Rockwell Automation Allen-Bradley Guardmaster 440C-CR30 Quick start guide

Guardmaster 440C-CR30 Configurable Safety Relay
Catalog Numbers 440C-CR30-22BBB
Wiring Diagram

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.
Labels may also be on or inside the equipment to provide specific precautions.
Allen-Bradley, Connected Components Workbench, Control Tower, Guardmaster, GuardShield, Lifeline, PHOTOSWITCH, PowerFlex, Rockwell Software, SensaGuard, Trojan, and Zero-Force Touch Buttons are
trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
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).

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 3
Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
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.
Resource Description
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Provides general guidelines for installing a Rockwell
Automation industrial system.
Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and
other certification details.

4Rockwell Automation Publication 440C-WD001A-EN-P - November 2014
Preface
Notes:

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 1
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Preface Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 1
Cat 1 Stop with Guardlocking
Interlock (TLS-ZR or 440G-LZ)
Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PowerFlex PF525 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 2
Cat 1 Stop with GuardShield Light
Curtain, T-15 Interlock, E-Stop, and
PowerFlex 525
Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PowerFlex PF525 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 3
Safety Mats - Two Zones
Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chapter 4
Enabling Switch (GripSwitch) with
Jog Function
Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2Rockwell Automation Publication 440C-WD001A-EN-P - November 2014
Table of Contents
Chapter 5
Muting 2-Sensor L-Type
Unidirectional
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Machine Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Connected Components Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Circuit Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Example Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Safety Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 6
Muting 2-Sensor T-Type Bidirectional
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Machine Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Connected Components Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Circuit Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Example Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Safety Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Chapter 7
Muting 4-sensor T-type Bidirectional
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Machine Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connected Components Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Circuit Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Example Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Safety Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Chapter 8
Single-wire Safety
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Connected Components Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Circuit Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Example Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Safety Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 3
Table of Contents
Chapter 9
Lifeline Cable Pull
Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chapter 10
Two-hand Control
Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Connected Components Workbench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Circuit Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Operational Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Example Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Safety Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4Rockwell Automation Publication 440C-WD001A-EN-P - November 2014
Table of Contents
Notes:

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 5
Chapter 1
Cat 1 Stop with Guardlocking Interlock
(TLS-ZR or 440G-LZ)
This example application shows how to configure the CR30 for a Guardlocking
application that requires a Category 1 stop function.
A TLS-ZR guardlocking interlock, which has OSSD outputs, locks a guard to
prevent full body access to the hazard. A PowerFlex® 525 is controlling a motor
that is considered the hazard. A selector switch requests access to the hazard area.
A push button locks access to the hazard. The CR30 performs the logic that
monitors the interlock and the drive, and allows access to the hazard under safe
conditions.
For partial body access, the 440G-LZ can be substituted for the TLS-ZR.
Product Overview Figure 1 - Overview

6Rockwell Automation Publication 440C-WD001A-EN-P - November 2014
Chapter 1 Cat 1 Stop with Guardlocking Interlock (TLS-ZR or 440G-LZ)
Schematic Figure 2 - Schematic
PowerFlex PF525 Settings Tab l e 1 shows a list of some of the parameter settings for this application. The list
is not a complete list of the parameters for the PF525. You may set many other
parameters to make this application successful.
Table 1 - Parameter Settings
05
CR30
020100 03 04
A1 15 20 2116
06
18A2
07
19
08 10 11
12 13 14
09
17
+24 VDC
24V DC Com
Reset
Red
Pink
Green
White
Blue
Grey
Yellow
Brown
Safety
Gate
Safety
TLS-ZR
440G-TZS21UPRH
889D-F8AC-2
440C-CR30-22BBB
Gate
Unlocked
Gate
Lock/
Unlock
Gate control
power supply
Gate control
circuit
M
4 Gnd
S1
S2
1 Stop
L1 L2 L3
PowerFlex
525
2 Start
R5
R6
RTS
UWV
Parameter Name Value Unit/Description
P042 Decel Time 3 Seconds
P045 Stop Mode 0 Stop and Clear Fault
P046 Start Source 2 Digital Input Terminal Block
P047 Speed Reference
1
1DrivePot
T081 Relay 2 2 Motor Running
Motor is receiving power from the drive.
T105 Safety Open En 1 Fault Disable

