not control a guard locking interlock. This setting ignores the unlock, lock, L12 inputs, and also the safety inputs S12 and S22. When the proximity sensors measure speed that is below SLS1, all outputs are OFF. When the speed is greater than SLS1, but less than SLS2, the 51 and L61 terminals are high and the 51/L61 status indicator is ON. When the speed exceeds SLS2, all outputs (51, L61, X14, X24, Y32, and L11) are high and the 51/L61 and X14/X24 L11 status indicators are ON. When the speed crosses the SLS1 and SLS2 levels, the outputs turn ON and OFF automatically. 12 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Installation 2 Chapter Mounting Dimensions This chapter explains the mounting and terminal removal procedures. It also provides information to select the proper enclosure and help prevent overheating. Figure 2 - Dimensions [mm (in.)] 22.5 (0.88) 113.6 (4.47) 119.14 (4.69) DIN Rail Mounting and Removal The GLP safety relay mounts onto 35 mm DIN rail: 35 x 7.5 x 1 mm (EN 50022 - 35 x 7.5). 1. Hold the top at an angle. 2. Slide down until the housing catches the rail. 3. Swing the bottom down and push until the latch clips onto the rail. Figure 3 - DIN Rail Mounting DIN Rail Latch DIN Rail Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 13 Chapter 2 Installation Removable Terminals Removal To remove the GLP safety relay, use a screwdriver to pry the DIN rail latch downwards until it is in the unlatched position. Then, swing the module up. Spacing The GLP safety relay can be mounted directly next to other GSR safety relays. When the catalog number 440R-ENETR EtherNet/IP network interface is used, the GSR must be mounted within 10 mm (0.4 in.) of adjacent modules to maintain effective communication. For adequate ventilation, maintain a space of 50.8 mm (2 in.) above and below the relay. The GLP safety relay has removable terminals to ease wiring and replacement. Figure 4 - Removable Terminals 1 2 1. Insert the tip of a small, screwdriver into the slot near the terminal screws. 2. To unlock the terminal block, rotate the screwdriver. The terminal block can then be removed from the housing. Enclosure Considerations Most applications require installation in an industrial enclosure to reduce the effects of electrical interference and environmental exposure. Pollution Degree 2 is an environment where normally only non-conductive pollution occurs except that occasionally temporary conductivity that is caused by condensation can be expected. Overvoltage Category II is the load level section of the electrical distribution system. At this level, transient voltages are controlled and do not exceed the impulse voltage capability of the products insulation. This equipment is intended for use in a Pollution Degree 2 industrial environment, in overvoltage Category II applications (as defined in IEC 606641), at altitudes up to 2000 m (6562 ft) without derating. This equipment is considered Group 1, Class A industrial equipment according to IEC/CISPR 11. Without appropriate precautions, there may be difficulties with electromagnetic compatibility in residential and other environments due to conducted and radiated disturbances. 14 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Installation Chapter 2 This equipment is supplied as open-type equipment. It must be mounted within an enclosure that is suitably designed for those specific environmental conditions that are present and appropriately designed to help prevent personal injury as a result of accessibility to live parts. The enclosure must have suitable flame-retardant properties to help prevent or minimize the spread of flame, complying with a flame spread rating of 5VA, V2, V1, V0 (or equivalent) if non-metallic. The interior of the enclosure must be accessible only by the use of a tool. Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications. For more information, see: � Industrial Automation Wiring and Grounding Guidelines, Rockwell Automation publication 1770-4.1, for additional installation requirements. � NEMA Standard 250 and IEC 60529, as applicable, for explanations of the degrees of protection that are provided by different types of enclosure. Preventing Excessive Heat For most applications, normal convective cooling keeps the relay within the specified operating range. Verify that the specified temperature range is maintained. Proper spacing of components within an enclosure is usually sufficient for heat dissipation. In some applications, other equipment inside or outside the enclosure can produce a substantial amount of heat. In this case, place blower fans inside the enclosure to help with air circulation and to reduce "hot spots" near the controller. Additional GLP safety relay cooling provisions might be necessary when high ambient temperatures are encountered. Do not bring in unfiltered outside air. Place the controller in an enclosure to help protect it from a corrosive atmosphere. Harmful contaminants or dirt could cause improper operation or damage to components. In extreme cases, you may need air conditioning to help protect against heat buildup within the enclosure. Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 15 Chapter 2 Installation Notes: 16 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Power, Ground, and Wire 3 Chapter Wiring Requirements and Recommendation ATTENTION: Before you install and wire any device, disconnect power to the system. ATTENTION: Calculate the maximum possible current in each power and common wire. Observe all electrical codes that dictate the maximum current allowable for each wire size. Current above the maximum ratings may cause wiring to overheat, which can cause damage. � Allow for at least 50 mm (2 in.) between I/O wiring ducts or terminal strips and the relay. � Route incoming power to the relay by a path separate from the device wiring. Where paths must cross, their intersection should be perpendicular. � Do not run signal or communication wiring and power wiring in the same conduit. Wires with different signal characteristics should be routed by separate paths. � Separate wiring by signal type. Bundle wiring with similar electrical characteristics together. � Separate input wiring from output wiring. � Label wiring to all devices in the system. Use tape, shrink-tubing, or other more dependable means for labeling purposes. In addition to labeling, use colored insulation to identify wiring based on signal characteristics. For example, you may use blue for DC wiring and red for AC wiring. Wire Size Each terminal can accommodate copper wire with size from 0.2...2.5 mm2 (24...14 AWG). Use copper that withstands 60/75 �C (140/167 �F). Terminal Torque Torque terminals to 0.4 N�m (4 lb�in). Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 17 Chapter 3 Power, Ground, and Wire Terminal Assignments Some terminals are designed to have one specific function. Some terminals can perform multiple functions; these terminals must be configured during a power-up routine. Figure 5 - Terminal Identification S12 S22 AP S54 X2 A1 A2 P12 P22 X1 X1 X2 PWR/Fault IN1 51/L61 Logic IN X14/X24 L11 L12 L11 Y32 S44 X3 X14 X24 51 L61 X4 X3 X4 Terminal A1 A2 AP P12 P22 S12 S22 S44 S54 Y32 L11 L12 51 L61 X14 X24 Function +24V Supply (+10%, -15%) 24V Common Power Supply for Proximity Sensors Proximity Sensor Input Channel 1 Proximity Sensor Input Channel 2 Safety Input for Channel 1 Safety Input for Channel 2 Reset and Lock Request Input Guard Locking Unlock Request Input Auxiliary Non-safety Output Single Wire Safety Output Single Wire Safety Input Guard Locking Solenoid Output Channel 1 (High Side) Guard Locking Solenoid Output Channel 2 (Low Side, High Side, or Logic Link Output) Configured as either a pulse test output that is expected at one of the safety input channels or an OSSD safety output Configured as either a pulse test output that is expected at one of the safety input channels or an OSSD safety output 18 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Grounding the Controller Power, Ground, and Wire Chapter 3 There are no special grounding requirements. Terminal A2 must be connected to the common of a 24V supply. Connecting a Power Supply An external 24V DC power supply source must provide power for the GLP safety relay. To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with safety extra low voltage (SELV) or protected extra low voltage (PELV) must power the GLP safety relay. To comply with the USA NFPA 79, a DC power source compliant with a protected extra low voltage (PELV) must power the GLP safety relay. That is, the 0V must be connected to protective earth. The following Bulletin 1606 power supply catalog