Guardmaster Safety Relays

Catalog Numbers 440R-S13R2, 440R-S12R2, 440R-D22R2,

440R-D22S2, 440R-EM4R2, 440R-EM4R2D

User Manual Original Instructions

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.

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.

These labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

The following icon may appear in the text of this document.

Identifies information that is useful and can help to make a process easier to do or easier to understand.

2 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Table of Contents

Preface
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Connect a Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Safety Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Devices with Mechanical Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Devices with OSSD Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Safety Mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Safedge Safety Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electromechanical Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Surge Suppressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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Table of Contents

Single Wire Safety Input and Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Auxiliary Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Reset and Monitor Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Automatic/Manual Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Monitored Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Monitor with Expansion Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Retriggerable Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Jog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Chapter 4
Configuration 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 Indicators During Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Indicators During Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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 Off Delay, Non-retriggerable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Functions 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Case 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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

4 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Table of Contents

EM Safety Relay (Cat. No. 440R-EM4R2). . . . . . . . . . . . . . . . . . . . . . . . . . . 44

EMD Safety Relay (Cat. No. 440R-EM4R2D) . . . . . . . . . . . . . . . . . . . . . . . 44
SI Safety Relay (Cat. No. 440R-S12R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Chapter 9
Application and Wiring CI Safety Relay (Cat. No. 440R-S13R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Examples 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Check the Single Wire Safety Circuit (Step 4) . . . . . . . . . . . . . . . . . . . . . . 64
SWS Connections L11 and L12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
EMD Expansion Safety Relay B1/B2 Inputs (Step 7). . . . . . . . . . . . . . . . . 74
Terminal Block Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . 75
Terminal Block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Terminal Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 5

Table of Contents

Series, Version, and Manufacturing Date Code . . . . . . . . . . . . . . . . . . . . 76

Current Product Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Old Product Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Appendix A
Specifications General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Safety Inputs IN, IN1, and IN2 Specifications . . . . . . . . . . . . . . . . . . . . . . 77
Reset Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
B1 Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Safety Outputs Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Auxiliary Output Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Single Wire Safety (SWS) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Appendix B
Regulatory Approvals Agency Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Compliance with European Union Directives . . . . . . . . . . . . . . . . . . . . . . 83
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Machine Safety Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SIL Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Performance Level/Category. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

6 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Preface

This manual is a reference guide for the family of Guardmaster® Safety Relays
(GSR). It describes the procedures that you use to install, wire, and
troubleshoot your relay. This manual also gives an overview of the operation of
safety relays.

Summary of Changes This manual contains new and updated information as indicated in the
following table.
Topic Page
Updated Figure 6 18
Updated Figure 11 22
Updated Safedge Safety Edges 23
Updated Recovery Time 64
Updated SWS Connections L11 and L12 65
Updated Table 19 84

Who Should Use This Use this manual if your responsibilities include design, installation,
programming, or troubleshooting of control systems that use safety relays,
Manual 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 using this product.

Definitions Publication AG-7.1 contains a glossary of terms and abbreviations that are used
by Rockwell Automation to describe industrial automation systems. The
following is a list of specific terms and abbreviations that are used in this
manual.
• 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.
• 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.
Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 7
Preface

- 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.
• 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.
• Single Wire Safety (SWS) - A unique, safety-rated signal that is sent over
one wire to indicate a safety status. The SWS can be used in 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.

Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
Describes procedures that you use to install, wire,
Guardmaster EtherNet/IP Network Interface User configure, troubleshoot, and use EtherNet/IP™
Manual, publication 440R-UM009 modules.
Industrial Automation Wiring and Grounding Provides general guidelines for installing a
Guidelines, publication 1770-4.1 Rockwell Automation® industrial system.
Product Certifications website, Provides declarations of conformity, certificates,
rok.auto/certifications. and other certification details.

You can view or download publications at rok.auto/literature.

8 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 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

Status Indicators

Multi-position Switches to
set functionality

Optical Communication Bus

Removable Terminal Blocks

Each 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 blinks in specific patterns to help
diagnose the fault. See Status Indicators on page 35 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 relay so you can
see the set position during, and after, configuration. During the configuration
process, status indicators on the front face of the relay confirm the switch
settings. See Switch Adjustment on page 31 for more information.

(a) The EM safety relay does not require configuration.

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 9

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 The CI safety relay has one dual-channel input with three electromechanical
relay outputs. The CI safety relay can be configured for automatic or
(Cat. No. 440R-S13R2) 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 safety monitoring relay. The CI
safety relay has the same number of inputs and outputs, the same width, and
the same terminal locations as the MSR127 relay.

DI Safety Relay 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.
(Cat. No. 440R-D22R2) 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 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-
(Cat. No. 440R-D22S2) 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 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
(Cat. No. 440R-EM4R2) 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 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
(Cat. No. 440R-EM4R2D) functions:
• On delay
• Off delay
• Jog

The settings of the two switches on the front face of the relay configure the
functionality and duration of the delay and jog.

10 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Chapter 1 Overview

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.

SI Safety Relay The SI safety relay has one dual-channel input with two electromechanical
relay outputs. The SI safety relay can be configured for automatic or
(Cat. No. 440R-S12R2) 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 safety monitoring

relay.

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 11

Chapter 1 Overview

Notes:

12 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Chapter 2

Installation

All safety relays in this manual have the same dimensions (see Figure 2).

Mounting Dimensions Figure 2 - Dimensions [mm (in.)]

22.5
(0.88) 113.6 (4.47)

119.14
(4.69)

DIN Rail Mounting and Safety relays mount onto 35 mm (1.38 in.) DIN rails: 35x7.5x1 mm
(1.38x0.3x0.04 in.)(EN 50022-35x7.5).
Removal
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

DIN Rail Latch

DIN
Rail

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.

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 13

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 relay for
adequate ventilation.

Removable Terminals Safety relays have removable terminals to ease wiring and replacement.
Figure 4 - Removable Terminals

1
2

1. Insert the tip of a small screwdriver into the slot near the terminal
screws.
2. To unlock the terminal block, rotate the screwdriver.

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 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:

• Industrial Automation Wiring and Grounding Guidelines, publication
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.
14 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021
 Chapter 2 Installation

Help Prevent Excessive For most applications, normal convective cooling keeps the relay within the
specified operating range. Verify that the specified temperature range is
Heat 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.

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 15

Chapter 2 Installation

Notes:

16 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Chapter 3

Power, Ground, and Wire

Wiring Requirements and

Recommendation
ATTENTION: Before you install and wire any device, disconnect power to the
system.

ATTENTION: Calculate the maximum possible current in each power and

common wire. Observe all electrical codes that dictate the maximum
current allowable for each wire size. Current above the maximum rating
causes wiring to overheat, which can cause damage.
• Allow adequate space between the I/O wire ducts and the top and bottom
of the relays and front face to maintain an ambient temperature below
the rated operating temperature of the relays.
• Route incoming power to the 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.

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Chapter 3 Power, Ground, and Wire

Figure 5 - Terminal Identification

S12 S22 AP S54 X2
A1 A2 P12 P22 X1
X1 X2

PWR/Fault
IN1
51/L61
Logic IN
X14/X24 L11

X3 X4
L12 L11 Y32 S44 X3
X14 X24 51 L61 X4

Figure 6 shows the markings on the front face of each safety relay, including
the terminal and status indicator identifications.
Figure 6 - Relay Face Markings

Table 1 lists the terminal functions. Many of the terminals perform common
functions on multiple relays.
Table 1 - 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 CI, 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, 43/44 Safety Outputs - electromechanical relay EM

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 Chapter 3 Power, Ground, and Wire

Table 1 - Terminal Assignments and Functions

Terminal Function Applies To
14, 24 Safety Outputs - OSSD DIS
34, 44 Safety Outputs - OSSD for capacitive loads DIS
17/18, 27/28, 37/38, 47/48 Safety Outputs, Delayed - electromechanical relay EMD

Ground the Relay There are no special grounding requirements. Terminal A2 must be connected
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
Connect +24V DC Connect 24V Connect +24V DC
to Terminal A1 Common to to Terminal A1
Terminal A2

Connect 24V
Common to
Terminal A2
DI, DIS, EM, CI
EMD, and SI

Safety Inputs GSR safety relays can be connected 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 be connected to safety devices that have
mechanical contacts. The relays can accommodate either 1 N.C. or 2 N.C.
circuits. Table 2 on page 20 shows some of the devices that can be connected to
safety relays.

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Chapter 3 Power, Ground, and Wire

Table 2 - Safety Devices with Mechanical Contacts

Rockwell Automation
Safety Device Contact Availability
Product Example s
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.
Noncontact 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 440T 1 N.C., 2 N.C.
electrical contacts
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.

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

Device 1 Device 1 Device 2

S11 S21 S12 S22 S11 S21 S12 S22 S32 S42
Pulse Pulse
Testing Input 1 Testing Input 1 Input 2
Outputs Outputs
CI and SI DI and DIS

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
Device 1 Device 1 Device 2

S11 S21 S12 S22 S11 S21 S12 S22 S32 S42
Pulse Pulse
Testing Input 1 Testing Input 1 Input 2
Outputs Outputs

CI and SI DI and DIS

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

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 Chapter 3 Power, Ground, and Wire

need to be connected 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 light
curtains or laser scanners, with non-cascadable OSSD outputs.
Figure 10 - Example Connections to Devices with Non-cascadable OSSD Outputs
+24V DC

Device 1 Device 1 Device 2

A1 A1 A1

A2 A2 A2

A1 S12 S22 A1 S12 S22 S32 S42

Input 1 Input 1 Input 2
A2 A2

CI and SI DI and DIS

24V Com

• OSSD1 can be connected to either S12 or S22 and OSSD2 can be connected to either
S12 or S22.
• The safeguarding devices must have the same voltage supply reference (24V Com)
as the safety relay.
Figure 11 on page 22 shows an example of a wiring configuration that includes
non-cascadable and cascadable devices. The non-cascadable devices (Devices 1
and 2) must always start the cascade. Many cascadable devices (Devices 3…6 or
more) can be included in the input circuit. All devices must have the same
voltage supply reference (for instance, 24V Com) as the safety relay.

Examples of non-cascadable devices include GuardShield light curtains,

SafeZone laser scanners, and safety sensors. Examples of cascadable devices
include SensaGuard interlocks, and the TLS-ZR and 440G-LZ guard locking
interlocks.

ATTENTION: You must consider the cumulative response time of all

cascaded devices, the relay, and output devices to verify that the safety
function is fulfilled within the required time that the risk assessment
determines.

Devices with electromechanical (EM) outputs must be placed after the non-
cascadable device. The EM safety relay devices can be placed anywhere in the
chain after the first OSSD device.

From the perspective of the GSR safety relay, only the OSSD device closest to
the relay (Device 3 in Figure 11 on page 22) is of concern. The other devices with
OSSD outputs do not affect the performance of the safety relay. The EM safety
relay devices can suffer from masked faults, their safety rating is limited to
Category 3 per ISO13849-1.

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Chapter 3 Power, Ground, and Wire

Figure 11 - Example Connections to Device with Cascaded and Non-cascaded OSSD Devices
+24V DC

Device 1 Device 1 Device 2

A1 A1 A1

A2 A2 A2

Device 3 Device 3 Device 4

A1 A1 A1

A2 A2 A2

Device 5 Device 5 Device 6

A1 A1 A1

A2 A2 A2

A1 S12 S22 A1 S12 S22 S32 S42

Input 1 Input 1 Input 2
A2 A2

CI and SI DI and DIS

24V Com

GSR safety relays cannot detect short circuits of the OSSD device outputs. The
PWR/Fault status indicator of your GSR safety relay remains steady green. The
device with the OSSD outputs must detect short circuits of its own OSSD
outputs. When detected, the device must shut off both OSSD outputs and go to
a faulted state. A status indicator must inform you that the OSSD is faulted.

Safety Mats
Guardmaster™ (and similar) safety mats can be connected to safety relays.
These mats use parallel metal-plate technology. Stepping on the mat shorts the
top metal plate to the bottom metal plate. With the proper connections, safety
relays detect the presence of an object on the mat and turn off their outputs.
With no presence on the mat, safety relays turn on their outputs.

When changing the function from mechanical switches or OSSDs to safety

mats, GSR safety relays must go through the complete configuration process.

Figure 12 on page 23 shows the typical connections for safety mats. You notice
the reverse of the wiring between a device with 2 N.C. contacts and the safety
mat.

When a safety mat is used, safety relays cannot detect short circuits between
the inputs or between the inputs and 24V DC. These conditions must be tested
during validation.

IMPORTANT For fault detection purposes, GSR safety relays must be configured for
monitored manual reset when connected to safety mats.

IMPORTANT When using safety mats, the DI and DIS safety relays must be set for AND
logic. If only one mat is used, the second input must be connected with
jumpers or to another safety device. If another safety device is
connected to the second input, the outputs of the safety device must be
ON during configuration and during power-up.

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 Chapter 3 Power, Ground, and Wire

Figure 12 - Example Connections to Safety Mats

Mat 1 Mat 1 Mat 2 Mat 1 EM Device

S11 S21 S22 S12 S11 S21 S22 S12 S42 S32 S11 S21 S22 S12 S42 S32
Pulse Pulse Pulse
Testing Input 1 Testing Input 1 Input 2 Testing Input 1 Input 2
Outputs Outputs Outputs

CI and SI DI and DIS DI and DIS

Because the safety mats are parallel plates, they have a significant capacitive
effect. The larger the mat, the more capacitance. If the capacitance is too large,
the safety relay does not function properly. See Capacitance Effect on page 61
for further information.
Older Allen-Bradley Guardmaster MSR relays could be tickled by tapping on the
safety mat, which generated fast cycles. This activity caused the relay to fault
because the fast cycles violated the recovery time specification. GSR safety relays
have a 20 ms recovery time, so this fault is not likely to occur.

