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Tech Data

Safety Functions Documents

E-stop, guarding, or presence sensing function are machine safety functions that require multiple elements. The elements include a sensor or input device, a logic device, and an output device. We provide guidance for specific safety functions that are based on functional requirement, equipment selection, and Performance Level requirement.

Built with you in mind, these safety functions minimize risk and speed development. Examples of the information that is provided in our safety functions documents include:

  • Set-up and wiring
  • Bill of materials
  • Wiring schemes
  • Configuration
  • Verification and validation plan
  • Calculation of Performance Level

Search for a document by common applications, or by products and safety rating standards.

Safety Functions Documents

Access and Door Guarding

Name & Operation Description Safety Ratings Products

Cat. 4, PLe Stop Category 0 using Programmable Controller, SensaGuard Interlock Switches, and Safety Motor Controller

This safety function is designed using a Compact GuardLogix® controller and ArmorBlock® Guard I/O™ module to monitor a safety gate interlocked with a SensaGuard™ safety switch. When the safety gate is opened or a fault is detected in the monitoring circuit, the safety controller de-energizes the final control device.

 Cat. 4, PLe to
EN ISO 13849-1: 2015
  • GuardLogix 5570 Controller or Compact GuardLogix 5370 Controller
  • ArmorBlock Guard I/O Module
  • SensaGuard Switch
  • ArmorStart ST Motor Controller (Safety Version)

Configurable Controller for Guard Door Interlocking

This safety function is designed using a configurable controller, safety interlock switch, and safety contactors.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • SensaGuard Switch
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • 100S-C Safety Contactors

Door Locking and Monitoring with a 442G Access Box and an Integrated Safety Controller

This safety function explains how to wire, configure, and program a GuardLogix® controller and POINT Guard I/O™ module to lock and monitor a 442G Multifunctional Access Box (MAB) mounted on a Power-to release door. If the door is opened or unlocked, or a fault is detected in the safety function, the GuardLogix controller de-energizes the final control device, a redundant pair of 100S contactors.

 Cat. 4, PLe to
EN ISO 13849-1: 2015
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • 442G Multifunctional Access Box
  • POINT Guard I/O Safety Modules

Door Locking and Monitoring via a TLSZR-GD2 Guard-locking Switch Safety Function Application Technique

This safety function application technique explains how to wire, configure, and program a GuardLogix® controller and POINT Guard I/O™ module to monitor and lock a TLSZR-GD2 guard locking switch that is mounted on a door. If the gate is opened or unlocked, or a fault is detected in the monitoring circuit, the GuardLogix controller de-energizes the redundant pair of 100S-C contactors.

 Cat. 4, PLe to
ISO 13849-1: 2015
  • GuardLogix Controller
  • TLSZR-GD2 Guard-locking Switch
  • POINT Guard I/O Safety Modules
  • 100S-C Contactors

Door-monitoring Interlock Switch with an Integrated Safety Controller

This safety function explains how to wire, configure, and program a GuardLogix® controller and POINT Guard I/O™ module to monitor a safety gate by using a SensaGuard™ safety switch. If the safety gate is opened, or if a fault is detected in the monitoring circuit, the GuardLogix controller de-energizes the final control device.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • POINT Guard I/O Safety Module
  • SensaGuard Switch

Enabling Switch with an Integrated Safety Controller and a POINT Guard I/O

This safety function explains how to wire, configure, and program a Compact GuardLogix® controller and POINT Guard I/O™ module to monitor an enabling switch. The operator squeezes the enabling switch to the middle position to bypass the primary, safety door interlock. This action allows the Compact GuardLogix controller to energize the final control device, a redundant pair of 100S contactors.

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • POINT Guard I/O Safety Module
  • 440J Enabling Switch
  • 440K Interlock Switch

Guard Door Interlocking Safety Function Application Technique

This application technique explains how to wire, configure, and program a GuardLogix® 5580 controller and two Compact 5000™ I/O modules to monitor a safety gate by using a SensaGuard safety switch. If the safety gate is opened or a fault is detected in the monitoring circuit, the GuardLogix controller de-energizes the 100S contactors.

 Cat. 3, PLd to
ISO 13849-1: 2015
  • GuardLogix 5580 or Compact GuardLogix 5380 Controller
  • 5069 Compact I/O Safety Module
  • SensaGuard switch

Programmable Controller for Guard Door Interlocking

This safety function is designed using a programmable controller, safety I/O, safety interlock switch, and safety contactors.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Trojan 5 Switch
  • GuardLogix Controller

Programmable Controller for Guard Door Interlocking and Enabling Switch Bypass

For partial body access applications with slow machine speed, the operator squeezes the enabling switch to the middle position to bypass the primary safety door interlock. This safety function is designed using a programmable controller, safety I/O, safety enabling switch, safety interlock switch, and safety contactors.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • 440J Enabling Switch
  • GuardLogix Controller
  • POINT Guard I/O Safety Module