numbers are SELV- and PELV-compliant. � 1606-XLP30E � 1606-XLP50E � 1606-XLP50EZ � 1606-XLP72E � 1606-XLP95E � 1606-XLDNET4 � 1606-XLSDNET4 Figure 6 - Power Supply Connections Connect +24V DC to Terminal A1 Connect 24V Common to Terminal A2 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 19 Chapter 3 Power, Ground, and Wire Proximity Sensor Connections Figure 7 - PNP Proximity Sensor Connections +24V DC Black (PNP) Black (PNP) Blue Brown Brown A1 P12 P22 AP Power Monitoring A2 GLP 24V Com Blue Proximity Sensors Figure 8 shows how to connect an NPN (sinking) proximity sensor. You must provide an NPN to PNP converter. The converter should get power from AP and have the same ground reference as the GLP safety relay. When an NPN/ PNP converter is used, a 4 A slow-blow fuse is required, and the NPN/PNP power (+) must be connected after the fuse. Figure 8 - PNP and NPN Proximity Sensor Connections +24V DC Fuse 4A SB PNP +- NPN User Supplied NPN/PNP Converter Black (NPN) A1 P12 P22 AP Brown Brown Power Monitoring A2 GLP Black (PNP) Blue Blue 24V Com Proximity Sensors Guard Locking Connections Devices with Mechanical Contacts Guard locking devices, like the TLS3-GD2 guard locking switch, have mechanical contact outputs, where the solenoid lock monitoring contacts are typically connected in series with the gate monitoring contacts. Some models of the TLS3-GD2 guard locking switch allow you to monitor the gate and solenoid contacts separately. With its sleek, narrow body, the GLP safety relay has only one set of safety inputs, so the series connection of the gate and solenoid contacts are required because the gate must be both closed and locked for production speed operations. Figure 9 shows an example of the wiring connections from the GLP safety relay to a TLS-GD2 guard locking switch. X14 and X24 generate test pulses that S12 and S22 receive. The test pulses check for short circuit conditions, which, if detected, turns off the GLP safety outputs. Figure 9 - Example Connections to Mechanical Contacts (TLS3-GD2) Safety Gate 11 21 33 X14 X24 A1 12 22 41 51 34 GLT A2 42 52 TLS3-GD2 S12 S22 20 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Unlock Request Input Power, Ground, and Wire Chapter 3 Because the TLS3-GD2 guard locking switch has multiple contacts in series, the maximum safety performance rating is Cat 3 PLd and SIL 2. TIP Pulse test output X14 can be connected to either S12 or S22. Pulse test output X24 can be connected to either S12 or S22. Safety Devices with OSSD Outputs Devices, such as the TLS-Z guard locking switch, 440G-LZ guard locking switch, and Bulletin 442G Multifunction Access Box (MAB) have currentsourcing PNP semiconductor outputs (OSSD), which send their own pulsetested safety signals to the GLP safety input terminals. These devices must have a common power-supply reference with the GLP safety relay. Figure 10 - Example Connections to TLS-Z, 440G-LZ, or MAB +24V DC 24V DC Com TLS-Z, 440G-LZ or MAB OSSD1 OSSD2 X14 X24 A1 GLP S12 S22 A2 TIP OSSD1 can be connected to either S12 or S22 and OSSD2 can be connected to either S12 or S22. When using the TLS-Z and 440G-LZ guard locking switches, the maximum safety performance rating is Cat 4 PLe and SIL 3. The Unlock Request input can be connected to the 24V supply through a momentary, normally open push button switch or to a 24V sourcing output of a programmable logic controller (PLC), where the PLC turns the request ON or OFF. Some examples of Rockwell Automation� PLC output modules are shown in Figure 11. The unlock request is connected to Terminal S54. Figure 11 - Unlock Request Wiring +24V DC Momentary Normally-Open Push Button A1 S54 GLP A2 A1 S54 GLP A2 + PLC Output PLC 1 Processor 2 1756-OB16 3 1769-OB8 1746-OB4 1734-OB2 1793-OB4 24V DC Com Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 21 Chapter 3 Power, Ground, and Wire Lock and Reset Request Input The Lock and Reset Input can be connected to the 24V supply through a momentary, normally open push button switch or to a 24V sourcing output of a PLC, where the PLC turns the request ON or OFF. Some examples of Rockwell Automation PLC output modules are shown in Figure 12. In some safety system applications, the reset signal also serves as a monitoring function. For example, when the safety outputs are driving safety contactors, the normally closed contacts of the safety contactors should be connected in series with lock and reset circuit. If an unlock request is made, and the machine speed has not dropped below the SLS1 setting, pressing the Reset button cancels the unlock request. The lock and reset request is connected to Terminal S44. Figure 12 - Lock Request Wiring +24V DC Momentary Normally-Open Push Button Contactor Monitoring + PLC Output PLC 1 Processor 2 1756-OB16 3 1769-OB8 1746-OB4 1734-OB2 1793-OB4 A1 S44 GLP A2 24V DC Com A1 S44 GLP A2 Lock and Unlock Signals The GLP safety relay is designed to ignore incidental actuations or stuck conditions on the Lock and Unlock inputs. The lock and unlock signals must be actuated for a duration between 0.25...3 seconds. The GLP safety relay ignores signal durations that are too short or too long. Figure 13 - Required Signal Duration +24V DC 250...3000ms 24V DC Com 22 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Lock Outputs Power, Ground, and Wire Chapter 3 Terminals 51 and L61 perform the solenoid lock command. There are various connection possibilities, and the GLP safety relay detects the type of connection during configuration. TLS3-GD2 Connections Figure 14 shows a connection from a GLP safety relay to one TLS3-GD2 guard locking switch. Terminal 51 is connected to A1 and terminal L61 is connected to A2. With this arrangement, the X14/X24 L11 status indicator flashes two times during the configuration process. Figure 14 - Single TLS3-GD2 Connection Safety Gate 11 21 33 51 A1 41 51 12 22 34 A2 TLS3-GD2 42 52 GLP L61 TLS-Z, 440G-LZ, and MAB Connections Figure 15 shows one connection from a GLP safety relay to one TLS-Z guard locking switch, 440G-LZ guard locking switch, and Bulletin 442G Multifunction Access Box (MAB). Terminal 51 is connected to A1 and terminal L61 is left open. The GLP safety relay and guard locking switch must have a common reference. With this arrangement, the X14/X24 L11 status indicator flashes one time during the configuration process. Figure 15 - Single TLS-Z, 440G-LZ, or MAB Connection +24V DC TLS-Z, 440G-LZ or MAB 51 A1 GLP A2 24V DC Com Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 23 Chapter 3 Power, Ground, and Wire Multiple Guard Locking Devices and Power to Lock When multiple guard locking devices must be connected to one GLP safety relay, an interposing relay or interposing relays may be required; the connection depends on the lock signal/coil characteristics. The solenoids would be driven by the contacts of the interposing relays. TIP The lock signal of TLS-Z and 440G-LZ guard locking switches draw under 4 mA, which allows you to connect the lock signal of multiple switches in parallel. The interposing relays must also be used to for those applications where Power to Lock guard locking is required. IMPORTANT The GLP safety relay requires a suppression diode, as shown in Figure 16, for proper operation. Some devices, like the TLS3-GD2 guard locking switch, 440G guard locking switch, and Bulletin 100S safety contactors (with electronic coils) have built-in diodes, so an external diode is not required. With CR1 connected between 51 and L61, the X14/X24 L11 status indicator flashes two times during the configuration process. With two relays (CR1 connected between 51 and ground and CR2 connected between L61 and ground), the X14/X24 L11 status indicator blinks one time during the configuration process. The 700-HPSXZ24 relay can be connected between 51 and L61. The 100S contactors cannot be connected between 51 and L61. The 100S contactors must be connected between 51 and 0V or L61 and 0V. Figure 16 - Interposing Relay Connections +24V DC 51 A1 CR1 GLP L61 A2 A1 GLP 51 L61 A2 24V DC Com CR1 CR2 24 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Safety Outputs Power, Ground, and Wire Chapter 3 No Guard Locking If no guard locking is required for Stop Cat 1 or SLS functions, then 51 and L61 can be left open. The safety inputs S12 and S22 must be connected to 24V DC. With this arrangement, the X14/X24 L11 status indicator blinks one time during the configuration process. Figure 17 - No Guard Locking Connections +24V DC 51 S12 S22 A1 GLP L61 A2 24V DC Com Terminal X14 and X24 can be configured as pulse test outputs or safety outputs. Start the configuration process from 9 to configure X14 and X24 as pulse test outputs. Start the configuration process from 0 to configure X14 and X24 as safety outputs. When configured as pulse test outputs, the GLP safety relay continuously provides 24V DC combined with short test-pulse signals on terminals X14 and X24. This configuration is used in applications with guard locking devices that have mechanical contacts. The purpose of the pulse testing is to test for the following short-circuit conditions: � Between X14 and X24 � From X14 or X24 to 24V DC � From X14 to X24 to 24V common Figure 18 shows an example wiring connection of the pulse testing outputs (X14 and X24) connected to a TLS3-GD2 guard locking switch. The output signals are fed through the mechanical contacts and back to the safety inputs (S12 and S22) of the GLP safety relay. Figure 18 - Pulse Test Output Connections Safety Gate 11 21 33 S12 S22 A1 12 22 41 51 34 GLP A2 42 52 TLS3-GD2 X14 X24 When configured as safety outputs, terminals X14 and X24 are safety outputs. The safety outputs are only turned ON when safe conditions are met. When configured as safety outputs, these terminals test for short circuits when they are turned ON. The safety outputs are commonly referred to as OSSD outputs. Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 25 Chapter 3 Power, Ground, and Wire Figure 19 shows an example wiring connection of the safety outputs to two contactors. When solenoid type loads are used, use a protective diode to suppress reverse voltage spikes when the contactors turn OFF. Figure 19 - Safety Output Connections +24V DC A1 GLP A2 X14 X24 24V DC Com K1 K2 Single Wire Safety (SWS) The GLP safety relay has two single wire safety connections: one input (terminal L12) and one output (terminal L11). These terminals can only be connected to other devices that support single wire safety. Use of the SWS input is determined during configuration. When used, the SWS input must be ON to lock the safety gate and reset the safety outputs (turn them ON). When the SWS input turns off, the GLP safety relay turns its safety outputs OFF and performs an unlock request. There can be many variations and combinations of series and parallel connections of the SWS. Each L11 terminal can be connected to up to ten L12 terminals. TIP Connecting two or more L11 terminals together is not allowed. Figure 20 shows an example wiring diagram with SWS input from a GSR DI safety relay and SWS output connection to a GSR EM expansion in parallel with a GSR DIS relay. The safety relays must have a common power reference (24V common). Figure 20 - Single Wire Safety Connections +24V DC +24V DC +24V DC +24V DC A1 DI A2 L12 L11 A1 GLP A2 L12 L11 A1 EM A2 L12 L11 A1 DIS A2 L12 L11 24V DC Com Figure 21 shows the characteristics of SWS signal when it is active. It starts with a 1-ms pulse, followed 600 �s later by a 600-�s pulse. This waveform is repeated every 4 ms. When inactive, the SWS is 0V. Figure 21 - SWS Waveform Terminals 24V L11 and L12 0V 0 1 1.6 2.2 4 ms 26 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Configuration 4 Chapter Logic Switch Settings The GLP safety relay has three multi-position switches on its front panel. These switches set the configuration of the GLP safety relay. The Logic switch determines the operating function of the GLP safety relay and is used to set the configuration. Table 2 - Logic Switch Setting Switch 1 Lock/ Unlock Door Control Application Setting Out Configuration Logic in 0 Configuration 1...8 Program mode X14 and X24 configured as OSSD Outputs 1 Guard Locking 2 Power to Release Cat 1 Stop Logic in OFF Logic in AND IN1 3 Safely Limited Speed Logic in OFF 4 Logic in AND IN1 5 Guard Locking On-delay 1...10 s 6 Power to Release Delayed Unlock On-delay 3...30 s 7 Automatic Reset On-delay 30...300 s 8 (1) (configuration from "0"only) On-delay 300...3000 s Logic in OFF Logic in OFF Logic in OFF Logic in OFF 8 (2) Speed1 and Max Speed status Status only only (Configuration from "9") Logic in OFF 9 Configuration 1...4 Program mode X14 and X24 are configured as Pulse Tested Outputs for the S12 and S22 Inputs 5...7 Program mode is not allowed 8 for speed status only with X14 and X24 as OSSD Outputs. Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 27 Chapter 4 Configuration SLS1 Switch Setting SLS1 is a 10-position switch that determines the safe limited slow speed, as detected by the proximity sensors, or the Safe Stop Threshold (Speed1). Switch SLS1 applies to all eight logic settings. Table 3 - SLS1 Settings SLS1 Switch Setting 0 1 2 3 4 5 6 7 8 9 Maximum SLOW Speed 0.5 Hz 1 Hz 2 Hz 3 Hz 4 Hz 5 Hz 6 Hz 7 Hz 8 Hz 10 Hz Frequency Measuring Time 10100 ms 5050 ms 2550 ms 1750 ms 1350 ms 1100 ms 950 ms 800 ms 700 ms 600 ms SLS2/Time Switch Setting SLS2/Time is a 10-position switch. When the Logic Switch is set to positions 1...4, SLS2/Time determines the safe limited fast speed, as detected by the proximity sensors. The safety outputs turn OFF when the speed exceeds the frequency that is shown in Table 4. When set to 0, the GLP safety relay does not test for maximum speed. When the Logic Switch is set to positions 5...8, SLS2/Time determines the time delay from 10...100% of the Range set by the Logic position. Time Delay = (10%...100% x Time Range) + Frequency Measuring Time ATTENTION: When the frequency of the objects that pass in front of the proximity sensors exceeds the sensors capability, the proximity sensors give a false signal. To help protect against this potential unsafe condition, you must set SLS2/Time to a value that does not exceed the maximum frequency rating of the proximity sensors. 28 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Configuration Chapter 4 Table 4 - SLS2/Times Settings SLS2/Time Switch Setting 0 1 2 3 4 5 6 7 8 9 Safe Maximum Speed Configuration 1...4 and 8 (Configured from 9) No limit 10 Hz 20 Hz 50 Hz 100 Hz 200 Hz 500 Hz 1000 Hz 2000 Hz 3000 Hz Time Configuration 5...8 (Configured from 0) 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Use a small slotted screwdriver to set the switches to the desired setting. The configuration switches are multi-position switches with a limited rotation. Figure 22 - Configuration Switch Adjustment Mechanical Stops Screwdriver Slot 0 IMPORTANT Adjust the switches gently and do not turn past the mechanical stops. Configuration Process Configuration is a five-step process. The process requires the wiring to the GLP safety relay to be completed. During the configuration process, GLP safety relay sends out test pulses to determine how it is wired and then configures the internal parameters to match the application. The GLP safety relay is configured in five steps: 1. With the power OFF, set the switches for configuration. Set the Logic switch to: � 0 if you want X14 and X24 configured as OSSD safety outputs. They turn ON simultaneously as the L11 SWS output. � 9 if you want to use X14 and X14 as test pulse outputs that the GLP safety relay expects to receive at S12 and S22 inputs. � You must always set the Logic Switch to 0 or 9 during configuration, even if you only want to change SLS1 or SLS2/Time. Set SLS1 to 0. Set SLS2/TIME to 0. Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 29 Chapter 4 Configuration 30 2. Apply power. The PWR/Fault status indicator flashes red continuously. The prior configuration in the EEPROM is erased and the device now prepared for a new configuration. 3. Adjust the Logic, SLS1, and SLS2/Time switches. After 500 ms, the new configuration parameters are acknowledged. Then, after 300 ms, the new parameter is stored in the EEPROM, the power status indicator is solid green. TIP You can change (or readjust) the switch settings during Step 3 and 4. The power status indicator momentarily flashes red again. 