Using the Safety Distribution R Box

Safety Application Example Using the Safety Distribution R Box Introduction...2 Important User Information...2 General Safety Information...3 Description...4 SensaGuard Connections...8 Tongue Interlock and Cable Pull Switch Connections...11 Guardlocking Connections...14 Mixed Device Connections...21 Additional Resources...26 TU UT TU UT UT TU TU UT TU UT TU UT TU UT UT TU TU UT TU UT

2 TIntroductionT This safety application note describes the basic features of the safety distribution R box and provides typical connection examples. The R box complements the existing Rockwell Automation safety distribution boxes by adding circuitry to accommodate SensaGuard interlock switches and guardlocking interlock switches. TImportant User InformationT Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication HTUSGI-1.1UTH available from your local Rockwell Automation sales office or online at HTUhttp://literature.rockwellautomation.comUTH) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. 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.

3 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. IMPORTANT Identifies information that is critical for successful application and understanding of the product. 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. 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. TGeneral Safety InformationT IMPORTANT This application example is for advanced users and assumes that you are trained and experienced in safety system requirements. ATTENTION: A risk assessment should be performed to make sure all task and hazard combinations have been identified and addressed. The risk assessment may require additional circuitry to reduce the risk to a tolerable level. Safety circuits must take into consideration safety distance calculations which are not part of the scope of this document. Contact Rockwell Automation to find out more about our safety risk assessment services.

4 TDescriptionT This new passive safety distribution R box helps facilitate quick installation of safety systems by using quick disconnect (QD) patchcords that eliminate individual wiring to specific terminals inside the interlocks. The new R box offers more connectivity functions than the existing distribution boxes. With a 4-port and an 8-port option, the new passive distribution safety box easily accommodates simple to complex safety systems. Some of the key features are shown below. 8-port R Distribution Box Green Enunciation LED Power to the Block 8 Port Connections M12 QD with 8 Pins Main Connection M23 QD with 19 Pins Amber Enunciation LED 1 per Port Labels for Each Port This distribution box is designed to accommodate SensaGuard interlock switches, tongue-operated interlock switches, the Lifeline cable pull switches, and tongue-operated guardlocking interlock switches. The table below summarizes the differences in the safety distribution boxes offered by Rockwell Automation. This application note describes ways to use the 898D-P84RT-M19 (4-port) and the 898D-P88RT-M19 (8-port) distribution boxes. Cat. No. Safety Circuit Enunciation Signal Power, Ground, and Lock/Shield 898D-44LT-DM4 898D-48LT-DM4 898D-44KT-DM4 898D-48KT-DM4 898D-P44JT-A5 898D-P44JT-A10 898D-P48JT-A5 898D-P48JT-A10 898D-P68MT-A5 898D-P68MT-A10 898D-P84RT-M19 898D-P88RT-M19

5 This distribution box has three types of circuits: (1) cascaded safety circuits, (2) enunciation circuits, and (3) power, ground and lock/shield circuits on all ports. Cascaded Dual-channel Safety Circuit The cascaded dual-channel safety circuit passes through each port. The block can be applied in single-channel applications, where only one circuit is used, or dual-channel applications that use both circuits. The circuits must be completed by the devices connected to each port or by a shorting plug. When the circuits are complete, the safety system interprets this as having the safety gates closed. The safety system can then energize its safety outputs. The safety circuit consists of two signals that pass through each port. You must supply +24V DC to the A+ and B+ signals. Then devices connected to the ports complete the connection from 4 to 6 and 8 to 5. The signal exits pins 3 and 17, through the gray and pink wires of the mating 19-wire cordset. The illustrations below show the connection of a typical port to a SensaGuard switch or an interlock switch with voltage-free contacts to complete the safety circuit. The SensaGuard switch receives the safety A+ power from pin 8 and the safety B+ power from pin 4. Diagnostic testing is performed on the safety power signals, and if OK, the output transistors are powered. The safety A output is pin 5 and the safety B output is pin 6. Those interlock switches with voltage-free contacts make a direct connection from pin 8 to pin 5 and from pin 4 to pin 6 to complete the safety circuit.

