Rockwell Automation 440R-S13R2 User manual

User Manual Original Instructions
Guardmaster Safety Relays
Catalog Numbers 440R-S13R2, 440R-S12R2, 440R-D22R2,
440R-D22S2, 440R-EM4R2, 440R-EM4R2D

2Rockwell Automation Publication 440R-UM013G-EN-P - December 2022
Guardmaster Safety Relays User Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before
you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to
requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably
trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this
equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with
any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
These labels may also be on or inside the equipment to provide specific precautions.
The following icon may appear in the text of this document.
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.
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).
Identifies information that is useful and can help to make a process easier to do or easier to understand.

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

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Table of Contents
Reset and Monitor Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Automatic/Manual Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Monitored Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Monitor with Expansion Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Retriggerable Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Jog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 4
Configuration Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DI and DIS Safety Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
EMD Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Configuration Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Five Steps to Configure Your GSR Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chapter 5
Status Indicators Status Indicators During Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Status Indicators During Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Status Indicators During Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chapter 6
Pulse Testing Functions Pulse Testing for Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CI Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DI, DIS, and SI Safety Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pulse Testing for OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Chapter 7
EMD Safety Relay Timing
Functions
Off Delay, Non-retriggerable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Case 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Case 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Case 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Off Delay, Retriggerable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Case 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Case 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
On Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Case 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Case 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Case 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Case 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Case 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chapter 8
Internal Circuit Block Diagrams CI Safety Relay (Cat.No.440R-S13R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DI Safety Relay (Cat.No.440R-D22R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DIS Safety Relay (Cat.No.440R-D22S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
EM Safety Relay (Cat.No.440R-EM4R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Table of Contents
EMD Safety Relay (Cat.No.440R-EM4R2D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SI Safety Relay (Cat.No.440R-S12R2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Chapter 9
Application and Wiring
Examples
CI Safety Relay (Cat.No.440R-S13R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DI Safety Relay (Cat.No.440R-D22R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
DIS Safety Relay (Cat.No.440R-D22S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
EM Safety Relay (Cat.No.440R-EM4R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
EMD Safety Relay (Cat.No.440R-EM4R2D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
SI Safety Relay (Cat.No.440R-S12R2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Chapter 10
Ethernet Communication Webpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Studio 5000 Logix Designer Add-on Profile (AOP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 11
Troubleshooting Tools Needed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Optional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Follow These Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
View the PWR/Fault Status Indicator (Step 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Check the Power Supply (Step 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Check Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Verify Grounding at the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Check Safety Device Inputs (Step 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Check Voltage-free Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Examine Pulse Test Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Effect of OSSD Test Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Detect Off Pulses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Capacitance Effect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Long Wire - Resistance Effect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Channel Simultaneity (Discrepancy). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Multiple-channel Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Recovery Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Check the Single Wire Safety Circuit (Step 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SWS Connections L11 and L12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check the Reset/Monitoring Circuit (Step 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Two-handed Reset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Applications with OSSD Outputs and Test Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Check the Safety Outputs (Step 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Electromechanical Output Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
OSSD Output Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Auxiliary Output Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
EMD Expansion Safety Relay B1/B2 Inputs (Step 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Terminal Block Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Terminal Block Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Terminal Block Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Series, Version, and Manufacturing Date Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 7
Preface
This publication is a reference guide for the family of Guardmaster® Safety Relays (GSR). This
publication describes the procedures to install, wire, and troubleshoot your relay. This
publication also gives an overview of the operation of safety relays.
Who Should Use This
Manual
Use this manual if your responsibilities include design, installation, programming, or
troubleshooting of control systems that use safety relays, including catalog numbers:
• 440R-S13R2 (CI safety relay)
• 440R-D22R2 (DI safety relay)
• 440R-D22S2 (DIS safety relay)
• 440R-EM4R2 (EM safety relay)
• 440R-EM4R2D (EMD safety relay)
• 440R-S12R2 (SI safety relay)
You must have a basic understanding of electrical circuitry and familiarity with safety-related
control systems. If you do not have this knowledge, obtain the proper training before you use
this product.
Summary of Changes This publication contains the following new or updated information. This list includes
substantive updates only and is not intended to reflect all changes.
Download Firmware, AOP,
EDS, and Other Files
Download firmware, associated files (such as AOP, EDS, and DTM), and access product release
notes from the Product Compatibility and Download Center at rok.auto/pcdc.
Topic Page
Updated Table 2.18
Updated Safety Mats section. 21
Updated Single Wire Safety Input and Output section. 26
Updated Auxiliary Output section. 26
Updated Introduction section. 31
Updated Figure 27.32
Updated Table 8.33
Updated Pulse Testing for Inputs section. 37
Updated EMD Safety Relay (Cat.No.440R-EM4R2D) section. 48
Updated View the PWR/Fault Status Indicator (Step 1) section. 54
Updated Recovery Time section. 64
Added Figure 74.65
Updated Applications with OSSD Outputs and Test Pulses section. 67
Updated General table. 77
Updated Safety Inputs IN, IN1, and IN2 table. 78
Updated Reset Input table. 78
Updated Safety Outputs table. 79
Updated Single Wire Safety (SWS) table. 80
Updated Regulatory Approvals 81
Updated Table 20 82
Updated Table 21 82