4. Verify the settings by counting the blink rates of the status indicators. The status indicators flash for 0.5 seconds to indicate the switch setting. The number of flashes is equal to the switch setting. The blinking repeats after a two-second pause. Figure 23 - Example of the Status Indicators Flashing during Configuration Mode IN1 - Indicates that the LOGIC switch is set to 3 0.5s Flash 2s Pause 51/L61 - Indicates that the SLS1 switch is set to 4 Logic IN - Indicates that the SLS2/time switch is set to 1 X14/X24 L11 - Indicates the solenoid connection to guard locking switch with OSSD outputs 5. Cycle the power to store the settings. After power-up, the current switch settings are compared to the values in the EEPROM, and the input and output circuits are checked. Upon successful completion of the internal checks, the GLP safety relay is ready for operation. The X14/X24 L11 status indicator indicates the type of connection that is made to terminals 51 and L61. Table 5 shows the conditions for the X14/X24 L11 status indicator blink rates. Table 5 - X14/X24/L11 Status Indicator X14/X24/L11 Status Indicator Blinks One time Two times Guard Locking Switch OSSD Guard Locking Switch (for example, TLS-ZR or 440G-LZ) Standard Guard Locking Switch (for example, TLS3-GD2) 51 High side High side L61 High side Low side Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 5 Chapter Diagnostic Status Indicators and Troubleshooting The GLP safety relay has five status indicators to provide operating status and diagnostic information. Status Indicators During Power-up During power-up, the status indicators turn ON and OFF during their selfcheck process. The self-check takes about 5 seconds for Status Only Logic and 10 seconds for all other Logic Settings. Status Indicators During Normal Operation Table 6 - Normal Operation Status Indicators Status Indicator PWR/FAULT IN 1 51/L61 LOGIC IN X14/X24 L11 State Solid Green Blinking Green Blinking Red Green with Blinking Red ON OFF ON OFF Blinking ON OFF ON OFF Blinking Description Normal operation. On power-up, the gate appears open. Close the gate or verify 24V DC at terminals S12 and S22. If your guard locking devices use mechanical inputs, start configuration from 9. Non-recoverable fault. See Table 7 on page 32. Correct fault and cycle power. Recoverable fault. See Table 7 on page 32. Correct fault and press reset. Input circuits at S12 and S22 are closed. Input circuits at S12 and S22 are open. Gate is locked with Logic Setting 1...4. Output is active with Logic Setting 5...8. 51 and L61 are ON with Status Only. Gate is unlocked with Logic Setting 1...4. Output is inactive with Logic Setting 5...8. 51 and L61 are OFF with Status Only. Timing cycle has started. Logic IN signal at L12 is active. Logic IN signal at L12 is OFF. L11 is active and X14/X24 are ON. L11 is active and X14/X24/Y32 are ON with Status Only. L11 is OFF and X14/X24 are OFF. L11 is OFF and X14/X24/Y32 are OFF with Status Only. Waiting for reset signal or timing cycle has started. Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 31 Chapter 5 Diagnostic Status Indicators and Troubleshooting Status Indicators During Diagnostics The flashing of the status indicators indicate diagnostics. The PWR/Fault indicator shows the major fault. The IN1 indicator shows more detail. The flashing rate pauses and then repeats itself. IMPORTANT For accurate diagnostics, always start counting after the first pause. The first cycle may not be accurate. Table 7 - Diagnostic Status Indicators Power/Status Indicator Status/Faults Solid red An undeclared fault has occurred. Cycle power to clear the fault and return the GLP safety relay to an operational state. Flashing red one time The GLP safety relay is in configuration mode. When the Logic Switch is set to 0 or 9 and the power is cycled, the PWR/Fault status indicator blinks at a 1X rate. The GLP safety relay is in configuration mode. Rotate the switches to the desired positions and cycle power. Green with flashing red two times The configuration does not agree with the EPROM. One or more of the rotary switches have changed during operation. The GLP safety relay continues to operate, and the switch or switches can be returned to their original position. Green with flashing red three times A lock request was made on terminal S44 but the gate remains open. Close the gate (the voltage at terminals S12 and S22 should be 24V DC), press the unlock request, and then press the lock request. Green with Flashing red four times Overspeed - the speed exceeded the SLS2/Time setting. Reduce the speed and press Reset. Green with flashing red five times Over Safe Speed Limit (SLS1). Reduce the speed. Green with flashing red six times Gate appears open when it should be closed and locked. Try reclosing the gate. Check voltage at S12 and S22 � they should be 24V. Flashing red two times Upon power-up, one or more of the rotary switch settings do not agree the value that is stored in the EEPROM. Return the switches to their proper settings and cycle power or reconfigure the GLP safety relay. Flashing red three times Proximity Position Fault (In Logic Settings 1...4, both proximity sensors are low). Flashing red four times The input at S12 and S22 opened while the safety gate was locked. Flashing red five times Logic Link output or L61 fault. Correct the fault and cycle power to the GLP safety relay. Flashing red six times S12 or S22 may be open. X14 or X24 fault. Check for short circuit from X14 to X24. Cycle gate. Check voltage at S12 and S22 � they should be 24V. Correct the fault and cycle power to the GLP safety relay. Flashing red seven times With a Logic setting of 1 or 2, the proximity sensors detected speed exceeding the SLS1 setting for more than four pulses on each proximity sensor when the GLP outputs (X14/X24/L11/Y32) are OFF. Note: This covers two cases: 1. On power-up, the gate is locked and the outputs are OFF. 2. After pressing unlock, the gate is unlocked and the outputs are OFF. Prevent excessive machine movement or set the SLS1 setting to a higher level. Flashing red eight times Proximity Sensor input fault. IN1 flashing 5 times: P12 ON and P22 changing state. IN1 flashing 5 times: P22 ON and P12 changing state. In Rev A 100, IN1 flashes 5 times whether it is P12 or P22. This fault occurs whether the GLP safety outputs are ON or OFF - the output state is irrelevant. In Rev A 202 and later, the IN1 indicator does not flash. Only the PWR/Fault indicator flashes 8 times. Check the proximity sensor connections and sensing distance. Check the voltages at P12 and P22. The voltage is 24V when the proximity sensor is ON and 0V when the proximity sensor is Off. Cycle power after fixing. Flashing red nine times 51 or L61 fault. Check the voltages at terminals 51 and L61. They are less than 3V when OFF and greater than 15V when ON. Flashing red ten times Overvoltage � The supply voltage exceeded 28V DC. Reduce the power supply to 24V +10/-15% and cycle the power. 32 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Pulse Testing Functions 6 Chapter Introduction to Pulse Testing The test pulses are used by the GLP safety relay to detect three short-circuit conditions: � Between the input terminals and +24V � Between the input terminals and 24V common � Between the two input terminals. The outputs have built in redundancy, as shown in Figure 24. A main transistor supplies power to individual transistors for each output terminal. This arrangement provides the redundant output to achieve the Cat. 3 and SIL 2 safety rating. Figure 24 - Output Transistor Arrangement Main Transistor Individual Transistors 51 L61 X14 X24 The GLP safety relay continuously tests all transistors. When the main transistor is tested, a 50-�s pulse appears on all outputs simultaneously. When the individual transistors are tested, the test pulse only appears on their respective terminals. The main transistor test is predominately 50 �s but can be as long as 350 �s. The pulse width on X14, X24, 51, and L61 is between 200...850 �s. Figure 25 - Output Pulse Test Width Main Transistor 24V X14, X24, 51, and L61 24V 0V 0 50...350 �s 0V 0 200...850 �s Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 33 Chapter 6 Pulse Testing Functions Pulse Testing for Inputs Test of OSSD Outputs When configuration starts with Logic Switch setting 9 and goes to a setting from 1 to 4, X14 and X24 terminals generate quick pulses that are used to test for short circuit conditions. This configuration is ideal for guard locking interlocks with mechanical contacts. It is required to achieve a Cat. 4 safety performance rating. X14 is connected through one mechanical contact to S12 or S22 and X24 is connected through the other mechanical contact to S22 or S12. TIP � X14 can be connected to S12 or S22 � X24 can be connected to either S12 or S22 Figure 26 shows a typical sequence of test pulses. The individual transistor tests are interspersed between the main transistor tests. Figure 26 - Pulse Test Sequence Terminal 24V X14 0V Main Transistor Tests 24V X24 0V 0 Individual Transistor Tests The GLP safety relay does not use pulse testing when X14 and X24 are configured as OSSD outputs. Instead, the GLP safety relay turns the OSSD outputs with a short delay between them. If a cross fault short circuit exists between X14 and X24, the GLP safety relay detects that condition and immediately turn the outputs OFF. Turn OFF occurs in less than 1 ms and the PWR/Fault status indicator flashes red six times. Figure 27 - OSSD Cross Fault Detection Terminal 24V X14 0V 24V X24 0V 0 500...1000 �s 34 