Rockwell Automation Allen-Bradley Guardmaster 440G-LZS21SPLB User Manual
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User Manual
Original Instructions
Guardmaster Guard Locking Switch
Catalog Numbers 440G-LZS21SP x , 440G-LZS21SPR x , 440G-LZS21STL x , 440G-LZS21STR x , 440G-LZS21UPL x , 440G-
LZS21UPR x , 440G-LZS21UTL x , 440G-LZS21UTR x
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
Safety Concept
Installation
Wiring
Table of Contents
Preface
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Guardmaster 440G-LZ Safety Switch Overview. . . . . . . . . . . . . . . . . . . 7
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 2
Safety Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 3
General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Correct Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Orientation of Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Actuator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Allowable Approach Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mounting the Switch Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Actuator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal of the Actuator Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Auxiliary/Manual Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 4
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OSSD Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connections Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Auxiliary Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lock Command. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Response Time When Connected in Series Circuit. . . . . . . . . . . . . . . 25
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 3
Table of Contents
Commissioning
Chapter 5
Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
First Time Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Learning Additional Replacement Actuators . . . . . . . . . . . . . . . . . . . . 28
Locking the Actuator Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Error Codes during the Commissioning Process . . . . . . . . . . . . . . . . . 29
Prove Basic Lock Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 6
Diagnostics and Troubleshooting
LED Indicators during Power-up Routine. . . . . . . . . . . . . . . . . . . . . . . 31
LED Indicators during Normal Operation . . . . . . . . . . . . . . . . . . . . . . 31
Diagnosis of Switch Condition Using LED Indicators. . . . . . . . . . . . 31
Diagnosis of Physical Switch Anomalies . . . . . . . . . . . . . . . . . . . . . . . . . 34
Troubleshoot Series Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Application Examples
Chapter 7
Wiring to GLP Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Wiring to GLT Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Wiring to DI and EMD Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring to DG Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wiring to CR30 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wiring to 1734 Guard Point I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Wiring to 1732 ArmorBlock Guard I/O . . . . . . . . . . . . . . . . . . . . . . . . 48
Appendix A
Specifications and Safety Ratings
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Compliance to European Union Directives. . . . . . . . . . . . . . . . . . . . . . 55
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Typical Installations
Appendix B
Switch Mounted Parallel to Hinge Axis . . . . . . . . . . . . . . . . . . . . . . . . . 57
Switch Mounted Perpendicularly to Hinge Axis . . . . . . . . . . . . . . . . . 58
Switch Mounted to a Sliding Guard Door . . . . . . . . . . . . . . . . . . . . . . . 59
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Preface
Summary of Changes
This manual contains new and updated information as indicated in the following table.
Topic
Added information about 440G-LZ being a Type 4 interlocking device with low and high coding, according to EN ISO 14119
Separated Installation & Wiring chapters
Added a note warning against the use of washers when mounting the switch body
Added information about mounting for Protection from particle build-up under
Environmental Considerations
Revised the Commissioning section for easier understanding
Created Diagnostics and Troubleshooting Chapter
Created Application Examples Chapter in order to add application examples for DG
Relay, CR30 and GSR GLT Relay
Added Mechanical Lifetime under Specifications
27
31
37
Page
13 and 21
16
18
53
Who Should Use This Manual
Use this manual to design, install, program, or troubleshoot systems that use the Guardmaster 440G-LZ guard lock 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 440G-LZ 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 440G-LZ switch, and
• Provides an overview of the Guardmaster 440G-LZ 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 document offers additional information about related Rockwell
Automation products:
Resource
Allen-Bradley Industrial Automation Glossary, publication AG-7.1
Description
Glossary of industrial automation terms and abbreviations
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 5
Preface
6
Terminology
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.
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 440G-LZ switch.
Apply 24V to the lock command to unlock the switch.
This command applies to the 440G-LZ 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
440G-LZL
440G-LZR
Same as Low coding as defined in EN IS O 14119:2013
440G-LZ power-to-lock guard locking switch
440G-LZ power-to-release guard locking switch
Unique coding Same as High coding as defined in EN I SO 14119:2013
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Chapter
1
General Description
Guardmaster 440G-LZ
Safety Switch Overview
This Guardmaster® 440G-LZ guard lock safety switch functions by extending a locking bolt from the switch through a hole in the actuator, which prohibits the opening of a guard.
The locking bolt drive mechanism and logic confirm that the locking bolt is allowed to extend only when the corresponding actuator is detected within range.
RFID technology enables high precision operation while meeting the requirements to prohibit actuator substitution as described in EN ISO 14119.
The 440G-LZ safety switches are classified according to ISO 14119 as Type 4 interlocking devices with guard locking. The unique coded actuators are classified as having a high level of coding.
The Guardmaster 440G-LZ guard lock safety switch features OSSD outputs.
These outputs are enabled only when the locking bolt is sensed in its extended position in the actuator. This action only happens when the guard is both closed and locked.
The locking bolt drive mechanism uses a bi-stable solenoid. As a result, the switch consumes little electrical power, with peak currents occurring (only briefly) on startup and after each movement of the locking bolt.
Because of its bi-stable drive, not only does the device consume minimal power, but it also does not produce heat while it is locked or unlocked.
Despite the bi-stable design of the locking bolt drive, the device logic and functionality are configured to replicate the functionality of a Power to Release or Power to Lock solenoid-operated switch (depending on type).
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 7
Chapter 1 General Description
Assembly Overview
Locking bolt
QR Code
Switch body
Actuator
Actuator mounting bracket
Alignment guide
8 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
General Description Chapter 1
Catalog Numbers
Table 1 - Catalog Number Explanation
Type
Power to Release
Power to Lock
Power to Release
Power to Lock a
S Standard Coding
U Unique Coding
Actuator Coding
Standard (Low level to
EN
I
SO
14119:2013)
Unique (High level to EN
ISO
14119:2013)
Standard (Low level to EN
ISO 14
119-2013)
Unique (High level to EN
ISO
14119:2013)
Standard (Low-level
EN
I
SO
14119:2013)
Unique (High-level
EN
I
SO
14119:2013)
Standard (Low-level
EN
I
SO
14119:2013)
Unique (High-level
EN
I
SO
14119:2013)
440G-LZS21 b
P AUX- Lock Status
T AUX- Door Proximity a b c d
L b
R Power to Release
Power to Lock
A
B
H d
3 m Cable
10 Cable
M12 8-pin
Table 2 - Complete Switches, including Switch Body, Actuator, and Actuator Mounting Bracket
3 m lead
440G-LZS21SPRA
440G-LZS21UPRA
440G-LZS21SPLA
440G-LZS21UPLA
440G-LZS21STRA
440G-LZS21UTRA
440G-LZS21STLA
440G-LZS21UTLA
10 m lead
440G-LZS21SPRB
440G-LZS21UPRB
440G-LZS21SPLB
440G-LZS21UPLB
Cat. No.
Connection
6 in. pigtail with M12
8-pin Quick Disconnect
440G-LZS21SPRH
440G-LZS21UPRH
440G-LZS21SPLH
440G-LZS21UPLH
440G-LZS21STRB
440G-LZS21UTRB
440G-LZS21STLB
440G-LZS21UTLB
440G-LZS21STRH
440G-LZS21UTRH
440G-LZS21STLH
440G-LZS21UTLH
Auxiliary Type
Lock Status
Lock Status
Lock Status
Lock Status
Door Proximity
Door Proximity
Door Proximity
Door Proximity
Type
Power to Release
Power to Lock
Table 3 - Spare Actuators and Actuator Mounting Bracket
Coding
Standard (Low-level EN
ISO
14119:2013)
Unique (High-level EN
ISO
14119:2013)
Standard (Low-level EN
ISO
14119:2013)
Unique (High-level EN
ISO
14119:2013)
Cat. No.
