Safety Connection Systems

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Overview

Overview

The Allen-Bradley Guardmaster^® Safety Connection Systems are complete wiring solutions dedicated to machine safety. These quick disconnect-based systems consist of safety wired T-Ports and distribution boxes as well as patchcords and shorting plugs. Specifically intended for use with dry-contact safety switches, Safety Connection Systems provide flexible and reliable connections between safety interlock switches, E-stops, cable pull switches and safety relays. And while this system is ideal for use with these components, it is not suitable for use with light curtains, safety mats or pressure sensitive safety edges.

Allen-Bradley Guardmaster Safety Connection Systems are designed to:

• Reduce installation cost
  
• Ease system expansion
  
• Simplify troubleshooting
  
• Promote system modularity
  
• Provide for Safety PLC input expansion
  
• Support systems up to Category 3 (per EN954-1)
  

Safety Connection Systems layouts are available with or without enunciation capabilities, allowing the user the option of direct feedback for the status of individual switches in the system. Enunciation systems utilize an auxiliary contact as input to tower lights, audible alarms, PLC input cards, etc.

Systems without Enunciation

As illustrated in the example layout below, wiring systems for applications not requiring enunciation use a combination of patchcords, shorting plugs, safety wired distribution boxes and T-ports for series wiring of safety circuits. Distribution boxes for such an application are dual channel models with 2 N.C. or 1 N.C. + 1 N.O. contact configurations. See the wiring diagrams below for connector pin assignments.

Dual Channel 2 N.C.



Dual Channel 1 N.C./1 N.O.



Note: Shorting plugs must be used on all unused ports for the system to operate.

Systems with Enunciation

As shown below, system layouts with enunciation require patchcords, shorting plugs and distribution boxes, which allow for series wiring of the safety circuits while providing a separate circuit for enunciation. Distribution boxes are offered for these applications in two contact configurations: dual channel with 2 N.C. or single channel with 1 N.C. Each type also provides a N.O. auxiliary contact that is interfaced with the enunciation device to provide visual or audible alarm indication. In addition, LEDs on the distribution boxes assist in the troubleshooting of this system. See the wiring diagrams below for the associated connector pin configurations.

Single Channel 1 N.C./1 N.O.



Dual Channel 2 N.C./1 N.O.



Note: Shorting plugs must be used on all unused ports for the system to operate.

Installation Considerations

Some important notes regarding Safety Connection Systems:

• To help ensure that only authorized personnel can access the connections, safety distribution boxes should be mounted in the ‘guarded’ area as defined in the risk assessment for the application.
  
• The safety connection system is designed to simplify the installation of safety devices—it does not control the safety circuit.
  
• Since the safety circuits are wired in series, shorting plugs must be installed in all unused distribution box ports in order for the system to operate.
  

Example Layout without Enunciation

1. Safety-Wired Splitter/T-Port		4. Device Patchcord		6. Safety Switch with QD
2. Safety-Wired Distribution Box		5. Device Cordset		7. Safety Relay
3. Shorting Plug

SensaGuard Units Wired in Series without Enunciation

Example Layout with Enunciation

1. Safety-Wired Distribution Box		3. Device Patchcord		5. Safety Relay
2. Shorting Plug		4. Safety Switch with QD		6. Tower Light