Rockwell Automation Allen-Bradley Guardmaster TLSZR-GD2 User Manual
Rockwell Automation Allen-Bradley Guardmaster TLSZR-GD2 is a safety switch designed for guard locking applications. It utilizes RFID technology to detect a specific target, ensuring secure operation and preventing unauthorized access to hazardous areas. The switch features OSSD outputs, providing safety-related signals for integration with your control system. It also includes a manual release feature and an optional manual override cover for added flexibility and safety.
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User Manual
Original Instructions
TLSZ Guardmaster Guard Locking Switch
Catalog Numbers 440G-TZS21UPRH, 440G-TZS21UPLH, 440G-TZS21UTRH, 440G-TZS21UTLH
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
General Description
Installation
Wiring
Commissioning
Functional Testing
Table of Contents
Preface
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Guardmaster TLSZ Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Allowable Approach Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Minimum Operating Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Learning Additional Targets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rockwell Automation Publication 440G-UM001C-EN-P - January 2018 3
Table of Contents
Application and Wiring Examples
Wiring to GLP Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wiring to GLT Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Wiring to DI and EMD Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Wiring to DG Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Wiring to CR30 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Wiring to 1734 Guard Point I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring to 1732 ArmorBlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Diagnostics and Troubleshooting
Tools Needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Optional Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Step 1 — Status Indicator OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Step 2 — Status Indicator Flashing Red at 4 Hz . . . . . . . . . . . . . . . . . 45
Wrong Target . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Missing Target . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Target Not Mounted Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Pair Proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mechanical Pressure on Safety Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Long Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Voltage Supply Dips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Rapid Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Step 3 - Status Indicator Flashes Red at 1 Hz . . . . . . . . . . . . . . . . . . . . 49
Capacitive Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Step 4 — Status Indicator Flashes Green at 1 Hz . . . . . . . . . . . . . . . . 50
Step 5 — Flashing Red and Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Step 6 — Indicator Solid Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Step 7 — Other Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Distribution Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
GSR Relays on Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Specifications and Safety Ratings
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Safety Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Rockwell Automation Publication 440G-UM001C-EN-P - January 2018
Preface
Read this preface to familiarize yourself with the rest of the manual. It provides information concerning:
• Who would use this manual
• The purpose of this manual
• Related documentation
• Conventions used in this manual
Who Should Use This Manual
Use this manual to design, install, program, or troubleshoot systems that use the TLSZ Guardmaster® guard locking safety switches.
You are required to have a basic understanding of electrical circuitry and familiarity with safety-related control systems. If you do not, obtain the proper training before using this product.
Purpose of This Manual
This manual is a reference guide for the Guardmaster TLSZ guard locking switch. It describes the procedures you use to install, wire, and troubleshoot your switch. This manual:
• Explains how to install and wire your TLSZ switch,
• Provides an overview of the Guardmaster TLSZ guard locking switch.
Conventions Used in This
Manual
The following conventions are used throughout this manual:
• Bulleted lists such as this one provide information, not procedural steps.
• Numbered lists provide sequential steps or hierarchical information.
Additional Resources
The following documents offers additional information about related
Rockwell Automation products.
Resource Description
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1
Provides general guidelines for installation of a
Rockwell Automation® industrial system.
Product Certifications website, rok.auto/certifications Provides declarations of conformity, certificates for the
TLSZ guard locking switch.
Rockwell Automation Functional Safety Data Sheet Provides functional safety data and details for
Rockwell Automation products.
Guardmaster 440C-CR30 Configurable Safety Relay
Wiring Diagrams
Allen-Bradley Industrial Automation Glossary
Provides example wiring diagrams for the CR30 software configuration safety relay.
Glossary of industrial automation terms and abbreviations
You can view and download publications at http:// www.rockwellautomation.com/literature/ . To order paper copies of technical documents, contact your local Rockwell Automation distributor or sales representative.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 5
6
Preface
Terminology
The Industrial Automation Glossary contains terms and abbreviations used by
Rockwell Automation to describe industrial automation systems. Below is a list of specific terms and abbreviations used in this manual.
NC
N.C. (Normally
Closed)
No connection
An electrical contact whose normal state (for example, no pressure or electrical potential applied) is in the closed position.
N.O. (Normally
Open)
An electrical contact whose normal state (i.e., no pressure or electrical potential applied) is in the open position.
PLC
PTL (Power to
Lock)
PTL (Power to
Release)
A programmable logic controller or a programmable automation controller.
Apply 24V to the lock command to lock the switch. This command applies to the TLSZL switch.
Apply 24V to the lock command to unlock the switch.
This command applies to the TLSZR switch.
Reaction Time Describes the time between the true state of the input to the ON state of the output.
Response Time Describes the time between the trigger of the input to the OFF state of the output. Throughout this manual, the safety outputs may be described as turning off immediately. This means that the safety outputs will turn off within the response time.
RFID
OSSD (Output
Signal
Switching
Device)
Radio frequency identification.
Typically a pair of solid-state signals pulled up to the DC source supply. The signals are usually tested for short circuits to the DC power supply, short circuits to the
DC common, and short circuits between the two signals.
Standard coding
TLSZL
TLSZR
Same as Low coding as defined in EN ISO 14119:2013
TLSZ power-to-lock guard locking switch
TLSZ power-to-release guard locking switch
Unique coding Same as High coding as defined in EN ISO 14119:2013
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Chapter
1
General Description
Guardmaster TLSZ Overview
This Guardmaster® TLSZ guard locking switch functions by locking it actuator, which prohibits the opening of a guard.
The TLSZ uses radio frequency identification, RFID, coding to detect the appropriate target.
This version of the Guardmaster TLSZ guard locking switch features OSSD outputs. These outputs are enabled only when the actuator is locked and the RF target is sensed.
This device is intended to be part of the safety-related control system of a machine. Perform a risk assessment before installation to determine whether the specifications of this device are suitable for all operational and
environmental characteristics of the machine. See Specifications on page 55 for
certification information and ratings.
Use nonremovable screws, bolts, or nuts to mount the switch and actuators. Do not over torque the mounting hardware.
TLSZ guard locking switches are classified according to ISO 14119 as Type 4 switching devices. The RFID targets are classified as having a high level of coding.
Measures are to be taken to minimize the need to defeat and to manage the use and availability of spare RFID targets.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 7
Chapter 1 General Description
Catalog Numbers
The schema for the TLSZ catalog number is shown in
Table 1 . The parts of the schema are shown in Table 2
.
Table 1 - TLSZ Catalog Number Setup
440
1
G
2
T
3
Z
4
S21
5
U
6
P
7
R H
8 9
Table 2 - TLSZ Catalog Number Detail
6
7
4
5
2
3
Parameter
1
8
9
R
L
H
U
P
T
Z
S21
G
T
Value
440
Description
Safeguards the Product
Guard locking switch
Titan Locking Switch
PLe rated, cascadable safety signals
Solid-state outputs, 2 safety (OSSD), 1 aux
Unique coded RFID target
Aux signal shows lock status
Aux signal shows door status
Power to Release
Power to Lock
8-pin M12 QD connector
ATTENTION: Guard lock switches that use the Power to Lock principle can only be used after a risk assessment has shown that the Power to Release principle is inappropriate for the application. If a power supply loss occurs with Power to Lock switches, the switches immediately become unlocked and the user may have access to the hazards.