440G-LZASPR
440G-LZAUPR
440G-LZASPL
440G-LZAUPL
Actuator mounting bracket
Table 4 - Accessories
Description
Switch body mounting bracket
440G-LZAM1
Cat. No.
440G-LZAM2
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 9
Chapter 1 General Description
Packaging Contents
The box includes the following components:
Figure 1 - Switch Body Including Connection Lead: 3 m or 10 m Flying Lead or Pigtail Equipped with M12 QD Connector
10
Figure 2 - Actuator Mounting Bracket
Figure 3 - Actuator
Figure 4 - Mounting Screws: 2 x T10 Torx
Figure 5 - Alignment Guide
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Safety Standards
Safety Certification
Chapter
2
Safety Concept
The Guardmaster® 440G-LZ safety switch satisfies applicable requirements in the following standards that are related to functional safety and machinery assembly:
• IEC 60947-5-1: 2003+A1: 2009
• IEC 60947-5-3: 1999/A: 2005
• IEC 61508:2010 SIL 3
• IEC 62061:2005 SIL 3
• EN ISO 13849-1:2008/AC: 2009 Performance Level e (PLe),
Category 4
• EN ISO 14119:2013
• UL 508 17 th
Edition dated 3/19/2013
The Guardmaster 440G-LZ safety switch is certified for use in safety applications up to and including SIL 3 according to IEC 61508 and IEC
62061 with a proof interval of 20 years, and Performance Level PLe Category 4 in compliance with ISO 13849-1.
Safety requirements are based on the standards applicable at the time of certification.
The TÜV Rheinland group has approved the Guardmaster 440G-LZ safety switch for use in safety-related applications where Performance Level “e” is required for the door position and lock monitor functions.
The 440G-LZ safety switch must be installed in accordance with the applicable regulation and standards.
While the 440G-LZ safety switch can be used for SIL 3, PLe, and Category 4 applications, the installer must comply with guard requirements (for example,
EN I SO13854 and EN ISO 13857), and in some cases minimum (safe) distance requirements (for example, EN ISO 13855).
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 11
Chapter 2 Safety Concept
ATTENTION: A risk assessment is required to prove that the selected switch can be used in the desired application. A functional test of the system is
necessary to validate that it works as expected (see Functional Testing on page 20 ).
Guard locking switches that are activated by the Power to Lock principle,
440G-LZS 21 **L* safety switch, must only be used after a risk assessment has shown that the use of a Power to Release principle, 440G-LZS21**R* safety switch is inappropriate. This assessment is necessary since the guard can be immediately opened after a loss of power supply or upon de-activation of the unlocking signal.
The installed system, including the safety control system and the means by which the machine stops, must achieve the needed safety performance. The
440G-LZ safety switch is one element in the safety system.
Additional guidance on guards, guard locking and guard interlock can be found in:
• EN ISO 12100
• EN ISO 13854
• EN ISO 13855
• EN ISO 13857
• EN ISO 14119
• EN ISO TR 24119
• EN ISO 14120
• Application-specific C-level standards
12 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Chapter
3
Installation
General Considerations
Correct Use
Installation must be in accordance with the present manual and implemented by qualified personnel exclusively. The 440G-LZ guard locking safety switch is intended to be part of the safety-related control system of a machine.
ATTENTION: Before installation, a thorough risk assessment must be performed to determine whether the specifications of this device are suitable for all foreseeable operational and environmental characteristics of the application.
Review the following requirements and guidelines for proper use of the safety switch in order to achieve optimal performance.
• The 440G-LZ guard locking safety switch is designed for use on small- and medium-sized guards that are engineered to be rigid without sag and allow partial body access to the safeguarded area.
• The switch is not to be used as a mechanical stop. Check that a separate door stop is used.
• Use in applications where the alignment tolerance falls within the stated specification (± 2.5 mm [0.10 in.] in X, Y, Z directions). A separately mounted latch (for example, magnetic or mechanical) is recommended to maintain proper alignment of the actuator. The locking bolt must be free to enter and withdraw from the hole in the actuator without binding.
• This switch can be used on guards that do not require escape, emergency, or remote releases.
• Use appropriate screws, bolts, or nuts that are fitted by tools to mount the switch and actuators to avoid tampering.
• Do not over torque the mounting hardware.
• The locking bolt must never be extended mechanically. Only extend the bolt electrically. These basic connections are required:
– Pin 2 (brown wire) must be connected to 24V DC
– Pin 7 (blue wire) must be connected to 0V (GND)
– Pin 3 (green wire) is the lock command (0 or 24V DC). See Lock
for description of lock command for PTR and
PTL type switches.
• Adjacent switches must be separated by a minimum distance of 200 m
(8
in.), see Pair Proximity on page 18 .
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 13
Chapter 3 Installation
Orientation of Switches
• Mount the switch away from any source of metal particles. See
Environmental Considerations on page 18 .
• The 440G-LZ is designed to be used in a NEC Class 2 circuit. Connect the 440G-LZ to a dedicated Class 2 power supply or use electronic circuit protection (for example, 1692-ZRCLSS) to achieve NEC Class 2 compliance.
ATTENTION: For the switch, actuator, and actuator mounting bracket:
• Only use the designated mounting holes.
• Never drill or use to support other structures such as a conduit, cable ways, or other hardware.
Can be used in all mounting orientations.
Actuator Mounting
The actuator must be fitted to the actuator mounting bracket in such a manner that the white alignment triangles that are marked on both the actuator and switch body are in the installed position.
Align the white triangles.
0.4 Nm
2 x T10 Torx screws
Verify that the locking bolt enters the actuator mounting bracket first.
14 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Installation Chapter 3
IMPORTANT The performance of the switch can only be guaranteed if the provided actuator mounting bracket is used. Mounting the actuator without the supplied bracket can result in the reduction of performance.
Verify that two fasteners are used with at least one fastener that is fitted close to the actuator bracket bend.
The following drawings show mounting possibilities when attaching to extruded aluminum profile and flat surface guard doors.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 15
Chapter 3 Installation
Allowable Approach
Directions
The actuator can approach the switch from all four directions.
Verify that the white arrow on the actuator aligns with the white arrow on the switch body.
Mounting the Switch Body
Three M5 fasteners (not provided) are required for proper mounting to a rigid guard door frame.
3 x M5
IMPORTANT Washers are not required and if used can cause the mounting holes on the switch body to crack.
If it is decided to use a standard thread-locking compound on the mounting screws of the switch body, check the manufacturer’s specification. Many standard thread-locking compounds can attack the plastic feet of the switch body, which can cause stress cracks. It is recommended to use cyanoacrylate-type thread-locking compounds.
16 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Actuator Alignment
There are three ways to achieve proper alignment.
1. By setting gap “G” 2.5 mm (0.09 in.)
[0…5 mm (0…0.19 in.)]
G
2. By mounting hole alignment “H” 6.5 mm
(0.25 in.) [4…9 mm (0.15…0.35 in.)]
H
Installation Chapter 3
3. Use the alignment guide provided
ATTENTION: After installation, verify that there is no possibility of lifting the actuator over the extended locking bolt.