8Rockwell Automation Publication 440R-UM013G-EN-P - December 2022
Preface
Definitions Publication AG-7.1 contains a glossary of terms and abbreviations that Rockwell Automation
uses to describe industrial automation systems. The following is a list of specific terms and
abbreviations that are used in this manual.
Additional Resources These documents contain additional information concerning related products from Rockwell
Automation.
You can view or download publications at rok.auto/literature.
Table 1 - Definitions
Term Definition
N.C. Normally Closed - An electrical contact whose normal state is in the closed position.
N.O. Normally Open - An electrical contact whose normal state is in the open position.
OSSD Output Signal Switching Device - Typically a pair of solid-state 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.
PLC A programmable logic controller or a programmable automation controller.
Reaction time The time between the true states of one input to the on state of the output.
Recovery time The time that is required for the input to be in the LO state before returning to the HI
state.
Reset
Safety relays offer two types of reset - Monitored manual and automatic/manual.
• Monitored Manual - The safety relay performs a reset function when the reset signal
goes from off to on and then back to off in a prescribed time-period. The reset
occurs on the trailing edge.
• Automatic/Manual - The safety relay performs a reset function if the reset input is
on. If the reset input is connected directly to 24V, the reset function is executed
immediately when the inputs become closed or active. If a contact (push button or
equivalent device) is used in the reset input, the reset function is executed on the
leading edge of the reset signal (if the inputs are closed or active).
Response time Describes the time between the trigger of one input to the off state of the output. Throughout this manual, the safety outputs are described as turning off immediately,
which means that the safety outputs turn off within the response time.
SWS
Single Wire Safety - A unique, safety-rated signal that is sent over one wire to indicate
a safety status. The SWS can be used in safety systems that require Category 4,
Performance Level e, per ISO 13849-1 and safety integrity level (SIL) 3, per IEC 62061
and IEC 61508. When an SWS signal is present, this publication describes this state as
ACTIVE or on. This signal is also referred to as the logic link signal.
Resource Description
Guardmaster EtherNet/IP Network Interface User Manual,
publication 440R-UM009
Describes the procedures that you use to install, wire,
configure, troubleshoot, and use EtherNet/IP™
modules.
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1 Provides general guidelines for installing a Rockwell
Automation® industrial system.
Product Certifications website,
rok.auto/certifications.Provides declarations of conformity, certificates, and
other certification details.

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 9
Chapter 1
Overview
The Guardmaster® safety relay (GSR) family is a group of advanced general-purpose and
special-purpose safety relays. This user manual addresses the CI, DI, DIS, EM, EMD, and SI
safety relays from this family of relays.
Hardware Features Figure 1 - Safety Relays
Removable Terminal Blocks
Each safety relay module is only 22.5 mm (0.9 in.) wide with four removable terminal blocks
(two on top and two on bottom). The terminal blocks are keyed to confirm that they are
installed in their proper slots. See Terminal Block Removal and Replacement on page 75.
Status Indicators
Multiple status indicators provide status and diagnostics. Under fault conditions, the PWR/
Fault status indicator flashes in specific patterns to help diagnose the fault. See
Status Indicators on page 9 and View the PWR/Fault Status Indicator (Step 1) on page 54 for
more information.
Multi-position Switches
Most safety relays are configured by adjusting multi-position switches to set their
functionality (a). The switches are on the front face of the safety relay so you can see the set
position during, and after, configuration. During the configuration process, status indicators
on the front face of the safety relay confirm the switch settings. See Switch Adjustment on
page 31 for more information.
(a) The EM safety relay does not require configuration.
Removable Terminal Blocks
Status Indicators
Multi-position Switches to set
functionality
Optical Communication Bus on page 10