8 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Packaging Contents
General Description Chapter 1
Figure 1 shows the contents in the shipping package. The contents include:
• Switch
• Actuator
• RFID target
• T20 security Torx bit
• Two steel bolts and nuts
• Plug
• Installation instructions (not shown)
Figure 1 - Package Contents
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 9
Chapter 1 General Description
Notes:
10 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Chapter
2
Installation
General Considerations
The TLSZ guard locking switch is designed for use on guards that are engineered to be rigid and without sag. The TLSZ uses radio frequency identification, RFID, coding to detect the appropriate target.
Actuator/Target Mounting
Figure 2 shows the correct and incorrect ways to mount the target with the
actuator.
The TLSZ must only be used with the fully flexible actuator. The replacement part number for the actuator is catalog number 440G-A27143.
Figure 2 - Target/Actuator Mounting
Target
Actuator
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 11
Chapter 2 Installation
Allowable Approach
Directions
The actuator and target must be always mounted as “close coupled” and can approach the switch in any of the three entry slot positions that are shown in
Figure 3 . Approach from the underside is not allowed, as the distance from the
target to the internal RF sensor is too far for reliable operation.
Figure 3 - Allowable Approach Direction
This approach requires guide repositioning, see
Minimum Operating Radius
When applied to hinged doors, the minimum operating distances along the
length and perpendicular is shown in Figure 4
.
Figure 4 - Minimum Operating Distance [mm (in.)]
80 (3.19) 80 (3.19)
80 (3.19) 80 (3.19)
Figure 5 shows the location of the two 1.5 mm (0.06 in.) set screws that can be
adjusted to preset the actuator to an optimal angle, if needed.
Figure 5 - Actuator Set Screw
12
1.5 mm (0.06 in.)
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Manual Release
Manual Override Cover
Installation Chapter 2
The manual release feature only applies to TLSZR (Power to Release) switch.
In some cases, you must manually release the locked actuator.
Figure 6 shows the two locations from which the actuator can be manually
released.
1.
Remove the T20 Torx screw .
2. To release the actuator, insert a small screwdriver or rod in the hole.
If power is applied to the switch when the actuator is released, the OSSD safety outputs turn OFF and the switch goes to a faulted state with the status indicator flashing red at 4 Hz. Power then has to be cycled to the switch to return it to an operational state.
Figure 6 - Manual Release
3
1
T20
2
2
≤ 2.5 (0.10)
Ø
shows an optional cover that is available only for the
TLSZR (Power to Release) switch. This cover has a lever that allows you to manually unlock the actuator at any time. Rotate the lever 90° to unlock the actuator.
If power is applied to the switch when the actuator is released, the OSSD safety outputs turn OFF, and the switch goes to a faulted state with the status indicator flashing red at 4 Hz. Power is then cycled to the switch to return it to an operational state.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 13
Chapter 2 Installation
Figure 7 - Manual Override Cover
1
90°
1.2 N•m (10.62 lb•in)
2
90°
Pair Proximity
Guide Repositioning
If a pair of TLSZ switches are mounted too close to each other, the two RF fields could interact causing crosstalk. Cross talk results in nuisance faults.
An absolute minimum of 200 mm (8 in.) must be used to help achieve correct operation.
The restriction also applies if a TLSZ switch is mounted close to the 440G-LZ guard locking and the 440N-Z SensaGuard™ switches.
The actuator guide can be repositioned to facilitate alignment of the actuator.
In steps 8…11, rotate the metal guide to allow the switch body to be fastened flush to the mounting surface.
Figure 8 - Guide Repositioning
2
3
7
8
1
5
4
10
180°
9
11
6
14 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Steel Locking Bolts
Installation Chapter 2
The TLSZ is assembled in the factory with plastic pins that secure the actuator guide. The plastic pins are rated for a holding force of 1500 N (337 lb). The plastic pins must be replaced with the steel bolts to achieve a holding force of
shows how to remove the cover to replace the blue plastic pins with steel bolts.
Figure 9 - Steel Bolt Installation
1.2 N•m (10.62 lb•in.)
Actuator Clearance
15 (0.59)
2 x M5
1.4 N•m (12.39 lb•in.)
Plastic pins Steel bolts
5 (0.20) dia.
2 x M5
1.4 N•m
(12.39 lb•in.)
1.2 N•m (10.62 lb•in.)
Fzh = 1500 N (337 lb) Fzh = 2000 N (450 lb)
shows the clearance requirements for the TLSZ. The switch must not be used as a guard stop. You must provide a mechanical stop at least 1 mm
(0.04 in.) away from the actuator guide. The actuator must be inserted within
4 mm (0.16 in.) or less from the actuator guide to be sure it locks.
Figure 10 - Clearance and Insertion Distance
1…4 (0.04…0.16)
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 15
Chapter 2 Installation
As shown in Figure 11 , the TLSZ has two slotted holes to facilitate
installation. The slots allow up to 8 mm (0.31 in.) of movement of the switch body to achieve the proper clearance with the actuator.
1. Use the slotted holes for initial installation.
2. After alignment with the actuator, secure the switch body in place by adding mounting hardware in the circular holes.
3. To attain the maximum holding force, replace the plastic pins with steel screws inside the cover.
Figure 11 - Mounting Slots for Alignment [mm (in.)]
Status/
Diagnostic
M5 2 1 3
8 (0.31)
16 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Dimensions
Installation Chapter 2
shows the dimensions for the switch, target, and actuator.
Figure 12 - Dimensions [mm (in.)]
14 (0.55)
21
(0.83)
17 (0.67)
43 (1.69)
Target Alignment Mark
6 (0.24)
23.2 (0.91)
11.9
(0.47)
19
(0.75)
126 (4.96)
105 (4.13)
5 (0.2)
6.5 (0.26)
Status/
Diagnostic
LED
M5 x 4
M5
440G-ATZAE-xxxx
29.3 (1.15)
31.5 (1.24)
52.5 (2.07)
60.5 (2.38)
67.5 (2.66)
14.5
(0.57)
4 (0.16)
7
(0.28)
Target
5.5
(0.22)
20
(0.79)
14
(0.55)
M12
2 x M3
18
(0.71)
19
(0.75)
13
(0.51)
51
(2.0)
Do not use cable gland knockouts, two places
4 x 5.5 (0.22)
6.8
(0.27)
31 (4.22)
40 (1.57)
52 (2.05)
Actuator
8
(0.31)
20
(0.79)
Use with flexible actuator only:
24
(0.94)
2.2 (0.09)
4.2 (0.17)
19.2 (0.76)
Connector location and dimensions
Figure 13 on page 18 shows the dimensions for mounting the target that is next
to the actuator.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 17
Chapter 2 Installation
Figure 13 - Actuator/Target Mounting Dimensions [mm (in.)]
7 (0.28)
5.5 (0.22) 35
(1.38)
6 (0.24)
6 (0.24)
20
(0.79)
40
(1.57)
13 (0.51)
19
(0.75)
3 x M5
Target
Actuator
86.5
(3.4)
18 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Connections
OSSD Inputs
OSSD Outputs
Chapter
3
Wiring
The TLSZ is only available with an 8-pin DC Micro M12 quick-disconnect connector. Figure 14 and Table 3 show the pin assignments and their functions and typical mating cordsets. Other cordsets are available at DC Micro Cordsets and Patchcords .