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 7
Cat 1 Stop with Guardlocking Interlock (TLS-ZR or 440G-LZ) Chapter 1
Connected Components
Workbench™
Figure 3 - Connected Components Workbench Example
Circuit Status The gate switch is closed and locked. The safety signals to the PF2525 drive are
off, and the drive is disabled. The motor is off.
Operational Sequence Table 2 -
Action Taken Results
1. Momentarily press the reset button. The safety outputs at terminal 17, 18 and 19 turn ON.
2. Press the drive Start button. The motor turns ON. The drive can now be used for normal
production processes.
The speed of the motor is controlled by the Drive Pot,
located on the front of the PF525.
3. Rotate the Unlock request to the Unlock (closed)
position.
The power is immediately removed from terminals 17,
and the drive executes a ramp to stop command in 3
seconds (P042 is configured for 3s).
After a 5 second delay, the gate switch is unlocked and the
safety outputs to the drive open.
4. Open the gate switch. The operator can access the hazard area.
5. Close the gate.
6. Rotate the Unlock switch to the locked (open) position. This locks the gate and the safety system is ready for reset.
Go to Step 1.

8Rockwell Automation Publication 440C-WD001A-EN-P - November 2014
Chapter 1 Cat 1 Stop with Guardlocking Interlock (TLS-ZR or 440G-LZ)
Example Bill of Materials Table 3 -
Safety Rating The safety function that is performed by the guard locking interlock meets the
safety performance requirements of SIL CL2 per IEC 61061:2012 and SIL 2 per
IEC 61508:2005 and has a Category 3 structure that can be used in systems
requiring Performance Levels up to PLd per ISO 13849-1: 2006. The circuit
executes a Category 1 stop.
Item Product Description Qty
1 440C-CR30-22BBB Guardmaster® 440C-CR30 Software Configured Safety Relay
PLe SIL 3, 22 Safety I/O, embedded serial port, USB programming
port, 2 plugin slots, 24V DC
1
2440G-TZS21UPRH Guard Locking Switch - TLS-Z GD2
Solenoid Voltage: 24V AC/DC
Contacts (Safety and Aux): 2 x PNP (0.2A max.), 1 x PNP (0.2A max.)
Actuator: Fully-flex
Conduit Entry: 8-pin micro (M12)
1
2.1 889D-F8AC-5 DC Micro (M12) Cordset
Female, straight, 8-pin, PVC cable, yellow, unshielded, 22 AWG, IEC
color coded, no connector, 5 m (16.4 ft)
1
3 800FM-P4MN3R 800F Pilot Light
Metal (IP66, 4/13, IP66), red, standard pack
1
4 800FM-SM22MX10 800F 2-position Selector Switch
Metal, maintained, black, standard knob, standard orientation,
1 N.O. contact block, standard pack
1
5 800FM-F611MX10 800F Push Button
Metal, flush, blue, R, metal latch mount, 1 N.O. contact, 0 N.C.
contacts, standard, standard pack
1
6 24B-V2P5A104AA-ND-P3 PowerFlex 525 Pre-engineered FasTrac, with Embedded
EtherNet/IP™ and Safety
120VAC, 1-phase, 0.5 Hp, 0.4 kW normal duty; 0.5 Hp, 0.4 kW heavy
duty, Type 1 / IP20, no filter, without bypass, without reactor, motor
circuit protector (-P3)
1
7 800FM-F301 800F Push Button
Metal, flush, green, START, standard pack
1
8 800FM-E402 800F Push Button
Metal, extended, red, STOP, standard pack
1