Safedge Safety Edges

Some of the Allen-Bradley Guardmaster Safedge pressure sensitive safety
edges (only profiles 0110N, 0110R, and 1610N) can be connected to CI, DI, DIS,
and SI safety relays. Figure 13 shows how Safedge edges are constructed of
conductive rubber with two embedded wires that run the length the edge. Each
wire forms a channel for the GSR safety relay. When the edge is compressed, a
low resistance is created between the two channels. The Safedge edge must be
constructed with four wires (two wires exit each end). See publication
440F-UM002 for further information on the Safedge edges.
Figure 13 - Safedge Operating Principle

Flexible Wire Wires on

Conductive
Cores Both Ends
Rubber
(Ch1 and Ch2) Compression
Creates a Low
Resistance from
Ch1 to Ch2

Non-conductive Rubber

Figure 14 on page 24 shows the typical wire connections. With the proper
connection, GSR safety relays detect the compression of the edge and turn off
their outputs. With no pressure on the edge, the GSR outputs can be turned
back on with a reset signal.

IMPORTANT Only Safedge profiles 0110N, 0110R, and 1610N can be used with the GSR
safety relays.

IMPORTANT For fault detection purposes, GSR safety relays must be configured for
monitored manual reset when connected to Safedge safety edges.

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Chapter 3 Power, Ground, and Wire

IMPORTANT When using safety edges, the DI and DIS safety relays must be set for
AND logic. If only one edge is used, the second input must either be
connected with jumpers or to another safety device. If another safety
device is connected to the second input, the outputs of the safety device
must be ON during configuration and during power-up.
Figure 14 - Example Connections to Safety Edges
Edge 1 Edge 1 Edge 2 Edge 1

EM Device

S11 S21 S22 S12 S11 S21 S22 S12 S42 S32 S11 S21 S22 S12 S42 S32
Pulse Pulse Pulse
Testing Input 1 Testing Input 1 Input 2 Testing Input 1 Input 2
Outputs Outputs Outputs
CI and SI DI and DIS DI and DIS

Safety Outputs GSR safety relays have two types of outputs:

• Electromechanical (CI, DI, EM, EMD, and SI safety relays)
• OSSD (DIS safety relay)

To extend the operating life of the safety relays, surge suppression is required.

Electromechanical Outputs
Internally, the CI, DI, EM, EMD, and SI safety relays have two positive-guided
relays that are connected in series to form the safety outputs. One side of the
contact must be connected to a voltage supply (see Specifications on page 77
for appropriate ratings). The other side of the contact must be connected to a
load.
Figure 15 - Electromechanical Output Connections
V supply V supply V supply V supply V supply

13 23 33 13 23 13 23 33 43 17 27 37 47 13 23

14 24 34 14 24 14 24 34 44 18 28 38 48 14 24

K1 K2 K3 K1 K2 K1 K2 K3 K4 K1 K2 K3 K4 K1 K2

V common V common V common V common V common

CI DI EM EMD SI

OSSD Outputs
The DIS safety relay has OSSD safety outputs on terminals 14, 24, 34 and 44.
Output terminals 14 and 24 are pulse tested and can switch loads up to 1.5 A.
They can only tolerate a load capacitance up to 1.6 μF. Terminals 34 and 44 have
a series diode and can switch loads up to 0.5 A. They can tolerate a load
capacitance up to 9 μF. Terminals 34 and 44 are also pulse tested, but these

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 Chapter 3 Power, Ground, and Wire

pulse tests are ignored as they are not used for short-circuit detection. These
terminals are intended for devices with high capacitance. For example, use
terminals 34 and 44 when connecting to the Enable input of the PowerFlex® 70
drive and the Safe Torque Off inputs of the PowerFlex and Kinetix® drives.

The pulse-tested outputs check for short circuits between the following:
• Each terminal.
• Each terminal and the 24V supply.
• Each terminal and 24V common. The load must be connected to the same
voltage reference as terminal A2.

The load must be connected to the same voltage reference as terminal A2. All
four OSSD outputs are short-circuit protected.
Figure 16 - OSSD Output Connections
24V DC supply

A1

A2 34 44 14 24

K1 K2 K3 K4

24V common
DIS

Surge Suppressors
Because of the potentially high current surges that occur when switching
inductive load devices, such as motor starters and solenoids, the use of surge
suppression to help protect and extend the operating life of the relays is
required. By adding a suppression device directly across the coil of an
inductive device, you prolong the life of the outputs. You also reduce the effects
of voltage transients and electrical noise from radiating into adjacent systems.
Figure 17 shows an output with a suppression device. We recommend that you
locate the suppression device as close as possible to the load device.
For outputs that use 24V DC, we recommend 1N4001 (50V reverse voltage) to
1N4007 (1000V reverse voltage) diodes for surge suppression for the OSSD
safety outputs (see Figure 17). The diode must be connected as close as possible
to the load coil.

For outputs that use 120V AC or 240V AC, we recommend metal oxide
varistors.
Figure 17 - Surge Suppressors
Metal Oxide Varistors Diodes for
for VAC Supply VDC Supplies

K1 K2 K1 K2

V common V common

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Chapter 3 Power, Ground, and Wire

Example surge suppressors include the following catalog numbers:

• 100-FSD250 for Bulletin 100S contactors
• 1492-LD4DF terminal block with built-in 1N4007 diode
• 1492-JD3SS terminal block with built-in varistor

Single Wire Safety Input and The Single Wire Safety (SWS) feature allows a safety relay to expand the safety
function to additional safety relays using one wire, provided all safety relays
Output have the same voltage supply reference.

The CI and SI safety relays only have SWS outputs (terminal L11). The DI, DIS,
EM, and EMD safety relays have both SWS inputs (terminal L12) and SWS
outputs (terminal L11).

There can be many variations and combinations of series and parallel

connections of the SWS. Each L11 terminal can be connected to up to ten L12
terminals.

IMPORTANT Do not connect two or more L11 terminals together.

Figure 18 shows an example wiring diagram with SWS input from a DI safety
relay and SWS output connection to an EM safety relay in parallel with a DIS
safety relay. The safety relays must have a common power reference (24V
common). In this example, the safety function started by the CI or SI safety
relay is expanded to the DI safety relay. The safety functions monitored by the
DI safety relay are expanded to the EM and DIS safety relays. The safety
functions monitored by the DIS safety relay are expanded to the EMD safety
relay.

ATTENTION: You must consider the additional response time of each SWS
connection when calculating the safety distance. See Specifications on
page 77 for the response time for each relay.
Figure 18 - Example SWS Connections
+24V DC +24V DC +24V DC +24V DC +24V DC

A1 A1 A1 A1 A1

CI or SI DI EM DIS EDM
A2 L11 A2 L12 L11 A2 L12 L11 A2 L12 L11 A2 L12 L11

SWS SWS SWS

24V DC Com (must have common reference)

Figure 19 shows the characteristics of SWS signal when it is active. It starts

with a 1 ms pulse, followed 700 μs later by a 500 μs pulse. This waveform is
repeated every 4 ms. When inactive, the SWS is 0V.
Figure 19 - SWS Waveform
24V
Terminals
L11 and L12
0V
0 1 1.7 2.2 4ms

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 Chapter 3 Power, Ground, and Wire

Auxiliary Output Each safety relay has an auxiliary output. The auxiliary output is not a safety
rated output; it is a low current output that is designed to indicate that the
safety output status is OFF. The auxiliary output is in the opposite state of the
safety outputs. When the safety outputs are ON, the auxiliary output is OFF.
When the safety outputs are OFF, the auxiliary output is ON.

When the EM and EMD safety relays are in a faulted state, the auxiliary
outputs are in an OFF state because the auxiliary outputs are often used as the
source of the monitoring circuit. If the EM or EMD safety relays are faulted,
the safety system must not reset until the fault is corrected.

The DI, DIS, EM, EMD, and SI safety relays have a solid-state transistor
auxiliary output. The CI safety relay has an electromechanical output. Table 3
summarizes the terminal connections of the auxiliary output.
Table 3 - Auxiliary Outputs
Relay Type of Output Terminal Connections
CI Electromechanical 41/42
DI, DIS, SI Transistor Y32
EM, EMD Transistor X32

Reset and Monitor Input The CI, DI, DIS, and SI safety relays have a reset/monitoring input (terminal
S34). The expansion safety relays (EM and EMD) do not have a reset input.

The reset action can be configured for either automatic or manual reset. When
the relay is configured for automatic reset, the safety relay outputs turn ON as
soon as the safety inputs are closed if terminal 34 is connected to 24V. If a
normally open switch is placed in the circuit, the reset function occurs on the
leading edge (when the switch is pressed).

When the relay is configured for manual reset, the safety relay outputs turn
ON after the inputs are closed and then the reset input is cycled from OFF to
ON and then back OFF again.
Monitoring of external devices, like safety control relays and safety contactors,
can be accomplished by adding normally closed contacts in series with the
reset signal. Figure 20 shows typical reset/monitoring circuits.
Figure 20 - Typical Reset/Monitoring Circuits
+24V DC
PLC
+
1
2
3

A1 S34 A1 S34 A1 S34 A1 S34 A1 S34 A1 A1 S34

EM or
A2 A2 A2 A2 A2 A2 EMD A2

24V DC Com
Circuit Circuit Circuit Circuit Circuit Circuit
1 2 3 4 5 6

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Chapter 3 Power, Ground, and Wire

Circuit Description
1 In automatic/manual reset, a direct connection can be made to 24V DC.
Output devices are monitored with their normally closed contacts. This circuit can only be used in
2 automatic/manual reset.
A normally open push button is used. The relay can be configured for automatic/manual reset or
3 monitored manual reset.
Output devices are monitored along with a normally open push button. The relay can be configured for
4 automatic/manual reset or monitored manual reset.
An EM or EMD expansion safety relay is used to supply the voltage to terminal S34. This circuit can also
5 contain feedback contacts and a reset push button, similar to circuits 2, 3, and 4.
A PLC is used to generate the reset signal. The GSR safety relay can be configured for either automatic/
6 manual or monitored manual reset.

Automatic/Manual Reset
Use automatic reset when the risk assessment does not require additional
manual intervention to reset the safety system. Automatic reset is often used
with partial body access or where an additional control is implemented in the
machine control system to start the hazardous portion of the machine after the
safety inputs are closed.
When automatic reset is desired, the S34 input must be connected to 24V DC.
Figure 21 shows three possibilities:
a. A direct connection
b. A connection through some monitoring contacts
c. A connection through a normally open push button.

You can combine the connection through a monitoring contact and push
button. When a push button is used, the reset occurs when the circuit is closed
(not when it is released).
Figure 21 - Automatic/Manual Reset Connections
+24V DC
Momentary Push
Contactor Button (N.O.)
Monitoring

A1 S34 A1 S34 A1 S34

CI, DI, DIS, or SI CI, DI, DIS, or SI CI, DI, DIS, or SI

A2 A2 A2

24V DC Com
(a) (b) (c)

Monitored Reset
Monitored reset requires a specific signal to turn on the safety outputs. The
safety inputs and single wire safety input (if used) must be closed before the
reset. The reset signal must cycle from 0V to 24V and back to 0V within a
duration of 250…3000 ms, as shown in Figure 22 on page 29. The reset occurs
on the trailing edge. If the reset signal is too short or too long, the reset
function is not executed and can be tried again.

Monitored reset must be used in applications that have full-body access to the
hazard. Monitored reset can also be used in applications that require partial
body access.

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 Chapter 3 Power, Ground, and Wire

Figure 22 - Monitored Reset Signal Duration

24V
250…3000 ms

0V

The signal can be created with a momentary push button or programmatically

created with logic controller. Figure 23 shows example wire connections for
the reset. The schematic also shows an example monitoring the mechanically
linked, normally closed contacts of two contactors.
When using a PLC to generate the reset signal, set the duration to 260…2990 ms
for a more reliable reset.
Figure 23 - Monitored Reset Connections
+24V DC
Momentary Push
Button (N.O.) + PLC Output PLC
1 Processor
2 1756-OB16
3 1769-OB8
Contactor 1746-OB4
1734-OB2
Monitoring 1793-OB4

A1 S34 A1 S34

CI, DI, DIS, or SI CI, DI, DIS, or SI

A2 A2

24V DC Com

Monitor with Expansion Relays

Monitoring of the expansion relays is recommended. This feature is especially
useful when the expansion relay is turning on loads (for example, solenoid-
operated valves) that do not have monitoring contacts. The auxiliary output of
the expansion relay must be the 24V DC source of the reset and monitoring
input. Figure 24 shows an example of the connections for a monitored reset
with additional contactor monitoring. This type of connection can also be used
for automatic reset applications.
Figure 24 - Monitor Expansion Relay
+24V DC

Momentary Push
Button (N.O.)
Contactor
Monitoring

A1 S34 X32 A1

CI, DI, DIS, or SI EM or EDM

A2 A2

24V DC Com

Retriggerable Input The B1 and B2 inputs determine the type of timing function.
• B1 and B2 open: Off-delay non-retriggerable or on-delay
• B1 connected to B2: Off-delay retriggerable
• B1 connected to 24V DC: Jog

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Chapter 3 Power, Ground, and Wire

The EMD safety relay has a retriggerable input. Retriggerable operation only
works in off-delay applications. Retriggerable operation is accomplished by
connecting a jumper from terminal B1 to B2. Table 4 describes the off-delay
operation.
Table 4 - Retriggerable Operation
Configuration Jumper Action
If the safety input is triggered and cleared within the duration of the time delay,
Retriggerable B1-B2 then the timing request is ignored and the safety output contacts remain closed.
The B1 indicator is ON.
The full time delay lapses and the safety output contacts open before the relay can
Non-retriggerable None be reset.
The B1 indicator is OFF.

Jog Input When the EMD safety relay is configured for the Jog functions, terminal B1
must be connected to +24V DC.

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 Chapter 4

Configuration

The multi-position, rotary switches on the front face of a GSR safety relay
determine its functionality. The configuration method of a GSR safety relay
must provide means to help protect against manipulation and maintain
integrity of the configuration.

The rotary switches accommodate a small screwdriver to turn the switch to the
desired switch position. The configuration procedure implies a willing action
by the person who configures the safety function to prove that the person is
conscious and able to perform this task. Therefore, GSR safety relays require a
procedure of turning a switch to position “0” to start the configuration mode
and then turn to the position desired.
The status indicators on the front panel provide continuous feedback by
flashing the switch positions. Power cycling the device in a timely manner
completes the configuration mode and the device enters operation.

IMPORTANT To keep your GSR safety relay from permanently faulting, complete the
configuration process by power cycling the relay within 5 minutes after
configuring rotary switches.