ATTENTION: After installation, confirm that there is no possibility of collision when the actuator approaches the switch body.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 17
Chapter 3 Installation
Pair Proximity
Maintain a minimum separation of approximately 200 mm (8 in.) between any two switches and actuators, as indicated in the following illustration.
Figure 6 - Minimum Required Distance Between Two Switches
200 mm (8 in.)
Environmental
Considerations
18
This restriction applies to both pairs of 440G-LZ safety switches and combinations of 440G-LZ safety switches with the TLS-Z guard locking switches and/or 440N-Z SensaGuard™ noncontact safety switches. All of these devices use inductive field technology for sensing actuator proximity and
RFID technology for actuator code identification.
IMPORTANT If the minimum separation distance is not observed, the inductive fields interact causing cross talk. Cross talk results in nuisance faults and false operation.
Mounting for Protection from Particle Build-up
Particle build-up in the vicinity of the locking bolt will likely cause jamming of the locking bolt, which over time causes switch failure. Ferromagnetic metal particles are especially harmful as they are attracted to the permanent magnet at the tip of the locking bolt.
IMPORTANT The correct installation is to mount the switch away from any source of metal particles. Perform preventative maintenance periodically to keep the switch clean of metallic particles. Pay particular attention during installation to be sure that any drilling swarf is excluded from the vicinity of the switch.
Mounting for Protection from Ingress of Liquids
The 440G-LZ safety switch is rated for IP69 in accordance with IEC
60529:192 + A2:2013. This rating involves a short-term test that is made with high-pressure water jets at 80° C (176° F). The test is passed if no water enters
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Installation Chapter 3 the enclosure of the switch that contains the electrical components and the switch function is not impaired.
This rating does not promise protection from any liquids other than water and does not promise the mechanical longevity from continuous or frequent exposure.
However, the 440G-LZ safety switch is used in CIP (clean-in-place) applications by virtue of the following features:
• Stainless steel is used for all metal parts including the M12 quickdisconnect.
• The product plastics are resistant to most alkaline cleaners used in CIP.
• An internal nitrile-rolling lip seal guards the locking bolt, which extends and retracts during locking/unlocking.
IMPORTANT To be sure of maximum longevity when exposed to CIP, it is recommended that the switch be mounted in the inverted position with the actuator at the bottom. This position allows liquids to drain away from the locking bolt.
Removing the plug in the middle of the actuator improves drainage (see
).
It is also recommended that the switch be thoroughly rinsed with water after exposure to CIP. This step prevents adverse effects that may occur with long-term exposure.
Removal of the Actuator Plug
This plug can be broken out from the actuator if a through-hole is required to avoid a food trap when mounted on the hazard side of a guard door.
Twist the plug with a screwdriver until it comes apart.
Figure 7 - Removal of Actuator Plug
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 19
Chapter 3 Installation
Auxiliary/Manual Release
The manual release is provided to allow you to unlock the guard door if an unforeseen and uncommon circumstance occurs.
If power is supplied to the switch and the switch is in its locked state, if you invoke the auxiliary release, it causes the switch to enter a fault condition
(blinking red status indicator).
To reset the switch, simply cycle the power.
< 2.5 (0.098) dia.
Functional Testing
20
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 a month for SIL 3/PLe
– Less than once a 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 does not cause a 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 is solid red.
3. Test to confirm that the machine cannot start.
4. Confirm the lock control 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 is solid green.
7. Test to confirm that the machine can start.
8. Change the lock control at pin 3 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-UM001C-EN-P - June 2019
Connections
OSSD Inputs
OSSD Outputs
Chapter
4
Wiring
The 440G-LZ safety switch is available with an 8-pin DC Micro M12 quick-
disconnect connector. Figure 8 and Table 5 show the pin assignments and their
functions and typical mating cordsets. Other cordsets are available at DC
Micro Cordsets and Patchcords .
Figure 8 - 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 5 - 440G-LZ Safety Switch Quick Disconnect Pin Assignments
Typical Mating Cordsets
889D-F8NBx
1
(Red, PVC)
889D-F8ABx
(Black, PVC)
1
Color
White
Brown
Green
Yellow
Gray
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
6
7
4
5
8
2
3
Pin
1
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 f t)] for standard cable lengths. The 440G-LZ safety switch 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 are 24V D C signals, which can contain test pulses. The OSSD inputs allow the 440G-LZ safety 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-UM001C-EN-P - June 2019 21
Chapter 4 Wiring
Connections Systems
IMPORTANT To prohibit nuisance tripping, mask the OSSD input channels of the safety system with an On to Off delay of at least 6 ms.
Figure 9 - Output Test Pulses
Occurs every 25 ms Occurs every 11 sec
Safety A
300 µs
Occurs every 25 ms
˂ 600 µs
Occurs every 11 sec
Safety B
300 µs ˂ 600 µs
The following connection system components facilitate connection.
24V
0V
Safety A
Safety B
Lock
5 4
1
4
1
4
3 3 3
1
2
22
3
5
Connection
1 —
Safety-wired Splitter/T-Port
8
3
4
5
2
—
Safety-wired Shorting Plug
4
2
1
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
PWR
OSSD 1+
NA
OSSD 2+
NA
2
6
7
1
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Cat. No.
1
898D-438Y-D8
898D-418U-DM
Auxiliary Output
Wiring Chapter 4
3 — 8-pin Device Patchcords
1 meter, 8-pin
2 meters, 8-pin
5 meters, 8-pin
10 meters, 8-pin
4 — 5-pin Patchcords
1 meter, 5-pin
2 meters, 5-pin
5 meters, 5-pin
10 meters, 5-pin
5 — 5-pin Cordsets
2 meters, 5-pin
5 meters, 5-pin
10 meters, 5-pin
1 Add the letter “S” to above catalog numbers for stainless steel connectors; for example, 889DS-F5AC-1.
889D-F8ABDM-1
889D-F8ABDM-2
889D-F8ABDM-5
889D-F8ABDM-10
889D-F5ACDM-1
889D-F5ACDM-2
889D-F5ACDM-5
889D-F5ACDM-10
889D-F5AC-2
889D-F5AC-5
889D-F5AC-10
Table 6 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 6 - Auxiliary Output Function
Catalog Number
440G-LZS21* P **
440G-LZS21* T**
Function
Lock Status
Door Proximity
Value
24V when switch is unlocked
0V when switch is locked
24V when guard door is open
0V when guard door is closed
Catalog codes for both types are explained in
IMPORTANT Door proximity models: Auxiliary output changes state when the actuator is in proximity to the switch body.
The proximity is such that the actuator is within 20 mm (0.79 in.) (measured centerline of lock bolt to centerline of the hole in the actuator).