Figure 14 - 8-pin Micro Quick Disconnect Cables
3 Lock Command
8 Safety A+ Input
4 Safety B+ Input
5 Safety A Output
2 24V DC+
1 Aux
7 0V
6 Safety B Output
Table 3 - TLSZ Quick Disconnect Pin Assignments
Typical Mating Cordsets
889D-F8NB-x
1
(Red, PVC)
889D-F8AB-x
1
(Black, PVC)
Color
White
Brown
Green
Yellow
Grey
Pink
Blue
Red
Function
Aux
24V DC Supply
Lock Command
Safety B+ Input
Safety A Output (OSSD A)
Safety B Output (OSSD B)
Ground (0V)
Safety A+ Input
5
6
3
4
7
8
Pin
1
2
1
Replace symbol with 2 [2 m (6.56 ft)], 5 [5 m (16.4 ft)], 10 [10 m (32.8 ft)], 15 [15 m (49.2 ft)] 20 [20 m [65.62 ft)] or 30 [30 m
(98.4 ft)] for standard cable lengths. The TLSZ has been tested to operate with up to 120 m (393.7 ft) of the mating cables.
The OSSD inputs are Safety A+ and Safety B+. These inputs can be pure
24V DC, or they can contain test pulses. The OSSD inputs allow the TLSZ switches to be connected in-series while maintaining a high level of safety performance.
The OSSD outputs are Safety A and Safety B. These outputs are 24V signals that contain test pulses. The test pulses are used to detect short circuits to 24V, to 0V and cross faults (from Safety A to Safety B). This description of the test pulses is provided for informational purposes; you cannot modify them.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 19
Chapter 3 Wiring
shows the safety output test pulses when connected to a 1K resistive load for hardware (HW) revisions A and B, and for firmware (FW) revisions A through C. The pulses are 25 μs wide and repeat every 20 ms. The exact shape of the pulses depends on the nature of the load. The capacitive and resistive effects of the load are determined with the combination of cabling, cable routing, and connected devices.
Figure 15 - Output Test Pulses
Safety B (Pink)
Safety A (Grey)
5V/Div
Auxiliary Output
Lock Command
20
25μs/Div
Table 4 shows the auxiliary output functions. The auxiliary output is a 24V
DC logic signal, whose function is dependent on the catalog number selected.
The auxiliary signal responds independently of the OSSD safety outputs. The auxiliary output is not a safety-rated signal and must only be used to indicate the status of the switch.
Table 4 - Auxiliary Output Function
Catalog Number
440G-TZS21U P RH
440G-TZS21U P LH
440G-TZS21U T RH
440G-TZS21U T LH
Function
Lock Status
Actuator Status
Value
24V when actuator is unlocked
0V when actuator is unlocked
24V when actuator inserted (gate closed)
0V when actuator removed (gate open)
Table 5 shows the lock command function. The lock command is a 24V logic signal, with a current of less than 5 mA. The function of the logic signal is dependent on the catalog number. The 24V power supply connection provides the power to operate the locking solenoid.
Table 5 - Lock Command Function
Catalog Number
440G-TZS21UP R H
440G-TZS21UT R H
440G-TZS21UP L H
440G-TZS21UT L H
Switch Type
Power to Release
Power to Lock
Function
24V unlocks the actuator
0V locks the actuator
24V locks the actuator
0V unlocks the actuator
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Preparation
Chapter
4
Commissioning
Before use, the switch must first “learn” a new RFID target. This step is not done at the factory.
The switch can learn up to eight targets consecutively. Use this process if there is a potential for the target to become damaged, inoperable, or lost. When a new target is learned, the switch no longer recognizes the older target.
Wire up the switch with at least the functionality shown in Figure 16
.
• Power — connect brown wire to +24V.
• Gnd — connect blue wire to 0V.
• Lock — Leave the green wire ‘open’ when learning the first target.
Connect the green wire to 24V to teach a TLSZR switch subsequent targets. The TLSZL switch ignores the Lock command during learning.
• Safety A+ and Safety B+ — connect red and yellow wires to 24V during commissioning. If 24V is not applied to the A+ and B+ inputs, then the indicator flashes green after commissioning if the switch is locked.
• Safety A and Safety B — optional, no connection required for commissioning.
• Aux — optional, no connection required for commissioning.
Figure 16 - Commissioning Wiring
+24V DC
TLSZ-GD2
Status Diag
889D-F8NB-x
or
889D-F8AB-x
Brown (+24)
Red (Safety A+)
Yellow (Safety B+)
Green (Lock)
Gray (Safety A)
Pink (Safety B)
White (Aux)
Blue (Gnd)
24V DC Com
NC
NC
NC
Lock
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 21
Chapter 4 Commissioning
First Time Power-up
Learn First Target
Turn on the 24V DC power without the actuator and target.
The Status/Diagnostic indicator blinks green 3 times, pauses 2 seconds, and then blinks green 8 times. Eight is the number of times a new target can be learned. The switch continuously repeats the two-second pause followed by the eight blink sequence.
shows the events that take place when the first target is learned. The lock command is ignored until after the switch learns its first target, therefore, the lock command can be 24V or 0V during the first-time learning sequence.
6
7
8
9
Table 6 - First Target Learning Events
4
5
2
3
Step
1
Event
Apply power to switch
Present actuator/target
Detect target
Indicator Color Blink Rate
Red Solid
Red
Red
Solid
Solid
1 Hz
—
Verifying target
Report commissioning error
(see Table 8) or continue
Programming switch
Green/Red
—
Green/Red
Finalizing Red
Number of learns remaining Green
4 Hz
Solid
# of learns
Learn completed
PTR
PTL
Green
Red
Solid
15 s
2 s
15 s
Duration
—
—
2…25 s
15 s
—
Continuous
Learning Additional Targets
Table 7 shows the steps that take place when teaching the switch to recognize an additional target. For PTR switches, the lock command must connect to
+24V to learn additional targets. The PTL switch ignores the lock command during learning.
2
4
5
6
7
8
Table 7 - Additional Target Learning Steps
Step
1
Event Indicator
Color
Red
Blink Rate
Apply power to switch
PTR: Apply 24V to lock command
PTL: Ignores lock command
Present new actuator/target
Detect target
PTR: Solenoid automatically locks
PTL: No action
Verifying target
Red
Red
Red
Solid
Sold
Solid
Solid
Green/Red 1 Hz
Report commissioning error (see Table 8) or continue —
Programming switch Green/Red
—
4 Hz
Duration
—
—
3…25 s
05.s
15 s
—
15 s
22 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Commissioning Errors
Power-up Self-check
Step
9
10
11
12
13
Event
Finalizing
Number of learns remaining
PTR: Solenoid unlocks then locks
PTL: no action
Learn completed
PTR
PTL
PTR: Cycle power
PTL: Ready for use
Commissioning Chapter 4
Indicator
Color
Red
Green
—
Blink Rate Duration
Solid 2 s
# of learns 15 s
— 0.5 s
Red
Red
—
4 Hz
Solid
—
Continuous
—
During commissioning, the switch performs certain checks. If an error is
detected, the Status/Diagnostic indicator reports the error. Table 8 lists the
commissioning error codes. The error code is generated after the switch verifies the target. If an error code is generated, the switch must be power cycled before further learning is started.
Table 8 - Commissioning Error Codes
Indicator Flashes (4 Hz)
Red-Red-Red-Green-Green
Red-Red-Red-Green-Green-Green
Red-Red-Red-Green-Green-Green-Green
Code
Target already learned
Bad RFID
Target that is removed while programming PTL
Exceeded learning eight targets
Upon power-up, the TLSZ performs an internal self-check, which takes approximately three seconds. Whether the actuator/target is inserted and the lock command is present; the indicator remains red or turns green after the self-check.
Table 9 shows the indicator sequence during self-check with the
actuator/target inserted. The self-check sequence occurs only once.