We recommend that the configuration is completed within 5 minutes. The

actual technical limitation of the internal EEPROM is around 8 hours. The
internal micro-controllers monitor and verify the switch positions during
configuration to achieve the required diagnostics coverage for the PLe safety
rating. The EEPROM read/write cycles are limited and can cause a permanent
fault of the GSR safety relay after several hours.

Switch Adjustment These safety relays have multi-position switches on their front face. Use a
small screwdriver to set the switches to the desired setting.

Make note of the mechanical stop location.

Figure 25 - Configuration Switch Adjustment

Mechanical
Stops

Screwdriver 0
Slot

IMPORTANT Adjust the switches gently and do not turn past the mechanical stops.

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Chapter 4 Configuration

CI and SI safety relays have a three-position Reset switch. This switch

determines whether the relay uses a monitored manual reset or an automatic/
manual switch (see Definitions on page 7).
Table 5 - CI and SI Safety Relay Logic Switch
Position Function
0 Start configuration
MM Monitored manual reset
AM Automatic/manual reset

DI and DIS Safety Relays

The DI and DIS safety relays have a 10-position switch and use only the first
nine positions. As shown in Table 6, this switch configures the relay for its
reset and logic functionality.
Table 6 - DI and DIS Safety Relay Logic Switch
Position Reset Function
0 Not applicable Start configuration
1 (IN1 OR IN2) OR L12
2 (IN1 AND IN2) OR L12
Monitored Manual
3 (IN1 OR IN2) AND L12
4 (IN1 AND IN2) AND L12
5 (IN1 OR IN2) OR L12
6 (IN1 AND IN2) OR L12
Automatic/Manual
7 (IN1 OR IN2) AND L12
8 (IN1 AND IN2) AND L12

Example 1: Logic setting 1 or 5: If any of the inputs (IN1, IN2, or L12) are ON,
then the safety relay refers to the reset logic.

Example 2: Logic setting 4 or 8: If all three of the inputs (IN1, IN2, and L12) are
ON, then the safety relay refers to the reset logic.

EMD Safety Relay

The EMD safety relay has two switches. The combination of the switch settings
determines the functionality and the duration. During configuration, the Time
switch determines the duration of the Range switch. Figure 26 and Table 7 on
page 33 show the setting options for the Range and Time switch.

With the Time switch set to 1 at the start of the configuration process, the
duration of the Range switch is the shorter range.

With the Time switch set to 10 at the start of the configuration process, the
duration of the Range switch is the longer range.
Figure 26 - EMD Safety Relay Range and Time
Start Configuration with Time Set to: x 10% or max 1: 10%
1 10 2: 20%
0 1: 0.1...1 s 10...100 s 3: 30%
RANGE TIME 1
1
Off 2: 1...10 s
3: 3...30 s
100...1000 s
300...3000 s
Off-Delay 2 4: 40%
9 2 — 3 5: 50%
4: 30...300 s 10
Jog 3 5: 0.3...3 s 30...300 s 4 6: 60%
8 9
6: 3...30 s 300...3000 s On-Delay 8 5 7: 70%
7 4 7: 30...300 s — 7 6 8: 80%
6 5 8: 0.1...10 s 100...1000 s
On Jog TIME 9: 90%
9: 3...30 s 300...3000 s
10: 100%

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 Chapter 4 Configuration

Table 7 - EMD Safety Relay Range and Time Settings

Range
Position Time
Function Range (Time 1) [s] Range (Time 10) [s]
0 Start Configuration — — —
1 0.1…1 10…100 10
2 1…10 100…1000 20
Off Delay
3 3…30 300…3000 30
4 30…300 — 40
5 0.3…3 30…300 50
6 On Delay 3…30 300…3000 60
7 30…300 — 70
8 0.1…10 100…1000 80
Jogging
9 3…30 300…3000 90
10 — — — 100

Example 1: The range setting is 3 (starting with the Time set to 1), and the Time
setting is 5. Then the off-delay is: 30 s * 50% = 15 seconds

Example 2: The range setting is 6 (starting with the Time set to 10), and the
Time setting is 1. Then the on-delay is: 3000 s * 10% = 300 seconds

Configuration Process Configuration is a five-step process. The process requires the wiring to be
completed and the inputs closed. During the configuration process, GSR safety
relays send out test pulses to determine how it is wired and then configures the
internal parameters to match the application.

Five Steps to Configure Your GSR safety relay

1. With the power OFF, prepare the switches.
Safety Relay Action
DI/DIS Set the Logic switch to position 0.
CI/SI Set the Reset switch to position 0
EMD expansion safety Set the Range switch to position 0 and set Time switch to 1 (short timing range) or 10 (long
relay timing range).
EM expansion safety No switches. No action necessary.
relay
2. Apply power.
After a short wait, the PWR/Fault status indicator flashes red
continuously at a 1 Hz rate (0.5 s ON, 0.5 s OFF). The prior
configuration in the EEPROM is erased, and the device is now
prepared for a new configuration.
3. Adjust the Logic, Reset, Time, and Range switch settings as needed for
your application.
You can change (or readjust) the switch settings during step 3 and
step 4. The power status indicator momentarily flashes red again.
4. Verify the settings by counting the blink rates of the status indicators.
Table 8 on page 34 shows the indicator that flashes for the
corresponding switch setting for each relay.

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Chapter 4 Configuration

Table 8 - Configuration Confirmation

Safety Relay Status Indicator Switch Setting
CI IN Reset
DI IN 1 Logic
DIS IN 1 Logic
B1 Range
EMD
Logic IN Time
SI IN Reset
Figure 27 shows an example of the blinking patterns for the EMD
expansion safety relay. The indicators flash for 0.5 seconds to indicate
the switch settings. The number of flashes is equal to the switch
setting. The blinking pattern repeats after a 2 second pause.
Figure 27 - EMD Expansion Safety Relay Status Indicators Flashing in Configuration Mode
B1 - Indicates that the RANGE Switch is set to 3.

0.5 s 2s
Flash Pause

Logic IN - Indicates that the TIME Switch is set to 4

5. Cycle the power to store the settings.

After power-up, the current switch settings are compared to the values
in the EEPROM (makes sure that the switches were not changed while
power was off), and the input and output circuits are checked. Upon
successful completion of the internal checks, the relays are ready for
operation.

IMPORTANT To keep your GSR safety relay from permanently faulting, complete the
configuration process by cycling the relay power within 5 minutes of
rotary switch configuration.

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 Chapter 5

Status Indicators

Indicators During Power-up The status indicators provide operating status and diagnostic information.

Indicators During Normal

Operation Table 9 - Status Indicators (Normal Operation)
Status Indicator Models State Description
Steady green Normal operation.
Nonrecoverable fault. See Table 11 on page 55. Correct
Flashing red
fault and cycle power
PWR/Fault All
Green with flashing Recoverable fault. See Table 12 on page 56.
red Correct fault and press Reset.
Steady red Internal Fault. Cycle power.
ON Input circuits at S12 and S22 are closed.
IN or IN 1 CI, DI, DIS, SI
OFF Input circuits at S12 and S22 are open.
ON Input circuits at S32 and S42 are closed.
IN 2 DI, DIS
OFF Input circuits at S32 and S42 are open.
ON Input circuit at B1 is closed.
B1 EMD
OFF Input circuit at B1 is open.
ON Logic IN signal (Single Wire Safety) at L12 is ON.
DI, DIS, EM, EMD
LOGIC IN OFF Logic IN signal at L12 is OFF.
EMD Flashing Timing cycle is in process.
ON L11 is ON.
All
OFF L11 is OFF.
ON 13/14, 23/24, 33/34 closed (41/42 open).
CI OFF 13/14, 23/24, 33/34 open (41/42 closed).
Flashing Safety input is closed, waiting for the reset input.
ON 13/14, 23/24 closed (Y32 OFF).
DI OFF 13/14, 23/24 open (Y32 ON).
Flashing Safety inputs are closed, waiting for the reset input.
ON 14, 24, 34, 44 ON (Y32 OFF).
OUT
DIS OFF 14, 24, 34, 44 OF (Y32 ON).
Flashing Safety inputs are closed, waiting for the reset input.
ON 13/14, 23/24, 33/34, 43/44 closed (X32 OFF).
EM
OFF 13/14, 23/24, 33/34, 43/44 open (X32 ON).
ON 17/18, 27/28, 37/38, 47/48 closed (X32 OFF).
EMD
OFF 17/18, 27/28, 37/38, 47/48 open (X32 ON).
ON 13/14, 23/24 closed (Y32 OFF).
SI OFF 13/14, 23/24 open (Y32 ON).
Flashing Safety input is closed, waiting for reset input.

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Chapter 5 Status Indicators

Indicators During See the following tables:

Diagnostics Table Page
PWR/Fault Status Indicator Is Steady Red 55
PWR/Fault Status Indicator Is Flashing Red 55
PWR/Fault Status Indicator Is Green with Flashing Red 56

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 Chapter 6

Pulse Testing Functions

Safety relays use pulse testing of inputs and outputs to verify that the safety
function is performed when called upon. Pulse testing for the inputs must be
used with devices with mechanical contacts like E-stop push buttons, tongue
operated interlock switches, and limit switches. The pulse testing cannot be
turned on or off and cannot be changed.
The test pulses are used to detect three short circuit conditions:
• Between the input terminals and +24V.
• Between the input terminals and 24V common.
• Between the two input terminals.

Pulse Testing for Inputs Pulse testing for the inputs is generated on terminals S11 and S21 of the CI, DI,
DIS, and SI safety relays. The EM and EMD safety relays do not use pulse
testing.

CI Safety Relay
The pulse testing that is associated with the CI safety relay is shown in
Figure 28. The pulse widths are 2.5 ms wide. The pulse testing on S11 and S21 is
offset by 1 ms. The pulses are repeated every 14 ms.
Figure 28 - Pulse Test Sequence for CI Safety Relay
24V
S11

0V
24V
S21
0V

0 2.5 3.5 6 14
Time (ms)

When using a digital multimeter, S11 measures approximately 19V and S21
measures approximately 19V when the supply voltage to A1 is 24V DC and the input
circuits are open.
At the minimum-rated input ON voltage (11V), a DC multimeter reads approximately
8.9V DC at S12 and S22.

DI, DIS, and SI Safety Relays

The pulse test sequence for the DI, DIS, and SI safety relays are shown in
Figure 29 on page 38. The sequence is repeated every 13.6 ms.

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Chapter 6 Pulse Testing Functions

Figure 29 - Pulse Test Sequence for DI, DIS, and SI Safety Relays
24V
S11
0V

0 3 6.4 9 13.6 16.8 20 22.5

24V
S21
0V

0 4 6.4 17.7 20
5.5 8 19 21.5
Time (ms)

When using a digital voltmeter, S11 measures approximately 14V DC and S21
measures approximately 18V DC when the supply voltage to A1 is 24V DC and the
input circuits are open.

Pulse Testing for OSSD The DIS safety relay has OSSD transistor outputs. One main transistor
supplies current to four individual transistors (see Figure 30). When the main
Outputs transistor is pulse tested, the pulse appears on all outputs. When the individual
transistors are tested, the pulse only appears on that transistor.
Figure 30 - Output Transistor Arrangement
Main Transistor

Individual Transistors

33 44 14 24

The pulse test pattern is shown in Figure 31. The pulse widths vary from
50…150 μs. The pulse pattern on terminal 14 is identical to terminal 34, and the
pulse pattern on 24 is identical to 44. The pattern is repeated every
3.371 seconds.
Figure 31 - OSSD Output Test Pulses on DIS Safety Relay
Main Transistor Test

Terminals
14 and 34 24V
0V
24V
24 and 44
0V
0 131 262 393 524 655 3371 (ms)

Individual Transistor Tests Repeats

Although pulse tests appear on terminals 34 and 44, the DIS safety relay does
not detect faults from A1 to 34, 44 or between 34 and 44 when the outputs are
ON.

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 Chapter 7

EMD Safety Relay Timing Functions

The EMD safety relay has three functions that use timing:
• Off delay
• On delay
• Jog

The off-delay timing depends on whether the function is retriggerable.

During the timing cycle, the Logic IN status indicator flashes.

Off Delay, Non- With input B1 open, the off-delay function is not retriggerable. The off-delay
timer starts when the logic link signal at terminal L12 turns off. Once started,
retriggerable the off-delay timer runs for its full duration. Figure 32 shows three cases of the
timing sequences that can occur with this configuration.
Figure 32 - Off-delay, Non-retriggerable Timing Diagram
Case 1 Case 2 Case 3
L12
Safety
Output
t t t
Fault

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Case 1
1. The logic link signal at terminal L12 turns on and the safety outputs turn
on immediately (that is, within the specified reaction time).
2. The logic link signal turns off and the off-delay timer starts.
3. The off-delay time has elapsed, and the safety outputs turn off.

Case 2
4. The logic link signal at terminal L12 turns on, and the safety outputs turn
on within the specified reaction time.
5. The logic link signal turns off and the off-delay timer starts.
6. During off-delay time, the logic link signal turns off. A recoverable fault
occurs. The PWR/Fault indicator is green and flashing red four times.
7. The off-delay time has elapsed, and the safety outputs turn off.
8. The logic link signal turns off.
9. Shortly after the logic link turns off, the fault is automatically cleared.
The PWR/Fault indicator is steady green.

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Chapter 7 EMD Safety Relay Timing Functions

Case 3
10. The logic link signal at terminal L12 turns on, and the safety outputs turn
on within the specified reaction time.
11. The logic link signal turns off and the off-delay timer starts.
12. During off-delay time, the logic link signal turns off. A recoverable fault
occurs. The PWR/Fault indicator is green and flashing red four times.
13. The logic link turns back off. The fault continues to exist.
14. The off-delay time has elapsed; the safety outputs turn off; and the fault
is automatically cleared.

Off Delay, Retriggerable To use the retriggerable off-delay function, input terminal B1 must be
connected to terminal B2 before the configuration process. The off-delay timer
starts when the logic link signal at terminal L12 turns off. During the timing
cycle, the off-delay timer is automatically reset to zero when the logic link
turns back on. Figure 33 shows two cases of the timing sequences that can
occur with this configuration.
Figure 33 - Off-delay, Retriggerable Timing Diagram
Case 1 Case 2
L12
Safety
Output
t t t

1 2 3 4 5 6 7 8

Case 1
1. The logic link signal at terminal L12 turns on, and the safety outputs turn
on immediately (that is, within the specified reaction time).
2. The logic link signal turns off, and the off-delay timer starts.
3. The off-delay time has elapsed, and the safety outputs turn off.