Can be used for door position if a latch is fitted such that a guard or door is either open or fully closed.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 23
Chapter 4 Wiring
Table 8 - Lock Status Auxiliary Power to Lock
Inputs
Door
Open
Closed
Closed
Closed
Closed
Table 7 - Lock Status Auxiliary Power to Release
Inputs
Door
Open
Closed
Closed
Closed
Closed
Lock Control OSSD Input
Off or On High or Low
Off 0V
On 24V
Low 0V
Low 0V
Off 0V
On 24V
High 24V
High 24V
Lock Control OSSD Input
Off or On High or Low
Off 0V
On 24V
Low 0V
Low 0V
Off 0V
On 24V
High 24V
High 24V
Outputs
Lock Status AUX
Unlocked
Locked
High 24V
Low 0V
Unlocked
Locked
Unlocked
High 24V
Low 0V
High 24V
Outputs
Lock Status AUX
Unlocked
Unlocked
High 24V
High 24V
Locked
Unlocked
Locked
Low 0V
High 24V
Low 0V
Table 9 - Door Proximity Auxiliary Power to Release
Inputs Outputs
Door
Open
Closed
Closed
Closed
Closed
Lock Control OSSD Input
Off or On High or Low
Off 0V
On 24V
Low 0V
Low 0V
Off 0V
On 24V
High 24V
High 24V
Lock Status AUX
Unlocked High 24V
Locked
Unlocked
Low 0V
Low 0V
Locked
Unlocked
Low 0V
Low 0V
Table 10 - Door Proximity Auxiliary Power to Lock
Inputs
Door
Open
Closed
Closed
Closed
Closed
Lock Control OSSD Input
Off or On High or Low
Off 0V
On 24V
Low 0V
Low 0V
Off 0V
On 24V
High 24V
High 24V
Outputs
Lock Status AUX
Unlocked
Unlocked
High 24V
Low 0V
Locked
Unlocked
Locked
Low 0V
Low 0V
Low 0V
OSSD Output
Low 0V
Low 0V
Low 0V
High 24V
Low 0V
OSSD Output
Low 0V
Low 0V
Low 0V
Low 0V
High 24V
OSSD Output
Low 0V
Low 0V
Low 0V
High 24V
Low 0V
OSSD Output
Low 0V
Low 0V
Low 0V
Low 0V
High 24V
24 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Lock Command
Wiring Chapter 4
Table 11 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, which extends and retracts the locking bolt.
Table 11 - Lock Command Function
Catalog Number Function
440G-LZS21** R * Power to release
440G-LZS21** L* Power to lock
Value
24V = Unlock
0V = Lock
24V = Lock
0V = Unlock
Catalog codes for both types are explained in
Response Time When
Connected in Series Circuit
24V DC
RTN
Supply +24
Switch 1 Blue
Pink
Grey
White
Red
Yel
Brown
Switch 2 Blue
Red
Yel
White
Pink
Grey
Brown
Switch 3
Blue
Pink
Grey
White
Red
Yel
Brow n
Initial Conditions:
All switches are locked
Switch 1 receives
Unlock command
(guard can then be opened).
Lock/unlock c
Switch 2 drops the 24V
(red and yellow) from switch 1 OSSD outputs.
Green indicator flashes .
Switch 3 drops the 24V
(red and yellow ) from switch 3 OSSD outputs.
Green indicator flashes .
Switch 1 guard is closed
0 ms
Switch 1 OSSD outputs are energized.
100 ms
Switch 2 OSSD inputs (red and yellow) transition to
24V DC from switch 1 OSSD outputs. Switch 2 OSSD outputs are energized.
150 ms 200 ms
Switch 3 OSSD inputs (red and yellow) transition to
24V DC from switch 2
OSSD outputs. Switch 3
OSSD outputs are energized.
0 ms 600 ms 625 ms 650 ms
A2 S11 S52 S12 13 23 33 41
440R-N23132
S21 S22 S34 A1 14 24 34 42
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 25
Chapter 4 Wiring
Notes:
26 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Set-up
Chapter
5
Commissioning
The 440G-LZ safety switch is available with standard coded actuators or unique coded actuators.
• Switches with standard coded actuators are ready for use and do not require commissioning.
• Switches with unique coded actuators need to be commissioned before use. The actuator teach process is not performed at the factory and must be performed when the switch is first put into use. After the first-time learn, this process can be repeated up to seven more times with unique coded replacement actuators.
IMPORTANT When the switch learns a new actuator, it no longer recognizes previously learned actuators.
During commissioning, connect the switch as shown in Figure 10 :
• Connect brown wire (PWR) to 24V DC.
• Connect blue wire (GND) to 0V DC.
• Connect red wire (Safety A+) and yellow wire (Safety B+) to 24V DC.
• Connect green wire (Lock Command) to 24V DC.
• Safety A (gray) and Safety B (pink) — optional, no connection required during commissioning
• Aux (white) — optional, no connection required during commissioning
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 27
Chapter 5 Commissioning
Figure 10 - Wiring
440G-LZ
Status
Diag
+24V DC
Brown (+24)
Red (Safety A+)
Yellow (Safety B+)
Green (Lock)
Grey (Safety A)
Pink (Safety B)
White (Aux)
Blue (Gnd)
NC
NC
NC
24V DC Com
Lock
First Time Learn
Learning Additional
Replacement Actuators
889D-F8NB-x
or
889D-F8AB-x
Apply power to the switch without the actuator present. After the switch completes the power-sequence (approximately eight seconds), the LED flashes green eight times, indicating the total number of times a new actuator can be learned. This LED sequence repeats until an actuator is placed in the sensing field, or “guard-closed” position, of the switch.
Table 12 - Commissioning Process for Unique Coded Switches
State
Step 1: Actuator Present
Step 2: Verifying Actuator
Step 3: Programming Switch
Step 4: Program Finalization
Step 5: Ready State
Approximate Duration
15 seconds
15 seconds
15 seconds
15 seconds
—
LED Indicators
Flashing green, slow
Flashing red/green, slow
Flashing red/green, fast
Flashing green (number of times a new actuator can be learned)
Solid red (Power to Release)
Solid green (Power to Lock)
The switch will automatically start a new learn process when a unique coded replacement actuator is placed in the sensing field, or “guard-closed” position, of the switch.
IMPORTANT When the switch learns a new actuator, it no longer recognizes previously learned actuators.
28 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Commissioning Chapter 5
Locking the Actuator Code
If the actuator is removed from the sensing field and then returned to the sensing field during the 15-second Program Finalization stage (see Step 4 in
), this triggers the switch to LOCK the actuator code. This action can be performed during any of the eight unique coded actuator learn cycles.
IMPORTANT After a unique coded actuator is locked using this method, no additional replacement actuators can be learned by the switch for the remaining life of the switch. If the actuator is lost or damaged, the switch will need to be replaced.
Error Codes during the
Commissioning Process
The following indicator patterns repeat until a Power Off/On cycle is completed.
Status/Diagnostic Indicator
Flashing green
Red-red-red-green
Red-red-red-green-green
Red-red-red-green-green-green
Red-red-red-green-green-green-green
Red-red-red-green-green-green-green-green
Error Code
OSSD inputs not valid
Cannot learn a standard actuator
Actuator already learned
Bad RFID; actuator moved out of range
Exceeded learning eight actuators
Unit locked: cannot learn another actuator
Prove Basic Lock Function
To prove basic lock function and to verify correct actuator alignment, it is necessary to extend the locking bolt electronically.
IMPORTANT Do not extend the locking bolt mechanically.
Using a tool to pull the bolt out of the switch can damage or cause misalignment of the magnet at the end of the bolt. This can cause unreliable operation of the switch.
These basic connections are required:
• Pin 2 (brown wire) must be connected to 24V DC
• Pin 7 (blue wire) must be connected to 0V (GND)
Power to Release
With a Power to Release switch, the locking bolt extends when the guard is closed and the actuator is aligned. Connect Pin 3 (green wire) to 24V DC to unlock the switch and withdraw the locking bolt.
If power is removed from a Power to Release switch in the locked position, the locking bolt remains in its extended position (switch locked). Use the manual auxiliary release to unlock the switch.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 29
Chapter 5 Commissioning
Power to Lock
With a Power to Lock switch, connect pin 3 (green wire) to 24V DC to lock the switch (for example, extend the locking bolt). When you disconnect pin 3, it unlocks the switch.