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Ethernet Communication 7 Chapter The GLP safety relay is equipped with optical communication via optical link. With the optical link, diagnostic data can be read from the GLP safety relay and transferred to other devices over an EtherNet/IP network. Figure 28 - Arrangement of EtherNet/IP Network Interface and GSR Relays Webpage The catalog number 440R-ENETR EtherNet/IP network interface must be in the left-most position. The EtherNet/IP network interface automatically determines the models present and their position. Up to six GSR relays can be mounted next to the EtherNet/IP network interface. See publication 440R-UM009 for further details on the EtherNet/IP network interface. IMPORTANT The 440R-ENETR Series B module does not have a webpage. The webpage is available with Series A modules only. The GLP safety relay provides the following data on the EtherNet/IP network interface webpage. To access the webpage, connect an Ethernet cable to your computer and type in the Ethernet address. Figure 29 - Access the EtherNet/IP Network Interface Webpage Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 35 Chapter 7 Ethernet Communication Logix AOP IMPORTANT Using an Ethernet browser to query the 440R-ENETR module is available only with Series A modules. Series B does not have the browsing capability. When you browse the GSR modules, the GLP safety relay appears as Device Type 8. Table 8 shows the GLP safety relay data that can be viewed from the webpage. Table 8 - GLP Safety Relay Data On Ethernet Website Device Type 8 Firmware Revision 32 Running True Has Recoverable Fault False Has Non-recoverable Fault False Operation State 1 4 Operation State 2 152 Recoverable Fault Processor 1 0 Recoverable Fault Processor 2 0 Communication Errors 0 Communication Retries 0 Non-recoverable Error Count 0 Recoverable Error Count 0 The catalog number 440R-ENETR EtherNet/IP network interface includes the Logix AOP for the GLP safety relay. Figure 30 shows the variables that are reported back from the GLP safety relay. The variables are all status inputs. In Series A, the AOP calls the position of the relay as a Slot number. Figure 30 - GLP Safety Relay Logix AOP for 440R-ENETR Series A 36 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Ethernet Communication Chapter 7 Figure 31 shows the GLP Logix AOP for the 440R-ENETR Series B. The relay position is now shown as Relayn, where n is the position of the relay with respect to the 440R-ENETR module. Figure 31 - GLP Safety Relay Logix AOP for 440R-ENETR Series B Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 37 Chapter 7 Ethernet Communication Notes: 38 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Proximity Sensors and Targets 8 Chapter Proximity Sensor Selection The GLP safety relay accepts proximity sensors that meet the following requirements: 1. 24V DC powered 2. 3-wire (Power, Ground, and Signal) 3. PNP Output Type 4. Leakage current less than 1 mA. The GLP safety relay does not require the use of safety-rated proximity sensors. Redundant standard-rated industrial sensors are sufficient to meet the safety ratings of the GLP safety relay. Proximity Sensor Targets The sensors must be mounted no further than 0.8 times their nominal sensing distance. To achieve maximum speed, the sensors must be mounted at 0.5 times their nominal sensing distance. The depth of the gear space must be at least three times the nominal sensing distance. The proximity sensors have the following requirements: 1. The space must be at least twice the diameter of the proximity sensors. 2. The mark (target) must be at least four times the diameter of the proximity sensor. 3. The detection of the targets must be alternating. 4. With logic settings 1...4, both sensors cannot be off simultaneously. With logic settings 5...8, both sensors can be off simultaneously, but the recommended arrangement is to mount the sensors so that both sensors are not off simultaneously. 5. Due to the overspeed detection time, speed limits must be set lower than the maximum allowable speed limit. ATTENTION: To avoid a single common cause failure to danger, the proximity sensors must be mounted on independent hardware brackets and fixtures when logic settings 5...8 are used. Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 39 Chapter 8 Proximity Sensors and Targets Figure 32 - Proximity Mark (Space Dimensions) >= 3d (1) d d Prox Prox <= 0.8 Sn >= 3 Sn Mark >= 4d Space >= 2d (1) The spacing distance depends on the type of proximity sensor. Verify the requirements of your proximity sensor. Figure 33 - Target Wheel Example 1 Recommended for all Logic settings Figure 34 - Target Wheel Example 2 Not recommended Both proximity sensors are OFF simultaneously. Alternating Not Alternating Targets do not necessarily have to be gear tooth. Figure 35 shows an example of a wheel with holes. The hole is equivalent to a space and the wheel is the mark. Figure 35 - Target Wheel Example 3 40 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Proximity Sensors and Targets Chapter 8 Figure 36 shows a target wheel that is configured to achieve the maximum resolution. Figure 36 - Maximum Resolution d Major Radius 2d 0.5 Sn 4d 3 Sn Minor Radius Minor Angle Major Angle The spreadsheet in Figure 37 can be used to calculate the target wheel dimensions to achieve the maximum resolution. The example shows a 12 mm (0.47 in.) proximity sensor with a 3 mm (0.12 in.) nominal sensing range. Figure 37 - Target Wheel Dimension Calculation In the formulas in Figure 37, the '$' indicates that the column or row is absolute and not relative to its current location. For example, "$B$1" always refers to column B row 1 when you copy the formula to another cell. Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 41 Chapter 8 Proximity Sensors and Targets Notes: 42 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 9 Chapter Example Operational Sequence Diagrams Stop Cat 1 Example This chapter provides operational sequence diagrams of typical GLP applications. The purpose of provide you with a better insight of some of the performance characteristics of the GLP safety relay. This example shows a typical application where the GLP safety relay is used in a Stop Category 1 application. Example Schematic In this example, we have a GLP safety relay that controls a 440G-LZ Power to Release guard locking interlock, drives a PowerFlex� 525 AC drive, and is connected to an EM expansion safety relay. The Y32 output is directly connected to the Start and Stop terminals of the PF525 drive. When Y32 goes HI, the PF525 drive can be started. When Y32 goes LO, the drive executes its pre-configured stop function. In this example, the 440G-LZ guard locking switch can easily replace by the TLS-ZR guard locking switch. Figure 38 - Schematic for Stop Cat 1 Example +24V DC LightLatch 440G-LZS21SPRA Fuse 4 A SB Brown Red Yellow Green Grey Pink Gate Unlock Request Reset & K1 Gate Lock Request K2 S12 S22 51 L61 S54 A1 S44 Y32 GLP LOGIC 0 1 9 2 8 3 7 6 54 SLS1 SLS2/TIME 0 0 1 1 9 2 8 7 6 3 54 9 2 8 7 6 3 54 440R-GL2S2P L12 A2 AP P12 P22 X14 X24 L11 X32 A1 13 23 33 43 EM 440R-EM4R2 L12 L11 A2 14 24 34 44 Black Black Blue Brown Blue White 24V DC Com Gate Unlocked Blue Proximity Sensors K1 K2 L1 L2 L3 PowerFlex R S T 525 1 Stop 2 Start 4 Gnd Gate control power supply Gate control circuit S1 S2 UV W M Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 43 Chapter 9 Example Operational Sequence Diagrams Max Safe Speed (SLS2) Sequence Diagram Figure 39 shows the sequence of operations. This diagram assumes that all components are operating properly and no faults are present. Figure 39 - Operational Sequence for Stop Cat 1 Example Overspeed Safely Limited Speed (SLS1) 1 Power On Off 23 Operator Location In Cell Out of Cell Gate Status (S12, S22) Locked Unlocked Unlock Request 24V 0V Reset & Lock Request 24V 0V 250ms Lock Signal (51/L61 24V Power to Release 0V Y32 24V 0V X14/X24 24V 0V L11 24V 0V EM Ouputs Closed Open Start Button 24V 0V Stop Button 24V 0V Proximity Sensors 24V 0V 45 6 7 8 250ms Operator in Cell Gate is unlocked Frequency Measurement Unlock Time 250ms Lock 9 10 11 Sequence Steps The following steps describe each of the highlighted points in Figure 39. 1. 24V DC power is applied to the safety system. Because the gate is closed, the 440G guard locking switch has locked the gate. With the gate closed and locked, the GLP safety relay is ready for reset. 2. You press and release the Reset button (hold for 250...3000 ms). The Y32 goes HI, which allows the PF525 drive to start after the Start button is pressed. Terminals X14 and X24 go HI, which enables the Safe Torque Off function of the PF525 drive. The single wire safety output at L11 starts oscillating. The EM expansion relay energizes and turns on contactors K1 and K2. 