Programmable Controller for Locking Closed Guard Door

This safety function is designed using a programmable controller, safety I/O, safety interlock switch with guard locking function and safety contactors.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • TLS3-GD2 Interlock Switch
  • GuardLogix Controller
  • POINT Guard I/O Safety Modules

Programmable Controller with Hinge Interlock Switch

This safety function is designed using Ensign 3 hinge interlock switches and Compact GuardLogix controllers.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Ensign 3 Hinge Interlock Switch
  • GuardLogix Controller

Programmable Controller with Interlock Switch and Safety Rated Variable Frequency Drive

This safety function is designed using a programmable controller with an interlock switch to a safety rated variable frequency drive.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Trojan 5 Interlock Switch
  • GuardLogix Controller
  • POINT Guard I/O Safety Modules
  • PowerFlex 525 Drive with Safe Torque Off

Programmable Controller with Non-Contact Interlock Switch

This safety function is designed using SensaGuard interlock switches and Compact GuardLogix controllers.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • SensaGuard Switch
  • GuardLogix Controller

Programmable Controllers with Non-Contact Magnetically Coded Interlock Switches

This safety function is designed using MC1 magnetic-coded non-contact interlock switches and Compact GuardLogix controllers.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • MC1 Magnetic-coded Switch
  • GuardLogix Controllers

Safe-monitored Access via a 442G Access Box and a Guardmaster 440C-CR30 Configurable Safety Relay Safety Function Application Technique

This document explains how to wire, configure, verify, and validate a safety system that is designed to provide safe, monitored, full-body access into a hard-guarded area only when hazardous motion within the area has ceased. The primary components that are used are a 442G multifunctional access box (MAB), a Guardmaster® 440C-CR30 configurable safety relay, and two 100S safety contactors.

 Cat. 4, PLe to
ISO 13849-1: 2015
  • 442G Access Box
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • 100S-C Contactors

Safe-monitored Access via a 442G Access Box and a Guardmaster GLP Safety Relay Safety Function Application Technique

This document explains how to wire, configure, verify, and validate a safety system that is designed to provide safe, monitored access into a hard-guarded area only after hazardous motion within the area has ceased. The system includes, and is specific to, a multifunctional access box (MAB), a Guardmaster® GLP safety relay, and 100S contactors as its primary devices. The GLP safety relay monitors two proximity sensors to determine the speed of hazardous motion and the state of the MAB to determine when the monitored motion is at a safe speed before allowing access to the guarded area by unlocking the MAB. The GLP safety relay monitors the proximity sensors, the MAB, and itself for faults. When a fault is detected, the GLP does not unlock the MAB to prevent access to the guarded area until the fault is corrected.

 Cat. 3, PLd to
ISO 13849-1: 2015
  • 442G Access Box
  • Guardmaster GLP Safety Relay
  • 100S-C Contactors

Safe Speed Monitoring using Programmable Controller, MSR57P Safety Relay, and a Kinetix Drive on EtherNet/IP

This safety function explains how to wire, configure, and program a GuardLogix® safety controller, a POINT Guard I/O™ module, and a Kinetix drive with integrated Safe Torque Off (STO) on EtherNet/IP™ to interface to a MSR57P speed monitoring safety relay to perform safe speed functions.

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • POINT Guard I/O Safety Modules
  • MSR57P Speed Monitoring Safety Relay
  • TLS-Z GD2 Guard Locking Switch
  • Kinetix 5500 or 5700 Servo Drive with Integrated Safety on EtherNet/IP
  • MP-Series Low Inertia Servo Motor

Safety Relay for Guard Door Interlocking and Enabling Switch Bypass

For partial body access applications with slow machine speed, the operator squeezes the enabling switch to the middle position to bypass the primary safety door interlock. This safety function is designed using a safety relay, safety enabling switch, safety interlock switch and safety contactors.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • 440J Enabling Switch
  • Guardmaster Single-input Safety Relay
  • Guardmaster Dual-input Safety Relay

Safety Relay for Locking Closed Guard Door

This safety function is designed using a safety relay, safety interlock switch with guard locking and safety contactors.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • Guardmaster Dual-input Safety Relay
  • Guardmaster Expansion Module
  • TLSZR-GD2 Safety Guard Locking Switch
  • E-Stop Button

Safety Relay with Door Interlock

This safety function is designed using a safety relay with a door interlock.