10 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022
Chapter 1 Overview
Optical Communication Bus
The DI, DIS, EM, EMD, and SI safety relays have an optical communications bus that delivers
status and diagnostics to the catalog number 440R-ENETR EtherNet/IP™ module (not shown in
Figure 1 on page 9) without additional wiring. See Ethernet Communication on page 51 for more
information.
Safety relays use single wire safety (SWS) signals that allow multiple safety relays to work in
coordination with one another in small to medium size safety systems. The SWS feature allows
safety relays to communicate the highest safety-rated control signal from one safety system
to another over one wire (plus a common ground connection). The wire must be less than 30 m
(98.4 ft) long.
CI Safety Relay
(Cat.No.440R-S13R2)
The CI safety relay has one dual-channel input with three electromechanical relay outputs. The
CI safety relay can be configured for automatic or monitored manual reset by adjusting the
switch on the front. The CI safety relay has an SWS output, but does not support SWS input.
The CI safety relay is compatible to the MSR127 monitoring safety relay. The CI safety relay has
the same number of inputs and outputs, the same width, and the same terminal locations as
the MSR127 safety relay.
DI Safety Relay
(Cat.No.440R-D22R2)
The DI safety relay has two dual-channel inputs and two electromechanical relay outputs. In
addition, the DI safety relay has an SWS input and output. The DI safety relay can be set for
automatic or monitored manual reset by adjusting the switch on the front panel. The
configuration switch also sets the AND/OR logic that is applied to the inputs.
DIS Safety Relay
(Cat.No.440R-D22S2)
The DIS safety relay has two dual-channel inputs and four solid-state outputs. Two of the four
solid-state outputs are designed to operate with high-capacitance loads. In addition, the DIS
safety relay has an SWS input and output. The DIS safety relay can be set for automatic or
monitored manual reset by adjusting the switch on the front panel. The configuration switch
also sets the AND/OR logic that is applied to the inputs.
EM Safety Relay
(Cat.No.440R-EM4R2)
The EM safety relay is an expansion module with four immediately operated electromechanical
relay outputs. The only input to the EM safety relay is an SWS input. The EM safety relay is
designed to expand the outputs of the GSR family of host relays. The EM safety relay also has
an SWS output for further expansion.
EMD Safety Relay
(Cat.No.440R-EM4R2D)
The EMD safety relay is an expansion module with delayed electromechanical relay outputs.
The EMD safety relay can be configured for one of the following functions:
•Ondelay
• Off delay
•Jog
The settings of the two switches on the front face of the safety relay configure the
functionality and duration of the delay and jog.
The main input to the EMD safety relay is the single wire safety input. With the SWS signal, the
EMD safety relay is designed to expand the outputs of the GSR family of host relays. The EMD
safety relay also has an SWS output for further expansion.
An additional input is used with the jog function or to set the off delay as retriggerable. See
EMD Safety Relay Timing Functions on page 39 for detailed descriptions on the EMD safety
relay timing functions.

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 11
Chapter 1 Overview
SI Safety Relay
(Cat.No.440R-S12R2)
The SI safety relay has one dual-channel input with two electromechanical relay outputs. The
SI safety relay can be configured for automatic or monitored manual reset by adjusting the
switch on the front. The SI safety relay also has an SWS output.
The SI safety relay is similar in functionality to the MSR126 monitoring safety relay.