44 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Example Operational Sequence Diagrams Chapter 9 3. You press the Start button and the motor begins to accelerate and the proximity sensors generate pulses. At some point, the speed becomes faster than the safely limited speed set by SLS1 on the GLP safety relay but stays below the maximum safe speed. This speed is the normal machine operating speed during production. 4. Later, you want to enter the cell. You press the Unlock Request button. Upon release, the signal at Y32 goes to zero, which is a Stop signal for the drive. The drive is configured to execute an orderly shutdown and ramps the speed of the motor to zero. The pulses from the proximity sensors reduce in frequency. 5. When the motor speed is slower than the configured Safely Limited Speed, the GLP safety relay begins the Frequency Measurement Time to verify that the motor speed remains below the SLS1 setting. 6. At the end of the frequency Measurement Time, the gate terminal 51 output turns ON to unlock the gate (the 51/L61 indicator turns OFF). Simultaneously, the L11 signal stops oscillating. This action causes the EM outputs to open which de-energizes K1and K2. IMPORTANT The motor can still be rotating slowly. The slowest rate must not cause harm to the operator. Now you can open the gate, enter the manufacturing cell, and perform normal production operations as specified in your procedures. You leave the cell and close the gate. 7. You press and release the Reset button. The lock command signal (terminal 51) goes low to lock the gate. The GLP safety relay interrogates S12 and S22. If the gate is locked, the GLP safety relay sets Y32, X14 and X24 high, and L11 begins oscillating. 8. You press the Start button. The motor ramps up to production speed. 9. You press the Stop button. The motor decelerates to a stop. When the speed drops below the safely limited speed, the GLP safety relay does not change the door status. 10. You press the Start button. The motor ramps up to production speed. 11. The motor exceeds the maximum speed set by SLS2. The GLP safety relay detects the speed by the proximity sensors and immediately turns off Y32, X14 and X24, and L11 stops oscillating. The drive executes a coast-to-stop. The safety gate remains locked. The PWR/Fault status indicator is green with 4x flashing red to indicate overspeed. Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 45 Chapter 9 Example Operational Sequence Diagrams SLS Example This example shows a typical application where the GLP safety relay is used in a Stop Category 1 application. Example Schematic In this example, we have a GLP safety relay that controls a 440G-LZ Power to Release guard locking interlock, drives a PowerFlex 525 AC drive, and is connected to an EM expansion safety relay. The Y32 output is directly connected to terminal 5 of the PF525 drive, which is configured to be set to a Preset Frequency. When Y32 goes HI, the PF525 drive immediately sets the motor to run at the predetermined speed. In this example, the 440G-LZ guard locking switch can easily replace by the TLS-ZR guard locking switch. Figure 40 - Schematic for Safely Limited Speed Example +24V DC LightLatch 440G-LZS21SPRA Fuse 4 A SB Brown Red Yellow Green Grey Pink Gate Unlock Request Reset & K1 Gate Lock Request K2 S12 S22 51 L61 S54 A1 S44 Y32 GLP LOGIC 0 1 9 2 8 3 7 6 54 SLS1 SLS2/TIME 0 0 1 1 9 2 8 7 6 5 3 4 9 2 8 7 6 3 54 440R-GL2S2P L12 A2 AP P12 P22 X14 X24 L11 X32 A1 13 23 33 43 EM 440R-EM4R2 L12 L11 A2 14 24 34 44 Black Black Blue Brown Blue White 24V DC Com Gate Unlocked Blue Proximity Sensors K1 K2 L1 L2 L3 PowerFlex R S T 525 11 +24V DC 1 Stop 2 Start 5 Preset Freq 4 Gnd Gate control power supply Gate control circuit S1 S2 UV W M 46 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Example Operational Sequence Diagrams Chapter 9 Max Safe Speed (SLS2) Sequence Diagram Figure 41 shows the sequence of operations. This diagram assumes that all components are operating properly and no faults are present. Figure 41 - Operational Sequence for Safely Limited Speed Example Overspeed Safely Limited Speed (SLS1) 1 On Power Off 23 Operator Location Out In of Cell Cell Locked Gate Status (S12, S22) Unlocked 24V Unlock Request 0V Reset & Lock Request 24V 0V 250ms Lock Signal (51/ L61) Power to Release 24V 0V 24V X14 and X24 0V Y32 24V 0V L11 24V 0V EM Ouputs Closed Open Start Button 24V 0V 24V Stop Button 0V 24V Proximity Sensors 0V 45 6 7 250ms Operator In Cell Gate is unlocked Frequency Measurement Unlock Time 250ms Lock 89 10 Sequence Steps The following steps describe each of the highlighted points in Figure 41. 1. 24V DC power is applied to the safety system. Because the gate is closed, the 440G guard locking switch has locked the gate. With the gate closed and locked, the GLP safety relay is ready for reset. 2. You press and release the Reset button (hold for 250...3000 ms). Terminals X14 and X24 go HI, which enables the Safe Torque Off function of the PowerFlex 525 drive. The single wire safety output at L11 starts oscillating. The EM expansion relay energizes and turns on contactors K1 and K2. Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 47 Chapter 9 Example Operational Sequence Diagrams 3. You press the Start button and the motor begins to accelerate and the proximity sensors generate pulses. At some point, the speed becomes faster than the safely limited speed set by SW2 on the GLP safety relay, but stays below the maximum safe speed. This speed is the normal machine operating speed during production. 4. Later, you want to enter the cell. You press the Unlock Request button. Upon release of the button: � The signal at Y32 goes HI, which commands the PowerFlex 525 drive to go to its preconfigured safe slow speed. � The 51/L61 indicator on the GLP safety relay starts blinking, waiting for the speed to reduce below the safely limited speed. 5. The pulses from the proximity sensors reduce in frequency. When they indicate that the speed is below the safely limited speed, the GLP safety relay begins the Frequency Measurement Time to verify that the speed is maintained below the SLS1 setting. The motor continues turning at the safe speed. 6. At the end of the Frequency Measurement Time, the gate terminal 51 output turns ON to unlock the gate (the 51/L61 indicator turns OFF). The motor continues turning at the safe speed. You enter the manufacturing cell, perform the required production functions, and then leave the cell. 7. You press and release the Reset and Lock Request. Upon release of the button: � The Lock signal (terminal 51) goes LO (the 51/L61 indicator turns ON). � The Gate Status signal (S12/S22) goes HI, which indicates that the door is closed and locked. � The Y32 signal then goes LO and the PowerFlex 525 drive ramps up to normal production speeds. 8. During the normal production process, you press the Stop button. The motor decelerates to a stop. When the speed drops below the maximum safe slow speed, the GLP safety relay does not change the door status. 9. You press the Start button. The motor ramps up to production speed. 10. The motor exceeds the maximum speed set by SLS2 (a fault condition). The GLP safety relay detects the speed by the proximity sensors and immediately turns the X14/X24 outputs and L11 stops oscillating. The EM outputs turn off and the PowerFlex 525 drive executes a coast-tostop. Terminal Y32 goes HI and the safety gate remains locked. The PWR/Fault indicator is green with 4x flashing red to indicate overspeed. 48 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Example Operational Sequence Diagrams Chapter 9 Delayed Unlock with Auto Reset Example This example can be used for Logic setting 5...8 when configuration is started from 0. Example Schematic In this example, we have a GLP safety relay with an EM expansion module. This arrangement operates similar to the Guardmaster CU2 relay; the outputs turn ON when the motion is below the threshold set by the SLS1 rotary switch. Brown Red Yellow Figure 42 - Schematic for Delayed Unlock with Auto Reset +24V DC LightLatch 440G-LZS21SPRA Green - Locked Red - Unlocked Green Grey Pink S12 S22 51 L61 S54 A1 S44 Y32 GLP LOGIC 0 1 9 2 8 3 7 6 54 SLS1 SLS2/TIME 0 0 1 1 9 2 8 7 6 3 54 9 2 8 7 6 3 54 440R-GL2S2P L12 A2 AP P12 P22 X14 X24 L11 Status to PLC X32 A1 13 23 33 43 EM 440R-EM4R2 L12 L11 A2 14 24 34 44 Black Black Blue Brown Blue White 24V DC Com Gate K1 K2 Unlocked Blue Proximity Sensors K3 K4 871TM-N10NP12-D4 889D-F4AC-2 K5 K6 K7 K8 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 49 Chapter 9 Example Operational Sequence Diagrams Sequence Diagram Figure 43 shows the sequence of operations. This diagram assumes that all components are operating properly and no faults are present. Figure 43 - Operational Sequence for Delayed Unlock with Auto Reset Safely Limited Speed On Power Off Operator Location In Cell Out of Cell Gate Status Locked Unlocked Lock Signal 24V (51/ L61) 0V 24V K1... K2 0V X14, X24 (K3... K4) 24V 0V Y32 24V 0V L11 EM Ouputs (K5...K8) Start Button (not shown) Stop Button (not shown) Proximity Sensors 24V 0V Closed Open 24V 0V 24V 0V 24V 0V 12 3 4 5 Gate is locked Gate is unlocked Unlock Unlock Delay Frequency Measurement Time 6 7 Gate is locked Lock Sequence Steps 8 9 10 11 12 Operator In Cell Gate is unlocked Unlock Delay Locked Frequency Measurement Time The following steps describe each of the highlighted points in Figure 43. 