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 9
Chapter 2
Cat 1 Stop with GuardShield™ Light Curtain, T-15
Interlock, E-Stop, and PowerFlex 525
This example application shows how to configure the CR30 for a guarding
application that requires a Category 1 stop function.
A light curtain is used where an operator frequently accesses the hazard area. A
mechanical tongue interlock switch is mounted on a gate where infrequent access
to the hazard. Both the light curtain and gate are located far enough away from
the hazard so the operator cannot reach the hazard until it has reached a safe state.
An E-stop button is also available at the control panel. Any of the three devices
must cause the machine to go to a safe OFF state.
Product Overview Figure 4 - Overview

10 Rockwell Automation Publication 440C-WD001A-EN-P - November 2014
Chapter 2 Cat 1 Stop with GuardShield™ Light Curtain, T-15 Interlock, E-Stop, and PowerFlex 525
Schematic Figure 5 - Schematic
PowerFlex PF525 Settings Tab l e 4 shows a list of some of the parameter settings for this application. The list
is not a complete list of the parameters for the PF525. You may set many other
parameters to make this application successful.
Table 4 - Parameter Settings
05
CR30
020100 03 04
A1 15 20 2116
06
18A2
07
19
08 10 11
12 13 14
09
17
+24 VDC
Gate control
power supply
Gate control
circuit
M
4 Gnd
S1
S2
1 Stop
L1 L2 L3
PowerFlex
525
2 Start
RTS
UWV
24V Com
12
6
5
3
7
3
Pink
Receiver
Brown
Brown
Transmitter
Grey
Blue
Green
Blue
11
12
21
22
Parameter Name Value Unit/Description
P042 Decel Time 1 Seconds
P045 Stop Mode 0 Stop and Clear Fault
P046 Start Source 2 Digital Input Terminal Block
P047 Speed Reference 1 1 Drive Pot
T081 Relay 2 2 Motor Running
Motor is receiving power from the drive.
T105 Safety Fault En 0 Fault Enable

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 11
Cat 1 Stop with GuardShield™ Light Curtain, T-15 Interlock, E-Stop, and PowerFlex 525 Chapter 2
Connected Components
Workbench
Figure 6 - Connected Components Workbench Example
Circuit Status The light curtain is clear. The gate switch is closed. The E-stop is reset. The
CR30 safety outputs at terminal 17, 18, and 19 are ON. The PF525 shows an
F059 fault. The motor is off.
Operational Sequence Table 5 - Operational Sequence
Action Taken Results
1. Press the drive Stop button. The F059 Fault on the PF25 is cleared. The motor is ready
to run.
Normally, the motor would be stopped by the machine
control system, which is not shown in the schematic.
2. Press the drive Start button. The motor turns ON. The drive can now be used for normal
production processes.
The speed of the motor is controlled by the Drive Pot,
located on the front of the PF525.
3. Do any of the following actions:
–Block the light curtain,
–Open the gate switch, or
–Press the E-stop.
The power is immediately removed from terminals 17,
and the drive executes a ramp to stop command in 1
seconds (P042 is configured for 1s). One second later,
terminals 18 and 19 turn off, and the PF525 executes a
safe torque off function. The PF525 shows an F059 fault in
its display.
4. Do the opposite action from Step 2:
–Clear the light curtain,
–Close the gate switch, or
–Release the E-stop.
The CR30 safety outputs at terminal 17, 18 and 19 are ON.
The PF525 still shows an F059 fault. The motor remains
off.
Go to Step 1.