Case 2
4. The logic link signal at terminal L12 turns on, and the safety outputs turn
on within the specified reaction time.
5. The logic link signal turns off, and the off-delay timer starts.
6. During off-delay time, the logic link signal turns on. The off-delay timer
is set back to zero, and the safety outputs remain on. No fault occurs.
7. The logic link signal turns off, and the off-delay timer starts.
8. The off-delay time has elapsed, and the safety outputs turn off.

On Delay To use the on-delay function, terminal B1 must be an open connection. The
on-delay timer starts when the logic link signal at terminal L12 turns on. The
safety outputs turn on after the delay time expires and remain on until the
logic link signal turns off. If the logic link signal turns off during the timing
cycle, the safety outputs turn off immediately. Figure 34 on page 41 shows two
cases of the timing sequences that can occur with this configuration.

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 Chapter 7 EMD Safety Relay Timing Functions

Figure 34 - On-delay Timing Diagram

Case 1 Case 2
L12
Safety
Output
t t t

1 2 3 4 5 6 7 8

Case 1
1. The logic link signal at terminal L12 turns on, and the on-delay timer
starts.
2. The on-delay timer elapses, and the safety outputs turn on.
3. When the logic link signal turns off, the safety outputs turn off.

Case 2
4. The logic link signal at terminal L12 turns on, and the on-delay timer
starts.
5. The logic link signal turns off before the on-delay time elapses. The on-
delay timer is reset to zero. No fault occurs.
6. After a brief interruption (even as short as 100 ms), the logic link signal
turns back on. The on-delay timer starts from zero.
7. The on-delay timer elapses, and the safety outputs turn on.
8. When the logic link signal turns off, the safety outputs turn off.

Jog The jog function has two timers: an on-timer and an off-timer. The Range and
Time switch settings set the on-timer during configuration. The on-timer
starts when both the B1 terminal is connected to 24V DC and the logic link
signal at terminal L12 is on. The order in which these two signals turn on is not
relevant. When both signals are on, the safety outputs turn on during the on-
timer. After the on-timer expires, the safety outputs turn off and the off-timer
starts. The off-timer is fixed at 500 ms. After the safety outputs turn off, they
remain off unit the off-timer elapses. Then the jog can be restarted. Figure 35
shows three cases of timing sequences.

During the on-timer cycle, the Logic IN indicator flashes at a 1 Hz rate. During
the off-timer cycle, the Logic IN indicator flashes at an 8 Hz rate.
Figure 35 - Jog Timing Diagram
Case 1 Case 2 Case 3
L12

B1
Safety
Output
t t t t

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

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Chapter 7 EMD Safety Relay Timing Functions

Case 1
1. The logic link signal at terminal L12 turns on.
2. The B1 terminal turns on. The jog on-timer starts, and the safety outputs
turn on.
3. The jog on-timer elapses, and the safety outputs turn off. The jog
off-timer starts.
4. After 500 ms, the jog function is complete.
5. The B1 inputs turn off.
6. With the logic link input still on, the jog function is repeated when the B1
signal turns on.
7. The logic link signal turns off.
The L12 and B1 signals are interchangeable. The B1 signal can remain on and the
L12 turns on and off to execute the jog function.

Case 2
8. The B1 signal turns on before the logic link signal.
9. The logic link signal turns on. The jog on-timer starts, and the safety
outputs turn on.
10. The B1 signal turns off before on-timer elapses. The safety outputs turn
off immediately and the off-timer starts.
11. The off-timer elapses. The logic link signal turns off to end Case 2.
The L12 and B1 signals are interchangeable. If the B1 signal remains on and the L12
turns off before the on-timer elapses, the safety outputs turn off immediately.

Case 3
12. The logic link signal at terminal L12 is on. The B1 signal turns on. The jog
on-timer starts, and the safety outputs turn on.
13. The on-timer elapses and the safety outputs turn off. The off-timer starts.
14. During the off-timer cycle, the B1 signal is turned off and then quickly
back on. The safety outputs remain off.
15. The B1 signal must turn off before a new jog cycle can begin.
The L12 and B1 signals are interchangeable. At least one of these two signals must
remain off throughout the off-timer cycle before a new jog cycle begins.

42 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Chapter 8

Internal Circuit Block Diagrams

The figures in this chapter show the internal circuit block diagrams of each
safety relay.

CI Safety Relay Figure 36 - CI Safety Relay Circuit Diagram

(Cat. No. 440R-S13R2)

Reset

DI Safety Relay Figure 37 - DI Safety Relay Circuit Diagram

(Cat. No. 440R-D22R2)
AND / OR
AND /
Reset
OR

DIS Safety Relay Figure 38 - DIS Safety Relay Circuit Diagram

(Cat. No. 440R-D22S2)
AND / OR
PWR
IN1 AND /
IN2
LOGIC IN OR
OUT
Logic

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Chapter 8 Internal Circuit Block Diagrams

EM Safety Relay Figure 39 - EM Safety Relay Circuit Diagram

(Cat. No. 440R-EM4R2)

Logic

EMD Safety Relay Figure 40 - EMD Safety Relay Circuit Diagram

(Cat. No. 440R-EM4R2D)
on delay
off delay
Range Time jogging

SI Safety Relay Figure 41 - SI Safety Relay Circuit Diagram

(Cat. No. 440R-S12R2)

Reset

44 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Chapter 9

Application and Wiring Examples

The application and wiring examples in this chapter show you how to put the
inputs and outputs together to create an operating safety system. These circuit
diagrams are examples; many features are interchangeable between relays.

Publication SAFETY-WD001 provides additional application and wiring

diagrams.

CI Safety Relay In Figure 42, the CI safety relay is monitoring a device (an E-stop push button)
with mechanically operated contacts. The CI safety relay is configured for
(Cat. No. 440R-S13R2) monitored manual (MM) reset. The output turns on if the E-stop is released
and the reset push button is pressed and released between 0.25…3 seconds. The
CI safety relay monitors the status of the two output contactors, K1 and K2. If
either fails to close their N.C. contacts, the CI safety relay does not reset. An
auxiliary signal, terminals 41/42, is sent to the PLC when the E-stop is pressed.
Figure 42 - Mechanical Contacts with Monitored Manual Reset
24V DC
K1

K2

Reset

S11 S21 S34 A1 13 23 33 41

RESET 0
AM
MM
CI
440R-S13R2
S12 S22 A2 L11 14 24 34 42
To PLC
K1 K2
24V Com

Figure 43 on page 46 shows a CI safety relay monitoring a light curtain with

two OSSD outputs. The CI safety relay is set to automatic/manual reset (AM).
The auxiliary signal (terminals 41/41) informs the PLC that the safety system is
OFF or ON. The CI safety relay outputs connect to AC voltage loads. When the
CI safety relay is ON, the PLC can then turn on the K1 and K2 contactors.

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Chapter 9 Application and Wiring Examples

Figure 43 - With Device Using OSSD Outputs, Automatic Reset, AC Load Voltage
L1
120/240V AC PLC
Input
Output
24V DC
K1

K2

S11 S21 S34 A1 13 23 33 41

RESET 0
AM
MM
CI
440R-S13R2
S12 S22 A2 L11 14 24 34 42
OSSD1
OSSD2
K1 K2

24V Com
N

DI Safety Relay The DI safety relay in Figure 44 monitors two devices having mechanical
contacts and is set for monitored manual reset. With the two devices closed,
(Cat. No. 440R-D22R2) the operator presses the reset button to energize contactors K1 and K2. The DI
safety relay verifies that contactors K1 and K2 are off by monitoring the
mechanically linked normally closed contacts in the reset circuit. When the DI
safety relay is off, the auxiliary signal at terminal Y32 turns on and reports the
status to a PLC.
Figure 44 - With Two Devices with Mechanical Contacts and Monitored Manual Reset
24V DC
K1

K2

Reset

S11 S21 S22 S12 A1 13 23 S34

LOGIC 0
1
2
8 3
DI 7 4
6 5
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
To PLC
K1 K2
24V Com

In Figure 45 on page 47, a DI safety relay monitors a safety mat and noncontact
interlock with OSSD outputs. Make note of the specific wiring for the mat.
Also, during configuration and for each power-up, the mat must be clear and
the interlock closed. The DI safety relay must be configured for AND logic for
the two inputs. The DI safety relay logic setting is 6: (IN1 AND IN2) OR L12 with
automatic reset. The DI safety relay verifies that contactors K1 and K2 are off
by monitoring the mechanically linked normally closed contacts in the S34
circuit. When the DI safety relay is off, the auxiliary signal at terminal Y32
turns on and reports the status to a PLC. Per ISO 13856-1, safety mat
applications require a manual reset function. For fault detection purposes, all
GSR safety relays used for safety mat control must be configured for
monitored manual reset.

46 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Chapter 9 Application and Wiring Examples

Figure 45 - With a Safety Mat and Device with OSSD Outputs, Monitored Manual Reset, AC Loads
L1
120/230V AC
24V DC
K1

K2

Reset

S11 S21 S22 S12 A1 13 23 S34

LOGIC 0
1
2
8 3
DI 7 4
6 5
440R-D22R2
S32 S42 L11 L12 A2 14 24 Y32
OSSD1
To PLC
OSSD2 K1 K2

24V Com
N

DIS Safety Relay Figure 46 shows the DIS safety relay with only one device. The DIS and DI
safety relays can monitor one device by configuring the relay for OR logic. The
(Cat. No. 440R-D22S2) DIS safety relay logic setting is 1: (IN1 OR IN2) OR L12 with monitored manual
reset. The second input (terminals S32 and S42) requires no connection. With
solid-state outputs, the contactors K1 and K2 must be 24V DC powered coils.
The DIS safety relay verifies that contactors K1 and K2 are off by monitoring
the mechanically linked normally closed contacts in the S34 circuit. When the
DIS safety relay is off, the auxiliary signal at terminal Y32 turns on and reports
the status to a PLC.
Figure 46 - Single Input, Monitored Reset
24V DC
K1

K2

Reset

S11 S21 S22 S12 S32 S42 A1 S34

LOGIC 0
1
2
8 3
7 4
6 5
DIS
440R-D22S2
L12 L11 Y32 A2 34 44 14 24
To PLC
K1 K2
24V Com

The DIS safety relay monitors two devices with OSSD outputs in Figure 47 on
page 48 The DIS safety relay logic setting is 6: (IN1 AND IN2) OR L12 with
automatic reset. The output terminals 34 and 44 are designed to tolerate higher
capacitance loads (but lower resistive load) as compared to terminals 14 and 24.

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Chapter 9 Application and Wiring Examples

Figure 47 - High Capacitive Load

24V DC
+
OSSD1
OSSD2
-
+
OSSD1
OSSD2
-
S11 S21 S12 S22 S32 S42 A1 S34
0
LOGIC 1
2
8 3
7 4
6 5
DIS
440R-D22S2
L12 L11 Y32 A2 34 44 14 24
To PLC

24V Com

EM Safety Relay The EM safety relay in Figure 48 expands the number of outputs of the DI
safety relay. The single wire safety signal from terminal L11 to L12 instructs the
(Cat. No. 440R-EM4R2) EM safety relay to turn on and off. The EM safety relay outputs mimic the DI
safety relay outputs. The DI safety relay monitors contactors K1…K6 and the
status of the EM safety relay by sourcing the reset signal from the X32 terminal
on the EM safety relay.
Figure 48 - Expansion of Immediate Safety Outputs
24V DC

K2 K3 K4 K5

K1 K6

Reset

S11 S21 S22 S12 A1 13 23 S34 X32 A1 13 23 33 43

LOGIC 0
1
2
8 3
DI 7 4 EM
6 5
440R-D22R2 440R-EM4R2
S32 S42 L11 L12 A2 14 24 Y32 L12 L11 A2 14 24 34 44

To PLC
K1 K2 K3 K4 K5 K6
24V Com

EMD Safety Relay The EMD safety relay in Figure 49 on page 49 is configured for a 5 second
off-delay. The single wire safety signal from terminals L11 to L12 instructs the
(Cat. No. 440R-EM4R2D) EMD safety relay to turn on and off. When the E-stop is pressed, the CI safety
relay turns off immediately and the EMD safety relay turns off 5 seconds later.
The CI safety relay monitors contactors K1…K6 and the status of the EMD
safety relay by sourcing the reset signal from the X32 terminal on the EMD
safety relay.
In this example, the jumper from B1 to B2 makes the EMD safety relay
retriggerable. If the E-stop is released and the reset is pressed within the
5 second delay time, the outputs of the EMD safety relay do not turn off
because the internal timer is retriggered.

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 Chapter 9 Application and Wiring Examples

Figure 49 - EMD Safety Relay - Off Delay

24V DC

K2 K3 K4 K5

K1 K6
Reset

S11 S21 A1 S34 13 23 33 41 B1 B2 X32 A1 17 27 37 47

RANGE 0 TIME 1
RESET 0 1 2
9 2 10 3
AM 8 3 9 4
7 6 5 4 8 5
MM 7 6
CI EMD
440R-S13R2 440R-EM4R2D
S12 S22 A2 L11 14 24 34 42 L12 L11 A2 18 28 38 48

To PLC
K1 K2 K3 K4 K5 K6
24V Com

Figure 50 shows the EMD safety relay that is configured for a 2.1 second
on-delay. The single wire safety signal from terminals L11 to L12 instructs the
EMD safety relay to turn on and off. When the reset button is pressed, the DIS
safety relay outputs turn on immediately. After a 2.1 second delay, the EMD
safety relay outputs turn on.

The DIS safety relay monitors contactors K1…K4 and the status of the EMD
safety relay by sourcing the reset signal from the X32 terminal on the EMD
safety relay.
Figure 50 - EMD Safety Relay - On Delay
24V DC

K1 K3

K2 K4

Reset

S11 S21 S12 S22 S32 S42 A1 S34 B1 B2 X32 A1 17 27 37 47

LOGIC 0
1
RANGE 0 1 TIME 1
2
2 9 2 10 3
8 3 8 3 9 4
7 4 7 6 5 4 8 5
6 5 7 6
DIS
EMD
440R-D22S2 440R-EM4R2D
L12 L11 Y32 A2 34 44 14 24 L12 L11 A2 18 28 38 48

To PLC K1 K2 K3 K4
24V Com

The EMD safety relay in Figure 51 on page 50 is configured for a maximum of a

100 second jog. The single wire safety signal from terminals L11 to L12 enables
the EMD safety relay. When enabled, the jog switch can be pressed and held
closed to turn on the EMD safety relay outputs. If the jog button is released
before the 100 second time, the EMD safety relay outputs turn off. If the jog
button is held longer than 100 seconds, the EMD safety relay outputs only turn
on for 100 seconds.