Table 9 - Self-check Indicator Sequence
Model
TLSZR
TLSZL
Lock Signal Indicator Sequence
OFF
ON
Green-Green-Green-Red-Green
Green-Green-Green-Red
OFF
ON
Green-Green-Green-Red
Green-Green-Green-Red-Green
OSSD Outputs
ON
OFF
OFF
ON
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 23
Chapter 4 Commissioning
Notes:
24 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Testing Procedure
Chapter
5
Functional Testing
A manual functional electric test must be made:
• After installation
• After any maintenance or change of component
• If the guard is used infrequently
– Less than once per month for SIL 3/PLe
– Less than once per year for SIL 2/PLd
ATTENTION: During the functional test, confirm that there are no persons in the danger area and that the machine startup causes no hazard.
1. Confirm that the guard door is open.
2. Connect the 24V DC power to pin 2 and ground (0V) to pin 7. The switch conducts a self-testing routine at the end of which the diagnostic indicator shows solid red.
3. Test to confirm that the machine cannot start.
4. Confirm the lock command at pin 3 is set to 0V for PTR and 24V for
PTL types.
5. Test again to confirm that the machine cannot start.
6. Close the guard door and then confirm that the guard is mechanically locked and the diagnostic indicator shows solid green.
7. Test to confirm that the machine can now start.
8. Change the lock command at pin 3. Set it to 24V for PTR and 0V for
PTL types.
9. Confirm the machine stops, the guard door is mechanically unlocked, and the machine cannot restart.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 25
Chapter 5 Functional Testing
Notes:
26 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Chapter
6
Application and Wiring Examples
Wiring to GLP Relay
+24V DC
TLSZR-GD2
Status Diag
24V DC Com
889D-F8NB-2
Brown (+24)
Red (OSSD A+)
Yellow (OSSD B+)
Green (Lock)
Grey (OSSD A)
Pink (OSSD B)
White (Aux)
Blue (Gnd)
Safety
Gate
The following application and wiring examples are intended to show how the
TLSZ products can be applied. If you are the user or the designer, you may require variations to these examples in order to meet their specific requirements.
The GLP safety relay is designed to operate with PTR switches. To use a PTL switch, you must use an interposing relay on the lock command at GLP terminal 51. In the example shown in
, the GLP allows the gate to be unlocked when the motor is running at a Safely-limited Speed.
Figure 17 - GLP and TLSZR Schematic
Gate
Unlock
Request
Reset &
Gate Lock
Request
L1 L2 L3
PowerFlex
525
11 +24V DC
1 Stop
2 Start
5 Preset Freq 1
R S T
4 Gnd
X14 X24 51
L61
S54 A1
AP
S44 Y32
P12 P22
L12
LOGIC
9
8
GLP
7
6 5
440R-GL2S2P
0
4
1
2
3
SLS1
9
8
7
6 5
0
4
1
2
3
SLS2/TIME
9
8
7
6 5
0
4
1
2
3
S12 S22 A2 L11
Proximity Sensors
871TM-DH10NP30-D4
889D-F4AC-2
Gate control power supply
S1
S2
Gate control circuit
U V W
M
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 27
Chapter 6 Application and Wiring Examples
Wiring to GLT Relay
Circuit Status as Shown
The gate is open and unlocked. The motor is off. The GLP is ready for reset.
The GLP has a Logic setting of 3: (Safely-limited Speed with Logic IN OFF), a
Safely-limited Speed (SLS1) setting of 5 (5 Hz) and a maximum (SLS2) speed setting of 8 (2000 Hz). The safety outputs (X14 & X24), the single wire safety output (L11), and the auxiliary output (Y32) are OFF.
IMPORTANT Start the GLP logic configuration from “0” to configure X14 and X24 for use as safety outputs.
Starting
Close the gate and press Reset to lock the gate and turn on the GLP safety outputs. Press Start to turn the motor ON.
Safely-limited Speed
A normal production stop is performed by pressing Stop. Access through the safety gate is initiated by pressing Gate Unlock Request. The Y32 output of the
GLP turns ON and commands the PowerFlex® drive to bring the motor to a safe slow speed (Preset Freq 1). When the proximity sensors detect the speed has dropped below the Safely-limited Speed (5 Hz), the gate becomes unlocked. The operator can enter the machine cell, as the motor continues to run at the safe slow speed. After you leave the cell and close the gate, press Reset to lock the gate and return the machine to production speeds.
The circuit meets the safety requirements up to Category 3, Performance
Level d in accordance with ISO 13849-1 and SIL CL 2 in accordance with
IEC 62061.
The GLT safety relay is designed to operate with PTR switches. To use a PTL switch, you must use an interposing relay on the lock command at terminal 51 of the GLP.
In this example shown in Figure 18 on page 29 , the GLT sends an immediate
command to the drive to turn OFF. After eight seconds, the GLT turns off its safety outputs and unlocks the gate. The risk assessment must determine adequate time delay for the machine to achieve a safe state before unlocking the gate.
28 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
+24V DC
TLSZR-GD2 440G-TZS21xxRH
Status Diag
24V DC Com
889D-F8NB-2
Brown (+24)
Red (OSSD A+)
Yellow (OSSD B+)
Green (Lock)
Gray (OSSD A)
Pink (OSSD B)
White (Aux)
Blue (Gnd)
Safety
Gate
Application and Wiring Examples Chapter 6
Figure 18 - GLT and TLSZR Schematic
Gate
Unlock
Request
Reset &
Gate Lock
Request
S11 S12 51
LOGIC
9
8
GLT
7
6
440R-GL2S2T
5
0
1
3
2
4
S54 A1
RANGE
9
8
7
6 5
0
1
3
2
4
S44 Y32 B2
TIME
9
8
7
6 5
0
1
3
2
4
S12 S22 L61 A2 L11 L12 14 24
L1 L2 L3
PowerFlex
525
11 +24V DC
1 Stop
2 Start
R S T
4 Gnd
Gate control power supply
S1
S2
Gate control circuit
U V W
M
Circuit status as shown: The gate is open and unlocked. The motor is off. The
GLT is ready for reset. The GLT has a Logic setting of 3: (Category 1 Stop), a
Range setting of 4 (10 seconds) and a Time setting of 8 (80%). The Y32 output turns OFF immediately; 8 seconds later, the safety outputs turn OFF.
The safety outputs (14 and 24) and the single wire safety output (L11) are
OFF and the auxiliary output (Y32) is ON.
IMPORTANT Start the GLT logic configuration from “0” to configure 14 and 24 for use with pulse testing; the PF525 can operate with pulse tested inputs to S1 and S2.
Starting
Close the gate. Press Reset and Gate Lock Request to lock the gate and turn on the GLT safety outputs. Press Start to turn the motor ON.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 29
Chapter 6 Application and Wiring Examples
Stopping
Normal production stops are performed by pressing Stop. Access through the safety gate is initiated by pressing the Gate Unlock Request. The Y32 output of the GLP turns OFF, which commands the PowerFlex drive to bring the motor to a stop. After the configured time delay (eight seconds) expires, the GLT safety outputs turn off, and the gate becomes unlocked. After you leave the cell and close the gate, press Reset to lock the gate and return the machine to a production state.
The circuit meets the safety requirements up to Category 3, Performance
Level d in accordance with ISO 13849-1 and SIL CL 2 in accordance with
IEC 62061.
Wiring to DI and EMD Relay
The TLZ can be connected to the DI and EMD safety relays. The DI monitors the safety outputs of the TLZR and the EMD enables the gate to be unlocked after a configured delay time expires.