If power is removed from a Power to Lock switch in the locked position, the switch unlocks.
In either type of lock, the locking bolt never extends in the absence of the actuator.
30 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Chapter
6
Diagnostics and Troubleshooting
LED Indicators during Powerup Routine
When power is applied to the switch, the green LED indicators flash slowly three times and then fast three times. See Table 13 for LED status at the conclusion of the power-up routine.
LED Indicators during Normal
Operation
Table 13 shows the LED status of the Guardmaster® 440G-LZ guard locking safety switch during normal operation.
Table 13 - Switch Status during Normal Operation
Guard
Status
Lock
CMD
OSSD
Input
Lock
Status
(1)
Status
Indicator
Unlock Off or on Unlocked Solid red Open or closed
Open Lock Off or on Unlocked Fast flash green
Closed Lock Off
OSSD
Status
Off
Off
Off
State
Safe
Safety Inputs (Safety A+ and Safety
B+) are not connected to 24V DC or there is a demand on the device connected in series.
Ready. Close guard door to lock
Closed Lock On
(1) See Lock Command on page 25 .
Locked Slow flash green
Locked Solid green On Operational
Diagnosis of Switch
Condition Using LED
Indicators
LED Indicators Off
When the LED indicators are OFF, Bulletin 440G-LZ is not connected properly to either the 24V power supply or ground. Check the power supply and the wiring to the switch. Check that the input voltage is within specification (measures between 20.4V and 26.4V DC).
LED Indicators Solid Green
When the LED indicators are solid green, the switch is in the operational state.
The guard door is closed and locked and the OSSD outputs are ON. This is normal operation and no action is required.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 31
Chapter 6 Diagnostics and Troubleshooting
LED Indicators Solid Red
When the LED indicators are solid red, the switch is in safe state, meaning the switch is unlocked.
To transition to operational state, close the door, and turn the lock command
ON, see
.
LED Indicators Flash Green at 1 Hz
When the LED indicators flash green at a 1 Hz rate, the switch is waiting for
24V DC to be applied to the OSSD input signals.
If the 440G-LZ is the only switch or the first switch in a series connection, check that the safety input signals Safety A+ (red wire) and Safety B+ (yellow wire) are connected to 24V DC.
In a series connection, check for a demand on the prior switch to determine
why its OSSD outputs are OFF. See Troubleshoot Series Circuit on page 35 .
LED Indicators Flash Green at 4 Hz
When the LED indicators are flashing green at a 4 Hz rate, it indicates the
Lock command is ON, but the guard door is in the open position (RFID signal is not detected).
If the guard door is confirmed closed and this condition continues, use a spare actuator to confirm the actuator is working properly.
LED Indicators Repeat Flash Pattern—Green 3x, Red 1x
This LED flash pattern occurs when a condition exists that prevents the switch from locking or unlocking successfully. This condition can happen when the guard door is slightly ajar. Confirm that the guard door is closed all the way.
If the door is misaligned and the bolt cannot enter the actuator freely during locking, or if there is a mechanical load applied to the guard door during unlocking, it can also prevent the switch from locking or unlocking successfully. The locking bolt must be free to enter and withdraw from the hole in the actuator without binding.
Check to see if there is a mechanical load applied to the guard door that prevents the bolt from retracting.
32 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Diagnostics and Troubleshooting Chapter 6
IMPORTANT A separately mounted latch (mechanical or magnetic) is recommended to help maintain proper alignment of the guard door.
LED Indicators Flash Red at
1 Hz
When the LEDs flash red at a 1 Hz rate, it indicates a fault condition caused by a possible short circuit. Check that the OSSD outputs are not shorted to ground (0V), 24V DC, or to each other. Cycle power to reset.
LED Indicators Flash Red at
4 Hz
The LED indicators flash red at a 4 Hz rate when an inconsistency is detected with the RFID sensor. This may also happen when there is a condition that prevents the switch from performing as expected. A number of scenarios can cause this fault indication.
Table 14 - Possible Causes of Flashing Red (4 Hz) Fault
Possible Cause Solution
Actuator moved out of range
Cross talk between two switches
Faulty actuator
Magnet misalignment
Failure to lock
Failure to unlock
Bolt unable to extend or retract
The switch will fault if the actuator moves out of range.
Check the guard door is rigid without sag. Alternatively, a separately mounted latch (mechanical or magnetic) is recommended to help maintain proper alignment of the guard door.
Adjacent switches are mounted too close to one another.
Confirm minimum distance between any two adjacent switches is 200 mm
(7.87 in.), see Pair Proximity on page 18 .
Damage to one or to both of the reeds inside the actuator can cause intermittent behavior of the switch.
Use a good actuator (known) with the switch to determine if the installed actuator is working properly.
Do not extend the locking bolt mechanically. Use of a tool to pull the bolt out of the switch can damage or cause misalignment of the magnet at the end of the bolt. This can cause unreliable operation of the switch.
Confirm that the guard door is closed all the way so that the bolt can enter the opening in the actuator without binding.
The locking bolt must be free to enter and withdraw from the hole in the actuator without binding.
Check to see if there is a mechanical load applied to the guard door that prevents the bolt from retracting.
Alternatively, use a door latch to prevent sagging of the guard door, which can cause binding.
Confirm the switch isn't mounted near a source of metal particles. An accumulation of debris can prevent the bolt from extending or retracting.
Power surges can cause permanent damage to the solenoid driver circuit. The
440G-LZ is designed to be used in a NEC Class 2 circuit. Connect the 440G-LZ to a dedicated Class 2 power supply or use electronic circuit protection (for example, cat. no. 1692-ZRCLSS) to confirm NEC Class 2 compliance.
The switch may need to be replaced.
Lock command switched too quickly It is recommended the locking frequency is limited to a
1 Hz maximum with
50% duty cycle (500 ms Lock, 500
ms
Unlock).
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 33
Chapter 6 Diagnostics and Troubleshooting
Diagnosis of Physical Switch
Anomalies
Mounting Holes of the Switch Body Cracked or Broken
The mounting holes of the switch body can crack when washers are used to mount the switch or when an incompatible thread locking compound is used to secure the mounting hardware. Three M5 fasteners are needed to properly mount the switch body. Washers are not required and when used can cause the holes to crack or break. Do not over torque the screws.
IMPORTANT Loctite 242 thread-locking adhesive is known to cause stress cracks in the
440G-LZ plastic housing and should not be used. Lab tests have determined that Loctite 425, a cyanoacrylate adhesive, does not cause cracking and can be considered if the faster cure time is acceptable in the application.
Check the manufacturer specifications of any thread-locking compound used to secure the screws. It is recommended to use a cyanoacrylate-type compound.
Other compounds can cause stress cracks in the plastic feet of the switch.
Locking Bolt Discolored and/or Corroded
Discoloration of the end of the locking bolt might be a sign of corrosion caused by incompatibility with a liquid used in the application.
Bulletin 440G-LZ is resistant to most alkaline clean-in-place (CIP) cleaners.
IMPORTANT Synergex is a cleaner that has been identified as marginally compatible.
It is recommended that the switch be thoroughly rinsed with water after exposure to CIP. This step prevents adverse effects that may occur with longterm exposure.
It is also recommended that the switch be mounted in the inverted position with the actuator at the bottom. This position allows liquids to drain away from the locking bolt.