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Chapter 9 Application and Wiring Examples

Figure 51 - EMD Safety Relay - Jog

24V DC

K2 K3 K4 K5

K1 K6

Reset Jog

S11 S21 S34 A1 13 23 B1 B2 X32 A1 17 27 37 47

RANGE 0 TIME 1
1 2
RESET 0 9 2 10 3
8 3 9 4
AM 7 6 5 4 8
7 6
5
SI MM EMD
440R-S12R2 440R-EM4R2D
S12 S22 Y32 L11 A2 14 24 L12 L11 A2 18 28 38 48

To PLC
K1 K2 K3 K4 K5 K6
24V Com

SI Safety Relay The SI safety relay monitors a gate interlock with mechanical contacts in
Figure 52. The SI safety relay is configured for automatic reset. When the gate
(Cat. No. 440R-S12R2) is closed, the SI safety relay outputs turn on if contactors K1 and K2 are already
off. The Start button can then be pressed to turn on contactors K1 and K2.
Figure 52 - SI Safety Relay Example
24V DC
K1
Start
K2

Stop

S11 S21 A1 S34 13 23

RESET 0
AM
SI MM
440R-S12R2
S12 S22 Y32 L11 A2 14 24

To PLC K1 K2
24V Com

50 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Chapter 10

Ethernet Communication

The DI, DIS, EM, EMD, and SI safety relays are equipped with optical
communication via an optical link. With an optical link, diagnostic data can be
read from these relays and transferred to other devices over EtherNet/IP™ with
the catalog number 440R-ENETR EtherNet/IP module. The CI safety relay does
not have an optical link.
The catalog number 440R-ENETR EtherNet/IP module must be in the leftmost
position (see Figure 53). See publication 440R-UM009 for further details on the
EtherNet/IP module. The safety relays must be Series A 200 or later.
Figure 53 - Arrangement of EtherNet/IP Module and Safety Relays

EtherNet/IP Up to Six Safety Relays

Module (in any order)

Webpage The catalog number 440R-ENETR EtherNet/IP module maintains its own
webpage (see Figure 54 on page 52). To access the webpage, connect an
Ethernet cable to your computer, open a web browser, and type in the IP
address of the ENETR module.

The webpage is only available with the 440R-ENETR Series A. The webpage is
not available in Series B or later.

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Chapter 10 Ethernet Communication

Figure 54 - ENETR Webpage

Type the IP address of the ENETR module

Click to browse
the safety relays

Studio 5000 Logix Designer The catalog number 440R-ENETR EtherNet/IP module includes the Studio
5000 Logix Designer® AOP for the DI, DIS, EM, EMD, and SI safety relays. The
Add-on Profile (AOP) AOP allows you to view the status of the relays, including open and closed
inputs, outputs ON and OFF, waiting for reset, and fault information.
Figure 55 shows an example of the AOP for the DI safety relay.

See publication 440R-UM009 for further details on the EtherNet/IP module.

Figure 55 - AOP for the DI Safety Relay

52 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Chapter 11

Troubleshooting

This chapter explains a systematic approach to determine the likely cause of

the GSR safety relay being in a faulted state or not operating properly. It
describes the procedures to use to troubleshoot your relay.

Tools Needed To troubleshoot your GSR safety relay, you need the following tools.

Required Tools
• Medium-sized Screwdriver: For terminal screws, to remove terminal
blocks, and to configure the switches on the front face of the relays.
0.5 mm (0.02 in.)
3 mm (0.12 in.)
• Digital Multimeter: To measure signal levels and contact resistance.

Optional Tools
• Oscilloscope: Dual- or four-channel storage scope to view input and
output signals and to capture noise transients.
• Metal Paper Clips: To insert into the terminals and allow connection of
scope probes to terminals.

Follow These Steps To diagnose the condition of the GSR safety relay, follow the steps in Figure 56
on page 54.

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Chapter 11 Troubleshooting

Figure 56 - Troubleshooting Flowchart

Start

Flashing OUT indicator Yes Go to Step 5

Go to Step 1 flashing green? (page 66)
PWR/Fault indicator No (page 54)
steady green? Off
Go to Step 2 No
(page 56)
Yes
OUT indicator is steady green
IN indicator steady No Go to Step 3
green? (page 58)
Output devices No Go to Step 6
energized? (page 67)
Yes
Yes
LOGIC IN indicator No Go to Step 4
steady green? (page 64) B1/B2 inputs of EMD Yes Go to Step 7
relay used? (page 74)

Yes No

Relay is functioning properly

View the PWR/Fault Status The first troubleshooting step is to examine the PWR/Fault status indicator on
the front of your GSR safety relay module. See Figure 57 for status indicator
Indicator (Step 1) location.
The PWR/Fault status indicator is in the same position on all GSR
safety relay modules.
Figure 57 - PWR/Fault Status Indicator

PWR/Fault status indicator

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 Chapter 11 Troubleshooting

The PWR/Fault status indicator has five possible states:

Status Description Action
Off No power to the relay. Apply power.
Steady green The relay is in the run state. None.
Steady red The relay is in a nonrecoverable faulted state. See Table 10.
Flashing red A nonrecoverable faulted state See Table 11.
Green and flashing red A recoverable faulted state. See Table 12 on page 56.

IMPORTANT For accurate diagnostics, always start counting the flashing after the
first pause. The first cycle can be inaccurate.

Table 10 - PWR/Fault Status Indicator Is Steady Red

Indicator Description Model Possible Causes Corrective Action
• A momentary power interruption.
All
• Noise on the power or signal wires.
Short circuit has occurred, or is present, from
Faults that are not CI, DI, DIS, and SI +24V DC (A1) to S11 or S21 or from 24V Common • Cycle power to clear the fault and return the GSR safety
described in Table 11 (A2) to S11 or S21. relay to an operational state.
Steady red and Table 12 on page 56 • Reconfigure the safety relay (see Configuration on page 31).
result in a steady red DIS Short circuit has occurred, or is present, from • See additional information in Verify Grounding at the Power
indicator. +24V DC (A1) to 14 or 24. Supply on page 57.
Excessive capacitance from input wiring to
SI ground, but not enough to cause flashing red four
times.

Table 11 - PWR/Fault Status Indicator Is Flashing Red

Indicator Description Model Possible Causes Corrective Action
• The relay is shipped from the factory with no
Flashing red The GSR safety relay is All configuration. Continue with the configuration process. Rotate the
1 time in configuration mode. • The configuration process was not completed switches to the desired positions and cycle power.
successfully.
• Upon power-up, one or more of the rotary • Return the switches/wiring to their proper settings/
switch settings do not agree with the value terminals and cycle power. (1)
All that is stored in the EEPROM. • Reconfigure the safety relay.
• Connections at S11 and S21 were swapped after
Flashing red Invalid configuration. configuration.
Record the switch setting on
2 times the front face. For example,
the logic setting is set to 3, but
A jumper was added from B1 to B2 after it must be set to 4.
EMD configuration and power was later cycled.

• During configuration, the Logic switch is set

for IN1 OR IN2 (position 1, 3, 5, or 7), but the
inputs are wired for safety mats. • Reconfigure the relays for IN1 AND IN2 (position 2, 4, 6, or 8).
Flashing red Invalid configuration on DI, DIS See Configuration on page 31
3 times DI or DIS safety relay. • If the inputs are not closed during
configuration, the DI and DIS safety relays • See additional information in Safety Mats on page 22.
show this fault on the next power cycle if the
inputs are closed.
• You modified the wiring after configuration.
All • You wired up one or more input connections as
a safety mat. When you stepped on the mat,
the GSR safety relay went to fault mode. • Check the wiring.
Flashing red Cross fault. • Remove the short circuit and cycle the power.
4 times • A short circuit occurred (and is no longer • See additional information in Check Voltage-free Contacts
present) or is present from S11 to S21. on page 58.
CI, DI, DIS, and SI • Excessive capacitance is detected on input
wiring to ground. The pulse tests waveform is
distorted.

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Chapter 11 Troubleshooting

Table 11 - PWR/Fault Status Indicator Is Flashing Red

Indicator Description Model Possible Causes Corrective Action
• A short circuit has occurred, or is present,
from +24V DC (A1) or S11 to L11.
CI
• A short circuit has occurred, or is present,
from 24V Common (A2) to L11when L11 is ON.
• Short circuit from L11 to L12
• Short circuit from L11 to A1 on the next
downstream relay. • Correct the fault and cycle power to the GSR safety relays.
Flashing red Output test has failed
5 times on L11. • The 24V common connection to the • See additional information in Check the Single Wire Safety
downstream relay has temporarily Circuit (Step 4) on page 64.
DI and DIS disconnected.
• One of the downstream relays exhibited a
momentary power interruption.
• For long SWS runs, L11 can pick up noise.
Consider running the SWS signal in shielded
cable.
• Check wiring.
• Remove fault or move high capacitance output connections
Flashing red Output test has failed • External cross fault to 34, 44.
DIS
6 times on 14, 24 (2) • High capacitance load • Cycle power to clear the fault.
• See additional information in OSSD Outputs on page 24.
(1) If you do not know the correct setting, you can rotate the switch to a new setting and cycle power. If the new setting does not agree with the EEPROM, the PWR/Fault indicator continues to
flash 2X red; make a new selection and cycle power again. If the new setting agrees with the EEPROM, the PWR/Fault indicator is steady green, the GSR safety relay functions properly.
(2) DIS safety relays only.

Table 12 - PWR/Fault Status Indicator Is Green with Flashing Red

Indicator Description Model Possible Causes Corrective Action
The safety relay continues to operate, and the
One or more of the rotary switches have changed switches
All can be returned to their original
Green with The configuration does not agree during operation. position, while powered.
flashing red with the EEPROM.
2 times On Version 200, B1 was jumpered to B2 after
configuration. In Version 203, this condition is Remove the jumper and the EMD safety relay
EMD functions properly.
ignored.
B2 is connected to B1, after configuration. The • Remove connection and fault is cleared
Green with fault indication occurs when the EMD output is automatically.
flashing red B1-B2 connection. All energized. If the output is already energized, this
3 times fault will be detected on the next energization of • See additional information in EMD Expansion
the EMD. Safety Relay B1/B2 Inputs (Step 7) on page 74.
Set for non-retriggerable and Logic IN input has
Cycle the Logic In input signal to clear the fault
turned off and then back ON before the time or let the timer expire and the fault clears
Green with expired. automatically.
flashing red Retriggerable input. EMD Repeat the configuration process; the B1-B2
4 times A connection was made from terminals B1 to B2, connection must be made before configuration.
after configuration. See additional information in EMD Expansion
Safety Relay B1/B2 Inputs (Step 7) on page 74.

Check the Power Supply The second troubleshooting step is to check the supply of power to your relay.
(Step 2)
Check Voltage
If the PWR/Fault indicator is OFF, check the voltage by placing a digital
multimeter on terminals A1 and A2 as shown in Figure 58 on page 57.

56 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Chapter 11 Troubleshooting

Figure 58 - Measure Power Supply Voltage

A2
A1 Acceptable Range
A1
20.4…26.4V DC

13 23 33 41
A1 S11 S12 L11 S12 S22
PWR/Fault A1 A2 S11 S21
DMM IN DMM PWR/Fault
IN

24 OUT
24
0 OUT
RESET

Volts Volts
AM 0
RESET
AM
MM
13 23 33 41
MM

14 24 34 42
CI 13 14 23 24

SI

S21 S22 S34 A2

14 24 34 42 L11 Y32 S34
34 14 23 24

A2
SI, DI, DIS, EM,
and EMD

CI

If the voltage is not within the acceptable range, verify that the power supply,
wiring, circuit breakers, and/or fuses are functioning properly.

Verify Grounding at the Power Supply

IEC 60204-1 and NFPA79 require that the 24V is supplied by a PELV-rated
power supply. The 24V common must be connected to protective earth, as
shown in Figure 59. The protective ground connection must only be in one
location and is often best when closest to the power supply.

Ground loops and noise transients on the ground can cause the GSR safety
relays to go into a fault state. This state is hard to capture. One method is to
remove the protective grounding connection between machine ground and
the 24V common temporarily. Then, wait to see if the fault does not occur (wait
time varies). If the fault occurs, then the grounding scheme must be
investigated further.
Figure 59 - 24V Common to Protective Earth Connection
+24V DC

++ -- A1 S11 S12
24V DC

PELV
Power GSR Safety Relay
Supply

L N A2 13

AC
Power +24V Common
Supply Temporarily remove the protective ground
connection for troubleshooting. Reconnect
ground after completing.

IEC 60204-1 edition 5.1 (Section 6.1) allows a SELV supply to be used when a
PELV is not practicable due to physical or operational conditions. NFPA79 does
not allow the use of a SELV supply. If you are meeting only IEC 60204-1, you

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Chapter 11 Troubleshooting

can install a separate SELV supply for your safety system and leave it
ungrounded (no protective ground).

Check Safety Device Inputs This step only applies to CI, DI, DIS, and SI safety relays. Each safety relay has
a status indicator for its inputs.
(Step 3)
Table 13 - Input Indicator
IN, IN1, and IN2 Indicator Status Action
Go to Check the Single Wire Safety
Green Both channels are closed Circuit (Step 4) on page 64.
Off One or both input channels are open Continue with this section.

IMPORTANT The following factors affect the value that is measured at the relay
inputs:
• Voltage-free contacts
• Pulse testing waveforms
• Capacitance
• Length of wire
• Contact resistance
• Channel sequence
Table 14 shows the voltage levels that are viewed on an oscilloscope versus a
digital multimeter.
Table 14 - ON/OFF Voltage
Measurement Device Turn ON Voltage Turn OFF Voltage
Oscilloscope 11V 5V
Digital Multimeter 6…8V 3…4V

Check Voltage-free Contacts

Safety devices (for example; interlock switches, E-stops, or cable pull switches)
with voltage-free contacts must be connected to the pulse testing outputs. You
can use a digital multimeter to measure the input levels.