12 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022
Chapter 1 Overview
Notes:

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 13
Chapter 2
Installation
All safety relays in this manual have the same dimensions (see Figure 2).
Mounting Dimensions Figure 2 - Dimensions [mm (in.)]
DIN Rail Mounting and
Removal
Safety relays mount onto 35 mm (1.38 in.) DIN rails: 35 x 7.5 x 1 mm (1.38 x 0.3 x 0.04 in.)
(EN50022-35x7.5).
1. Hold the top at an angle (see Figure 3).
2. Slide down until the housing catches the rail.
3. Swing the bottom down and push until the latch clips onto the rail.
Figure 3 - DIN Rail Mounting
Removal
To remove a safety relay, use a screwdriver to pry the DIN rail latch downwards until it is in the
unlatched position. Then, swing the module up.
113.6 (4.47)
119.14
(4.69)
22.5
(0.88)
DIN Rail Latch DIN Rail

14 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022
Chapter 2 Installation
Spacing
You can mount safety relays directly next to other safety relays. When using the EtherNet/IP™
module, you must mount the safety relay within 10mm (0.4 in.) of the neighboring module to
maintain effective communication.
Maintain a space of 50.8 mm (2 in.) above, below, and in front of the safety relay for adequate
ventilation.
Removable Terminals Safety relays have removable terminals to ease wiring and replacement.
Figure 4 - Removable Terminals
1. Insert the tip of a small screwdriver into the slot near the terminal screws.
2. To unlock the terminal block, rotate the screwdriver.
You can now remove the terminal block from the housing.
Enclosure Considerations Most applications require installation in an industrial enclosure to reduce the effects of
electrical interference and environmental exposure. Pollution Degree2 is an environment
where normally only non-conductive pollution occurs with the expectation that condensation
causes occasional temporary conductivity. Overvoltage Category II is the load level section of
the electrical distribution system. At this level, transient voltages are controlled and do not
exceed the impulse voltage capability of the product insulation.
This equipment is intended for use in a Pollution Degree 2 industrial environment, in
overvoltage Category II applications (as defined in IEC 60664-1), at altitudes up to 2000 m
(6562 ft) without derating. This equipment is considered Group 1, Class A industrial equipment
according to IEC/CISPR 11. Without appropriate precautions, there can be difficulties with
electromagnetic compatibility in residential and other environments due to conducted and
radiated disturbances.
This equipment is supplied as open-type equipment. The safety relays must be mounted
within an enclosure that is suitably designed for those specific environmental conditions that
are present and appropriately designed to help prevent personal injury as a result of
accessibility to live parts. The enclosure must have suitable flame-retardant properties to help
prevent or minimize the spread of flame, in compliance with a flame spread rating of 5VA, V2,
V1, V0 (or equivalent) if non-metallic. The interior of the enclosure must be accessible only by
the use of a tool. Subsequent sections of this publication contain additional information
regarding specific enclosure-type ratings that are required to comply with certain product
safety certifications.
For more information, see publications:
•1770-4.1, for additional installation requirements.
• NEMA Standard 250 and IEC 60529, as applicable, for explanations of the degrees of
protection provided by different types of enclosure.
1
2

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 15
Chapter 2 Installation
Help Prevent Excessive
Heat
For most applications, normal convective cooling keeps the safety relay within the specified
operating range. Verify that the specified temperature range is maintained. Proper spacing of
components within an enclosure is sufficient for heat dissipation.
In some applications, other equipment inside or outside the enclosure can produce a
substantial amount of heat. In this case, place blower fans inside the enclosure to help with air
circulation and to reduce “hot spots” near the controller.
Additional provisions for cooling are necessary when high ambient temperatures are
encountered. Do not bring in unfiltered outside air. Place the controller in an enclosure to help
protect it from a corrosive atmosphere. Harmful contaminants or dirt could cause improper
operation or damage to components. In extreme cases, you must use air conditioning to help
protect against heat buildup within the enclosure.