 Cat. 4, PLe to
EN ISO 13849-1 2008
  • SensaGuard™ / GSR DI

Safety Relay with Door Switch Monitoring

This safety function is designed using a safety relay with door switch monitoring.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • MC1 Magnetically-coded Door Switch
  • Guardmaster Dual-input Safety Relay

Safety Relay with Interlock Switch and Safe Limited Speed Variable Frequency Drive

This safety function is designed using a safety relay with an interlock switch and using an AC drive with safe limited speed.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • TLSZR-GD2 Guard Locking Switch
  • Guardmaster Safety Relay
  • PowerFlex 70 Drive

Safety Relays with Hinge Interlock Switch

This safety function is designed using Ensign 3 hinge interlock switches and Guardmaster dual-input safety relays.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Ensign 3 Hinge Interlock Switch
  • Guardmaster Dual-input Safety Relay

Safety Relays with Interlock Switch and Safety Rated AC Drives

This safety function is designed using Trojan 5 interlock switches, Guardmaster safety relays and PowerFlex® 525 AC Drives with Safe Torque Off.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • E-Stop Button
  • Trojan 5 Interlock Switch
  • Guardmaster® Safety Relay
  • PowerFlex® 525 Drive with Safe Torque Off

Safety Relays with Non-Contact Interlock Switch with Emergency Stop

This safety function is designed using Guardmaster dual-input safety relays and SensaGuard interlock switches.

 Cat. 4, PLe to
EN ISO 13849-1: 2008
  • Guardmaster Dual-input Safety Relay
  • SensaGuard Switch

Stop Category 0 or 1 Using Programmable Controller and Kinetix Drive with Integrated Safe Torque Off on EtherNet/IP Networks

This document explains how to use a GuardLogix® controller and configure the Kinetix® drive with integrated safe torque off subsystems of a safety function. The GuardLogix controller de-energizes the final control devices. The final control element is de-energized immediately for a stop category 0, and a delay is introduced before de-energizing for a stop category 1.

 Cat. 3, PLe to
EN ISO 13849-1: 2015
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • Kinetix 5500 or Kinetix 5700 Servo Drive

Zero Speed, Safe Limited Speed, and Safe Direction

This safety function explains how to wire, configure, and program a Compact GuardLogix® controller and a POINT Guard I/O™ module to interface with a PowerFlex® 750 safe speed monitor option (-S1) module to perform safe speed functions.

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • PowerFlex 750 Safe Speed Monitor Option Module
  • TLS3-GD2 Switch
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • POINT Guard I/O Safety Modules

Zero Speed, Safe Limited Speed, and Safe Direction Safety Function using Programmable Controller with Guardlocking and AC Drive

This safety function uses a safety relay with a programmable controller with guardlocking and an AC Drive with Zero Speed/Safe Limited Speed/Safe Direction.

 Cat. 3, PLd to
EN ISO 13849-1: 2008
  • PowerFlex 750 Safe Speed Monitor Option Module
  • TLS3-GD2 Switch
  • GuardLogix Controller
  • POINT Guard Safety I/O Modules



Emergency Stop

Name & Operation Description Safety Ratings Products

Cat. 4, PLe Stop Category 0 Using Single-Input Safety Relay and Cable Pull Safety Switch

This safety function is designed using a Guardmaster® single-input safety relay to monitor a pair of Lifeline™ 5 cable pull safety switches. When a demand is placed on a cable pull switch or a fault is detected in the safety function, the safety relay de-energizes the contactors, removiong power from the controlled motor to perform a stop category 0 (coast to a stop).

 Cat. 4, PLe to
EN ISO 13849-1: 2015
  • Guardmaster Single-input Safety Relay
  • Lifeline 5 Cable Pull Safety Switch
  • 100S-C Safety Contactor

Configurable Controller for Emergency Stop to PLe / Cat. 4

This safety function is designed using a configurable controller, E-Stop push button and safety contactors.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • Emergency Stop
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • 100S-C Safety Contactors

Configurable Controller for Emergency Stop to PLd / Cat. 3

This safety function is designed using a configurable controller, E-Stop push button, a cable pull switch and safety contactors.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Lifeline 4 Cable Pull Switch
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • 100S-C Safety Contactors

Configurable Safety Relay and Cable Pull Switch

This safety function is designed using a Guardmaster® 440C-CR30 configurable safety relay with a Guardmaster 440C-ENET plug-in Ethernet module to provide an emergency stop safety function. The 440C-CR30 relay monitors a Lifeline™ 5 cable pull switch and controls two redundant 100S safety contactors. When the cable is pulled or severed, or a fault is detected, the 440C-CR30 relay de-energizes the two contactors, which removes power from the controlled motor. Hazardous motion coasts to an uncontrolled, stop category 0.

 Cat. 4, PLe to
EN ISO 13849-1: 2015
  • Lifeline 5 Cable Pull Switch
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • Guardmaster 440C-ENET Ethernet Module

Emergency Stop: Integrated Safety Controller Connected to a Series of Dual-Channel Emergency Stop Buttons

This safety function explains how to wire, configure, and program a Compact GuardLogix® controller and POINT Guard I/O™ module to monitor a series of dual-channel safety E-Stop devices. If any E-Stop is actuated, or a fault is detected in the monitoring circuit, the Compact GuardLogix controller de-energizes the final control device

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • GuardLogix® 5570 or Compact GuardLogix 5370 Controller
  • POINT Guard I/O Safety Module
  • Dual-channel E-Stop Button

GuardLink Safe Stop Safety Function Application Technique

This safety function application technique explains how to connect, configure, and test a Guardmaster® 440R-DG2R2T safety relay (DG safety relay) to monitor two GuardLink® circuits. Two E-stops are installed on each of two GuardLink circuits. If either of the E-stops are actuated, or a fault is detected in the monitoring circuit, the safety relay de-energizes a redundant pair of 100S contactors. Hazardous motion coasts, uncontrolled, to a stop (stop category 0).