6 Enunciation Auxiliary Signals for Each Port A single enunciation circuit comes from pin 1 of each port and goes to the M23 connector. It turns on an amber status indicator when active. Typically, the enunciation signal is connected to a sourcing input card of a PLC and informs the machine control system that the safety gate monitored by the port is open. The enunciation signal can be changed by the user to release individual guardlocking gate interlocks. See UXGuardlocking by Using Individual Locking SignalsX on page X19XU for details. Power, Ground and Lock/Shield Circuits Unique to this distribution box are three wires that are connected to every port. Two of these wires are used for power and ground and provide power to SensaGuard interlock switches or to the solenoids of guardlocking interlock switches. The third wire performs one of two different functions, depending on what type of devices are connected to the port. For metal interlocks, this circuit is connected to the metal body and is used to ground the housing body. In guardlocking applications, this circuit can be used as the reference to the locking or gate status. The circuit diagram below shows the connection of the power, ground, and lock/shield circuits from the M23 QD to the 8-pin QD.

7 The housing of metal-bodied interlocks must be connected to earth ground. This can be accomplished via the mounting hardware or by a connection in the device. The 440G-MT and MT-GD2 interlocks have an internal ground lug. The ground lug of the MT-GD2 is connected to pin 3 of the 8-pin QD. Since the 440G-MT is a solenoid locking switch, the 8 wires are used for the contacts and the solenoid. Therefore, the ground lug is not connected to the 8-pin QD. You must ground the 440G-MT housing by using the mounting hardware. 440G-MT MT-GD2 Ground lug is not connected to the 8-pin QD. Ground lug goes to pin 3 of the 8-pin QD. Connections for M23 QD Connector Description M23 QD Connector Pin --1 Safety A+ (OSSD) 2 Safety B (OSSD) 3 Aux J2 4 --5 24V Common 6 Aux J1 7 Aux J3 8 Aux J5* 9 Aux J7* 10 Lock/Shield 11 Ground 12 Aux J6* 13 Aux J4 14 --15 Safety B+ (OSSD) 16 Safety A (OSSD) 17 Aux J8* 18 +24V DC 19 *Not applicable to the 4-port distribution box. Mating Cable Wire Color No Connection Red Gray Red/Blue No Connection Blue Gray/Pink White/Green White/Yellow White/Gray Black Green/Yellow Yellow/Brown Brown/Green No Connection Yellow Pink Gray/Brown Brown

8 TSensaGuard ConnectionsT This example illustrates a typical SensaGuard switch application in which five SensaGuard interlock switches ❹ and ❺ are connected to the 8-port distribution box ❶, by using 8-wire patchcords ❸. All ports must be occupied to complete the safety circuit. Three shorting plugs ❷ are used to fill the empty ports, as shown below. The distribution box has a 19-pin M23 connector to interface with the machine safety system and control system. A patchcord ❻ to a bulkhead connector ❼ can be used or a 19-wired cordset (not shown) could also be used. A 24V power supply provides power to the SensaGuard interlock switches and the safety A+ and safety B+ signals. The safety A and safety B signals are connected directly to a safety relay ❽, safety controller, or safety PLC. The auxiliary signals are connected to a DC sinking input card in the non-safety-rated PLC, which may send a signal to a Tower stacklight ❿.

The illustration below shows the typical safety signal connections to the MSR127 safety relay and to input 1 of the next generation dual-input DI safety relay. Note that only one safety relay is needed, and Rockwell Automation has other relays that may be better suited to your application. 9 Safety-rated Performance In the USensaGuard ConnectionsU example on Upage 8U, the connection of only SensaGuard interlocks and shorting plugs to the distribution block meets the requirements of Category 4 per ISO 13849-1. To complete the Category 4 rating, you must connect the two safety output signals to a device, like an MSR 127 safety relay or a SmartGuard 600 safety controller, that is also rated to Category 4. Example Bill of Material This application example uses these components. Item Catalog Number Description Quantity ❶ 898D-P88RT-M19 Distribution box - 8 port 1 ❷ 898D-81RU-DM Shorting plug 3 ❸ 889D-F8ABDM-2 Patchcord, 8-wire, 2 m 5 ❹ 440N-Z21SS2HN SensaGuard switch, rectangular 3 ❺ 440N-Z21S26H SensaGuard switch, cylindrical 2 ❻ 889M-R19RMMU-2 Patchcord, M23, 19-wire 1 ❼ 888M-F19AE-1F Bulkhead receptacle, 19-pin 1 ❽ 440R-N23132 MSR127 safety relay 1 ❾ 1606-XLP50E 24V power supply, 50 W 1 ❿ 855E-B24Y3Y5 Tower stacklight 1