B1 is connected to B2 to allow for retriggering. If you open and close the
E-stop and press Reset before the delay expires, the EMD timer resets.
Upon initial power-up, the TLSZ must be cycled for the DI to recognize the
TLSZ OSSD signals.
In the example shown in
, an E-stop initiates the machine shutdown. After an eight-second delay, the TLZR is allowed to be unlocked and the hazards that remain are turned OFF. A selector switch is required to maintain the gate in an unlock state. The risk assessment must determine adequate time delay for the machine to achieve a safe state before unlocking the gate.
30 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Application and Wiring Examples Chapter 6
+24V DC
TLSZR-GD2 440G-TZS21xxRH
Status Diag
Safety
Gate
Figure 19 - DI with EMD and TLSZR Schematic
Reset
24V DC Com
889D-F8NB-2
Brown (+24)
Red (OSSD A+)
Yellow (OSSD B+)
Green (Lock)
Grey (OSSD A)
Pink (OSSD B)
White (Aux)
Blue (Gnd)
S11 S21
LOGIC
8
DI
440R-D22R2
7
6
S22 S12
5
0
1
2
4
3
S32 S42 L11 L12
A1
A2
13
14
23 S34
24 Y32
A1 X32
RANGE
9
8
7
6 5
0
4
1
2
3
EMD
440R-EM4R2D
B1 B2
TIME
10
9
8
7 6
1
5
2
3
4
17 27 37 47
A2 L12 L11 X32 18 28 38 48
Unlock
K1 K2 K3 K4
Circuit Status as Shown
The E-stop is released. The gate is open and unlocked. K1, K2, K3, and K4 are
OFF. The DI is configured for two inputs with monitored manual reset. The
EMD is configured for 8-second off-delay; Range setting of 2 is 10 s, Time setting of 8 is 80% of the range. The X32 terminal is ON because the EMD safety outputs are OFF.
Starting
With the Unlock switch open, close the gate. Press Reset to lock the gate and turn on the K1…K4 safety contactors.
Stopping
Stopping is initiated by pressing the E-stop. K1 and K2 contactors turn off immediately. The single wire safety signal from the DI (L11) to the EMD
(L12) also turns off immediately, and the EMD starts the off-delay timer. After
8 seconds, contactors K3 and K4 turn OFF and X32 goes to 24V. The unlock switch is enabled, and the gate can be unlocked. While the gate is unlocked, the
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 31
Chapter 6 Application and Wiring Examples
Wiring to DG Relay
TLSZR
DI cannot turn the safety outputs back ON. After you leave the cell and close the gate, open the unlock switch to lock the gate, and release the E-stop.
The circuit can meet the safety requirements up to Category 4, Performance
Level e in accordance with ISO 13849-1 and SIL CL 3 in accordance with
IEC 62061.
+24V DC
The TLSZR can be used in GuardLink® applications; the TLSZL cannot be used in GuardLink applications. The GuardLink system uses taps to connect a series of devices to one relay. The GuardLink system provides control and status information between the machine control system and the safety system.
shows four TLSZR switches that are connected on two GuardLink circuits from one DG relay. The DG relay can accommodate up to 32 devices on each input. The devices can be a mix of many different safety devices. When guard locking devices are included in the GuardLink system, the lock/unlock command must come from the machine control system through the
440R-ENETR module.
See publication 440R-UM015 for further details.
Figure 20 - DG with TLSZR Schematic
TLSZR
32
INPUT INPUT
INPUT
TLSZR
INPUT
+24V Com
TLSZR
Machine
Control
System
Control
Status
+
S12 S22 S11
A
B
C
440R-ENETR
Control
Status
DG
440R-DG2R2T
S32 S42 X2
S21
TIME
.14
.
0.2.4
.10
A1
X1 A2
13 23 X4
14 24 X3
K1 K2
L1 L2 L3
K1
K2
M
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Wiring to CR30 Relay
+24V DC
TLSZR-GD2
440G-TZS21UTRH
Status Diag
24V DC Com
889D-F8NB-2
Brown (+24)
Red (OSSD A+)
Yellow (OSSD B+)
White (Aux)
Gray (OSSD A)
Pink (OSSD B)
NC
Green (Lock)
Blue (Gnd)
Safety
Gate
Application and Wiring Examples Chapter 6
The CR30 is a software configurable relay that can easily interface with the
TLSZ guard locking switch. Version 10 and later of Connected Components
Workbench™ has a locking function that is useful for guard locking applications.
shows an example schematic. The CR30 monitors the motor running signal from the PowerFlex® 525. When the motor is not running, the safety gate can be unlocked, and the PowerFlex 525 goes to a Safe Torque Off state.
Figure 21 - CR30 Schematic
L1 L2 L3
Reset
Lock
Unlock
Motor Not Running
00 01
CR30
A1 A2
02 03 04 05
440C-CR30-22BBB
06
12 13 14 15 16
07 08
17 18
09 10 11
19 20 21
PowerFlex
525
11 +24V DC
1 Stop
R S T
2 Start
R5
R6 t081=2
4 Gnd
Gate control power supply
S1
S2
Gate control circuit
U V W
M
Figure 22 on page 34 shows an example CR30 configuration that works with
the schematic in Figure 21.
The TLSZR OSSD outputs drive the Safe Torque Off (STO) signals of the
PF525. The STO is enabled after the gate is locked and the Reset is pressed.
The PF525 STO inputs can tolerate the pulse test that is generated by the
CR30 outputs.
The Lock_Ctrl_1 block controls the unlock command to the TLSZR. The unlock Stop Time delay is set to five seconds, and the ULR Latch (Unlock
Request) is set to ON. When an unlock request is made, the command is issued five seconds after the motor stops running, and the unlock request is latched
ON.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 33
Chapter 6 Application and Wiring Examples
Figure 22 - CR30 Configuration in CCW
Wiring to 1734
Guard Point I/O
The TLSZ can be connected to a 1734 Guard POINT I/O™. The catalog number 889D-F8NB cordset has 24-AWG wires; which allows three wires that are connected to one terminal. This wiring example shows a Power to Lock switch with a Door Status auxiliary signal. The PLC logic checks to see if the door is closed before issuing a lock command. The schematic for this example is shown in
34 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Application and Wiring Examples Chapter 6
Figure 23 - 1734 and TLSZL Schematic
Safety
Gate
TLSZL-GD2
Status Diag
440G-TZS21STLH
Power to Lock
Aux = Gate Status
889D-F8NB-10
White (Aux)
Gray (OSSD A)
Pink (OSSD B)
Blue (0V)
Green (Lock)
Red (OSSD A+)
Yellow (OSSD B+)
Brown (+24V)
1734-AENT
Ethernet I/P to GuardLogix
PLC and HMI
24V DC Com
+24V DC
0
2
6
4
1
3
I0
I2
5
7
COM
T0
COM
T1M
I1
I3
K1
K2
1734-IB8S 1734-OB8S
I4
I6
I5
I7
O0
O2
O1
O3
COM
T2
COM COM
T3M COM
COM
COM
O4
O6
O5
O7
COM COM
COM COM
K1 K2
shows the General Tab of the 1734-IB8S Module Properties. The
Input Status must be set to “Combined Status – Muting” as this setting is used by the Dual Channel Input Stop logic block to verify that 1734-IB8S is operational. The Output Data must be set to “Test,” as the test outputs are used to generate test pulses for the output contactors.