 Cat. 4, PLe to
ISO 13849-1: 2015
  • GuardLink Electromechanical Safety Switch
  • Guardmaster DG Safety Relay
  • 100S-C Safety Contactors

Programmable Controller and Cable Pull Switch

This safety function is designed using a Compact GuardLogix® controller and POINT Guard I/O™ module to monitor a series of dual-channel cable pull switches. If any of the cable pull switches are actuated, or if a fault is detected in the monitoring circuit, the GuardLogix controller de-energizes the contactors.

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • Lifeline 5 Cable Pull Switch
  • POINT Guard I/O Safety Modules

Programmable Controller for Emergency Stop

This safety function is designed using a programmable controller, safety I/O, E-Stop push buttons in series and safety contactor.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Compact GuardLogix Controller
  • POINT Guard I/O Module
  • Dual-channel E-Stop Button

Programmable Controller with Cable Pull Switch (Series)

This safety function is designed using a programmable controller and cable pull switch.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Compact GuardLogix® Controller
  • Lifeline™ 4 Cable Pull Switch
  • E-Stop Button
  • POINT Guard I/O™ Safety Modules

Programmable Controller with Pneumatic Safety Valve and Emergency Stop

This safety function is designed using a programmable controller and E-Stop to pneumatic safety valves.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • GuardLogix Controller
  • E-Stop Button
  • Safety I/O Module
  • DM2 Pneumatic Safety Valve

Safety Relay for Emergency Stop

This safety function is designed using a safety relay, E-Stop push buttons in series and safety contactors.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • 800F E-Stop
  • Guardmaster Single-input Safety Relay
  • 100S Safety Contactors

Safety Relay with Cable Pull Switch

This safety function is designed using a safety relay and cable pull switch.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Guardmaster Single-input Safety Relay
  • Lifeline 4 Cable Pull Switch

Safety Relay with Pneumatic Safety Valve and Emergency Stop

This safety function is designed using E-Stops, Guardmaster safety relays and DM2 safety valves.

 Cat. 4, PLe to
EN ISO 13849-1: 2015
  • E-Stop Button
  • Guardmaster® Compatibility Input Safety Relay
  • DM2 Safety Valve



Position and Hand Control

Name & Operation Description Safety Ratings Products

Programmable Controller and Two Hand Control

This safety function is designed using a programmable controller, safety I/O, two hand control station and safety contactors.

 Cat. 4, PLe to
EN ISO 13849-1: 2008
  • 800Z Zero-Force Buttons
  • GuardLogix® Controller
  • POINT Guard Safety I/O™ Modules

Safety Relay and Two Hand Control

This safety function is designed using safety relays, two hand control station and safety contactors.

 Cat. 4, PLe to
EN ISO 13849-1 2008
  • 800Z Zero-Force Buttons
  • MSR125 Safety Relay
  • GSR SI Safety Relay

Two-Hand Control with Configurable Safety Relay and Zero-Force Touch Buttons

This safety function is designed using a Guardmaster® 440C-CR30 configurable safety relay with a Guardmaster 440C-ENET plug-in Ethernet module to provide a hold-to-run (two-hand control) safety function. The 440C-CR30 safety relay monitors two 800Z-GL2065 Zero-Force Touch Buttons™ and controls two redundant 100S safety contactors to provide this hold-to-run safety function. Hazardous motion cannot be run unless both hands are placed on and remain on each of the two touch buttons.

 Cat. 4, PLe to
EN ISO 13849-1: 2015
  • 800Z Zero-Force Touch Buttons
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • 100S-C Safety Contactors

Two-Hand Run Station Start/Stop using Programmable Controller, with Zero-Force Touch Buttons

This safety function is designed using a programmable controller to monitor a two-hand run station. Only when the operator places both hands on the buttons can the GuardLogix controller energize the safety actuators and send an output to the standard controller to initiate the operation of a machine.

 Cat. 4, PLe to
EN ISO 13849-1: 2015
  • 800Z Zero-Force Touch Buttons
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • POINT Guard I/O Modules



Presence Sensing

Name & Operation Description Safety Ratings Products

Cat 3, PLd Stop using Programmable Controller and Safety Mat

This safety function is designed using a Compact GuardLogix® controller and POINT Guard I/O™ module to monitor a 440F safety mat. This application technique assumes the use of a dual-channel safety mat shorted together whenever the safety mat is stepped on allowing operation.

