6 Rockwell Automation Publication SAFETY-AT140A-EN-P - May 2015
Safety Function: Actuator Subsystems – Stop Category 1 via the PowerFlex 525 and PowerFlex 527 Drives with Safe Torque-off
Bill of Material
This Logic and Output subsystems in this document use these products.
Setup and Wiring
For detailed information on installing and wiring, refer to the publications listed in the Additional Resources on page 22.
System Overview
Safety-related Stop Function Initiated by a Safeguard
The Guardmaster dual-input safety relay monitors the status of a safety input device, for example a SensaGuard switch.
When the input device is tripped (guard door opened), the safety relay de-energizes its two safety outputs and sends a
safety stop command downstream to the Guardmaster multifunction-delay expansion module via its SWS. After the
100 ms configured delay time, the Guardmaster multifunction-delay expansion module deactivates its safety outputs,
which remove power from the drive's (PowerFlex 525 or PowerFlex 527 drive) STO inputs. The drive disables its output
power transistors, leaving the hazardous motion to coast to a stop. When the input device is returned to its safe state (guard
door closed), and the reset button is pressed and released properly, the Guardmaster dual-input safety relay’s safety outputs
energize, the Guardmaster multifunction delay expansion module energizes its safety outputs, and the drive's STO inputs
are powered. The hazardous motion can then be restarted by pressing a PAC-controlled Start button.
Prevention of an Unexpected Start-up
The Guardmaster dual-input safety relay cannot be reset while its input device is in a tripped (guard door open) state. The
Guardmaster multifunction-delay expansion module cannot reset until the Guardmaster dual-input safety relay is reset, the
drive's STO inputs remain off, and the hazardous motion cannot be restarted. When the input device is returned to its safe
state (guard door closed), and the reset button is pressed and released properly, the Guardmaster dual-input safety relay’s
safety outputs energize, the Guardmaster multifunction-delay expansion module energizes its safety outputs, and the drive's
STO inputs are powered. The hazardous motion can then be restarted by pressing a PAC-controlled Start button.
Cat. No. Description Quantity
440R-D22R2 Guardmaster dual-input safety relay (DI) 1
440R-EM4R2D Guardmaster multifunction-delay expansion module, 4 N.O. safety contacts 1
800FP-R611PQ10V 800F reset, round plastic 1
1606-XLP72E 1606-XLP72E compact power supply, 24…28V DC, class 2 1
25C-V2P5N104 PowerFlex 527 AC drive, with embedded EtherNet/IP™ and safe torque-off 1
or
25B-B5PON104 PowerFlex 525 AC drive, with embedded EtherNet/IP and safe torque-off 1
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