1. 24V DC power is applied to the safety system. The safety devices perform their internal tests. 2. The GLP safety relay begins its Frequency Measurement Time to check the proximity sensor speed. 3. After the GLP safety relay determines the speed is below the SLS2 setting, the X14/X24/L11 outputs turn ON and the unlock delay timer starts. If the proximity sensor speed is greater than SLS1 upon power-up, the GLP safety relay keeps the gate locked and maintains its outputs in the OFF state. 4. The 51/L61 outputs turn ON and unlock the gate. 5. You press the Start button. The machine begins to accelerate and the proximity sensors generate pulses. 50 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Example Operational Sequence Diagrams Chapter 9 6. Then, the speed becomes faster than the safely limited speed set by SLS1 on the GLP safety relay. The GLP safety relay issues a lock command and turns off its outputs (X14/X24/L11/Y32). The gate switch outputs turn ON and energize K1 and K2. This speed is the normal machine operating speed during production. 7. Later, you want to enter the cell. You press the Stop button and the machine begins to decelerate. 8. When the speed of the machine decelerates below the safely limited speed, the GLP safety relay begins its Frequency Measurement Timer to help verify that the machine is consistently below the SLS1 setting. 9. The GLP safety relay turns its outputs (X14/X24/L11/Y32) ON and starts the unlock delay time. The combination of the Logic and SLS2/ Time settings set the unlock delay time. 10. At the end of the unlock delay time, the GLP safety relay unlocks the gate, which allows you into the cell. After completing the production operations, you leave the cell and close the gate. 11. You press the Start button to begin production operations. 12. When the speed of the machine reaches the SLS1 setting, the GLP locks the gate and turns its outputs OFF. Status Only Example This example only applies for Logic setting 8, when the configuration process starts from 9. The GLP safety relay does not perform any guard locking or resetting. Example Schematic Figure 44 shows the outputs that turn ON based on the speed the proximity sensors detect. When the speed exceeds SLS1, the 51/61 outputs turn ON. When the speed exceeds SLS2, the remaining outputs turn ON; that is, all outputs are ON, when the speed exceeds SLS2. Figure 44 - Schematic for Status Only +24V DC A1 L12 51 L61 L11 X14 X24 Y32 GLP LOGIC 0 1 9 2 8 3 7 6 54 SLS1 SLS2/TIME 0 0 1 1 9 2 8 7 6 3 54 9 2 8 7 6 3 54 440R-GL2S2P A2 AP P12 P22 S12 S22 S44 S54 Speed Exceeds SLS1 OSSD Outputs Speed Exceeds SLS2 Single Wire Safety Output OSSD Outputs Auxiliary Output Black Black Blue Brown 24V DC Com Blue Proximity Sensors 872C-D8NP18-D4 989D-F4AC-2 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 51 Chapter 9 Example Operational Sequence Diagrams Sequence Diagram Figure 45 the sequence of operations. This diagram assumes that all components are operating properly and no faults are present. Figure 45 - Operational Sequence for Status Only Example SLS2 Speed SLS1 Speed Sequence Steps 1 23 4 5 6 On Power Off 51/L61 24V 0V Y32 24V 0V X14/X24 24V 0V L11 24V 0V Proximity Sensors 24V 0V Sequence Steps The following steps describe each of the highlighted points in Figure 45. 1. 24V DC power is applied to the safety system. The safety devices perform their internal tests. 2. Because the proximity sensors do not detect any motion, the GLP safety relay maintains all of its outputs in the OFF state. The proximity sensors detect and increase in the speed of the machine. 3. When the speed increases past the SLS1 setting, the 51/L61 outputs turn ON. 4. When the speed increases past the SLS2 setting, the GLP safety relay turns on the remaining outputs (X14/X24/L11 and Y32). 5. When the speed decreases below SLS2, the GLP safety relay turns X14/X24/L11 and Y32 OFF. 6. When the speed decreases below SLS2, the GLP safety relay turns 51/L61 OFF. 52 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 A Appendix Specifications General Specifications Table 9 - General Specifications Attribute Dimensions, WxHxD Shipping weight, approx. Wire size Wiring category Terminal screw torque Power supply voltage range Power consumption Fuse Case material Terminal protection Enclosure protection 440R-GL2S2P 22.5 x 119.14 x 113.6 mm (0.88 x 4.69 x 4.47 in.) 150 g (0.33 lb) 0.2...2.5 mm2(24...14 AWG) Copper that withstands 75 �C (167 �F) 0.4 N�m (4 lb�in) 24V DC PELV/SELV 0.85...1.1 x rated voltage 2 W 4 A, slow blow (slow release) Polyamide PA 6.6 IP20 IP40 (NEMA 1) Environmental Specifications Table 10 - Environmental Specifications Attribute 440R-GL2S2P Temperature, operating Relative humidity -5...+55 �C (23...131 �F) 90% Vibration Shock 10...55 Hz, 0.35 mm 10 g, 16 ms Pollution level 2 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 53 Appendix A Specifications Input IN1 Table 11 - Inputs IN1 Attribute Input signals ON voltage, max ON voltage, min OFF voltage, max OFF current, max ON current at 24V DC, max ON current at 26.4V DC, max Galvanic isolation: I/O from logic Overvoltage protection Test out pulse duration Test out pulse period Off pulse accepted for OSSD setting without declaring the input as OFF Reverse voltage protection Input capacitance 440R-GL2S2P S12, S22 26.4V 11V 5V 2 mA 11.0 mA 11.1 mA No Yes 850 �s 17 ms Min = 0 �s Max = 850 �s Yes 10 nF Proximity Sensor Signals Table 12 - Proximity Sensor Signals Attribute Input signals ON voltage, max ON voltage, min OFF voltage, max OFF current, max ON current at 24V DC, max Hole pulse time (low pulse), min Pulse Resolution, max Galvanic isolation: I/O from logic Input capacitance Overvoltage protection 440R-GL2S2P P12, P22 26.4V 6V 5V 2 mA 6.5 mA 40 �s 4 kHz No 1 nF Yes 54 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Lock Unlock Request Lock Unlock Signals Table 13 - Lock Unlock Request Attribute Input signals ON voltage, max ON voltage, min OFF voltage, max OFF current, max ON current at 24V DC, max ON current at 26.4V DC, max Galvanic isolation: I/O from logic Overvoltage protection Input capacitance Duration 440R-GL2S2P S44, S54 26.4V 11V 5V 2 mA 11.0 mA 11.1 mA No Yes 10 nF 0.5...3.0 s Table 14 - Lock Unlock Signals Attribute Output signals Continuous output current, max High side voltage, max High side voltage, min Low side voltage, max Surge output current, max Surge output current duration, max Load capacitance, max OFF state leakage current, max Short-circuit detection Short-circuit protection 440R-GL2S2P 51 & L62 0.300 A 26.4V 15V 3V 3 A 10 �s 1 �F < 0.1 mA Yes Yes Specifications Appendix A Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 55 Appendix A Specifications Auxiliary Signal Table 15 - Auxiliary Signal Attribute Output signals Continuous output current, max ON state voltage drop (P/S to +), max Surge output current, max Surge output current duration, max Load capacitance, max OFF state leakage current, max Short-circuit detection Short-circuit protection Galvanic isolation: I/O from logic 440R-GL2S2P Y32 50 mA 0.2V 700 mA 5 ms 1 �F < 0.1 mA No Yes No Single Wire Safety Input Signal Table 16 - Single Wire Safety Input Signal Attribute Input signals ON voltage, max ON voltage, min OFF voltage, max OFF current, max ON current at 24V DC, max ON current at 26.4V DC, max Galvanic isolation: I/O from logic Overvoltage protection Reverse voltage protection Input capacitance 440R-GL2S2P L12 26.4V 11V 5V 2 mA 11.0 mA 11.1 mA No Yes Yes 10 nF 56 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Single Wire Safety Output Signal Table 17 - Single Wire Safety Output Signal Attribute Output signals Continuous output current, max ON state voltage drop (P/S to +), max Surge output