Allen Bradley Guardmaster 440R Safety Relay Troubleshooting and Configuration Guide

5 Automatic/Manual (IN1 OR IN2) OR L12

6 Automatic/Manual (IN1 AND IN2) OR L12

7 Automatic/Manual (IN1 or IN2) AND L12

8 Automatic/Manual (IN1 AND IN2) AND L12

Example: If two safety doors are connected in series and need to be closed simultaneously to reset, select position 4 or 8 (AND logic). If one of them is closed, choose OR logic.

4.2 CI/SI Reset Switch (3rd gear)

Location function

MM monitoring manual reset (requires rising edge+falling edge, pulse width 0.25... 3 seconds)

AM automatic/manual (when connected to 24V, it automatically resets; when connected to a button, it resets with a rising edge)

4.3 EMD Delay/Jogging Configuration (Range × Time)

Range switch: Select the function type (turn off delay, turn on delay, jog) and range (in conjunction with Time switch).

Time switch: If set to 1 at the beginning of the configuration, use a short range (such as 0.1... 10 seconds); If set to 10, use a long range (10... 3000 seconds).

Actual delay=Range reference value x (Time switch value x 10%).

For example: Range=3 (turn off delay, baseline 30 seconds), Time=5 → 30 × 50%=15 seconds.

Jogging function: It needs to be triggered when B1 is connected to 24V and L12 is ON. The ON time is the set value, and the OFF time is fixed at 500 ms.

Configuration precautions:

To make the shutdown delay retrievable, B1 and B2 must be short circuited before configuration.

If delay is required, B1 must be suspended.

After configuration is completed, the device must be powered off and saved within 5 minutes, otherwise it will permanently malfunction.

LED status diagnosis (quick reference)

5.1 Normal operation of LED

Meaning of LED color/status

PWR/Fault green is always on and normal

IN/IN1 green first input channel closed

IN2 green second input channel closed (DI/DIS)

LOGIC IN green SWS input L12 is ON

OUT green constant light safety output has been closed

OUT green flashing (1Hz) safety input closed, waiting for reset signal

B1 (EMD) green B1 input closed

LOGIC IN (EMD) flashing (1Hz) timing in progress (shutdown delay not yet expired)

LOGIC IN (EMD) fast flashing (8Hz) jog OFF time

5.2 Fault LED code (PWR/Fault indicator light)

Display status, fault types, possible causes, and solutions

The red light is constantly on and cannot be restored. The input or output is short circuited to 24V/0V, and there is an internal hardware error. Power off, restart, and reconfigure.

Red flashing (1Hz) configuration mode is normal, waiting for the switch to be set.

Red flashing twice (intermittent) configuration conflict. After power on, the switch position is inconsistent with the EEPROM. Reconfigure or check the switch.

Red flashes three times, B1-B2 connection error. After configuring EMD, B2 was short circuited to B1. Remove the short circuit and the fault will be automatically cleared.

Red flashing 4 times can trigger the input error EMD to non triggered mode, but L12 is turned on again during the shutdown delay period. Wait for the delay to end or reconfigure to trigger again.

Red flashing 5 times SWS fault L11/L12 signal abnormality, check wiring, shielding, and cable length (<30m).

The fault can be recovered by keeping the green light on and flashing the red light 4 times. If L12 flips more than once during the shutdown delay, it will automatically recover after the delay is over.

Common troubleshooting process (step-by-step)

Step 1: Check the PWR/Fault indicator light

Extinguish: No power supply. Check the A1/A2 voltage (should be 24V DC ± 15%).

Red flashing twice: The switch position does not match the stored value → Repeat the five step configuration.

Red flashing 4 times (under constant green background): see the table above.

Step 2: Check the power supply and grounding

Measure the voltage of A1-A2.

Confirm that the 24V common terminal is connected to the protective ground (only required for PELV). If the on-site grounding is poor and causes irregular faults, the grounding test can be temporarily disconnected (note: it is only for troubleshooting and must ultimately meet the standards).

Step 3: Check the security input

Measure the voltage between S11 and S21 and A2 using a multimeter. When the mechanical contact is disconnected, the S11/S21 of CI is about 19V; DI/DIS/SI is about 14V/18V (due to different pulse test waveforms).

After closing the contacts, the voltage of S12 and S22 should be close to the voltage of S11/S21. If the difference is greater than 2V, check the resistance or capacitance effect of the circuit.

Capacitive effect: Long line to ground capacitance will slow down the pulse front, but it can still work (for example, 1 μ F to ground can still operate).

Resistance effect: The total circuit resistance should be less than 900 Ω, and the round-trip of 22AWG wire within 200m is only about 21 Ω, which is rarely a problem.

OSSD device: Connect OSSD1/2 directly to S12/S22 and must share the same 24V reference. GSR cannot detect OSSD output short circuit, and upstream equipment needs to self diagnose.

Step 4: Check the SWS (Single Wire Safety) circuit

L11 output waveform: Send a set of pulses every 4ms (1ms+0.5ms), with a valid reading of 8-9V on the digital multimeter.

L12 input: LED LOGIC IN should light up. If it is not lit and L12 is not used, set the DI/DIS logic switch to 1, 2, 5, 6 (OR logic) to ignore L12.