Figure 24 - 1734-IB8S Module Properties – General
Figure 25 on page 36 shows the Input Configuration tab of the 1734-IB8S
Module Properties. In this example, Points 0 and 1 monitor the OSSD outputs of the TLSZL. The Type is set to Single (to allow the Logix program to detect
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 35
Chapter 6 Application and Wiring Examples potential faults) and Mode must be set to Safety. Points 2 and 3 monitor the status of the output contactors K1 and K2. Set the Type to Single (to allow the program to detect potential faults). Safety pulse testing detects potential faults in the monitoring circuit. The TLSZ can operate with the Input Delay Time set to zero.
Figure 25 - 1734-IB8S Module Properties – Input Configuration
shows the Test Output tab of the 1734-IB8S Module Properties. In this example, Points 0 and 1 are set to pulse test as these points help check the integrity of contactors K1 and K2. Points 2 and 3 are set to “Standard.” Point 2 is the lock command, and Point 3 applies power to the TLSZL and supplies power to the OSSD inputs. By setting it to standard, you can programmatically turn Points 2 and 3 off and on.
Figure 26 - 1734-IB8S Module Properties –Test Output
36 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Application and Wiring Examples Chapter 6
shows the General Tab of the 1734-OB8S Module Properties. The
Output Data must be set to “Safety,” as it is controlling the output safety contactors.
Figure 27 - 1734-OB8S Module Properties – General
shows the Output Configuration tab of the 1734-OB8S Module
Properties. Points 0 and 1 drive the output contactors K1 and K2. The point
Types are set to Dual, and the Modes are set to Safety.
Figure 28 - 1734-OB8S Module Properties – Output Configuration
Figure 29 on page 38 shows an example logic program. A Dual Channel Input
Stop function block monitors the TLSZL and a Configurable Redundant
Output function block controls two contactors. This example can be used as a starting point for implementation; you must incorporate additional logic that is based on the risk assessment for the machine.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 37
Chapter 6 Application and Wiring Examples
Figure 29 - Studio 5000® Example Logic Program
38 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Application and Wiring Examples Chapter 6
Wiring to 1732 ArmorBlock
The TLSZ can be connected to a 1732ES or 1732DS ArmorBlock® by using an
871A-TS5-DM1 field attachable connector. The cordset 889D-F8NB has 24-
AWG wires that connect to one pin. An example schematic is shown in
.
As an alternative, you can use an 871A-TS8-D1 field attachable connector at the TLSZ and a 5-wire cordset (889D-M5NC-x).
Figure 30 - ArmorBlock Schematic
871A-TS5-DM1 5 pin
Field Attachable Connector
1732ES-IB12XOB4
2 1
5
3 4
EtherNet
2 1
5
3 4
X100 X10 X1
Brown (+24)
Red (OSSD A+)
Yellow (OSSD B+)
Gray (OSSD A)
Blue (Gnd)
Pink (OSSD B)
Green (Lock)
White (Aux)
N/C
889D-F8NB-5
Status Diag
TLSZR-GD2
889D-E5NC-10
24V Com
1 T1
2 I1
3 C
4 I0
5 T0
A E
1 T1
2 I1
3 C
4 I0
5 T0
1 T1
2 I1
3 C
4 I0
5 T0
B F
1 T1
2 I1
3 C
4 I0
5 T0
1 T1
2 I1
3 C
4 I0
5 T0
C G
1+24
2 O1
3 C
4 O0
5 C
889D-E5NC-10
1 T1
2 I1
3 C
4 I0
5 T0
4
3
1
2
D H
1+24
2 O1
3 C
4 O0
5 C
Power
1
2
4
3
100S or 700S or 700-HPS
Contactors and Relays
White (2) A1
Black (4) A1
K1
A2 Blue (3)
K2
A2 Gray (5)
Safety
Gate
Brown (1)
Black (4)
K1
K2
White (2)
Gray (5)
+24V DC
Figure 31 on page 40 shows the General Tab of the ArmorBlock Module
Properties. The Input Status must be set to “Combined Status — Muting” and the Output Data must be set to “Combined.”
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 39
Chapter 6 Application and Wiring Examples
Figure 31 - Module Properties - General
shows the Input Configuration tab of the ArmorBlock Module
Properties. In this example, Points 0 and 1 monitor the OSSD outputs of the
TLSZR. The Type is set to Single (to allow the Logix program to detect potential faults), and Mode must be set to Safety. Points 4 and 5 monitor the status of the output contactors K1 and K2. Set the Type to Single to allow the
Logix program to detect potential faults. The safety pulse test is used to detect potential faults in the monitoring circuit.
Figure 32 - Module Properties – Input Configuration
40
Figure 33 on page 41 shows the Test Output tab of the ArmorBlock Module
Properties. In this example, Points 0 and 1 are set to Standard. The Standard setting allows these two points to be controlled by the program. Point 0 applies power to the TLSZR. By setting it to Standard, you can programmatically turn
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Application and Wiring Examples Chapter 6 this point off and on if the TLSZ switch has a fault condition. Point 1 is the lock/unlock command. In this example, the TLSZ is a PTR type, so 24V unlocks the switch. Use Points 4 and 5 to monitor the contactor outputs and are set to pulse test.
Figure 33 - Module Properties – Test Output
shows the Output Configuration tab of the ArmorBlock Module
Properties. Points 0 and 1 drive the output contactors K1 and K2. The point
Types are set to Dual, and the Modes are set to Safety.
Figure 34 - Module Properties – Output Configuration
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 41
Chapter 6 Application and Wiring Examples
shows an example program. A Dual Channel Input Stop function block monitors the TLSZR and a Configurable Redundant Output function block controls two contactors. This example can be used as a starting point for implementation; based on the risk assessment for the machine, you can incorporate additional logic.
Figure 35 - Example Studio 5000 Program
42 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Tools Needed
Chapter
7
Diagnostics and Troubleshooting
Most importantly, persons who are trained in the safety of machine systems must conduct troubleshooting procedures. This training includes knowledge of all sources of energy (for example electrical, pneumatic, safety, thermal, others).
The best approach to troubleshooting the TLSZ guard locking switches is to observe the status indicator on the switch and follow the flow diagram that is shown in
Required Tools
1. T20 security-Torx screwdriver bit. Notice that the security Torx has a hollowed center. You need this bit to remove the cover of the TLSZ.
2. You need a medium-sized flat screwdriver for terminal screws, to remove terminal blocks, and to configure the switches on the front face of the relays.
3. Digital Multi-meter (DMM) — to measure signal levels and resistance.
Optional Tools
1. Oscilloscope — dual or four channel storage scope to view input and output signals and to capture signals and noise transients.
2. Metal paper clips — to insert into the terminals and allow connection of scope probes to terminals.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 43
Chapter 7 Diagnostics and Troubleshooting
Flowchart
shows a flow diagram to help diagnose the condition of the TLSZ switch.
Figure 36 - Troubleshooting Flow Diagram
Look at the Status Indicator
Yes
Is it OFF?
No
Go to Step 1
Is it Flashing Red
at 4Hz?
No
Yes
Go to Step 2
Is it Flashing Red
at 1Hz?
No
Yes
Go to Step 3
Is it Flashing Green at 1Hz?
No
Yes
Go to Step 4
Is it Flashing
Red and Green?
No
Yes
Go to Step 5
Is it Solid Red?
No
Yes
Go to Step 6
Is it Solid Green?
No
Contact Product Support
Yes
Go to Step 7
Step 1 — Status
Indicator OFF
When the status indicator is OFF, the TLSZ is not connected properly to either the 24V power supply or ground.