34 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Diagnostics and Troubleshooting Chapter 6
Troubleshoot Series Circuit
+24
24V DC
Power
Supply
RTN
Switch 1 Switch 2 Switch 3 Switch 4 Switch 5
Green
Brown
+24V
+24V
Green
Brow n
+24V
+24V
Green
Brow n
0V
0V
Green
Brow n
0V
0V
Green
Brow n
0V
0V
Recoverable
Fault
Lock/Unlock
Actuator 1 is in sensing range and guard is locked.
Guard 1 functions properly.
OSSDs are energized to 24V.
Green LED is ON.
Lock/Unlock
Actuator 2 is in sensing range and guard is locked.
Guard 2 functions properly.
OSSDs are energized to 24V.
Green LED is ON.
Lock/Unlock
Actuator 3 is in sensing range and guard is locked.
Guard 3 has a fault.
See Diagnostic table.
Red LED is flashing .
Lock/Unlock
Actuator 4 is in sensing range and guard is locked. Guard
4 functions properly. Series inputs are 0V. OSSDs are de-energized to 0V. Green
LED is flashing to indicate series inputs are not 24V.
Lock/Unlock
Actuator 5 is in sensing range and guard is locked. Guard 5 functions properly.
Series inputs are 0V. OSSDs are de-energized to 0V. Green
LED is flashing to indicate series inputs are not 24V.
OSSDs are OFF
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 35
Chapter 6 Diagnostics and Troubleshooting
Notes:
36 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Chapter
7
Application Examples
The following application and wiring examples are intended to show how the
440G-LZ safety switch 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.
Wiring to GLP Relay
The GLP safety relay is designed to operate with Power to Release (PTR) switches. To use a Power to Lock (PTL) switch, you must use an interposing relay on the lock command at GLP terminal 51. In the example shown in
Figure 11 , the GLP allows the gate to be unlocked when the motor is running at a Safely-limited Speed.
Figure 11 - GLP and 440G-LZ Safety Switch Schematic
Reset Reset
Brn Red Yel
Yel
Grn Grn
Reset &
Gate Lock
Request
Gate
Unlock
Request
SLS
Request to PLC
X14 51 S44
GLP
LOGIC
GLP
9
8
LOGIC
7
6
9
8
5
7
0 1
2
3
4
6 5
01
4
SL1
3
2
9
8
7
SL1
9
8
6
7
5
0
4 6
1
2
3
5
0
4
1
3
SL2
2
9
8
SL2
9
8
7
6
7
5
6
0
4
5
1
2
3
0
4
1
2
3
S12 S22
L61
A2
AP
AP
Gate Open
- Unlocked
Gate Open
- Unlocked
24V DC COM
24V DC COM
872C-D8NP18-E5 (2)
872C-D8NP18-E5 (2)
Brn
Brn
Brn
Brn
Blu
Blu
Blu
Blu
E-Stop
800FM-MT44
800F-MX02S
Drive Status
to PLC
E-Stop
E-Stop
S S12 S S21 S
8
8
7
7 5
0 1
2
4
3
5
4
0 1
2
6
3
6
A1 13 23 23 S34 S34
Status to PLC
Status to PLC
S42 L12
14
14
24
24
Y32
Y32
800FM-MT44
800F-MX02S
Stop/Start/SLS
from PLC
Safe Torque-o ff (STO)
Wiring Header
+24V DC
COM
COM
Status
Status
Safety Input 1
Safety Input 1
Safety Common
Safety Input 2
Safety Input 2
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 37
Chapter 7 Application 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.
Safety-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
Leve l 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 12 on page 39 , 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.
38 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Application Examples Chapter 7
Figure 12 - GLT and 440G-LZ Safety Switch Schematic
+24V DC
Safety
Gate
440G-LZ
Status
Diag
440G-LZS21SPRH
Power-To-Release
Aux = Lock Status Gate
Unlock
Request
Reset &
Gate Lock
Request
PowerFlex
11 +24V DC
1 Stop
2 Start
L1 L2 L3
R S T
889D-F8NB-2
Brown (+24)
Red (OSSD A+)
Yellow (OSSD B+)
Green (Lock)
Grey (OSSD A)
Pink (OSSD B)
White (Aux)
Blue (Gnd)
S11 S12 51
LOGIC
GLT
9
8
7
6 5
4
440R-GL2S2T
01
3
2
S12 S22 L61
S54 A1
RANGE
9
8
7
6 5
01
2
4
3
S44 Y32
TIME
9
8
7
6
B2
5
01
4
3
2
A2 L11 L12 14 24
4 Gnd
S1
S2
U V W
M
24V DC Com
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.
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 GLT 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
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 39
Chapter 7 Application Examples 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
Leve l d in accordance with ISO 13849-1 and SIL CL 2 in accordance with
IEC 62061.
Wiring to DI and EMD Relay
The 440G-LZ safety switch can be connected to the DI and EMD safety relays. The DI monitors the safety outputs of the safety switch 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 safety switch must be cycled for the DI to recognize the safety switch OSSD signals.
In the example shown in Figure 13 , an E-stop initiates the machine shutdown.
After an eight-second delay, the safety switch 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.
Figure 13 - DI with EMD and 440G-LZ Safety Switch Schematic
24V DC Supply
Reset
440G-LZS
E-Stop
Pigtail
889D-F8AX-X
N/C
Wht Pnk Gry Blu
Unlock
Grn
40
In 1
In 2
Out
Logic
+
A2
24V DC
DI
Test Out
LOGIC
8
7
01
4
3
5 6
L12 L11 Y3 2 S3 4 13 14 23 24
K1 K2
24V DC COM
+
EMD
A2
24V DC
-
B1 B2 37
L12 L11 X32
38 47 48
3738 4748
17 18
17 18 2728
27 28
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
M
K1
K2
Wiring to DG Relay
Application Examples Chapter 7
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
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
IE
C 62061.
The 440G-LZ safety switch can be used in GuardLink® applications. The
GuardLink system:
• Is designed to operate with Power to Release switches,
• Uses taps to connect a series of devices to one relay,
• Provides control and status information between the machine control system and the safety system.
Figure 14 on page 42 shows four 440G-LZ safety 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.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 41
Chapter 7 Application Examples
Figure 14 - DG with 440G-LZ Safety Switch Schematic
+24V DC
440G-LZ
Status
Diag
440G-LZ
Status
Diag
INPUT INPUT
Wiring to CR30 Relay
INPUT
440G-LZ
Status
Diag
INPUT
+24V Com
440G-LZ
Status
Diag
Machine
Control
System
Control
Status
A
+
B
C
440R-ENETR
S12 S22 S11 S21 A1
Control
Status
DG
440R-DG2R2T
S32 S42 X2
TIME
.14
.
0.2.4.6
X1 A2
13 23
14 24
X4
X3
K1 K2
L1 L2 L3
K1
K2
M
The CR30 is a software configurable relay that can easily interface with the
440G-LZ guard locking safety switch. Version 10 and later of Connected
Components Workbench™ has a locking function that is useful for guard locking applications.
Figure 15 on page 43 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.
42 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Application Examples Chapter 7
+24 VDC
Figure 15 - CR30 Schematic
Safety
Gate
440G-LZ
Status
Diag
440G-LZS21SPRH
Power-To-Release
Aux = Lock Status
L1 L2 L3
Reset
Lock
Unlock
00 01
CR30
A1 A2
02 03 04 05 06
440C-CR30-22BBB
12 13 14 15 16
07
17
08 09
18 19 20 21
PowerFlex
525
11 +24V DC
1 Stop
Motor Not Running
10 11
2 Start
R5
R6 t081=2
4 Gnd
Gate control
R S T
S1
S2
U V W
M
24V DC Com
889D-F8NB-2
Brown (+24)
Red (OSSD A+)
Yellow (OSSD B+)
White (Aux)
Grey (OSSD A)
NC
Pink (OSSD B)
Green (Lock)
Blue (Gnd)
Figure 16 on page 44 shows an example CR30 configuration that works with the schematic in Figure 21.
