Allen-Bradley Guardmaster 440R-W23219 Safety Relay

The Allen-Bradley 440R-W23219 is a Guardmaster MSR310P modular safety relay designed for high-demand safety applications. Operating on 24 V DC, this relay features 3 normally open auxiliary solid-state outputs and supports both automatic and manually monitored reset modes. Rated for Category 4, Performance Level e (ISO 13849-1) and SIL CL3 (IEC 61508/62061), the 440R-W23219 is suitable for emergency stop, safety gate, and two-hand control monitoring in industrial machinery.

Technical Specifications

The 440R-W23219 operates on a supply voltage of 24 V DC. The unit is housed in a 35 mm width enclosure designed for DIN rail mounting. It includes 3 normally open (N.O.) auxiliary solid-state outputs, each rated at 50 mA at 24 V DC. Input configuration supports single-channel or dual-channel wiring with cross-circuit detection. Reset types are selectable: automatic reset or manually monitored reset (with feedback loop). The relay includes an RS232 serial interface for diagnostic communication and parameter configuration. Response time is less than 25 ms. The unit features removable terminal blocks for ease of wiring. Operating temperature range is -10°C to +55°C. The relay is red in color per Guardmaster safety product identification.

Key Features

• 3 N.O. auxiliary solid-state outputs (50 mA, 24 V DC)

• 24 V DC supply voltage

• Automatic or manually monitored reset modes

• Single-channel or dual-channel input wiring

• Cross-circuit detection for dual-channel applications

• RS232 port for diagnostics and configuration

• 35 mm DIN rail mounting width

• Removable screw-type terminal blocks

• Category 4 / PL e / SIL CL3 safety rating

Safety Functions

The 440R-W23219 is configured for monitoring emergency stop pushbuttons, interlocking guard doors, light curtains, and safety mats. In dual-channel mode, the relay monitors both input channels for simultaneous closure; any discrepancy greater than the configured simultaneity tolerance results in a safety trip. The cross-circuit detection feature identifies short circuits between the two input channels or between a channel and the power supply. A monitored manual reset requires a feedback loop from external contactors, ensuring that reset is only possible after the contactors have properly de-energized and re-energized.

Configuration and Operation

The relay is configured using the integrated DIP switches on the module front panel. Settings include operating mode (single/dual channel), reset type (automatic/monitored manual), and input filter time. The RS232 port can be used with Guardmaster configuration software (e.g., Connected Components Workbench) for advanced parameterization, diagnostics, and monitoring of internal status. LEDs on the front provide clear indication of power status (green), input channels status (yellow), output status (green), and fault conditions (red). When a safety demand occurs, the safety outputs de-energize within 25 ms. The auxiliary solid-state outputs are suitable for low-current signaling to a PLC or indicator light.

Applications

Typical applications include safety monitoring of machine tools, packaging equipment, conveyor systems, robotic cells, and assembly lines. The 440R-W23219 is particularly suited to applications where the safety outputs do not directly switch contactor coils but instead signal a safety-rated output module or a PLC safety input. The solid-state outputs are ideal for high-cycle applications where relay contact wear would be a concern.

Wiring and Installation

Mount the 440R-W23219 on 35 mm DIN rail (EN 60715). Connect the 24 V DC supply to the A1 (+) and A2 (-) terminals. Wire the safety input devices to the S10, S11, S12, and S21, S22 terminals (depending on single or dual-channel configuration). For manual monitored reset, wire a normally open reset button between terminals Y1 and Y2, and connect the feedback loop from external contactors to terminals Y3 and Y4. The solid-state outputs (13-14, 23-24, 33-34) are rated for 50 mA maximum; do not exceed this rating. The RS232 port uses a standard 4-pin connector for connection to a programming cable. All wiring should comply with local safety regulations and machine directive requirements. The removable terminal blocks facilitate pre-wiring of the panel before relay installation.

Standards and Certifications

The 440R-W23219 is certified by TÜV and UL. It meets ISO 13849-1 Category 4, Performance Level e, and IEC 61508 SIL CL3. The relay also complies with IEC 62061 (SIL CL3) and EN 60204-1 (safety of machinery). It is CE marked and RoHS compliant. The solid-state outputs provide reinforced insulation from input and supply circuits.

Conclusion

The Allen-Bradley 440R-W23219 Guardmaster MSR310P safety relay offers a flexible, high-integrity solution for machine safety monitoring. Its 3 NO solid-state outputs, selectable reset modes, and RS232 diagnostics make it a suitable choice for applications requiring reliable safety performance and easy configuration.