How to Factory Reset an Allen-Bradley 440R-D22R2 Safety Relay

 How to Factory Reset an Allen-Bradley 440R-D22R2 Safety Relay Overview

The 440R-D22R2 has no separate "factory reset" button. Its equivalent is the configuration start: with power off, set the LOGIC switch to 0, then power up. The relay erases its stored configuration from EEPROM and returns to the same unconfigured state it ships in. You then choose a new setting and cycle power to lock it in (Rockwell user manual 440R-UM013I).

The 440R-D22R2 is the Guardmaster DI safety relay. It has two dual-channel safety inputs (IN1 and IN2), a single wire safety (SWS) input and output, and two electromechanical safety outputs. One rotary LOGIC switch on the front sets both the reset type and the AND/OR logic between the inputs.

Do a reset when the relay shows a configuration fault, when it was moved to a new application, when input wiring changed, or when you are not sure what setting is stored.

Before you start

This relay is part of a safety function, so treat a reset as a change to the safety system. Only trained, authorized personnel should do it, and the machine must be revalidated afterward.

• ☐ Machine is stopped and locked out per your site's lockout/tagout procedure
• ☐ You know the correct LOGIC setting (1–8) from the electrical drawings or risk assessment
• ☐ All safety input wiring is complete and connected
• ☐ All safety inputs are closed: E-stops released, guards shut, light curtains clear, mats unoccupied
• ☐ 24V DC supply is available at A1/A2 and reads 20.4–26.4V DC
• Nothing wired to L12: use an OR-with-L12 setting (1, 2, 5 or 6), or the relay will never turn on.
• Safety mats or Safedge edges: use AND logic with monitored manual reset (position 2 or 4).
• Only one device on IN1 or IN2: use OR logic between the inputs (1, 3, 5 or 7).
• ☐ Press Reset (monitored manual) and confirm OUT turns on. The reset signal must go on and off within 250–3,000 ms; the relay resets on release.
• ☐ Open each safety device in turn and confirm the outputs drop out.
• ☐ Confirm the auxiliary output Y32 reports correctly to the PLC (on when the safety outputs are off).
• ☐ Record the new LOGIC position and date on the drawings or maintenance log.
• ☐ Revalidate the safety function before returning the machine to production.
• Guardmaster Safety Relays User Manual, 440R-UM013I-EN-P — Rockwell Automation, July 2024 (Chapter 4 Configuration, Chapter 5 Status Indicators, Chapter 11 Troubleshooting)

You need a small flat-blade screwdriver for the rotary switch and a digital multimeter. Turn the switch gently and do not force it past its mechanical stops.

The inputs must be closed during configuration because the relay sends test pulses to learn how it is wired. If an input is open, you may get a configuration fault on the next power-up.

Reset procedure

1. Remove power. Switch off the 24V DC supply at A1/A2.
2. Set LOGIC to 0. Turn the LOGIC rotary switch to position 0 (start configuration).
3. Apply power. After a short wait, the PWR/Fault indicator flashes red at 1 Hz (0.5 s on, 0.5 s off). This means the old configuration has been erased and the relay is in configuration mode.
4. Select the new setting. Turn the LOGIC switch to the required position from the table below. The PWR/Fault indicator flashes red briefly each time you move it.
5. Confirm the setting. Count the flashes on the IN 1 indicator. The number of flashes equals the switch position, and the pattern repeats after a 2-second pause. Start counting after the first pause.
6. Cycle power within 5 minutes. Switch power off, then back on. The relay stores the setting, checks its inputs and outputs, and goes into run mode.

Important: If you do not cycle power within 5 minutes of setting the switch, the relay can go into a permanent fault.

LOGIC position	Reset type	Input logic
0	—	Start configuration (reset)
1	Monitored manual	(IN1 OR IN2) OR L12
2	Monitored manual	(IN1 AND IN2) OR L12
3	Monitored manual	(IN1 OR IN2) AND L12
4	Monitored manual	(IN1 AND IN2) AND L12
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

Source: 440R-UM013I, Chapter 4. The switch has 10 positions, but only 0–8 are used.

Choosing a setting:

• Nothing wired to L12: use an OR-with-L12 setting (1, 2, 5 or 6), or the relay will never turn on.
• Safety mats or Safedge edges: use AND logic with monitored manual reset (position 2 or 4).
• Only one device on IN1 or IN2: use OR logic between the inputs (1, 3, 5 or 7).

Verify after reset

After the final power cycle, the relay should settle into the normal states below.

Indicator	Expected state	Meaning
PWR/Fault	Steady green	Configuration stored, relay running
IN 1 / IN 2	On	Input circuits closed
LOGIC IN	On if L12 is used; off if not	SWS input status
OUT	Flashing	Inputs closed, waiting for reset (monitored manual)
OUT	On	Outputs 13/14 and 23/24 closed

Then do these checks:

• ☐ Press Reset (monitored manual) and confirm OUT turns on. The reset signal must go on and off within 250–3,000 ms; the relay resets on release.
• ☐ Open each safety device in turn and confirm the outputs drop out.
• ☐ Confirm the auxiliary output Y32 reports correctly to the PLC (on when the safety outputs are off).
• ☐ Record the new LOGIC position and date on the drawings or maintenance log.
• ☐ Revalidate the safety function before returning the machine to production.

Do not move the LOGIC switch while the relay is running. If the switch is moved, the relay keeps running but shows green with 2 red flashes until the switch is returned to its stored position.

Troubleshooting

Read the PWR/Fault indicator first, and start counting flashes after the first pause; the first cycle can be wrong.

PWR/Fault indicator	Meaning	What to do
Off	No power	Check 24V at A1/A2 (20.4–26.4V DC), fuses and breakers
Flashing red, 1 Hz	In configuration mode, or configuration not finished (new relays ship this way)	Set LOGIC to the required position and cycle power
Flashing red, 2×	Invalid configuration: EEPROM setting corrupted, or S11/S21 swapped after configuration	Repeat the reset procedure
Flashing red, 3×	Invalid configuration: OR logic chosen with mats wired, or inputs were open during configuration	Close all inputs and reconfigure; use AND logic (2, 4, 6, 8) for mats
Flashing red, 4×	Cross fault: short between S11 and S21, wiring changed after configuration, or high input capacitance	Check wiring, remove the short, then cycle the input or power
Flashing red, 5×	SWS output (L11) test failed	Check for shorts on L11 and the downstream relay's power and common
Green with red flashing 2×	LOGIC switch does not match stored setting	Return the switch to its stored position, or reconfigure
Steady red	Internal fault, often from a power blip, noise, or a short from A1/A2 to S11/S21	Cycle power; if it returns, reconfigure and check grounding

Source: 440R-UM013I, Chapter 11.

If the relay will not leave configuration mode after a reset, confirm that power was fully removed before you set the switch to 0, and that the 5-minute window was not exceeded. A relay that keeps returning to steady red after reconfiguration should be replaced.

Sources 

• Guardmaster Safety Relays User Manual, 440R-UM013I-EN-P — Rockwell Automation, July 2024 (Chapter 4 Configuration, Chapter 5 Status Indicators, Chapter 11 Troubleshooting)