The safety switch 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 safety switch.
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-UM001C-EN-P - June 2019 43
Chapter 7 Application Examples
Figure 16 - CR30 Configuration in CCW
Wiring to 1734
Guard Point I/O
44
The 440G-LZ safety switch can be connected to a 1734 Guard Point I/O. The cordset (catalog number 889D-F8NB) has 24 AWG wires, which allows three wires to be connected to one terminal.
Figure 17 on page 44 shows a wiring example of 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
Figure 22 on page 47 .
Figure 17 - 1734 and 440G-LZ Safety Switch Schematic
Safety
Gate
440G-LZ
Status
Diag
440G-LZS21STLH
Power-to-Lock
Aux = Gate Status
889D-F8NB-10
White (Aux)
Grey (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
0
2
1
3
24V DC Com
+24V DC
6
4 5
7
1734-IB8S 1734-OB8S
I0
I2
I1
I3
COM COM
T0 T1M
I4
I6
I5
I7
O0
O2
O1
O3
COM COM
T2 T3M
COM COM
COM COM
O4
O6
O5
O7
COM COM
COM COM
K1 K2
K1 K2
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Application Examples Chapter 7
Figure 18 shows the General tab of the 1734-IB8S Module Properties.
The Input Status must be set to “Combined Status – Power – Muting” as this setting is used by the Dual Channel Input Stop (DCS) logic block to verify that the 1734-IB8S switch is operational. The Output Data must be set to
“Test,” as the test outputs are used to generate test pulses for the output contactors, K1 and K2.
Figure 18 - 1734-IB8S Module Properties – General
Figure 19 shows the Input Configuration tab of the 1734-IB8S switch Module
Properties.
In this example, Points 0 and 1 monitor the OSSD outputs of the 440G-LZ safety switch. The Type is set to Single and the Mode must be set to Safety. Set the On- Off- delay time to 6 ms to filter out the test pulses from the 440G-LZ safety switch.
Points 2 and 3 monitor the status of the output contactors, K1 and K2. The
Type should be set to Single. The discrepancy time will be dependent on the contactor device. A value other than 30 ms is suggested to prevent nuisance faults over the life of the contactors; other values can be more appropriate. Set
Mode to Safety Pulse Test. Safety pulse testing is used to detect potential faults in the monitoring circuit.
Point 4 monitors the auxilary output of the safety switch. The auxiliary output indicates whether or not the gate is closed. Set Type to Single and Mode to
Standard.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 45
Chapter 7 Application Examples
Figure 19 - 1734-IB8S Module Properties – Input Configuration
Figure 20 on page 46 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 the contactors K1 and K2, to be sure they are off before the logic program energizes the contactors.
Points 2 and 3 are set to Standard. Point 2 is the LOCK command. Point 3 applies power to the safety switch, as well as, supplies power to the OSSD inputs. By setting it to Standard, you can programmatically turn these points
OFF and ON.
Figure 20 - 1734-IB8S Module Properties –Test Output
46
Figure 21 shows the General Tab of the 1734-OB8S Module Properties.
The Input Data Status can be set to None. The Output Data must be set to
Safety, as it is controlling the output safety contactors.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Figure 21 - 1734-OB8S Module Properties – General
Application Examples Chapter 7
Figure 22 on page 47 shows the Output Configuration tab of the 1734-OB8S switch Module Properties.
Points 0 and 1 drive the output contactors K1 and K2. For both points, Type is set to Dual, and the Mode is set to Safety Pulse Test.
Figure 22 - 1734-OB8S Module Properties – Output Configuration
Figure 23 on page 48 shows an example logic program.
A Dual Channel Input Stop (DCS) function block monitors the safety switch and a Configurable Redundant Output (CROUT) function block control contactors K1 and K2.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 47
Chapter 7 Application Examples
Figure 23 - Studio 5000® Example Logic Program
Wiring to 1732 ArmorBlock
Guard I/O
The 440G-LZ 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; which allows three wires connected to one pin. An example schematic is shown in
48 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Application Examples Chapter 7
As an alternative, the user can use an 871A-TS8-D1 field attachable connector at the 440G-LZ and a 5-wire cordset (889D-M5NC-x)
Figure 24 - ArmorBlock Schematic
871A-TS5-DM1 5 pin
Field Attachable Connector
1732ES-IB12XOB4
2
3
5
4
1
EtherNet
2
3
5
1
4
X100 X10 X1
Brown (+24)
Red (OSSD A+)
Yellow (OSSD B+)
Grey (OSSD A)
Blue (Gnd)
Pink (OSSD B)
Green (Lock)
White (Aux)
N/C
889D-F8NB-5
Brown (1)
Black (4)
K1
K2
White(2)
Grey(5)
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
1 T1
2 I1
3 C
4 I0
5 T0
4
3 2
1
D H
1+24
2 O1
3 C
4 O0
5 C
Power
1
2
4
3
889D-E5NC-10 100S or 700S or 700-HPS
Contactors and Relays
White (2) A1
K1
A2 Blue (3)
Black(4) A1
K2
A2 (Grey(5)
Diag
Status
440G-LZ
440G-LZS21SPRH
Power-To-Release
Aux = Lock Status
+24V DC
Safety
Gate
Figure 25 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.”
Figure 25 - Module Properties — General
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 49
Chapter 7 Application Examples
Figure 26 shows the Input Configuration tab of the ArmorBlock Module
Properties. In this example, Points 0 and 1 monitor the OSSD outputs of the safety switch. The Type must be set to Equivalent, and Mode must be set to
Safety. Points 4 and 5 monitor the status of the output contactors K1 and K2.
The Type should be set to Equivalent. The discrepancy time will be dependent on the contactor device — a value other than 30 may be needed. Safety pulse testing is used to detect potential faults in the monitoring circuit.
Figure 26 - Module Properties — Input Configuration
50
Figure 27 shows the Test Output tab of the ArmorBlock Module Properties.
In this example, Points 0 and 1 are set to Standard. This allows these points to be controlled by the program. Point 0 applies power to the 440G-LZ. By setting it to standard, the user can programmatically turn this point off and on if the 440G-LZ switch has a fault condition. Point 1 is the lock/unlock command. In this example, the 440G-LZ is a PTR type, so 24V unlocks the switch. Points 4 and 5 are used to monitor the contactor outputs and are set to
Pulse Test.
Figure 27 - Module Properties – Test Output
Figure 28 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 28 - Module Properties — Output Configuration
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Application Examples Chapter 7
Figure 29 shows an example program. A Dual Channel Input Stop function
block monitors the 440G-LZ and a Redundant Output function block controls two contactors. This example can be used as a starting point for implementation; users must incorporate additional logic based on the risk assessment for the machine.
Figure 29 - Example Studio 5000 Program
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 51
Chapter 7 Application Examples
Notes:
52 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Introduction
Appendix
A
Specifications and Safety Ratings
This appendix provides the specifications and safety ratings for the
Guardmaster® 440G-LZ guard locking safety switch.