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • MatGuard Safety Mat
  • GuardLogix 5570 Controller or Compact GuardLogix 5370 Controller
  • POINT Guard I/O Safety Modules

Configurable Controller with Area Scanner

This safety function is designed using a configurable controller with area scanner.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • 442L SafeZone Laser Scanner
  • 100S-C Safety Contactors

Configurable Controller with Safety Light Curtain and Emergency Stop

This safety function is designed using a configurable controller, safety light curtain and emergency stop function.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • GuardShield Light Curtain
  • 100S-C Safety Contactors
  • 800F E-Stop Button
  • 800F Reset Button

Configurable Controller with Safety Light Curtain and Muting Function

This safety function is designed using a configurable controller, safety light curtain with muting function and emergency stop function.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • 440L GuardShield Light Curtain
  • 42EF RightSight Photoelectric

Light Curtain and Configurable Safety Relay Safety Function

This safety function application technique explains how to wire and configure a Point of Operation Control (POC) GuardShield™ light curtain and an E-Stop function. The system is based on a Guardmaster® 440C-CR30 configurable safety relay.

 Cat. 4, PLe to
ISO 13849-1: 2015
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • 450L GuardShield Light Curtain
  • 800 E-stop Button
  • 100S-C Safety Contactors

Light Curtain with a Dual-input Safety Relay Safety Function Application Technique

This safety function application technique explains how to wire and configure a Guardmaster® dual-input safety relay to monitor a GuardShield™ light curtain. When an object intrudes into the light curtain field-of-view, the safety relay de-energizes the 100S-C safety contactors.

 Cat. 4, PLe to
ISO 13849-1: 2015
  • Guardmaster Dual-input Safety Relay
  • Guardshield Light Curtain
  • 100S-C Safety Contactors

Light Curtain with Muting (Two Sensor L-type) and Guardmaster DIS Safety Relay Safety Function Application Technique

This safety function application example explains how to wire and configure a two-sensor L-type (single-direction) muting system with override. The system is based on a Guardmaster® DIS safety relay.

 Cat. 4, PLe to
ISO 13849-1: 2015
  • Guardmaster DIS Safety Relay
  • 450L GuardShield Light Curtain
  • 42EF RightSight Photoelectric Sensors
  • 100S-C Safety Contactors

Light Curtain with Muting (Two Sensor L-type) and Configurable Safety Relay Safety Function

This safety function application technique explains how to wire and configure a two-sensor L-type (single-direction) muting system with override and an additional E-Stop function. The system is based on a Guardmaster® 440C-CR30 configurable safety relay.

 Cat. 4, PLe to
ISO 13849-1: 2015
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • 450L GuardShield Light Curtain
  • 42EF RightSight Photoelectric Sensors
  • 100S-C Safety Contactors

Light Curtain with Optical Sensors and a GuardLogix Controller

This safety function explains how to wire, configure, and program a Compact GuardLogix® controller and a POINT Guard I/O™ module to monitor a GuardShield® 440L light curtain in a muting application. If a demand is placed on the light curtain when it is not muted, or a fault is detected in the monitoring circuit, the GuardLogix® controller de-energizes the final control device.

 Cat. 4, PLe to
EN ISO 13849-1: 2015
  • GuardShield Safety Light Curtain
  • Photoelectric Sensor
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller

Programmable Controller with Presence Sensing Area Scanners (Multizone)

This safety function is designed using Compact GuardLogix controllers and SafeZone multizone laser scanners.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • GuardLogix Controller
  • SafeZone Multizone Laser Scanner

Programmable Controller with Presence Sensing Area Scanners (Single Zone)

This safety function is designed using Compact GuardLogix controllers and SafeZone laser scanners.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • GuardLogix Controller
  • SafeZone Laser Scanner

Programmable Controller with Pressure Sensitive Safety Mats

This safety function is designed using pressure sensitive safety mats and Compact GuardLogix controller.

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • MatGuard Safety Mat
  • GuardLogix Controller
  • POINT Guard I/O Safety Modules
  • 100S-C Safety Contactors

Programmable Controller with Safety Camera

This safety function is designed using SC300 safety cameras and Compact GuardLogix controllers.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • SC300 Safety Camera
  • GuardLogix Controller

Programmable Controller with Safety Light Curtain

This safety function is designed using a programmable controller, safety I/O, safety light curtain and safety contactors.

 PLe, Cat. 4 to
EN ISO 13849.1 2008
  • Light Curtain
  • GuardLogix Controller

Programmable Controller with Safety Light Curtain and Muting Sensors

This safety function is designed using a programmable controller, safety I/O, safety light curtain with muting functionality via sensors and safety contactors.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • GuardShieldR Safety Light Curtain
  • Photoelectric Sensor
  • Compact GuardLogix Controller

Programmable Controller with Safety Light Curtain for Area Access Control

This safety function is designed using single-beam area access control light curtains and Compact GuardLogix controllers.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • Single-beam Area Access Control Sensors
  • GuardLogix Controllers

Safety Relay with Area Scanner

This safety function is designed using a safety relay with an area scanner.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Guardmaster Dual-input Safety Relay
  • SafeZone Laser Scanner

Safety Relay with Laser Scanner (MultiZone)

This safety function is designed using a safety relay with a multizone area scanner.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Guardmaster Dual-input Safety Relay
  • SafeZone Laser Scanner

Safety Relay with Safety Camera

This safety function is designed using SC300 safety cameras and Guardmaster dual-input safety relay with emergency stop.