1. Use the Torx screwdriver to remove the TLSZ cover.
2. Use a digital multi-meter (DMM) to measure the voltage at the power supply terminals (blue wire is 0V and brown wire is plus), as shown in
The voltage must measure between 20.4V and 26.4V DC.
44 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Diagnostics and Troubleshooting Chapter 7
Figure 37 - Measure the Voltage at the Power Supply Terminals
Acceptable Range
20.4V DC to 26.4V DC
DMM
24
Volts
Terminal Color: QD pin - Function
Green: 3 - Lock/Unlock
White: 1 - Aux
Red/Yellow: 4 - Safety B+
Red/White: 6 - Safety B
Red: 8 - Safety A+
Red/Black: 5 - Safety A
No Connection
Brown: 2 - +24V DC
Blue: 7 - 0V
If 24V is present at the wiring terminals, then check that the wires are stripped and the terminal screws are tight. If the wires are okay, then replace the switch.
If 24V is not present at the terminals, then check the power supply and the wiring up to the TLSZ switch.
Step 2 — Status Indicator
Flashing Red at 4 Hz
The status indicator flashes red at a 4-Hz rate when an inconsistency is detected with the RFID sensor. A number of scenarios can cause this fault indication.
Wrong Target
The TLSZ is configured to detect a specific target. If a non-configured target is presented to the TLSZ, the TLSZ goes into fault mode and its status indicator flashes red at 4 Hz.
To correct this condition:
1. Replace the incorrect target with a correct target.
2. Cycle the power to clear the fault.
When received from the factory, the TLSZ is not configured to detect any target. You must configure the TLSZ to detect a target. The configuration can be a one-time event, or the TLSZ can be configured to be able to learn up to eight different targets. The TLSZ can only recognize one target. If the target gets damaged, the TLSZ can be configured to learn another target, if initial configuration is set to multi-time learning, see
Commissioning Errors on page 23 .
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 45
Chapter 7 Diagnostics and Troubleshooting
Missing Target
If the actuator is inserted into the TLSZR without the target present, the status indicator flashes red at 4 Hz.
To correct this condition:
1. Remove the actuator from the switch.
2. Cycle power to the TLSZR
3. Mount the target next to the actuator as shown in
.
Insert the actuator/target into the switch.
Target Not Mounted Correctly
If the actuator is mounted incorrectly, the TLSZ can operate correctly, but with reduced tolerance to misalignment of the target. The status indicator intermittently goes to a fault state with the status indicator flashing red at 4 Hz.
To correct this condition:
1. Remove the actuator/target from the switch.
2. Cycle power to the TLSZ to clear the fault.
3. Mount the target next to the actuator as shown in
.
4. Insert the actuator/target into the switch.
Figure 38 - Mounting of Target and Actuator
Target
Actuator
46 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Diagnostics and Troubleshooting Chapter 7
Pair Proximity
The RF field from a neighboring switch can cause intermittent faults. Switches with similar RF technology include the TLSZ, the SensaGuard™ switches, and the 440G-LZ guard locking switches.
To correct this condition:
1. Make sure that the neighboring switches are mounted at least 200 mm
(8 in.) from any edge of the TLSZ.
2. Cycle power to the TLSZ switch to clear the fault.
Mechanical Pressure on Safety Gate
If a mechanical load (pressure) is applied to the gate during unlocking, the
TLSZR goes to a fault mode. The status indicator flashes green three times and then red once. It repeats this process for 10 seconds, and then the status indicator flashes red at 4 Hz. Firmware 1.003 and earlier have a 10-second limit. Firmware 1.004 attempts to lock for 10 minutes.
1. Check the allowable spacing between the TLS and mechanical gate stop.
2. Adjust the spacing to be between 1 mm (0.04 in.) and 4 mm (0.16 in.)
between the actuator and the metal guide as shown in Figure 39 .
3. Cycle power to the TLSZ switch to clear the fault.
The safety gate needs a little freedom to move when locked.
Figure 39 - Clearance in Closed Position [mm (in.)]
1…4 (0.04…0.16)
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 47
Chapter 7 Diagnostics and Troubleshooting
Long Wiring
Long input wiring adds resistance and decreases the supply voltage to the switch and reduces the safety OSSD outputs. The size of the wire also makes a difference; smaller wires have higher resistance.
shows the typical TLSZ test pulses when connected to a resistive load with short [2 m (6.56 ft) wiring. The test pulses are about 25 ms wide.
IMPORTANT The OSSD outputs are about 23V and the test pulses go to zero volts.
Figure 40 - TLSZ Test Pulses Into a 1K Resistive Load
In Figure 41 on page 49 , a TLSZR and GSR-SI operate successfully with long
wiring. The OSSD outputs drop to approximately 21V and the test pulses only drop to approximately 8V (not 0V).
48 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Diagnostics and Troubleshooting Chapter 7
Figure 41 - Effect of 300 ohms of Wire Resistance Going Into a GSR-SI Safety Relay
Voltage Supply Dips
When you energize the TLSZ solenoid, it causes a 350 mA in-rush current on the power supply wire. If multiple TLSZ switches are energized simultaneously, the voltage supply can dip below the 20.4V voltage specification and cause the switch to go to fault mode.
Voltage drop is by:
1. The number of switches being energized simultaneously,
2. The power supply wire size, and
3. The wire length.
IMPORTANT The lock/unlock command on the TLSZ is not like the older TLS1, TLS2, and on the TLSZ (both Power to Lock and Power to Release) is a logic level signal; about 3…5 mA. The power to energize the solenoid is provided by the
‘brown’ power supply wire.
To avoid the power supply dip, it is recommended that you stagger the lock/ unlock command to successive switches by at least 170 ms.
Rapid Locking
The TLSZL Power to Lock switches cannot withstand rapid locking and unlocking. This action results in the indicator flashing red at 4 Hz. Although the TLSZR Power to Release switches are more tolerant to rapid unlocking/ locking, they can also go to a fault state with the indicator flashing red at 4 Hz.
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 49
Chapter 7 Diagnostics and Troubleshooting
Step 3 - Status Indicator
Flashes Red at 1 Hz
It is recommended you check that the locking operation frequency is no faster than 1 Hz with 50% duty cycle (500 ms lock, 500 ms unlock).
This status indicates that an undetermined fault has occurred.
Cycle the power. If the switch does not recover, cycle it again. If the switch does not recover, then run a separate cable directly from the power supply to the switch. This cable can run on the floor away from any extraneous signals. You can also provide a temporary selector switch to execute the lock/unlock command.
Case 1. Switch Operates OK. Check the routing of the cable from the power supply to the switch. Be sure of adequate separation of switch cabling to sources of electromagnetic noise, such as drives and motion systems.
Case 2: Switch Faults. If the switch fails with the cabling on the floor (clear of all electromechanical noise), then replace the switch.
Capacitive Loading
The OSSD outputs of the TLSZ uses pulse testing to detect faults. The pulse testing is subjected to the capacitive loading of the cabling (longer cabling creates additional capacitance) and capacitance from the device to which it is connected.
Cable capacitive loading is not an intermittent issue. Once resolved, the capacitance can remain unchanged until conditions, such as cabling changes, occur.
Use an oscilloscope to measure the pulse tests.
Figure 42 on page 51 shows the
typical effect; curved leading edge indicates capacitive loading.
The TLSZR can withstand a capacitive load up to 375 nF. Higher capacitance causes the OSSD outputs to turn OFF and the indicator flashes red at 1 Hz.
Higher levels of capacitance can be tolerated by adding a 10K resistor from the
OSSD signal to ground.