12 Rockwell Automation Publication 440C-WD001A-EN-P - November 2014
Chapter 2 Cat 1 Stop with GuardShield™ Light Curtain, T-15 Interlock, E-Stop, and PowerFlex 525
Example Bill of Materials Table 6 - Bill of Materials
Safety Rating The safety function that is initiated by the light curtain can meet up to Cat 3 PLd
per IS013849-1, SIL CL2 per IEC 62061, and SIL 2 per IEC 61508. It does not
achieve Cat 4 PLe due to the rating of the PF5252 drive
The safety function that is initiated by the gate interlock switch can meet up to
Cat 3 PLd per IS013849-1, SIL CL2 per IEC 62061, and SIL 2 per IEC 61508
when using fault exclusion as described in ISO 14119.
The safety function that is initiated by the E-stop can meet up to Cat 3 PLd per
IS013849-1, SIL CL2 per IEC 62061, and SIL 2 per IEC 61508.
Item Product Description Qty
1 440C-CR30-22BBB Guardmaster 440C-CR30 Software Configured Safety Relay
PLe SIL 3, 22 Safety I/O, embedded serial port, USB programming
port, 2 plugin slots, 24V DC
1
2 440L-P4K1760YD GuardShield Safety Light Curtain
Res 30 mm, Pt Ht 1760 mm, 88 beams
1
2.1 889D-F4AC-5 DC Micro (M12)
Female, straight, 4-pin, PVC cable, yellow, unshielded,
22 AWG, 5 m (16.4 ft)
1
2.2 889D-F8AB-5 DC Micro (M12)
Female, straight, 8-pin, PVC cable, yellow, unshielded,
24 AWG, 5 m (16.4 ft)
1
3 440K-T11287 Tongue Switch - Trojan™ T15
Contacts (safety and aux): 2 N.C., BBM
Preference: N/A
Actuator: Fully-flex
Model Type: GD2 front entry
Conduit Entry: 1/2in NPT conduit
1
4 800FM-LMT64 800F Illuminated Mushroom Operators
Illuminated, twist-to-release, 60 mm, round metal (Type 4/13, IP66),
red, standard pack (Qty. 1)
1
5 800F-X01L 22.5 mm Push Button
No latch, screw contact block, 1 N.C.L.B.
1
6 800F-ALM Metal Latch 1
7 800F-X01S 22.5 mm PB
No latch, screw contact block, 1 N.C. self-monitoring
1
8 800F-N3R Integrated LED
Latch mount, 24V AC/DC, red LED
1
9 800F-X10 22.5 mm Push Button
No latch, screw contact block, 1 N.O.
1
10 800FM-F301 800F Push Button
Metal, flush, green, START, standard pack (Qty. 1)
1
11 800FM-E402 800F Push Button
Metal, extended, red, STOP, standard pack (Qty. 1)
1
12 24B-V2P5A104AA-ND-P3 PowerFlex 525 Pre-engineered FasTrac, with Embedded
EtherNet/IP and Safety
120V AC, 1-phase, 0.5 Hp, 0.4 kW normal duty; 0.5 Hp, 0.4 kW heavy
duty, Type 1 / IP20, no filter, without bypass, without reactor, motor
circuit protector (-P3)
1

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 13
Chapter 3
Safety Mats - Two Zones
This application demonstrates two zones using safety mats and E-stop push
buttons. Each zone is controlled by a safety mat and an E-stop push button. In
this example, a sequential manufacturing process has two zones. If an operator
enters the first zone, that zone stops while the second zone continues to function.
If an operator enters zone 2, then both zones 1 and 2 must stop. An indicator
lamp shows which zone is not operating, and the user is allowed to enter for
normal production type operations.
The safety mats for each zone can be single mats or multiple mats that are
connected in series. The safety mats must be connected to pulse tested outputs to
operate properly with the CR30. In this example, the Zone 1 mats use pulses
from 12 and 13 and Zone 2 uses pulses from 16 and 17.
The two E-stop buttons use the same test pulses, from terminals 14 and 15 - this
arrangement is preferred. Alternatively, the E-stops can be powered directly by
the 24V DC supply, but powering directly from 24V does not provide cross
channel fault detection.
Note: The outputs of the CR30 are driving 100S contactors. Due to the
inrush current limitations of the CR30, the CR30 can only switch the
100S-C09EJ contactors. The CR30 cannot switch the C43EJ contactors.
Product Overview Figure 7 - Overview

