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Allen-Bradley
Connection Systems

Connection Systems

Product catalog summary

Overview
The document is a comprehensive guide on Allen-Bradley Guardmaster Safety Connection Systems, designed to enhance machine safety through efficient wiring solutions. These systems are suitable for use with dry-contact safety switches, E-stops, cable pull switches, and safety relays, but not with light curtains, safety mats, or pressure-sensitive safety edges.

Key Features

Reduction in installation costs and simplification of system expansion and troubleshooting.
Support for systems up to Category 3 as per EN954-1 standards.
Options for systems with or without enunciation capabilities, providing direct feedback on the status of individual switches.

System Configurations
Without Enunciation: Utilizes patchcords, shorting plugs, safety wired distribution boxes, and T-ports for series wiring of safety circuits. Dual-channel models with 2 N.C. or 1 N.C. + 1 N.O. contact configurations are available.
With Enunciation: Includes additional circuits for enunciation, using distribution boxes with dual-channel 2 N.C. or single-channel 1 N.C. configurations, and an auxiliary N.O. contact for alarm indications.

Installation Considerations

Safety distribution boxes should be mounted in guarded areas to restrict access to authorized personnel only.
Shorting plugs are necessary for all unused ports to ensure system operation.

Product Specifications

Materials: Epoxy coated zinc for connector shells, brass with gold over nickel plating for contacts, and fluoroelastomer for O-rings.
Enclosure Type Rating: IP67, NEMA 6P.
Operating Temperature: -20 to 105°C (-13 to 221°F).

Product Selection
The document lists various configurations and part numbers for different connection systems, including:

Field attachable connectors in DC Micro, M23 styles.
Receptacles in DC & AC Micro Male styles.
Cordsets & Patchcords in DC Micro, AC Micro, Mini, Mini-Plus, and M23 styles.
Safety Wired T-Port and Distribution Boxes in DC and AC Micro styles.

Conclusion
Allen-Bradley Guardmaster Safety Connection Systems offer a modular and reliable solution for machine safety wiring, ensuring compliance with safety standards and facilitating easy system integration and maintenance.

Specifications

Connector Materials: The connectors are made from materials such as PUR, PVC, and epoxy-coated zinc, with contacts made of gold over nickel-plated brass.
Enclosure Ratings: Products are rated IP67, NEMA 6P, and some up to IP69K, indicating high resistance to dust and water ingress.
Operating Temperature: The operating temperature ranges from -20°C to +105°C for most products, with some variations depending on the material used.

Product Features

Ratcheting coupling nuts for vibration resistance.
Oil and chemical-resistant jackets available in PVC, PUR, and TPE materials.
Various pin configurations (4-pin, 5-pin, 6-pin, 8-pin) to suit different applications.

Product Selection

Products are available in different lengths and configurations, with options for straight or right-angle connectors.
Standard cable lengths include 1m, 2m, 3m, 5m, and 10m, with custom lengths available.
Stainless steel connectors can be ordered by adding an 'S' to the catalog number.

Applications These cordsets and patchcords are suitable for use in safety-wired distribution boxes, presence-sensing safety devices, and operator interfaces, among other applications.

Connection Systems

Cordsets & Patchcords, M23 Style: Features include a 12-pin configuration suitable for SafeShield light curtains, with a highly visible yellow PVC jacket that is oil and chemical resistant. The cable rating is 300V with an IP67, NEMA 6P enclosure type rating.
Field Attachables, DC Micro Style: Available in 4-pin, 5-pin, and 8-pin configurations. Features include field installable screw terminals and embedded thermistor models for cold junction compensation.
Insulation Displacement Connector: 4-pin DC micro style connectors that are field installable without hand tools, using insulation displacement technology for secure installation.
Solder Connector: M23 style connectors available in straight or right angle, male or female configurations, allowing for field creation of special cable lengths.
Receptacles, DC Micro Male: Male bulkhead receptacles available in 4-, 5-, or 8-pin configurations with various mounting thread sizes.
Receptacles, M23 Male: 12-pin configuration with 18 AWG conductors, suitable for mounting to safety switches with included mounting nut and rubber sealing washer.

Specifications

Certifications: Products are UL Recognized and CSA Certified.
Mechanical: Various materials used for coupling nuts and connector shells, including nickel-plated brass and PBT.
Electrical: Cable ratings vary by product, with assembly ratings up to 300V and 12 A.
Environmental: Enclosure type ratings include IP67 and NEMA 6P, with operating temperatures ranging from -40°C to +105°C.

Pinout and Color Code

Detailed pinout and color code information is provided for various connector configurations, ensuring correct wiring and installation.

Catalog excerpts

Connection Systems Overview 7-Overview Overview Systems with Enunciation 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,...

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Connection Systems Safety Wired T-Port, DC Micro Style Dual Channel, No Enunciation Specifications 7-Safety Wired Systems Connector Shell Material Epoxy coated zinc Contact Material Brass, gold over nickel plating O-Ring Material Fluorelastomer Enclosure Type Rating IP67, NEMA 6P Operating Temperature [C (F)] -20…105° (-13…221°) Features 8- T-port/splitter designed for use with dual-channel safety devices with 4-pin DC micro connector PUR body offers good oil and chemical resistance Ratcheting coupling nut for vibration resistance For use in Category 2 or 3 systems per EN 954-1 SensaGuard units...