Check CI Safety Relay

1. With the device contacts open, measure the voltage at the pulse testing
outputs with a digital multimeter, as shown in Figure 60. The voltage
must be 18…19V on both pulse testing outputs of the CI safety relay.
Figure 60 - Typical Voltage Measurements of the CI Safety Relay

DMM
19
DMM Volts
19 S12 S11 S21 S22
Volts
Pulse Testing
Outputs A2

2. Check the voltage at each of the inputs with the device contacts closed, as
shown in Figure 61 on page 59. The values must be very close to the values
measured at terminals S11 and S21.

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 Chapter 11 Troubleshooting

a. If both channels are closed, a voltmeter must read about 19V and the
IN indicator is green. The voltage levels are approximately the same on
Channel 1 (S12) and Channel 2 (S22) because the pulse testing
waveforms are similar on both channels.
b. If only one input is above the turn ON voltage level, then the IN
indicator is red.
c. Try cycling the input device.
d. If the contacts of the safety device do not operate consistently, the
safety device must be replaced.
Figure 61 - Check the CI Safety Inputs with the Device Contacts Closed
DMM
19
DMM Volts
19 S12 S11 S21 S22
Volts
Pulse Testing
A2
Outputs

3. If a significant difference in voltage levels exists, see Capacitance Effect

on page 61 and Long Wire — Resistance Effect on page 62.
To find where the voltage drop is occurring, you have to trace the wiring
of the circuit that is not achieving at least 11V as measured by an
oscilloscope.

Check DI, DIS, and SI Safety Relays

DI, DIS, and SI safety relays can also be checked in a similar fashion. The
voltage of Channel 1 is lower (about 14V) than Channel 2 (about 18V). The
reason for the difference in voltage levels is due to the difference in the pulse
test wave forms (see Figure 65 on page 61). S11 is effectively OFF longer
than S21.
1. Check the safety inputs with the device contacts open, as shown in
Figure 62.

The SI safety relay does not have terminals S32 and S42.

Figure 62 - Typical Voltage Measurements of the DI, DIS, and SI Safety Relays with Contacts Open

Device 1 Device 2

DMM
DMM S11 S21 S12 S22 S32 S42
14 Pulse
18 Testing Input 1 Input 2
Volts Outputs
Volts
A2

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Chapter 11 Troubleshooting

2. Check the voltage at each of the inputs with the device contacts closed.
The values must be very close to the values measured at terminals S11 and
S21.
Figure 63 - Typical Voltage Measurements of the DI, DIS, and SI Safety Relays with Contacts Closed

Device 1 Device 2

DMM
DMM S11 S21 S12 S22 S32 S42
14 Pulse
18 Testing Input 1 Input 2
Volts Outputs
Volts
A2

3. If a significant difference in voltage levels exists, see Capacitance Effect

on page 61 and Long Wire — Resistance Effect on page 62.

Examine Pulse Test Waveforms

If you have an oscilloscope, you can examine the pulse tests. The test pulses are
used to check for short-circuit conditions; the test pulses are not used to turn
the inputs ON and OFF. If they are clean and square, then they are OK.

The test pulses are generated on terminals S11 and S21. The waveforms, which
are shown in Figure 64 and Figure 65 on page 61, must always be present on
their respective relays; the test pulses cannot be turned off or adjusted.
Figure 64 - CI Safety Relay Pulse Test Waveforms

Terminal
S11

Terminal
S21

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Figure 65 - DI, DIS, and SI Safety Relay Pulse Test Waveforms

Terminal S11

Terminal S21

Effect of OSSD Test Pulses

GSR safety relays cannot detect short circuits of OSSD outputs. The PWR/Fault
status indicator of your GSR safety relay remains steady green. The device with
the OSSD outputs must detect short circuits of its own OSSD outputs. When
detected, the device must shut off both OSSD outputs and go to a faulted state.
A status indicator must inform you that the OSSD is faulted. See Devices with
OSSD Output on page 20 for more information.

Detect Off Pulses

When configured for monitored manual (or manual) reset, the GSR safety
relay detects off pulses as described in Table 15.
Table 15 - Off Pulses
Time Description
GSR safety relays always detect when the input device turns OFF. GSR safety relays also
Off time ≥25 ms detect that the input device has turned back ON.
7 ms < Off time < 25 ms When the off pulse is between 7…25 ms, GSR safety relays turn their output OFF, but the
input does not turn back ON. The input must be cycled again.
Off time <7 ms GSR safety relays cannot detect inputs that turn OFF for 7 ms or less.

Test pulses on OSSD outputs are less than 1 ms; therefore the GSR safety relay
ignores the test pulses.

Capacitance Effect
Capacitance leakage of the input wiring to ground causes a deformation of the
leading edge of the pulses. Figure 66 on page 62 shows the deformation with
1 μF on each signal to ground. With this high capacitance, the CI safety relay
still operates.

Capacitance from Ch1 to Ch2 looks the same as Ch1 to ground and Ch2 ground.

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Figure 66 - Capacitive Effect on Pulse Tests

Capacitance causes
deformation of leading edge

Long Wire — Resistance Effect

Long input wiring adds resistance and decreases the input signal voltage.
Figure 67 shows the effects on the pulse tests. Notice that the shape of the
pulses has not changed, only the amplitude. If the wiring is too long, the safety
relay does not turn ON.
Figure 67 - Resistance Effect on Input Signal

Long Wiring adds resistance and

decreases the input signal voltage

GSR safety relays have a maximum input resistance of 900 ohms.

Table 16 on page 63 shows the resistance of wire sizes that are typically used to
connect to safety devices. For example, if you used 200 m (656.2 ft) of a 4-wire
cable that contains 0.33 mm2 (22 AWG) wire, the wire resistance from the relay
pulse test outputs to the safety device and back to the relay inputs, would be:
200 m x 52.94 Ω / 1000 m x 2 directions = 21 Ω

As the example shows, long wires are not a likely cause of safety input issues.

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Table 16 - Wire Resistance

ISO Cross Section AWG Ω Per 1000 m Ω Per 1000 ft
[mm²]
0.33 22 52.94 16.14
0.5 20 33.30 10.15
0.75 18 20.95 6.386
1.5 16 13.18 4.016
2.5 14 8.28 2.525
4 12 5.21 1.588

Channel Simultaneity (Discrepancy)

GSR safety relays have infinite simultaneity (sometimes referred to as
discrepancy). One channel can close (at T1) and the other channel can close
much later (at T2), and the input circuit is satisfied. The order in which the
channels close is not significant; either channel can close before the other (see
Figure 68).
Figure 68 - GSR Safety Relays Have Infinite Simultaneity (Discrepancy)
Closed
Channel 1
Open

Closed
Channel 2

Open

T1 T2 T1 T2
Time Time

 
Multiple-channel Cycling
GSR safety relay inputs are not satisfied if one channel turns ON and OFF
multiple times, followed by the closure of the second channel (see Figure 69).
The input status indicator remains red. This condition is not shown as a fault
condition by the PWR/Fault status indicator. To clear this condition, open both
channels and then reclose them.
Figure 69 - Multiple Cycles on One Channel Are Not Allowed
Closed

Channel 1
Open

Closed
Channel 2
Open

T1 T2 T1 T2
Time Time

 
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Recovery Time
Recovery time is a delay time that is required, measured from when the relay
outputs turned OFF until they can turn back ON again. GSR safety relays have
a 100 ms recovery time specification (see Figure 70).

The GSR family of safety relays has conservative recovery time specifications.
Actual measurements show the recovery time to be as fast as 20 ms. As a result,
recovery time is unlikely to cause spurious trips.
Figure 70 - Recovery Time
Closed

Channel 1
Open

Closed
Channel 2
Open

0 100 0 15 100
Time (ms) Time (ms)

 
Fast input cycling, where both input channels are cycled simultaneously, has
three outcomes:
• Cycles shorter than 7 ms are ignored.
• Cycles of 7...20 ms: An input cycle causes the output to turn off. The IN1
or IN2 indicator is off and the output is off (even with automatic reset).
Repeated cycles of the input at less than 20 ms cause the output to be off
or on, but a true state is always present. An example in automatic reset: If
the inputs are green, the outputs are green, and if one of the inputs is off,
the output is off.
• Cycles longer than 20 ms are processed properly.

Check the Single Wire The Logic IN status indicator represents the single-wire safety (SWS) signal at
terminal L12. The SWS output is terminal L11.
Safety Circuit (Step 4)
Check the Logic IN status indicator.
Table 17 - Logic IN Indicator
Logic IN Indicator Status Action
Go to Check the Reset/Monitoring Circuit
Green L12 input is active (closed) (Step 5) on page 66.
Off L12 input is inactive (open) See SWS Connections L11 and L12.

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SWS Connections L11 and L12

CI and SI safety relays only have SWS outputs (terminal L11); they do not have
SWS inputs.

DI and DIS safety relays have both SWS input and output signals. If you have a
DI or DIS safety relay and the SWS input signal is not used, then the Logic IN
indicator is always OFF. If no wire is connected to terminal L12, then make
sure that the LOGIC switch is set is to either 1, 2, 5, or 6 (switch positions with
OR logic).

EM or EMD expansion safety relays have both SWS input and output signals.
You must connect a wire to L12. Your application requirements determine
whether L11 is used.

Figure 71 shows an example of an SWS connection. Note the L11 terminal

(which is the SWS output) can be connected to multiple L12 terminals (SWS
input), but the L12 terminal cannot be connected to multiple L11 terminals.
Figure 71 - Example SWS Connections
+24V DC +24V DC +24V DC +24V DC +24V DC

A1 A1 A1 A1 A1

CI or SI DI EM DIS EMD

A2 L11 A2 L12 L11 A2 L12 L11 A2 L12 L11 A2 L12 L11

SWS SWS SWS

24V DC Com (must have common reference)

For long wire runs of the SWS signal, a shielded cable can be necessary to help
prevent nuisance faults from electromagnetic and motor noise.
Figure 72 shows the characteristics of SWS signal when it is active. It starts
with a 1 ms pulse, followed 700 μs later by a 500 μs pulse. This waveform is
repeated every 4 ms. When inactive, the SWS is 0V.
Figure 72 - SWS Waveform
Terminals 24V
L11 and L12
0V
0 1 1.7 2.2 4 ms

When the signal is active, use a digital multimeter to measure the voltage. The
digital multimeter shows 8…9V.

If a fault occurs with either an SWS input or SWS output, then that circuit is
held high. If a digital multimeter reads a voltage measurement of
approximately 21V, the signal is high. The PWR/Fault status indicator flashes
red five times.
Figure 73 on page 66 shows an example timing of a momentary interruption of
the SWS input. If a momentary interruption of the SWS signals occurs, the
downstream unit ignores interruptions less than 5.7 ms. The downstream unit
automatically turns off and then back on when the interruption is greater than
5.7 ms.

The momentary interruption does not cause a 'recovery' type fault, where the
output turns off and stays off and requires a further cycling of the SWS signal.

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Figure 73 - Momentary Interruption of SWS Input

Command to open SWS

SWS opens SW closes in 5.7 ms

The Downstream unit

turns off its Output

The Downstream unit

turns its Output back
on auto-reset

Check the Reset/Monitoring The OUT status indicator blinks green when the inputs to the GSR safety relay
are satisfied and the GSR safety relay is ready to turn on its outputs. The OUT
Circuit (Step 5) status indicator flashes green at a 1 Hz rate. The GSR safety relay is waiting for
the appropriate reset signal at terminal S34.

If the OUT status indicator is flashing green, but the relay does not turn on its
outputs when the reset button is pressed, measure the voltage at terminal S34
(point 1) as shown in Figure 74. If 24V is not present when the reset button is
pushed, then check the other connections (points 2...7) in the circuit. If 24V is
present at terminal S34, then you must consider the reset configuration:
• Automatic/Manual: The GSR safety relay must be replaced as the output
indicator must turn steady green as soon as the voltage was present at
terminal S34.
• Monitored/Manual: If the output indicator does not turn steady green
when voltage at S34 is present between 0.25…3 seconds, then GSR safety
relay must be replaced.
Figure 74 - Measure Reset/Monitoring Circuit Voltage
+24V DC
7
6
5
4 DMM


3 24
2 Volts
1
A1 S34

OUT

A2

24V DC Com

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Two-handed Reset Operation

Reset signals for GSR safety relays can be pressed 10 ms after the relay inputs
are satisfied. Therefore, GSR safety relays are useful for application scenarios
such as:
• The application has an E-stop mounted close to the reset button, which
allows you to release the E-stop with one hand and press the reset button
with the other.
• The application allows you to close a safety gate with one hand and press
the reset button with the other hand.

Applications with OSSD Outputs and Test Pulses

If your application uses an OSSD output with test pulses as the source of the
reset signal, the GSR safety relays execute the reset function properly as shown
in Figure 75.

Test pulses are much less than 1 ms long. GSR safety relays ignore test pulses
up to 6 ms in duration. Figure 75 shows a reset signal that is 2500 ms long.
During this time, a 6 ms test pulse occurs. This test pulse is ignored. A test
pulse of 7 ms causes the GSR safety relay to execute the reset function,
provided the test pulse occurs after 250 ms.
Figure 75 - Reset Input Ignores Test Pulses Up to 6 ms
Reset occurs on trailing edge
24V
Ignores Test
Pulse up to
6 ms
0V
0V 2500 ms

Check the Safety Outputs The GSR family of safety relays has two types of outputs:
(Step 6) • Electromechanical outputs: CI, DI, EM, EMD, and SI safety relays
• OSSD outputs: DIS safety relay

Electromechanical Output Issues

If the OUT status indicator is steady green, but the output device does not
energize, begin troubleshooting by measuring the terminal voltage.

Measure the Terminal Voltage

Confirm that voltage is present at the relay terminals and the load. Figure 76
on page 68 shows an example of the measurement points for one output
channel (13/14). Since most safety circuits consist of two channels, repeat the
checking on the second channel (23/24).