16 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022
Chapter 2 Installation
Notes:

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 17
Chapter 3
Power, Ground, and Wire
Wiring Requirements and
Recommendation
• Allow adequate space between the I/O wire ducts and the top and bottom of the safety
relays and front face to maintain an ambient temperature below the rated operating
temperature of the safety relays.
• Route incoming power to the safety relay by a path separate from the device wiring.
Where paths must cross, their intersection must be perpendicular.
• Do not run signal or communications wiring and power wiring in the same conduit.
Route wires with different signal characteristics by separate paths.
• Separate wiring by signal type. Bundle wiring with similar electrical characteristics
together.
• Separate input wiring from output wiring.
• Label wiring to all devices in the system. Use tape, shrink-tubing, or other more
dependable means to label wire. Use colored insulation as well to identify wiring by
signal characteristics. For example, use blue for DC wiring and red for AC wiring.
Wire Size
Each terminal accommodates copper wire with size from 0.2…2.5 mm² (24…14 AWG). Use
copper that withstands 60…75 °C (140…167 °F).
Terminal Torque
Torque terminals to 0.4 N•m (4 lb•in).
Terminal Assignments
Safety relays have four terminals: two on the top and two on the bottom. As shown in Figure 5
on page 18, the X2 and X4 terminal markings apply to the rear terminals. The X1 and X3
terminals apply to the front terminals.
ATTENTION: Before you install and wire any device, disconnect power to the
system.
ATTENTION: Calculate the maximum possible current in each power and
common wire. Observe all electrical codes that dictate the maximum
current allowable for each wire size. Current above the maximum rating
causes the wiring to overheat, which can cause damage.

18 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022
Chapter 3 Power, Ground, and Wire
Figure 5 - Terminal Identification
Figure 6 shows the markings on the front face of each safety relay, including the terminal and
status indicator identifications.
Figure 6 - Safety Relay Face Markings
Table 2 lists the terminal functions. Many of the terminals perform common functions on
multiple safety relays.
Table 2 - Terminal Assignments and Functions
Terminal Function Applies To
A1 +24V supply (+10%, -15%) All
A2 24V common All
S11 Pulse test output for Channel 1 CI, DI, DIS, and SI
S21 Pulse test output for Channel 2 CI, DI, DIS, and SI
S12 Safety input for IN1 Channel 1 CI, DI, DIS, and SI
S22 Safety input for IN1 Channel 2 CI, DI, DIS, and SI
S32 Safety input for IN2 Channel 1 DI and DIS
S34 Reset input CI, DI, DIS, and SI
S42 Safety input for IN2 Channel 2 DI and DIS
Y32 Auxiliary non-safety output DI, DIS, and SI
X32 Auxiliary non-safety output EM and EMD
B1 Jog input EMD
B2 Retrigger input EMD
L11 Single wire safety output All
L12 Single wire safety input DI, DIS, EM, and EMD
13/14, 23/24 Safety outputs - electromechanical relay CI, DI, EM, and SI
33/34 Safety outputs - electromechanical relay CI and EM
43/44 Safety outputs - electromechanical relay EM
14, 24 Safety Outputs - OSSD DIS
34, 44 Safety Outputs - OSSD for capacitive loads DIS
41/42 Auxiliary non-safety output CI
17/18, 27/28, 37/38, 47/48 Safety Outputs, Delayed - electromechanical relay EMD
S12 S22 AP S54
A1 A2 P12 P22
X2
X1 X1 X2
X3
X4
X3 X4
PWR/Fault
IN1
51/L61
Logic IN
X14/X24 L11
L12 L11 Y32 S44
X14 X24 51 L61