 Cat. 3, PLd to
EN ISO 13849-1: 2008
  • Guardmaster Dual-input Safety Relay
  • Guardmaster SC300 Safety Camera

Safety Relay with Safety Light Curtain and Emergency Stop

This safety function is designed using safety relays, safety light curtain with muting functionality via sensors and safety contactors.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • Guardmaster Dual-input Safety Relay
  • GuardShield Light Curtain
  • 100S-C Safety Contactors

Safety Relay with Safety Light Curtain and Muting Sensors

This safety function is designed using safety relays, safety, emergency stop device and safety contactors.

 Cat. 4, PLe to
EN ISO 13849-1:2008
  • Muting Products Light Curtain
  • RightSight™r
  • Guardmaster® Safety Relays

Safety Relay with Safety Light Curtain for Area Access Control

This safety function is designed using Guardmaster dual-input safety relays and single-beam area access control light curtains with emergency stop.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • Guardmaster Dual-input Safety Relay
  • Single-beam Area Access Control Sensors with E-Stop

Safety Relays with Pressure Sensitive Safety Mats

This safety function is designed using Guardmaster dual-input safety relays and pressure sensitive safety mats with emergency stops.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Guardmaster Dual-input Safety Relay
  • 440F Safety Mats with E-Stop

Stop Category 0 with a 440F Safedge Profile and a GuardLogix Integrated Safety Controller

This safety function explains how to wire, configure, and program a GuardLogix® controller and POINT Guard I/O™ module to monitor a 440F Safedge™ profile without the requirement for a Safedge controller. If a demand is placed on the Safedge profile, or a fault is detected in the safety function, the GuardLogix controller de-energizes the final control device, in this safety function, a redundant pair of 100S contactors.

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • 440F Safedge Profile
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • POINT Guard I/O Safety Modules



Process

Name & Operation Description Safety Ratings Products

SIL 2 Safety Function: High Pressure Monitoring with Low Demand

This safety function is designed using a GuardLogix controller and POINT Guard I/O with analog input to monitor a pressure transmitter.

 SIL 2 to
IEC 61511
  • GuardLogix Controller
  • Cerabar Pressure Transmitter
  • POINT Guard I/O Analog Input Safety Module
  • POINT Guard I/O Output Safety Module
  • Samson Globe Valve

SIL 2 Safety Function: High Pressure Monitoring with Low Demand Application Technique

This low-demand safety function application technique explains how to wire, configure, and program a GuardLogix® controller and a POINT Guard I/O™ analog input module to monitor a pressure transmitter. If there is high pressure in the process loop, a demand is placed on the safety function. The safety function drops power to a solenoid valve, which vents a pneumatic actuator, and places a globe valve into fail-safe position.

 SIL 2 to
IEC 61511
  • GuardLogix Controller
  • Cerabar Pressure Transmitter
  • POINT Guard I/O Analog Input Safety Module
  • POINT Guard I/O Output Safety Module
  • Samson Globe Valve

SIL 3 Safety Function: High Pressure Monitoring with Low Demand

This safety function is designed using a GuardLogix controller and POINT Guard I/O with analog input to monitor a pressure transmitter.

 SIL 3 to
IEC 61511
  • GuardLogix Controller
  • Cerabar Pressure Transmitter
  • POINT Guard I/O Analog Input Safety Module
  • POINT Guard I/O Safety Modules
  • Samson Globe Valve

SIL 3 Safety Function: High Pressure Monitoring with Low Demand Application Technique

This low-demand safety function application technique explains how to wire, configure, and program a GuardLogix® controller and a POINT Guard I/O™ analog input module to monitor a pressure transmitter. If there is high pressure in the process loop, a demand is placed on the safety function. The safety function drops power to a pair of solenoid valves, which vent a pneumatic actuator, and place a pair of globe valves into fail-safe position.

 SIL 3 to
IEC 61511
  • GuardLogix Controller
  • Cerabar Pressure Transmitter
  • POINT Guard I/O Analog Input Safety Module
  • POINT Guard I/O Safety Modules
  • Samson Globe Valve



Subsystem

Name & Operation Description Safety Ratings Products

Actuator Subsystems - Stop Category 0 or 1 Safety Function via an Integrated Safety Controller and an ArmorStart ST Controller with Integrated Safety Application Technique

This partial safety function application technique describes the logic and output subsystems of an overall safety system. The document illustrates how to combine a GuardLogix® safety controller with an ArmorStart® ST controller that includes an integrated safety variable-frequency drive and Safe Torque Off (STO). This combination of controllers can provide an actuator motor stop safety function with stop category 0 coast-to-stop STO, or stop category 1 controlled stop followed by STO.