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Figure 76 - Measure the Terminal Voltage

+V supply

DMM 1
+Vs 13 23
Volts
OUT

14 24
2

3
A1 A1
K1 K2
A2 A2
4
0V

Step Description
The voltage at 13 must be the same as the supply voltage. If not, check for an open circuit (broken
1 wire), blown fuse, or tripped circuit breaker.
The voltage at 14 must be the same as the supply voltage. If not, the positive-guided relay inside the
2 GSR safety relay is not closing. Measure the contact resistance; see Figure 77 on page 69.
The voltage at A1 must be the same as the supply voltage. If not, check for an open circuit (broken
3 wire) between terminal 14 and A1.
The voltage at A2 must be zero. If not, check for an open circuit between A1 and the voltage supply
4 ground connection. If A2 measures zero volts and A1 measures the supply voltage, then K1 is not
operating properly and must be replaced.

Measure the Contact Resistance

If the voltage at terminal 13 is the same as the supply voltage but terminal 14
measures 0V, measure the contact resistance.

SHOCK HAZARD: Turn off power before power connection is removed if +V

supply is greater than 50V.

Measure the contact resistance to confirm that the relay is not functioning
properly. As shown in Figure 77 on page 69, remove the power wires to
terminal 13 and set the digital multimeter to ohms. Be sure that the OUT status
indicator is green.

The contact resistance must be less than 1 ohm. If it is not, then the internal
positive-guided relay is not functioning properly, and the GSR safety relay
must be replaced.

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Figure 77 - Measure the Contact Resistance

+V supply

SHOCK HAZARD: Remove the

DMM power connections to terminal
<1 23
13 before measuring the
13
contact resistance.
Ohms
OUT

14 24

A1 A1
K1 K2
A2 A2
0V

OSSD Output Issues

If the OUT status indicator is steady green, but the output device that is
connected to terminal 14 or 24 does not energize, begin troubleshooting by
checking the voltage at the output connections. See Check the OSSD
Connections on page 69.
If the OUT status indicator is steady green, but the PowerFlex™ drive is
providing indication that the safety circuit is open, check the connections to
the PowerFlex drive. See Check the PowerFlex Drive Connections on page 70.

Check the OSSD Connections

Confirm that voltage is present at the relay terminals and the load. Figure 78
shows an example of the measurement points for one output channel
(terminal 14). Since most safety circuits consist of two channels, repeat the
checking on the second channel (terminal 24).
Figure 78 - OSSD Output Connections
24V DC supply

A1
DMM
OUT
23
Volts
A2 34 44 14 24
1

2
A1 A1
K1 K2
A2 A2
3

24V common

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Step Description
The voltage at 14 must be slightly less than the supply voltage. If not, then the DIS safety relay must be
1 replaced.
The voltage at A1 must be slightly less than the supply voltage and must be the same voltage as
2 measured at terminal 14. If not, check for an open circuit (broken wire) between terminal 14 and A1.
The voltage at A2 must be zero. If not, check for an open circuit between A1 and the voltage supply
3 ground connection. If A2 measures zero volts and A1 measures the supply voltage, then K1 is not
operating properly, and must be replaced.

Check the PowerFlex Drive Connections

Confirm that voltage is present at the relay terminals and the safety input
terminals of the PowerFlex drive. Figure 79 shows an example of the
measurement points for one output channel (terminal 34). Repeat the checking
on the second channel (terminal 44). The terminal connections from 34 and 44
to S1 and S2 can be reversed.
Figure 79 - Typical Connections to PowerFlex Drive
24V DC supply

A1
DMM
OUT
23 PowerFlex 525
Volts AC Drive

A2 34 44 14 24
1
S1
S2
2
3 4

Motor

24V common

Step Description
The voltage at 34 must be slightly less than the supply voltage. If not, then the DIS safety relay must be
1 replaced.
The voltage at S2 must be slightly less than the supply voltage and must be the same as the voltage at
2 terminal 34. If not, check for an open circuit (broken wire) between terminal 34 and S2.
The voltage at terminal 4 must be zero. If not, check for an open circuit between terminal 4 and the
3 voltage supply ground connection. Figure 80 on page 71 shows how to verify the continuity from
terminal 4 of the drive to terminal A2 of the DIS safety relay.

Figure 80 on page 71 shows the test connections to verify the common

reference between the DIS safety relay and the AC Drive. Remove power from
the application and set the digital multimeter to ohms. If possible, measure
directly at the terminals. The resistance must be less than 1 ohm.

SHOCK HAZARD: Turn power OFF before continuity is tested.

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Figure 80 - Continuity Test of the Voltage Supply Common Connection

24V DC supply

DMM
A1
<1
OUT
Ohms PowerFlex 525
AC Drive

A2 34 44 14 24
S1
S2
4

Motor

24V common

The OSSD test pulses of the DIS safety relay, as viewed by an oscilloscope, are
shown in Figure 81 and Figure 82. Most often, the main transistor triggers the
scope; this test pulse appears on all four terminals simultaneously. The main
transistor pulses are about 110 μs wide. Each channel is tested individually as
shown in Figure 82. The individual pulses are about 50 μs wide. These pulse
widths are provided for informational purposes; the pulses cannot be turned
OFF or adjusted.
Figure 81 - OSSD Main Transistor Test Pulses

110 µs

Figure 82 - OSSD Channel Transistor Test Pulse

Terminal 14, 34
50 µs

50 µs Terminal 24, 44

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Auxiliary Output Issues

Table 18 - Auxiliary Output Issues
State Symptom Action
My PLC does not know that the relay is OFF or my auxiliary status See Measure the Auxiliary Output Terminal Voltage on page 72.
indicator does not turn ON.
The OUT status indicator is The voltage at terminal 41 is the same as the supply voltage. However, See Measure the Contact Resistance on page 72.
OFF. terminal 42 measures 0V.
Terminal Y32 does not turn ON. See Check the Y32 Output on page 73.
Terminal X32 does not turn ON. See Check the X32 Output on page 74.
The Y32 output must be ON. This is true for both faulted and running
The safety outputs are OFF. See Check the Y32 Output on page 73.
states.

For more information on auxiliary outputs, see Auxiliary Output on page 27.

Measure the Auxiliary Output Terminal Voltage

When OUT status indicator is OFF, my PLC does not know that the relay is OFF
or my auxiliary status indicator does not turn ON.
Confirm that voltage is present at the relay terminals and the load. Figure 83
shows an example of the measurement points for one output channel (41/42).
Figure 83 - Measure Voltage Aux Output Terminals
+V supply

DMM 1
+Vs 41
Volts
OUT

PLC
42
Input
2
3
Com
5 4
6
0V

Step Description
The voltage at 41 must be the same as the supply voltage. If not, check for an open circuit (broken
1 wire), blown fuse, or tripped circuit breaker.
The voltage at 42 must be the same as the supply voltage. If not, the positive-guided relay inside GSR
2 safety relay is not closing. Measure the contact resistance; see Figure 84 on page 73.
The voltage at the PLC input must be the same as the supply voltage. If not, check for an open circuit
3 (broken wire), a bad contact at a terminal connection), or go to step 4.
Place the black test probe on the PLC common terminal. Verify that the common of the PLC is
4 connected to the common of the voltage supply.
The aux output voltage at one side of the auxiliary status indicator must be the same as the supply
5 voltage. If not, check for an open circuit (broken wire) between terminal 14 and aux status indicator.
Verify that the aux status indicator is connected to the voltage supply common. The aux status
6 indicator must be replaced.

Measure the Contact Resistance

The OUT status indicator is OFF, and the voltage at terminal 41 is the same as
the supply voltage. However, terminal 42 measures 0V.
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 Chapter 11 Troubleshooting

SHOCK HAZARD: Turn off power before power connection is removed if +V

supply is greater than 50V.

Measure the contact resistance to confirm that the relay is not functioning
properly. As shown in Figure 84, remove the power wires to terminal 41 and set
the digital multimeter to ohms. Be sure that the OUT status indicator is OFF.

The contact resistance must be less than 1 ohm. If it is not, then the internal
positive-guided relay is not functioning properly, and the GSR safety relay
must be replaced.
Figure 84 - Measure Contact Resistance of Aux Output Terminals
+V supply

SHOCK HAZARD: Remove the

DMM power connections to terminal
<1 41 before measuring the
41
contact resistance.
Ohms
OUT

42
PLC
Input

Com

0V

Check the Y32 Output

When OUT status indicator is OFF, terminal Y32 does not turn ON, or when
the safety outputs are OFF, the Y32 output must be ON. This is true for both
faulted and running states.

Use a digital multimeter to measure the voltage at Y32 (point 1 in Figure 85).
The voltage must be around 23V DC. Figure 85 shows a typical schematic for
the aux output; the aux signal can go to a PLC input or to an indicator on a
control panel. If it is 23V, then check the remaining points (2…5). If Y32
measures 0V, then the relay must be replaced.
Figure 85 - Measure Y32 Voltage
+24V DC

CI, DI, DIS, or SI

A1
DMM
23 PWR/Fault
OUT
Volts
PLC
A2 Y32
Input
1
2
Com
4 3

5
0V

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Check the X32 Output

When OUT status indicator is OFF, terminal X32 does not turn ON.
This is proper operation for the EM and EMD safety relays if they are in a
nonrecoverable faulted state. If so, then the PWR/Fault status indicator is steady
red or flashing red.
Correct the fault and cycle power. The relay must be reconfigured to correct
the fault.

If the PWR/Fault status indicator is green, then measure the voltage at

terminal X32 with a digital multimeter. Figure 86 shows a typical usage of X32
(point 1) as the source for the monitoring circuit. The voltage must be around
23V DC. If it is 23V, then follow the circuit and check the voltage at each of the
remaining points (2…6). If X32 measures 0V, then the relay must be replaced.
Figure 86 - Measure X32 Voltage
+24V DC

EM or EMD CI, DI, DIS, or SI

A1 A1
DMM PWR/Fault PWR/Fault
23
OUT OUT
Volts
A2 X32 A2 S34
1 6

2 3 4 5

0V

EMD Expansion Safety Relay Figure 87 on page 75 shows the waveform from B1 to B2. This waveform is the
same as the single wire safety waveform. The waveform is present only when
B1/B2 Inputs (Step 7) the output of the EMD expansion safety relay is ON. With a digital multimeter,
the voltage measures 8…9V DC.

If the B1 status indicator is on, but no voltage is read, the expansion relay must
be replaced.
For more information on retriggerable inputs, see See Retriggerable Input on
page 29.

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Figure 87 - The B1-B2 Waveform When the EMD Safety Relay Output is ON

Terminal Block Removal Terminal blocks can be replaced following these instructions.
and Replacement
Terminal Block Removal
GSR safety relays have removable terminal blocks. Use a screwdriver as a lever
to remove the blocks. As shown in Figure 88, insert the screwdriver into the
slot and pry up.
Figure 88 - Terminal Block Removal

1. Insert 2. Pry Up

Terminal Block Replacement

The terminal blocks are keyed to help prevent a block from being inserted into
an incorrect location. The orange-colored insert provides the orientation of the
key (see Figure 89 on page 76).

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Figure 89 - Orange-colored Keyway

Orange inserts
match keys

Series, Version, and The product label differs slightly depending on when you purchased your relay.
Manufacturing Date Code
Current Product Label
The series, firmware revision number, and manufacturing date code are
identified on the safety relay label, as shown in Figure 90.
Figure 90 - Product Label - Series and Revision Identification
Manufactured during
the 18th week of 2015

Old Product Label

The initial production runs of GSR safety relays excluded a firmware revision
number, as shown in Figure 91.
Figure 91 - Early Version of Product Label

Manufactured during
the 34th week of 2012

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 Appendix A

Specifications

General Specifications
Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI)
Dimensions, HxWxD [mm (in)] 119.14 x 22.5 x 113.6 (0.88 x 4.69 x 4.47)
Shipping Weight, Approx. [g 225 (0.5) 180 (0.4) 50 (0.33) 225 (0.5) 220 (0.49) 150 (0.33)
(lb)]
Wire Size [mm² (AWG)] 0.2…2.5 (24…14)
Wiring Category Copper that withstands 75 °C (167 °F)
Terminal Screw Torque
0.4 (4)
[N·m (lb·in)]
Power Supply Voltage Range 24V DC PELV/SELV, 0.85…1.1 x rated voltage
Power On Delay [s] 5.5
Power Consumption [W] 3.5 2.5 2 3.5 3.5 2.5
Case Material Polyamide PA 6.6
Terminal Protection IP20
Enclosure Protection IP40 (NEMA 1)
Mounting 35 mm (1.38 in.) DIN rail in enclosure that is rated to a minimum of IP54

Environmental Specifications
Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI)
Temperature, Operating [°C
(°F)] -5…+55 (23…131)
Relative Humidity 90%
Vibration 10…55 Hz, 0.35 mm (0.01 in.)
Shock 10 g, 16 ms
Pollution Level 2
Installation Group Overvoltage Category III, VDE 0110-1
Impulse Withstand Voltage 2500V

Safety Inputs IN, IN1, and IN2 Specifications

Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI)
Inputs 1 NC, 1 PNP (OSSD) 2 NC, 2 PNP (OSSD) 2 NC, 2 PNP (OSSD) — — 1 NC, 1 PNP (OSSD)
Wiring Terminals S12, S22 S12, S22, and S32, S42 S12, S22, and S32, S42 — — S12, S22
Max [V] 26.4 — — 26.4
ON Voltage
Min [V] 11 — — 11
OFF Voltage, Max [V] 5 — — 5
OFF Current, Max [mA] 2 — — 2
ON Current, At 24V DC [mA] 11.0 — — 11.0
Max At 26.4V DC [mA] 11.1 — — 11.1
Galvanic Isolation: I/O from
No — — No
Logic
Overvoltage Protection Yes — — Yes

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 77

Appendix A Specifications

Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI)
Test Out Duration [ms] 2.5 1.5, 3 — — 1.5, 3
Pulse Period [ms] 14 13.6 — — 13.6
Off Pulse Accepted for OSSD
Setting Without Declaring the 3.1 2.2 — — 2.2
Input as OFF, Max [ms]
Recovery Time, Min [ms] 30 — — 30
Reverse Voltage Protection Yes — — Yes
Input Capacitance [nF] 10 — — 10
Input Simultaneity Infinite — — Infinite
Allowable Input Resistance,
900 — — 900
Max (Ω)
Allowable S11 to S21 350 160 — — 160
Cable
Capacitance, S11 to Ground 350 320 — — 320
Max [nF] S21 to Ground 350 320 — — 320
Safety Mat, Max Size [m²] 23 35 — — 35