Rockwell Automation Publication 440R-UM013G-EN-P - December 2022 19
Chapter 3 Power, Ground, and Wire
Ground the Safety Relay There are no special grounding requirements. Terminal A2 must connect to the common of a
24V supply.
Connect a Power Supply An external 24V DC power supply source must provide power for safety relays.
To comply with the CE (European) Low Voltage Directive (LVD), a DC source compliant with
safety extra low voltage (SELV) or protected extra low voltage (PELV) must power the safety
relays. Bulletin 1606 power supplies are SELV and PELV-compliant.
Figure 7 shows the power supply connections. The DI, DIS, EM, EMD, and SI safety relays have
the power supply connections at the top. The CI safety relay, which is backward compatible
with the MSR127 monitoring safety relay, has A1 at the top and A2 at the bottom.
Figure 7 - Power Supply Connections
Safety Inputs GSR safety relays can connect to the following devices:
• Devices with mechanical contacts
• Devices with OSSD output
• Safety mats
• Safedge™ safety edges
Devices with Mechanical Contacts
The GSR family of safety relays can connect to safety devices that have mechanical contacts.
The safety relays can accommodate either 1 N.C. or 2 N.C. circuits. Table 3 shows some of the
devices that can connect to safety relays.
Connect +24V DC
to Terminal A1
Connect 24V
Common to
Terminal A2
Connect +24V DC
to Terminal A1
Connect 24V
Common to
Terminal A2
DI, DIS, EM,
EMD, and SI CI
Table 3 - Safety Devices with Mechanical Contacts
Safety Device Rockwell Automation
Product Example s Contact Availability
E-stop push buttons 800F, 800T 1 N.C., 2 N.C., self-monitoring
Tongue-operated interlock switches Trojan™, MT-GD2, Cadet™, Elf™ 1 N.C., 2 N.C.
Guard locking interlock switches 440G-LZ, TLS-Z, TLS-GD2, Atlas™ 1 N.C., 2 N.C.
Non-contact switches with reed relays Ferrogard™, Sipha™, magnetically coded 1 N.C., 2 N.C.
Hinge-operated interlock switches Rotacam™, Ensign, Sprite 1 N.C., 2 N.C.
Limit switches 440P, 802T 1 N.C., 2 N.C.
Trapped key interlocks with electrical
contacts 440T 1 N.C., 2 N.C.
Cable pull switches Lifeline™ 1 N.C., 2 N.C.
Enabling devices GripSwitch 1 N.C., 2 N.C.
Interposing relays 700-HPS 1 N.C., 2 N.C.

20 Rockwell Automation Publication 440R-UM013G-EN-P - December 2022
Chapter 3 Power, Ground, and Wire
Figure 8 shows the typical connections for devices with 2 N.C. mechanical contacts. One side
of each contact is connected to a pulse-testing outputs S11 and S21. The other side is
connected to an input terminal. The CI and SI safety relays have one set of input terminals. The
DI and DIS safety relays have two sets of input terminals. The DI and DIS safety relays can
operate with only one device that is connected to either input or with devices that are
connected to both inputs.
Figure 8 - Example Connections to 2 N.C. Mechanical Contacts
Figure 9 shows the typical connections for devices with 1 N.C. mechanical contact. One side of
the contact is connected to a pulse-testing output S11. The other side is connected to two input
terminals. The CI and SI safety relays only have one set of input terminals. The DI and DIS
safety relays have two sets of input terminals. The DI and DIS safety relays can operate with
only one device that is connected or with devices that are connected to both inputs.
Figure 9 - Example Connections to 1 N.C. Mechanical Contact
Devices with OSSD Output
Devices, such as the GuardShield™ safety light curtains, SafeZone™ laser scanners,
SensaGuard™ interlock switch, TLS-Z and 440G-LZ guard locking switches, and Bulletin 442G
Multifunction Access Box (MAB), have current-sourcing PNP semiconductor outputs (OSSD).
Devices with OSSD send their own pulse-tested safety signals through their outputs. These
devices do not need to connect to the safety relay pulse-testing outputs. These devices must
have a common power supply reference (24V Com).
Figure 10 shows a typical example of the connections for devices, like safety light curtains or
laser scanners, with non-cascadable OSSD outputs.
Figure 10 - Example Connections to Devices with Non-cascadable OSSD Outputs
S11 S21 S12 S22 S32 S42S11 S21 S12 S22
Device 1 Device 1 Device 2
Input 1 Input 1 Input 2
Pulse
Testing
Outputs
Pulse
Testing
Outputs
CI and SI DI and DIS
S11 S21 S12 S22 S32 S42S11 S21 S12 S22
Device 1 Device 1 Device 2
Input 1 Input 1 Input 2
Pulse
Testing
Outputs
Pulse
Testing
Outputs
CI and SI DI and DIS
S12
A2
A1
A2
S22 S32 S42
A1
A2
A1A1 S12 S22
A2
+24V DC
24V Com
A1
A2
Device 1 Device 1 Device 2
Input 1 Input 1 Input 2
CI and SI DI and DIS