10 Schematic for SensaGuard Connections Example

11 Tongue Interlock and Cable TPull Switch ConnectionsT Rockwell Automation offers several tongue-operated interlock switches and cable pull switches that can be connected to this distribution box. The devices have voltage-free mechanical contacts. The 8-pin Micro QD connectors make wiring easier during installation and maintenance. These devices use only seven of the eight wires. Four wires are used to complete the safety circuit. Two wires are used for the enunciation circuit. The enunciation circuit must be connected to a DC sourcing input card in the non-safety-rated programmable controller. The seventh wire is used to make the ground connection of the metal-bodied switches. TIP: Both the Ferrogard GD2 and Sipha GD2 switches are available with 8-pin Micro QD connectors. These two interlock switches cannot be used with the R box due to wiring differences. The figure below shows the typical safety signal connections to the popular MSR127 safety relay and to input 1 of the next generation dualinput DI safety relays. Note that only one safety relay is needed, and Rockwell Automation has other relays that may be better suited to your application.

12 Safety-rated Performance In the Tongue Interlock and Cable Pull Switch Connections example, the connection of voltage-free contacts in series limits the circuit to Category 3 per ISO 13849-1. Example Bill of Material This application example uses these components. Item Catalog Number Description Quantity ❶ 898D-P84RT-M19 Distribution box 4 port 1 ❷ 889D-F8ABDM-2 Patchcord, 8-wire, 2 m 4 ❸ 440K-W21BNPH Trojan 6 switch 3 ❹ 440K-M21MNDH MT-GD2 switch 1 ❺ 440E-D21BNYH Lifeline 2 switch 1 ❻ 440E-L21BNYH Lifeline 4 switch 1 ❼ 889M-R19RMMU-2 Patchcord M23 19-pin 1 ❽ 888M-F19AE-1F Bulkhead receptacle, 19-pin 1 ❾ 440R-N23132 MSR127 safety relay 1 ❿ 855E-B24Y3Y5 Tower stacklight 1

13 Schematic for Tongue Interlocks and Cable Pull Switches Connection Example

14 TGuardlocking ConnectionsT This distribution box can also be used three different ways with guardlocking interlocks: (1) simultaneous locking by using the power signal, (2) simultaneous locking by using the lock command signal, (3) individual locking. The distribution box can be used with either powerto-lock or power-to-unlock switches. The guardlocking interlocks that are available with 8-pin Micro QD connectors include the 440G-MT, TLS-GD2, and the Atlas 5 switches. The dual-channel safety circuit is the same for both simultaneous and individual locking. The safety circuit passes through all devices. Safety A starts at pin 2 and ends at pin 3 of the 19-pin connectors. Safety B starts at pin 16 and ends at pin 17. The safety signals must be connected to a safety-rated relay or control system in a manner typical of connecting voltage-free contacts to a safety relay. The figure below shows the typical safety signal connections to the MSR127 safety relay and to input 1 of the next generation dual-input DI safety relay. Note that only one safety relay is needed, and Rockwell Automation has other relays that may be better suited to your application.