50 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Figure 42 - Typical Capacitive Effect on Pulse Tests
Diagnostics and Troubleshooting Chapter 7
Step 4 — Status Indicator
Flashes Green at 1 Hz
When the status indicator is flashing green at 1 Hz, the switch is indicating that it is waiting for 24V to be applied to the OSSD A+ and OSSD B+ input signals.
Upon power-up, the TLSZ performs internal checks. During this time, the status indicator flashes green three times, shows solid red for about two seconds. If the OSSD A+ and OSSD B+ inputs are not connected to 24V, the status indicator then flashes green at 1 Hz.
Corrective Action:
1. If you have multiple switches that are connected in series, check the
OSSD outputs of the prior switch.
a. If the prior switch is flashing green, go to then next prior switch to determine why its OSSD outputs are OFF.
b. If the TLS is the only switch or the first switch in a series connection of switches, check the power supply connections of OSSD A+ (red wire) and OSSD B+ (yellow wire).
Step 5 — Flashing Red and
Green
The TLSZ switch was initially configured for multi-time use. The flashing red and green indicator indicates the number of configurations that can be completed, see
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 51
Chapter 7 Diagnostics and Troubleshooting
Step 6 — Indicator Solid Red
The solid red indicator occurs when specific faults have not been detected.
1. Try to cycle power.
2. Remove the cable and reconnect the switch to a separate cable and use the existing power supply.
a. If the switch recovers, check the existing cable routing to be sure that the switch cable is not along motor or other high–noise wiring. Also check the grounding scheme, the 0V of the switch must be very close to the safety logic device to which it interfaces.
a. If the switch does not recover, proceed to Step 3.
3. Remove the switch from the installation and apply a bench test circuit.
a. If the switch still exhibits solid red indicator, replace the switch.
b. If the switch recovers, then re-examine the cable routing and the grounding scheme.
Step 7 — Other
Considerations
Distribution Block
The TLZ can be connected the 898D distribution block. The block is available with either four or eight ports. An example with eight ports is shown in
Figure 43 on page 53 . This application requires a couple of special
considerations:
1. The cable length in this example, are all 30 m (98.4 ft) long. The cable length causes a 1.5V drop in power at the switch.
2. If the power supply is set to 24V, the voltage at the terminals inside each switch is 22.5V.
Common Lock Signal
The lock/unlock command is simultaneously applied to all eight switches.
Each switch has a 300 mA nominal (350 mA max) inrush current that lasts about 110 ms (see
Figure 44 on page 53 ). With all 8 switches locked/unlocked
at the same, the inrush current is 2.4 A. The power supply must be able to accommodate this inrush.
52 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Figure 43 - TLSZ with 898D Distribution Block
Diagnostics and Troubleshooting Chapter 7
Figure 44 - In-rush Current on the Power Supply at the Switch
GSR Relays on Power-up
Upon power-up, the Guardmaster safety relays (GSR) input does not recognize the status of the TLSZ outputs; the IN1 indicator remains OFF. The TLSZR must be unlocked and then locked. Then the GSR relay recognizes the OSSD outputs of the TLS. This sequence only occurs on power-up and is a function of the GSR (not the TLSZ).
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 53
Chapter 7 Diagnostics and Troubleshooting
Notes:
54 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Specifications
Specifications and Safety Ratings
Appendix
A
Attribute 440G-TZS21UPRH, 440G-TZS21UPLH,
440G-TZS21UTRH, 440G-TZS21UTLH Cat. Nos.
Operating Characteristics
TLSZR-GD2
TLSZL-GD2
Assured Locking Distance
Torque for M5 Mounting
Torque for Cover Mounting
Locking Force Fmax
Locking Force Fzh per EN/ISO 14119
Power to Release
Power to Lock
13 mm (0.51 in.) Maximum target distance
4 mm (0.16 in.) Maximum clearance between actuator base and switch in the door closed position
1.4 N•m (12.39 lb•in)
1.2 N•m (10.62 lb•in)
Plastic pins: 1950 N (488 lb)
Steel bolts: 2600 N (585 lb)
Plastic pins: 1500 N (337 lb)
Steel bolts: 2000 N (450 lb)
200 mA Maximum Output Current (all outputs)
Current Consumption solenoid not energized, no output load solenoid energized, no output load
Inrush Current
Solenoid Duty Cycle
Off-State Current
Maximum number of switches connected in series
Operating Voltage Ue
Frequency of Solenoid Operating Cycle
Actuation Speed
Response Time (turn Off)
Utilization Category per IEC 60947-5-2
Impulse Withstand Voltage Uimp
Protection Class
Mechanical Life
Environmental
Operating Temperature [C (F)]
75 mA
120 mA
350 mA
100%
< 0.5 mA DC
Unlimited. See Unit Response Time on page 8
24V DC +10% / -15%, Class 2 Source Required
1 Hz, max
160 mm/s (6.29 in/s), max
100 mm/min (3.94 in/min), min
75 ms first switch, 25 ms additional for each switch
DC-13, 24V 200 mA
250V
2
1,000,000 cycles
Operating Humidity [% relative]
Risk Time, Max [ms]
If the RFID door target moves outside of the operating distance, the safety outputs are deactivated
Rated Insulation Voltage Ui [V]
Enclosure Ingress Rating
Shock per IEC 68-2-27 [g, ms]
-10…+60 °C (+14…140 °F)
5…95
60
500
NEMA 3, 4X, 12, 13, IP66, IP67, IP69K
30, 11
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 55
Appendix A Specifications and Safety Ratings
Safety Ratings
Attribute
Vibration IEC 68-2-6 [Hz, mm]
Radio frequency
Pollution Degree
Altitude, Max [m(ft)]
General
Housing Material
Actuator Material
Target Material
Connection
Protection
Short Circuit Protection
Attribute
Standards
Category per ISO 13849-1
Performance Level per ISO 13849-1
SIL Claim Limit per IEC 62061
PFHd [1/h]
Proof test Interval [years]
Certifications
440G-TZS21UPRH, 440G-TZS21UPLH,
440G-TZS21UTRH, 440G-TZS21UTLH Cat. Nos.
10…55, 0.35
IEC 61000-4-3
IEC 61000-4-6
3
2000 (6562)
UL Approved glass-filled PBT
Stainless steel
UL Approved glass-filled PBT
M12 8-pin connector
Incorporated
440G-TZS21UPRH, 440G-TZS21UPLH,
440G-TZS21UTRH, 440G-TZS21UTLH Cat. Nos.
IEC 60947-5-3, IEC 60947-5-1, IEC 62061, IEC 61508,
ISO 138491, ISO 14119
4
PLe, includes guard door position and lock monitoring
3
1.70E-09
20
CE Marked for all applicable EU directives, c-UL-us (UL 508), and
TÜV
56 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Index
A
C
common techniques used in this manual 5
D
G
H
I
L
O
OSSD 6, 33, 35, 36, 40, 48, 50, 51, 53
P
Power to Lock 6, 8, 20, 34, 49, 55
Power to Release 6, 8, 13, 20, 49, 55
R
RFID 6, 7, 8, 9, 11, 21, 23, 45, 55
T
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 57
Index
Notes:
58 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
Notes:
Index
Rockwell Automation Publication 440G-UM002A-EN-P - March 2019 59
Index
60 Rockwell Automation Publication 440G-UM002A-EN-P - March 2019
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Publication 440G-UM002A-EN-P - March 2019
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Key features
- RFID target detection
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- Manual release
- Manual override cover
- Power to Release
- Unique coding
- Type 4 switching device