Reset Input Specifications

Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI)
Wiring Terminal S34 — — S34
Max [V] 26.4 — — 26.4
ON Voltage
Min [V] 11 — — 11
OFF Voltage, Max [V] 5 — — 5
OFF Current, Max [mA] 2 — — 2
ON Current, At 24V DC [mA] 11.0 — — 11.0
Max At 26.4V DC [mA] 11.1 — — 11.1
Galvanic Isolation:
No — — No
I/O from Logic
Overvoltage Protection Yes — — Yes
Input Capacitance [nF] 10 — — 10
Duration [s] 0.5…3.0 — — 0.5…3.0

B1 Input Specifications
Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI)
Wiring Terminal — — — — B1 —
Max [V] — — — — 26.4 —
ON Voltage
Min [V] — — — — 11 —
OFF Voltage, Max [V] — — — — 5 —
OFF Current, Max [mA] — — — — 2 —
ON Current, At 24V DC [mA] — — — — 11.0 —
Max At 26.4V DC [mA] — — — — 11.1 —
Galvanic Isolation: I/O from
Logic — — — — No —

Overvoltage Protection — — — — Yes —

Input Capacitance [nF] — — — — 10 —

78 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Appendix A Specifications

Safety Outputs Specifications

Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI)
13/14, 17/18,
Wiring Terminal 13/14, 13/14, 23/24 14, 24, 23/24, 27/28, 13/14, 23/24
23/24, 33/34 34, 44
33/34, 43/44 37/38, 47/48
Output Type 3 N.O. 2 N.O. 4 PNP 4 N.O. 4 N.O. delayed 2 N.O.
Thermic Current Ith 1x6A — 1x6A
Fuses output (external) 6 A slow blow or 10 A quick blow — 6 A slow blow or 10 A quick blow
Switched Current, Min [mA] 10 — 10
Switched Voltage, Min [V] 10 — 10
Mechanical Life 10,000,000 cycles — 10,000,000 cycles
UL: C300
UL: C300 UL: B300
Rating AC-15: 1.5 A / 250V AC 14, 24: 1.5 A each AC-15: 1.5 A / 250V AC AC-15: 1.5 A/ 250V AC
34, 44: 0.5 A each DC13: 2 A/24V DC (0.1
DC13: 2 A / 24V DC (0.1 Hz) DC13: 2 A / 24V DC (0.1 Hz) Hz)
14, 24: 1.6 µF each
Capacitance — —
34, 44: 9 µF each
Contact material AgNi AgNi + 0.2 µ Au — AgNi
Reaction Time L12 45 35
Safety Output Inputs 150 35 25 100 150 150
[ms]
Mat Operation 40 30
Reaction Time L12 — 35 35 —
Single Wire
Safety Output Inputs 25 25 25 0 150 25
[ms] Mat Operation 30 30 30 30
Response Inputs 35 35 25 35
Time
Safety Output 35
Mat Operation 45 40 30 45
[ms]
Response Inputs 25 25 25 25
Time
Single Wire Mat Operation 35 30 30 25 35
Safety Output Single-wire 45 45 45 45
[ms] Fault
Recovery Time [ms] 100 100 100 150 150 100

Auxiliary Output Specification

Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI)
Wiring Terminal — Y32 X32 Y32
Output Type 1 N.C. 1 PNP, 50 mA max

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 79

Appendix A Specifications

Single Wire Safety (SWS) Specifications

Attribute 440R-S13R2 (CI) 440R-D22R2 (DI) 440R-D22S2 (DIS) 440R-EM4R2 (EM) 440R-EM4R2D (EMD) 440R-S12R2 (SI)
Output - L11
Wiring Terminal Input - L12
Continuous Output Current,
50
Max [mA]
ON State Voltage Drop 0.2
(P/S to +), Max [V]
Surge Output Current, Max [mA] 700
Surge Output Current Duration,
Max [ms] 5

Load Capacitance, Max [µF] 1

Off State Leakage Current, Max
< 0.1
[mA]
Short Circuit Detection No
Short Circuit Protection Yes
Galvanic Isolation: No
I/O from Logic
Fanout (Max number of
connections to L11) 10

Cable length between L11 and

30
L12 [m]

80 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Appendix A Specifications

Notes:

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 81

Appendix A Specifications

82 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Appendix B

Regulatory Approvals

Agency Certifications • UL Listed Industrial Control Equipment, certified for US and Canada.
• CE marked for all applicable directives
• C-Tick marked for all applicable acts
• CCC Mark
• S-Mark

Compliance with European This product has the CE marking and is approved for installation within the
European Union and EEA regions. It has been designed and tested to meet the
Union Directives following directives.

EMC Directive
This product is designed and tested to meet the European Council Directive
2004/108/EC on Electromagnetic Compatibility (EMC) and the following
standards:
• EN 61000-6-4: Generic Standards - Emission Standard for Industrial
Environments
• EN 61000-6-2: Generic Standards - Immunity for Industrial
Environments

This product is intended for use in an industrial environment.

Machine Safety Directive

This product is designed and tested to meet the European Council Directive
2006/42/EC on machinery and the following standards.
• IEC/EN 61508 - Functional safety of electrical/electronic/programmable
electronic safety-related systems
• IEC/EN 62061 - Safety of machinery - Functional safety of safety-related
electrical, electronic, and programmable electronic control systems
• EN ISO 13849-1 - Safety of machinery -- Safety-related parts of control
systems -- Part 1: General principles for design

This product is intended for use in an industrial environment.

The performance of the safety function is dependent on the structure of all

devices that comprise the safety function. Table 19 on page 84 and Table 20 on
page 84 provide the data that must be used to represent safety relays when
calculating the safety integrity level (SIL) or the Performance Level (PL).

Safety relays can be used in safety circuits according to DIN EN 60204-1/VDE

0113 part 1. The following safety requirements are achievable in maximum
based on the operation mode and wiring.

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 83

Appendix B Regulatory Approvals

Specifications are applicable only if the safety function is demanded at least

once within six months. All diagnostic tests are conducted at least before next
demand. At mission time (TM), the proof test interval (PTI) is assumed.
Components failure rates are according to SN29500.

SIL Rating
Safety relays meet the requirements in Table 19 in accordance with
IEC/EN 61508 and IEC 62061.
Table 19 - SIL Rating
440R-S13R2 440R-D22R2 440R-D22S2 440R-EM4R2 440R-EM4R2D 440R-S12R2
(CI) (DI) (DIS) (EM) (EMD) (SI)
PFHd (1/h) 4.39 E-09 4.49 E-09 4.39 E-09 1.52 E-09 4.55 E-09 3.98 E-09
Safety Integrity Level Claim 3
Limit
Mode of Operation High demand
Hardware Fault Tolerance 1
Safe Failure Fraction 99%

Performance Level/Category
Safety relays can be used in safety systems that meet up to Category 4 and
Performance Level PLe in accordance with ISO 13849-1.
Table 20 - Performance Level/Category
440R-S13R2 440R-D22R2 440R-D22S2 440R-EM4R2 440R-EM4R2D 440R-S12R2
(CI) (DI) (DIS) (EM) (EMD) (SI)
MTTFd 164 355 484 190 165 262
Category Up to 4
Performance Level Up to e
DC avg 99%
Mission Time 20 years
Days of Operation 365 days
Hours of Operation 24 hr
T cycle 8 hr / 8.28 s

84 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Index

A contact
resistance 72
add-on profile voltage-free 58
Studio 5000 Logix Designer 52 cycling
adjustment
multiple-channel 63
switch 31
agency certifications 83
AOP D
Studio 5000 Logix Designer 52 date code
application
manufacturing 76
examples 45 detect
CI safety relay 45
off pulse 61
DI safety relay 46
devices
DIS safety relay 47
EM safety relay 48 mechanical contacts 19
EMD safety relay 48 safety, OSSD output 20
SI safety relay 50 DI safety relay
approvals overview 10
regulatory 83 safety mat 46
assignments switch adjustment 32
terminal 17 diagnostics
automatic indicators 36
diagram
reset 28
auxiliary output 27, 72 internal circuit block 43
CI safety relay 43
issues 72
DI safety relay 43
specifications 79
DIS safety relay 43
EM safety relay 44
B EMD safety relay 44
SI safety relay 44
B1 input dimensions
specifications 78 mounting 13
DIN rail 13
mounting 13
C removal 13
capacitance effect 61 directive
category 84 EMC 83
certifications European Union 83
agency 83 machine safety 83
DIS safety relay
channel simultaneity 63
overview 10
check switch adjustment 32
power supply 56 discrepancy 63
safety device input 58
safety output 67
single wire safety circuit 64 E
voltage 56
CI safety relay effect
overview 10 OSSD test pulse 61
circuit block diagram 43, 44 electromechanical
communication output 24
Ethernet 51 electromechanical output
compliance issues 67
European Union (EU) directives 83 EM safety relay
configuration 31 overview 10
process 33 EMC
connect directive 83
power supply 19 EMD safety relay
considerations overview 10
enclosure 14 switch adjustment 32
timing functions 39
enclosure
considerations 14

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 85

Index

environmental indicators
specifications 77 diagnostics 36
Ethernet normal operation 35
communication 51 powerup 35
European Union (EU) directives status 35
compliance 83 input
examples jog 30
application 45 monitor 27
CI safety relay 45 pulse testing 37
DI safety relay 46 CI safety relay 37
DIS safety relay 47 DI, DIS, and SI safety relay 37
EM safety relay 48 reset 27
EMD safety relay 48 retriggerable 29
SI safety relay 50 safety 19
wiring 45 single wire safety 26
CI safety relay 45 SWS 26
DI safety relay 46 installation 13
DIS safety relay 47 internal circuit block
EM safety relay 48 diagram 43
EMD safety relay 48 CI safety relay 43
SI safety relay 50 DI safety relay 43
excessive heat DIS safety relay 43
prevent 15 EM safety relay 44
expansion relays EMD safety relay 44
monitor 29 SI safety relay 44

F J
features jog 41
hardware 9 input 30
functions
pulse testing 37 L
label
G product (current) 76
general product (old) 76
long wire 62
specifications 77
ground 17, 57
relay 19 M
Guardmaster safety relay
CI 10, 43, 45 machine safety
DI 10, 32, 43, 46 directive 83
DIS 10, 32, 43, 47 manual
EM 10, 44, 48 reset 28
EMD 10, 32, 39, 44, 48 manufacturing date code 76
SI 11, 44, 50 mats
safety 22
mechanical contacts
H devices 19
hardware monitor
features 9 expansion relays 29
heat input 27
prevent excessive 15 monitored reset 28
mounting
dimensions 13
I DIN rail 13
indicator multiple-channel
PWR/fault 54 cycling 63
flashing red 55 multi-position
green with flashing red 56 switch 9
solid red 55

N
non-retriggerable
off delay 39
86 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021
 Index

normal operation R
indicators 35
rating
SIL 84
O recommendation
wiring 17
off delay
recovery time 64
non-retriggerable 39
retriggerable 40 regulatory approvals 83
off pulse relay
detect 61 ground 19
on delay 40 removable
optical communication bus 10 rerminals 14
terminal blocks 9
OSSD output 24
removal 13
issues 69
safety devices 20 terminal block 75
replacement
OSSD outputs
terminal block 75
pulse testing 38
requirements
OSSD test pulse
wiring 17
effect 61
rerminals
output
removable 14
auxiliary 27, 72
reset
issues 72
electromechanical 24 automatic 28
OSSD 24 input 27
safety 24 input, specifications 78
single wire safety 26 manual 28
SWS 26 monitored 28
X32 74 resistance
overview 9 contact 72
CI safety relay 10 resistance effect 62
DI safety relay 10 retriggerable
DIS safety relay 10 input 29
EM safety relay 10 off delay 40
EMD safety relay 10
SI safety relay 11
S
P safety
input 19
performance level 84 mats 22
power 17 output 24
power supply safety device input
check 56 check 58
connect 19 safety inputs IN, IN1, and IN2
ground 57 specifications 77
powerup safety mat
indicators 35 DI safety relay 46
prevent safety output
excessive heat 15 check 67
process electromechanical output
configuration 33 issues 67
product label OSSD output
current 76 issues 69
old 76 safety outputs
pulse testing specifications 79
functions 37 safety relay
input 37 CI 10, 43, 45
CI safety relay 37 DI 10, 32, 43, 46
DI, DIS, and SI safety relay 37 DIS 10, 32, 43, 47
OSSD outputs 38 EM 10, 44, 48
PWR/fault status indicator 54 EMD 10, 32, 39, 44, 48
flashing red 55 SI 11, 44, 50
green with flashing red 56 series 76
solid red 55 SI safety relay
overview 11

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 87

Index

SIL torque
rating 84 terminal 17
simultaneity troubleshooting 35
channel 63 steps 53
single wire safety
input 26
output 26 V
specifications 80 version 76
single wire safety circuit voltage
check 64 check 56
spacing 14 voltage-free contact 58
specifications 77
auxiliary output 79
B1 input 78 W
environmental 77
general 77 web page 51
reset input 78 wire 17
safety inputs IN, IN1, and IN2 77 size 17
safety outputs 79 wiring
single wire safety 80 examples 45
SWS 80 CI safety relay 45
status indicator DI safety relay 46
PWR/fault 54 DIS safety relay 47
flashing red 55 EM safety relay 48
green with flashing red 56 EMD safety relay 48
solid red 55 SI safety relay 50
status indicators 9, 35 recommendation 17
diagnostics 36 requirements 17
normal operation 35
powerup 35
steps X
troubleshooting 53 X32 output 74
Studio 5000 Logix Designer
add-on profile (AOP) 52
suppressors
surge 25
surge suppressors 25
switch
adjustment 31
DI safety relay 32
DIS safety relays 32
EMD safety relay 32
multi-position 9
SWS
input 26
output 26
specifications 80
SWS circuit
check 64

T
terminal
assignments 17
torque 17
terminal block
removal 75
replacement 75
terminal blocks
removable 9
time
recovery 64
timing functions
EMD safety relay 39
tools 53

88 Rockwell Automation Publication 440R-UM013F-EN-P - July 2021

 Guardmaster Safety Relays User Manual

Rockwell Automation Publication 440R-UM013F-EN-P - July 2021 89

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