 Cat. 4, PLe to
ISO 13849-1: 2015
  • GuardLogix 5580 Controller
  • ArmorStart ST Controller with Integrated Safety Variable Frequency Drive

Actuator Subsystems – Stop Cateogry 0 or 1 via an Integrated Safety Controller and a PowerFlex 7000 Drive with Hardwired Safe Torque Off Safety Function Application Technique

This partial safety function application technique is concerned with the logic and output subsystems of an overall safety system. The publication illustrates how to combine a GuardLogix® safety controller with a PowerFlex® 7000-Series Medium Voltage AC drive with the Safe Torque Off (STO) option to provide a stop category 0 or stop category 1 safety function. The safety function uses POINT Guard I/O™ modules and interposing safety control relays hardwired to the STO inputs of the drive.

 Cat. 3, PLe to
ISO 13849-1: 2015
  • GuardLogix 5580 or Compact GuardLogix 5380 Controller
  • PowerFlex 7000 Medium Voltage Drive with Safe Torque Off

Safe Speed Monitoring using Programmable Controller, MSR57P Safety Relay, and a Kinetix Drive on EtherNet/IP

This safety function explains how to wire, configure, and program a GuardLogix® safety controller, a POINT Guard I/O™ module, and a Kinetix drive with integrated Safe Torque Off (STO) on EtherNet/IP™ to interface to a MSR57P speed monitoring safety relay to perform safe speed functions.

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • POINT Guard I/O Safety Modules
  • MSR57P Speed Monitoring Safety Relay
  • TLS-Z GD2 Guard Locking Switch
  • Kinetix 5500 or 5700 Servo Drive with Integrated Safety on EtherNet/IP
  • MP-Series Low Inertia Servo Motor

Safely-limited Speed (SLS) Safety Function Application Technique

This safety function application technique explains how to configure and program a GuardLogix® 5580 controller and a Kinetix® 5700 2198-xxxx-ERS4 inverter or PowerFlex® 755/755T variable frequency drive with a 20-750-S4 safety option module to perform the safely-limited speed (SLS) function. This document also includes a safe stop 1 (SS1) safety function. In addition, it describes how to use the Safe Torque Off (STO) function to prevent hazardous motion.

 Cat. 3, PLd to
ISO 13849-1: 2015
  • Kinetix 5700 ERS4 Drive or PowerFlex 755/755T Drive With an S4 Safety Module
  • GuardLogix 5580 or Compact GuardLogix 5380 Safety Controller
  • TLS3-GD2 Locking Gate Switch
  • Motor With an SIL 2 or Higher Rated Encoder

Safe Torque Off AC Drive to Stop Category 0

This safety function is designed to provide a safety-related stop function initiated by a safeguard using a safety relay and safe torque off AC Drive.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Guardmaster Dual-input Safety Relay
  • Guardmaster Expansion Module
  • PowerFlex 525 Drive
  • PowerFlex 527 Drive

Safe Torque Off AC Drive to Stop Category 1

This safety function is designed to provide a safety-related stop function initiated by a safeguard using a safety relay and safe torque off AC Drive.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Guardmaster Dual-input Safety Relay
  • Guardmaster Multifunction-delay Expansion Module
  • PowerFlex 525 Drive
  • PowerFlex 527 Drive

Stop Category 0 or 1 Using Programmable Controller and Kinetix Drive with Integrated Safe Torque Off on EtherNet/IP Networks

This document explains how to use a GuardLogix® controller and configure the Kinetix® drive with integrated safe torque off subsystems of a safety function. The GuardLogix controller de-energizes the final control devices. The final control element is de-energized immediately for a stop category 0, and a delay is introduced before de-energizing for a stop category 1.

 Cat. 3, PLe to
EN ISO 13849-1: 2015
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • Kinetix 5500
  • Kinetix 5700 Servo Drive

Stop Category 0 or 1 via a Configurable Safety Relay and PowerFlex 525 Drive with Hardwired Safe Torque Off

This safety function is designed to provide a safety-related stop function initiated by a safeguard using a Configurable Safety Relay and PowerFlex 525 AC Drive with hardwired safe torque off.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • PowerFlex 525 AC Drive

Stop Category 0 or 1 via a Configurable Safety Relay and PowerFlex 755 Drive with Hardwired Safe Torque Off

This safety function is designed to provide a safety-related stop function initiated by a safeguard using a Configurable Safety Relay and PowerFlex 755 AC Drive with hardwired safe torque off.

 CAT. 3, PLe to
EN ISO 13849-1: 2008
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • PowerFlex 755 Drive

Stop Category 0 or 1 via an Integrated Safety Controller and PowerFlex 525 Drive with Hardwired Safe Torque Off

This safety function is designed to provide a safety-related stop function initiated by a safeguard using an Integrated Safety Controller and PowerFlex 525 AC Drive with hardwired safe torque off.