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Connection Systems Safety Wired Distribution Box, DC Micro Style Dual-Channel N.C., No Enunciation 7-Safety Wired Systems Specifications Housing Material Red PBT Connector Insert Material PBT Connector Shell Material Nickel-plated brass Contact Material Gold-plated palladium/nickel Cable O.D. 9.8 mm (0.39 in.) Cable Type Oil-resistant yellow PVC jacket, 22 AWG conductors Enclosure Type Rating IP67 Operating Temperature [C (F)] -20…105° (-13…221°) Features 8- Prewired for dual-channel N.C. safety 4 or 8 safety wired 4-pin DC micro connectors 4-pin male DC micro pigtail main connection For use...

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Connection Systems Safety Wired Distribution Box, DC Micro Style Dual-Channel N.C./N.O., No Enunciation Specifications 7-Safety Wired Systems Housing Material Red PBT Connector Insert Material PBT Connector Shell Material Nickel-plated brass Contact Material Gold-plated palladium/nickel Cable O.D. 9.8 mm (0.39 in.) Cable Type Oil-resistant yellow PVC jacket, 22 AWG conductors Enclosure Type Rating IP67 Operating Temperature [C (F)] -20…105° (-13…221°) Features 8- Prewired for dual-channel (one N.O./one N.C.) safety 4 or 8 safety wired 4-pin DC micro connectors 4-pin male DC micro pigtail main...

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Connection Systems Safety Wired Distribution Box, DC Micro Style Single-Channel N.C. plus Individual N.O. Enunciation Housing Material Red PBT Connector Insert Material PBT Connector Shell Material Nickel-plated brass Contact Material Gold-plated palladium/nickel Cable O.D. 9.8 mm (0.39 in.) Cable Type Oil-resistant yellow PVC jacket, (12) 18 AWG conductors 7-Safety Wired Systems Specifications Enclosure Type Rating IP67 Operating Temperature [C (F)] -20…105° (-13…221°) Features 8- Prewired for single-channel (N.C.) safety with enunciation 8 safety wired 4-pin DC micro connectors Individual enunciation...

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Connection Systems Safety Wired Distribution Box, AC Micro Style 8-Port, Dual-Channel (2 N.C.) plus Individual N.O. Enunciation Specifications 7-Safety Wired Systems Housing Material Red PBT Connector Insert Material PBT Connector Shell Material Nickle-plated brass Contact Material Gold-plated palladium/nickel Cable O.D. 9.8 mm (0.39 in.) OD Oil-resistant yellow PVC jacket, (6) Cable Type 19 AWG conductors and (8) 22 AWG conductors Enclosure Type Rating IP67 Operating Temperature [C (F)] -20…105° (-13…221°) Features 8- Prewired for dual-channel N.C. safety plus individual N.O. enunciation Eight...

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Connection Systems Safety Wired Shorting Plug DC & AC Micro Style Connector Insert Material PUR Connector Shell Material RED PVC Contact Material Brass, gold over nickel plating O-Ring Material Fluorelastomer Enclosure Type Rating IP67, NEMA 6P Operating Temperature [C (F)] -20…105° (-13…221°) 7-Safety Wired Systems Specifications Features 8- Shorting plug designed for use with safety-wired distribution boxes PVC body offers good oil and chemical resistance Ratcheting coupling nut on 4-pin models for vibration resistance Face View of Male Rating Configuration Wiring Coupling Nut Material Cat....

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Connection Systems Cordsets & Patchcords, DC Micro Style 18 and 22 AWG, Yellow, Black, or Blue PVC Specifications Certifications UL Recognized and CSA Certified 7-Cables Mechanical Coupling Nut Material Epoxy-coated zinc Connector Shell Material Molded oil resistant PVC or PUR Contact Material Gold over nickel-plated brass Cable Type Oil resistant yellow PVC jacket, 20 AWG stranded copper, 300V, UL Recognized and CSA Certified Home Run Connection 10 x diameter Cable Diameter 4/c = 5 mm (0.21 in.); 5/c = 6.5 mm (0.25 in.) Electrical 8- Cable Rating Features presence-Sensing Safety Devces Ratcheting...

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Connection Systems Cordsets & Patchcords, DC Micro Style 18 and 22 AWG, Yellow, Black, or Blue PVC Pinout and Color Code 5-Pin 2 1 Color Code 5 2 3 1 3 4 1 Brown 2 White 3 Blue 1 Brown 2 White 3 Blue 4 Black 5 NA 4 4 Black 5 Grey 8- A 7-Cables Face View Pinout 4-Pin Product Selection Cordsets Cat. No. Straight Female Right Angle Female Straight Male Right Angle Male 22 AWG 889D-F4AC-21 889D-R4AC-21 889D-M4AC-21 889D-E4AC-21 Yellow A Wire Size Yellow 4-Pin Jacket Color 18 AWG 889D-F4AE-21 889D-R4AE-21 889D-M4AE-21 889D-E4AE-21 889D-F4BC-21 889D-R4BC-21 889D-M4BC-21 889D-E4BC-21 Black Blue Yellow...

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Connection Systems Cordsets & Patchcords, DC Micro Style 18 and 22 AWG, PUR, TPE, or TPR Specifications Certifications UL Recognized and CSA Certified 7-Cables Mechanical Coupling Nut Material Epoxy-coated zinc Connector Shell Material Molded oil-resistant PVC or PUR Contact Material Gold over nickel-plated brass Cable Type Oil-resistant PVC jacket, 18 & 22 AWG or 24 AWG conductors, 300V; UL Recognized and CSA Certified Cable Diameter 4/c 4/c 5/c 7/c 8/c (PUR); 5 mm (0.21 in.); (18 AWG TPE); 7 mm (0.28 in.); 6.5 mm (0.25 in.); 7.4 mm (0.29 in.); 7.4 mm (0.29 in.) 8- Electrical Cable Rating Features...

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