15 Safety-rated Performance The series connection of the voltage-free contacts in the three Guardlocking Connections examples that follow, limit their circuits to Category 3 per ISO 13849-1. Example Bill of Material This application example uses these components. Item Catalog Number Description Quantity ❶ 898D-P84RT-M19 Distribution Block 4 port 1 ❷ 889D-F8ABDM-2 Patchcord, 8-wire, 2 m 4 ❸ 440G-T2NBBPH-2R TLS3-GD2 switch 1 ❹ 440G-T2NBBPH-1R TLS1-GD2 switch with 8-pin Micro QD 1 or 440G-T2NBBPH-1R TLS2-GD2 switch with 8-pin Micro QD ❺ 440G-M3NBGDH-AC 440G-MT switch 1 ❻ 440G-L2NNSDH-3N Atlas 5 switch 1 ❼ 889M-R19RMMU-2 Patchcord, M23, 19-pin 1 ❽ 888M-F19AE-1F Bulkhead Receptacle, 19-pin 1 ❾ 440R-N23132 MSR127 safety relay ❿ 1606-XLP50E 24V power supply, 50 W 1 855E-B24Y3Y5 Tower stacklight 1 Guardlocking By Using the Power Signal Using the power signal to simultaneously lock or unlock all the guards is the easiest of the three methods to use the R block. This method is simplest because all of the connections are made via quick disconnect patchcords. Internal wiring changes are not necessary. This method works when all of the devices connected to the orts are guardlocking devices from Rockwell Automation. This method uses the 24V supply circuit, which is connected to all of the ports. When 24V DC power is applied, the solenoids in all of the guardlocking switches are energized. The gates are unlocked if power-tounlock devices are used. The gates are locked if power-to-lock devices are used. The enunciation signals are connected to the auxiliary contacts operated by the solenoid (except for the TLS3-GD2 switch). When active, this indicates to the machine control system, such as a programmable controller, that the gates are unlocked. The gates may not necessarily be open, but they are unlocked. In the TLS3-GD2 switch, the enunciation signal is connected to the auxiliary contact of the gate and indicates that the gate is open, and therefore, unlocked. When the auxiliary signals are connected to a programmable controller input card, a DC sourcing card must be sued to power the amber LED status indicators. When the amber status indicator is on, the door is closed and locked. When the amber status indicator is off, the gate is unlocked. The guardlocking solenoids draw either 7 W or 13 W continuously when power is applied. The 24V DC power supply must be selected to provide enough power.

16 The circuit below shows four different guardlocking switches that are connected to a 4-port distribution box so that they are simultaneously locked or unlocked. Guardlocking Connections with Simultaneous Locking Example

17 Guardlocking by Using the Lock Command Signal Simultaneous locking can also be accomplished by using the lock command signal. The guardlocking interlocks require two wires being changed internally. 440G-MT switch: Swap the wires at A1 and terminal 44. TLS1-GD2 switch: Swap the wires at A1 and terminal 54. TLS2-GD2 switch: Swap the wires at A1 and terminal 54. TLS3-GD2 switch: Swap the wires at A1 and terminal 34. Atlas 5 switch: Swap the wires at A1 and terminal 1. When 24V DC is applied, the solenoids in all the guardlocking switches are energized. All of the gates are unlocked if power-to-unlock devices are used. The gates are locked if power-to-lock devices are used. This method should be considered as an alternative to using the power signal if a potential exists for expanding the safety system to include SensaGuard interlock switches. The enunciation signals are connected to the auxiliary contacts operated by the solenoid, except for the TLS3-GD2. When active, this indicates to the machine control system, such as a programmable controller, that the gates are unlocked. The gates may not necessarily be open, but they are unlocked. In the TLS3-GD2 switch, the enunciation signal is connected to the auxiliary contact of the gate and indicates that the gate is open, and therefore, unlocked. When the auxiliary signals are connected to a programmable controller input card, a DC sourcing card must be sued to power the amber LED status indicators. When the amber status indicator is on, the door is closed and locked. When the amber status indicator is off, the gate is unlocked. The guardlocking solenoids draw either 7 W or 13 W continuously when power is applied. The 24V DC power supply must be selected to provide enough power.

18 The circuit below shows four different guardlocking switches that are connected to a 4-port distribution box so that they are simultaneously locked or unlocked. Guardlocking Connections with Lock Command Signal Example

19 Guardlocking by Using Individual Locking Signals If you want to use individual locking and unlocking, you can modify the wiring inside the guardlocking switch. The modification requires moving two wires. In the 440G-MT switch, move the solenoid power wire to terminal 43 and the auxiliary signal from terminal 43 to the solenoid power terminal. Solenoid Power Enunciation Signal Similar changes can be made to the TLS1, TLS2, TLS3, and Atlas interlock switches. The auxiliary signals should be connected to a PLC output card that can source 24V DC. Each solenoid would be connected to a different terminal in the output module, letting the programmable controller open specific individual gates. The lock/shield wire can be connected to a sinking DC input card of a programmable controller. This will inform the programmable controller that one or more of the gates are unlocked or open.