14 Rockwell Automation Publication 440C-WD001A-EN-P - November 2014
Chapter 3 Safety Mats - Two Zones
Schematic Figure 8 - Schematic
05
CR30
020100 03 04
A1 15 20 2116
06
18A2
07
19
08 10 11
12 13 14
09
17
K2
K1
K4
K3
440C-CR30-22BBB
24V Com
+ 24V DC
Mat
E-Stop E-Stop
Mat
K1 K2 K3 K4
K2
K1
K4
K3
Reset
Zone 1
Zone 1 Zone 2
Zone 2
Zone 1
O Zone 2
O
Reset
COMI-02 I-03
COMI-00 I-01
2080-IQ4OB4
-24DC O-02 O-03
+24DC O-00 O-01
L1 L2 L3L1 L2 L3
M1 M2

Rockwell Automation Publication 440C-WD001A-EN-P - November 2014 15
Safety Mats - Two Zones Chapter 3
Connected Components
Workbench
Figure 9 - Connected Components Workbench Example

16 Rockwell Automation Publication 440C-WD001A-EN-P - November 2014
Chapter 3 Safety Mats - Two Zones
Circuit Status No presence is sensed on both mat systems. All four contactors are off, and both
motors (hazards) are off. The system is ready for reset.
Operational Sequence Press Reset 1 to enable the start of Zone 1. Press Reset to enable the start of
Zone2.
To gain access to either zone, the operator steps on the mat or presses the E-stop
button. Both devices initiate an immediate stop command to its associated
hazard. An indicator at Plug-in terminal P200 and P201 show when someone or
something is on the mat or if the E-stop is pressed for that zone.
If the operator enters Zone 1, then only Zone 1 stops and Zone 2 continues to
run. If the operator enters Zone 2, then both zones stop.
After leaving the Zone 2, the operator must press the reset button to enable the
restart of Zone 2. After leaving Zone 1, the operator must press the reset buttons
for both Zone 1 and 2 to enable the restart the machine.
Example Bill of Materials Table 7 - Bill of Materials
Safety Rating The safety function that is initiated by the safety mats can meet up to Cat 3 PLd
per IS013849-1, SIL CL2 per IEC 62061, and SIL 2 per IEC 61508.
The safety function that is initiated by the E-stops can meet up to Cat 4, PLe and
SIL3 per IEC61508 and SIL CL3 per IEC 62061.
Item Product Description Qty
1 2080-IQ4OB4 4-ch Digital Input/Output Combination Module 1
2 440C-CR30-22BBB Guardmaster 440C-CR30 Software Configured Safety Relay
PLe SIL 3, 22 Safety I/O, embedded serial port, USB programming
port, 2 plugin slots, 24V DC
1
3 800FM-P4MN3R 800F Pilot Light
Rd. Metal (IP66, 4/13, IP66), red, standard pack (Qty. 1)
2
4 800FM-MT44 800F Non-illuminated Mushroom Operators
Twist-to-release, 40 mm, round metal (Type 4/13, IP66), red,
standard pack (Qty. 1)
2
4.1 800F-ALM Metal Latch 2
4.2 800F-X01S 22.5 mm PB No Latch
Screw contact block, 1 N.C. self-monitoring
4
5 440F-M2036BYNN Safety Mat
Yellow, 1000 x 1800 mm, two 4.5 m (15 ft) 2-wire cables, exit out “B”
corners, no trim, no controller
2
6 440F-T2036 Trim Kit
Standard trim, 1000 x 1800 mm
2
7 100S-C09EJ14BC MCS 100S-C Safety Contactor
9A, 24V DC (with elec. coil), bifurated contact
4
8 800FM-P7MN3W 800F Pilot Light
Rd. metal (IP66, 4/13, IP66), clear, standard pack (Qty. 1)
2