current, max Surge output current duration, max Load capacitance, max OFF state leakage current, max Short-circuit detection Short-circuit protection Galvanic isolation: I/O from logic Fanout (# connections to L11, max) Cable length between L11 and L12 440R-GL2S2P L11 50 mA 0.2V 700 mA 5 ms 1 �F < 0.1 mA No Yes No 10 30 m (98.4 ft) Specifications Appendix A Safety/Pulse Test Outputs Table 18 - Safety/Pulse Test Outputs Attribute Output signals Continuous output current, max Surge output current, max Surge output current duration, max Residual voltage (drop from P/S), max Load capacitance, max OFF state leakage current, max Short-circuit protection Reverse voltage protection Aggregate current of outputs per module, max Galvanic isolation: I/O from logic Pulse test duration Pulse test period 440R-GL2S2P X14, X24 0.5 A 1.5 A 5 ms 0.2V 1 �F < 0.1 mA Yes Yes (with external fuse required) 1.8 A No 850 �s 13000 ms (<15 s) Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 57 Appendix A Specifications Response Times Table 19 - Response Times Unlock request (S54) Single wire safety input, L12 Safety inputs (S12, S22) Proximity frequency exceeds SLS1 Proximity frequency drops below SLS1 Proximity frequency drops below SLS2 Logic 1...4 X14, X24, Cat 1 Y32 L11 See SLS1 27 ms Frequency Measuring Time 53 ms (page 28) 53 ms -- Logic 5...8 X14, X24, L11, Y32 -- 345 ms -- Status Only 51, L61 X14, X24, L11, Y32 -- -- -- -- 2.6 s -- -- 250 ms 58 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Regulatory Approvals B Appendix Agency Certifications � UL Listed Industrial Control Equipment, certified for US and Canada. � CE marked for all applicable directives � C-Tick marked for all applicable acts � CCC Mark � S-Mark Compliance to European Union Directives This product has the CE marking and is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives. Machine Safety Directive This product is designed and tested to meet the European Council Directive 2006/42/EC on machinery and the following standards. � IEC/EN 61508 -- Functional safety of electrical/electronic/ programmable electronic safety-related systems � IEC/EN 62061 -- Safety of machinery -- Functional safety of safety-related electrical, electronic, and programmable electronic control systems � EN ISO 13849-1 -- Safety of machinery -- Safety-related parts of control systems -- Part 1: General principles for design This product is intended for use in an industrial environment. The performance of the safety function is dependent on the structure of all devices that comprise the safety function. The following two tables provide the data that must be used to represent the GLP safety relay when calculating the safety integrity level (SIL) or the Performance Level (PL). Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 59 Appendix B Regulatory Approvals SIL Rating The GLP safety relay meets the requirements of SIL CL 2 in accordance with IEC/EN 61508 and IEC 62061. Table 20 - SIL Rating Attribute Safety Integrity Level Claim Limit PFD PFH Mode of Operation Hardware Fault Tolerance Safe Failure Fraction 440R-GL2S2P 2 4.13E-09 7.19E-9 High Demand 1 98.95% Performance Level/Category The GLP safety relay can be used in safety systems that meet up to Category 3 and Performance Level PLd in accordance with ISO 13849-1. Table 21 - Performance Level Attribute Category Performance Level MTTFd DC Avg Mission Time (a) Days Of Operation (d) Hours of Operation (h) T cycle (h/s) 440R-GL2S2P Up to 3 Up to d 378 97.66% 20 365 24 8/28.8 EMC Directive This product is designed and tested to meet the European Council Directive 2015/30/EU on Electromagnetic Compatibility (EMC) and the following standards: � EN 61000-6-4: Generic Standards -- Emission Standard for Industrial Environments � EN 61000-6-2: Generic Standards -- Immunity for Industrial Environments This product is intended for use in an industrial environment. 60 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Numerics 440G-LZ connection 23 A agency certifications 59 AOP Logix 36 approvals regulatory 59 assignments terminal 18 auxiliary signal specifications 56 C category performance 60 certifications agency 59 communication Ethernet 35 compliance 59 European Union directives 59 configuration 27 process 29 connect power supply 19 connection 440G-LZ 23 guard locking 20 MAB 23 proximity sensor 20 TLS3-GD2 23 TLS-Z 23 consideration enclosure 14 controller ground 19 Index D delayed unlock with auto reset example 49 schematic 49 sequence diagram 50 sequence steps 50 devices mechanical contacts 20 diagnostic status indicators 31, 32 diagram operational sequence 43 dimensions mount 13 DIN rail mount 13 removal 13 directive EMC 60 machine safety 59 E EMC directive 60 enclosure consideration 14 environmental specifications 53 Ethernet communication 35 European Union directives 59 example delayed unlock with auto reset 49 SLS 46 status only 51 stop Cat 1 43 excessive heat prevent 15 F features hardware 9 functions logic 10 pulse testing 33 G general specifications 53 ground 17 controller 19 guard locking connection 20 no 25 power to lock 24 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 61 Index H hardware features 9 heat 15 I input IN1 specifications 54 lock and reset request 22 pulse testing 34 unlock request 21 input signal single wire safety specifications 56 installation 13 introduction pulse testing 33 L level performance 60 lock outputs 23 signals 22 lock and reset request input 22 lock unlock request specifications 55 lock unlock signal specifications 55 logic functions 10 setting 1 10 setting 2 10 setting 3 11 setting 4 11 setting 5...8 12 setting 8 12 switch setting 27 Logix AOP 36 M MAB connection 23 machine safety directive 59 mechanical contacts devices 20 mount dimensions 13 DIN rail 13 N no guard locking 25 normal operation status indicators 31 O operational sequence diagram 43 OSSD outputs safety devices 21 test 34 output signal single wire safety specifications 57 outputs lock 23 OSSD test 34 safety 25 overview 9 P performance level/category 60 power 17 power supply connect 19 power to lock guard locking 24 power-up status indicators 31 prevent excessive heat 15 prevent excessive 15 process configuration 29 proximity sensor connection 20 selection 39 signal specifications 54 targets 39 pulse testing functions 33 input 34 introduction 33 R recommendation wire 17 regulatory approvals 59 removable terminal 14 removal 14 DIN rail 13 requirements wire 17 response times specifications 58 62 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 Index S safety outputs 25 single wire 26 safety devices OSSD outputs 21 safety/pulse test outputs specifications 57 schematic delayed unlock with auto reset 49 SLS 46 status only 51 stop Cat 1 43 selection proximity sensor 39 sequence diagram delayed unlock with auto reset 50 SLS 47 status only 52 stop Cat 1 44 sequence steps delayed unlock with auto reset 50 SLS 47 status only 52 stop Cat 1 44 setting logic switch 27 SLS1 switch 28 SLS2 switch 28 time switch 28 signals lock 22 unlock 22 SIL rating 60 single wire safety 26 input signal specifications 56 output signal specifications 57 SLS example 46 schematic 46 sequence diagram 47 sequence steps 47 SLS1 switch setting 28 SLS2 switch setting 28 spacing 14 specifications 53 auxiliary signal 56 environmental 53 general 53 input IN1 54 lock unlock request 55 lock unlock signal 55 proximity sensor signal 54 response times 58 safety/pulse test outputs 57 single wire safety input signal 56 single wire safety output signal 57 status indicators diagnostic 31, 32 normal operation 31 power-up 31 status only example 51 schematic 51 sequence diagram 52 sequence steps 52 stop Cat 1 example 43 schematic 43 sequence diagram 44 sequence steps 44 SWS 26 T targets proximity sensor 39 terminal assignments 18 removable 14 torque 17 test OSSD outputs 34 time switch setting 28 TLS3-GD2 connection 23 TLS-Z connection 23 torque terminal 17 troubleshooting 31 U unlock signals 22 unlock request input 21 W web page 35 wire 17 recommendation 17 requirements 17 size 17 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 63 Index Notes: 64 Rockwell Automation Publication 440R-UM012E-EN-P - November 2018 . 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Allen-Bradley, Guardmaster, PowerFlex, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of ODVA, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Rockwell Otomasyon Ticaret A.., Kar Plaza Merkezi E Blok Kat:6 34752 �erenk�y, stanbul, Tel: +90 (216) 5698400 Publication 440R-UM012E-EN-P - November 2018 Supersedes Publication 440R-UM012D-EN-P - July 2016 Copyright � 2018 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.