20 The circuit below shows the connections from the M23 quick disconnect to the interlock switches that are using the 4-port distribution box. The connections from pin 1 and pin 3 of the M12 QDs have been swapped for each of the guardlocking interlock switches. Guardlocking Connections with Individual Locking Example

21 TMixed Device ConnectionsT Mixing the voltage-free contacts with the solid state output of the SensaGuard switch and the solenoid-powered guardlocking interlock switches is possible. Depending on the features needed, some internal rewiring of the interlocks may be necessary. The figure below shows the typical safety signal connections to the MSR127 safety relay and to input 1 of the next generation dual-input DI safety relay. Note that only one safety relay is needed, and Rockwell Automation has other relays that may be better suited to your application. Safety-rated Perfomance The series connection of the of the voltage-free contacts in the two Mixed Devices Connections examples that follow, limit their circuits to Category 3 per ISO 13849-1.

22 Example Bill of Material This example uses these components. Item Catalog Number Description Quantity ❶ 898D-P84RT-M19 Distribution Block 4 port 1 ❷ 889D-F8ABDM-2 Patchcord, 8-wire, 2 m 4 ❸ 440N-Z21SS2HN SensaGuard switch, rectangular 1 ❹ 440K-M21MNDH MT-GD2 switch 1 ❺ 440G-M3NBGDH-AC 440G-MT switch 1 ❻ 440G-T2NBBPH-1R TLS1-GD2 switch with 8-pin Micro QD 1 or 440G-T2NBBPH-1R TLS2-GD2 switch with 9-pin Micro QD ❼ 889M-R19RMMU-2 Patchcord, M23, 19-pin 1 ❽ 888M-F19AE-1F Bulkhead receptacle, 19-pin 1 ❾ 440R-N23132 MSR127 safety relay ❿ 1606-XLP50E 24V power supply, 50 W 1 855E-B24Y3Y5 Tower stacklight 1 Mixed Devices Using Individual Locking Signals In this circuit example, two guardlocking interlock switches with individual control are combined with an MT-GD2 switch and a SensaGuard interlock switch. The changes needed are: 440G-MT switch: Internally, swap the solenoid power wire with the enunciation wire on terminal 43. TLS1-GD2 switch: Swap the solenoid power wire on A1 with the enunciation wire on terminal 53. MT-GD2 switch: Remove the wire from the ground lug and prevent it from shorting to other signals or the housing. On the 19-pin connector, connect the following pins to the programmable controller. Sinking input card: Pin 11 indicates if the 440G-MT or the TLS1-GD2 switch is not closed and locked. Pin 7 indicates if the SensaGuard switch is open. Sourcing input card: Pin 4 indicates if the MT-GD2 switch is open. Output Card: Pin 8 controls the solenoid of the 440G-MT switch. Pin 14 controls the solenoid of the TLS1-GD2 switch. The programmable controller can unlock either gate as needed by the application.

In this example, the guardlocking solenoids are rewired for locking by the enunciation circuits. This lets a programmable controller unlock individual gates while leaving the remaining gates locked. Terminal 11 indicates that at least one guardlocking interlock is unlocked. Mixed Interlocking Connections with Individual Locking 23

24 Mixed Devices Using the Lock Command Signal In this circuit example, two guardlocking interlock switches with individual control are combined with an MT-GD2 switch and a SensaGuard interlock switch. The changes needed are: 440G-MT switch: Internally, swap the solenoid power wire with the enunciation wire on terminal 43. TLS1-GD2 switch: Swap the solenoid power wire on A1 with the enunciation wire on terminal 53. MT-GD2 switch: Remove the wire from the ground lug and prevent it from shorting to other signals or the housing. On the 19-pin connector, connect the following pins to the programmable controller. Sinking input card: Pin 11 indicates if the 440G-MT or the TLS1-GD2 switch is not closed and locked. Pin 7 indicates if the SensaGuard switch is open. Sourcing input card: Pin 4 indicates if the MT-GD2 switch is open. Output Card: Pin 8 controls the solenoid of the 440G-MT switch. Pin 14 controls the solenoid of the TLS1-GD2 switch. The programmable controller can unlock either gate as needed by the application. In the example on the following page, the guardlocking solenoids are rewired for locking by using the lock command signal on terminal 11. The advantage of this approach is that the enunciation circuits indicate which gates are open.

25 Mixed Interlocking Connections with Lock Command Locking

TAdditional ResourcesT For more information about the products used in this example refer to the HUSafety Products CatalogUH. You can view or download publications at HTUhttp://www.rockwellautomation.com/literatureUTH. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative. Rockwell Automation, Allen-Bradley, Ferrogard, Lifeline, and SensaGuard are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Copyright 2010 Rockwell Automation, Inc. All rights reserved. Printed in USA.