 CAT. 3, PLd to
EN ISO 13849-1: 2008
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • PowerFlex 525 AC Drive
  • POINT Guard I/O Modules

Stop Category 0 or 1 via Configurable Safety Relay and Kinetix Servo Drives with Hardwired Safe Torque Off

This safety function explains how to combine the logic and output subsystems of a safety system using a Guardmaster® 440C-CR30 configurable safety relay and a Kinetix® 5500 or 5700 servo drive to provide a stop category 0 or stop category 1 via a hardwired connection.

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • Kinetix 5500 Servo Drives
  • Kinetix 5700 Single-axis Inverters
  • Kinetix 5700
  • Dual-axis Inverters

Stop Category 0 or 1 via Configurable Safety Relay and PowerFlex 527 Drive with Hardwired Safe Torque Off

This safety function is designed to provide a safety-related stop function initiated by a safeguard, using a Configurable Safety Relay and PowerFlex 527 AC Drive with hardwired safe torque off.

 Cat. 3, PLe to
ISO 13849-1: 2008
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • PowerFlex 527 Drive

Stop Category 0 or 1 via Integrated Safety Controller and PowerFlex 527 Drive with Hardwired Safe Torque Off

This safety function is designed to provide a safety-related stop function initiated by a safeguard, using an Integrated Safety Controller and PowerFlex 527 AC Drive.

 Cat. 3, PLe to
ISO 13849-1: 2008
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • PowerFlex 527 Drive

Stop Category 0 or 1 via Integrated Safety Controller and PowerFlex 755 Drive with Hardwired Safe Torque Off

This safety function is designed to provide a safety-related stop function initiated by an input device using an Integrated Safety Controller and PowerFlex 755 AC Drive with hardwired safe torque off.

 CAT. 3, PLe to
EN ISO 13849-1: 2008
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • PowerFlex 755 Drive

Stop Category 0 or 1 via PowerFlex 527 AC Drive

This safety function is designed to provide a safety-related stop function initiated by a safeguard using a GuardLogix programmable controller and safe torque off AC Drive.

 Cat. 3, PLe to
EN ISO 13849-1: 2015
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • PowerFlex 527
  • PowerFlex 755 AC Drive
  • PowerFlex 755T AC Drive Product

Stop Category 0 via Kinetix 5000 Servo Drives with Hardwired Safe Torque Off

This safety function explains how to combine a Guardmaster® dual-input safety relay and the actuator subsystems of a safety function. In this application technique, the Guardmaster dual-input safety relay de-energizes the final control device - in this case, the hard-wired safe torque off inputs on the Kinetix 5500 or Kinetix 5700 servo drive. The final control element is de-energized immediately for a stop category 0.

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • Guardmaster® Dual-input Safety Relay
  • Kinetix® 5500 Servo Drive
  • Kinetix 5700 Servo Drive

Stop Category 0 via Safety Relay and PowerFlex 755 Drive with Hardwired Safe Torque Off

This safety function is designed to provide a safety-related stop function initiated by a safeguard, using a Guardmaster Dual-Input Safety Relay and PowerFlex 755 AC Drive.

 CAT. 3, PLe to
ISO 13849-1: 2008
  • Guardmaster Dual-Input Safety Relay
  • PowerFlex 755 Drive

Stop Category 1 via Safety Relay and PowerFlex 755 Drive with Hardwired Safe Torque Off

This safety function is designed to provide a safety-related stop function initiated by a safeguard, using a Safety Relay and PowerFlex 755 AC Drive with hardwired safe torque off.

 CAT. 3, PLe to
ISO 13849-1: 2008
  • Guardmaster Dual-input Safety Relay
  • Guardmaster Multifunction-delay Expansion Module
  • PowerFlex 755 Drive

Stop Category 1 via the Kinetix 5000 Servo Drives with Hardwire

This safety function explains how to combine a Guardmaster® dual-input safety relay, a Guardmaster multifunction-delay expansion module, and the actuator (Kinetix® 5500 or Kinetix 5700 servo drive with safe torque off) subsystems of a safety function.

 CAT. 4, PLe to
EN ISO 13849-1: 2008
  • Guardmaster 440C-CR30 Configurable Safety Relay
  • 440L GuardShield Light Curtain
  • 100S-C Safety Contactors
  • 800F E-Stop Button
  • 800F Reset Button

Zero Speed, Safe Limited Speed, and Safe Direction

This safety function explains how to wire, configure, and program a Compact GuardLogix® controller and a POINT Guard I/O™ module to interface with a PowerFlex® 750 safe speed monitor option (-S1) module to perform safe speed functions.

 Cat. 3, PLd to
EN ISO 13849-1: 2015
  • PowerFlex 750 Safe Speed Monitor Option Module
  • TLS3-GD2 Switch
  • GuardLogix 5570 or Compact GuardLogix 5370 Controller
  • POINT Guard I/O Safety Modules
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