Table 15 - Operating Characteristics
Attribute
Switch function
Torque for M5 mounting of switch and actuator mounting bracket
Lock bolt insertion for assured lock and hold force
Approach speed
Lock bolt alignment tolerance X, Y, Z
Hold force F max (EN ISO
14119)
Hold force F zh (EN I
S
O 1
4119)
(1)
Maximum output current (each output)
Quiescent power consumption, locked or unlocked
Lock signal current
Peak current, during turn-on or after Lock/Unlock operation
Duration of peak current, at turn-on or after Lock/Unlock operation
Number of switches connectable in series
Value
OSSDs enable when guard closed and locked
2 N•m (17.7 lb•in) max
5 mm (0.19 in.) min, 10 mm
(0.39 in.) max
2 mm/s, min
± 2.5 mm (0.1 in.), max
1,690 N
1,300 N
200 mA
2.5 W
3.5 mA signal on green lock/unlock wire
400 mA
100 ms
Operating voltage U e
Frequency of operating cycles
Dwell time between subsequent locking/unlocking
Response time (Off)
Risk time
Start-up time
Usage category
Insulation voltage U i
(IEC 60947-5-1)
Impulse withstand voltage U imp
(IEC 60947-5-1)
Pollution degree (IEC 60947-5-1)
Manual (auxiliary) release
Emergency release
Escape release
Protection class (IEC 61140)
Mechanical life
Unlimited, see Response Time When Connected in Series
24V DC + 10%/-15% Class 2 SELV
0.2 Hz, max
2.5 s
100 ms first switch, +50 ms for each additional switch
100 ms (according to IEC 60947-5-3)
5 s (availability)
DC-13 24V 200 mA, (IEC 60947-5-2)
75V
1 kV
No
No
3
Built-in
Class II
500,000 cyles
(1) The holding force F zh
is in accordance to EN
ISO 1411
9:2013, clause 5.7.4. Additional validation was performed in accordance with IEC 60947-5-1:2009, clause C.1.2.2.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 53
Appendix A Specifications and Safety Ratings
54
Table 16 - Safety Ratings
Category
Standards
Safety Classification: Guard door sensing and lock monitoring
Functional Safety Data: Guard door sensing and lock monitoring
Safety Rating
IEC 60947-5-3, IEC 60947-5-1, IEC 61508,
EN ISO 1
3849-
1, IEC 62061, EN/ISO14119, UL 508
Type 4 Interlocking Device with Guard Locking with low
(standard) and high (unique) coding per ISO 14119
PLe Category 4 per ISO 13949-1, SIL 3 per IEC 61508 and
IEC 62061
PFHD: 9.1 x 10
-10
Dual channel interlock is suitable for use in applications up to PLe (in accordance with ISO 13849-1) and for use up to SIL 3 systems (in accordance with IEC 62061), depending on application characteristics.
Mission time/PTI: 20 years
Table 17 - Outputs
Guard Closed and Locked
Safety
Auxiliary
Table 18 - Environmental
Attribute
Operating temperature
Storage temperature
Operating humidity
Enclosure ingress rating
Shock and vibration
Hygienic
Description/Status
2 x PNP, 0.2 A max / ON (+24V DC)
1 x PNP, 0.2 A max / OFF (+0V DC)
Value
0…55 °C (+32…131 °F)
-25…+75 °C (-13…+167 °F)
5…95%, relative
NEMA 3, 4x, 12, 13, IP66, IP67, IP69K
IEC 68-2-27 30 g (1.06 oz), 11 ms/IEC 68-2-6 10…55 Hz
ISO 14159:2004 and EN 1672-2005 (for part of the machine that is defined as food splash area)
Suitable for sodium hydroxide-based washdown fluids
IEC-60947-5-3, FCC-1 (Parts 18 & 15), R&TTE
Washdown
Radio frequency / EMC
Table 19 - General
Attribute
Materials
Weight switch/actuator
Connection
Value
ABS, lock bolt and mount bracket 304 stainless steel
Switch 400 g (14.1 oz), actuator 22 g (0.78 oz), actuator mounting bracket 60 g (2.12 oz)
Flying lead or pigtail with M12 8-pin QD connector
(stainless steel)
Table 20 - Protection
Attribute
Short circuit protection
Current limitation
Overload protection
Reverse polarity protection
Overvoltage protection
Thermal shutdown/restart
(1)
Value
Incorporated
Incorporated
Incorporated
Incorporated
Incorporated (up to 60V max.)
Incorporated
(1) The OSSD outputs are semi-conductor PNP transistors and are safeguarded against over-temperature at the semi-conductor junction. They are rated at 0.2
A and don’t exceed the trip temperature unless the current significantly exceeds this rated value.
This protection does not trip out the complete switch when it is exposed to ambient temperatures greater than 55 °C (131 °F). It would only switch off the OSSDs and the LED indicators would flash red to indicate a non-recoverable fault.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Certifications
Compliance to European
Union Directives
Dimensions
Specifications and Safety Ratings Appendix A
See the Product Certification link at http://www.rockwellautomation.com/ rockwellautomation/certification/ for Declaration of Conformity,
Certificates, and other certification details.
• UL Listed Industrial Control Equipment, Certified for US and Canada
• CE Marked for all applicable directives
• C-Tick Marked
• TÜV Certified for Functional Safety up to SIL 3 Category 4 for use in safety applications up to and including SIL 3. Also in accordance with
IEC 61508 and EN 62061, Performance Level e and Category 4 in accordance with ISO 13849-1, both for guard position and for lock monitor according to
EN I
SO
14119:2013.
This product bears the CE Mark and is approved for installations within the
European Union and EEA regions. It has been designed and tested to meet the following directives (Machine Safety and EMC).
For a complete list of standards used (including Machine Safety Directive and
EMC Directive), see Compliance to European Union Directives on page 55 of
this manual.
Figure 24 - Switch Body
9.525
(0.37) dia.
33
(1.29)
2 x 5.5
(0.22) dia.
10
(0.39)
134.5 (5.29)
50
(1.97)
25
(0.98)
45 (1.77)
22.5
(0.89)
10
(0.39)
Figure 25 - Actuator and Actuator Mounting Bracket
140 (5.51)
51.5 (2.03)
40 (1.57)
22.9
(0.90)
22.5
(0.88)
9.5
(0.37)
8
(0.31)
65
(2.56)
25.4
(1.0)
7
(0.28)
25 (0.98)
47
(1.85)
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 55
Appendix A Specifications and Safety Ratings
Figure 26 - Switch Mounting Bracket 440G-LZAM2
2x 15
(2x 0.59)
54
(2.12)
2x 33
(2x 1.3)
+1
-3
6.35
(0.25)
4x R6
± 1 mm
145.5
(5.72)
3x 5.5
(3x 0.22)
(2x 0.25)
18.5
(0.73)
2x 15.5 (2x 0.61)
3 x 5.5
(3x 0.22)
2x 31.5
(2x 1.24) x 0.8-6H
56 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Appendix
B
Typical Installations
Switch Mounted Parallel to
Hinge Axis
The X and Y positions can be adjusted using the slotted holes of the mounting bracket and appropriate selection of the three pairs of actuator bracket holes, once the bracket is centered.
The tolerance to misalignment is
±2.5 mm (0.10 in.).
Y
Mounting bracket
440G-LZAM2
Z
X
The Z (height) position is adjusted by sliding the actuator bracket up/down on the profile. If the setting gap is centered between the minimum of 0 mm and the maximum of 5 mm
(0.20
in.), a tolerance to misalignment of ±2.5 mm
(0.10 in.) is achieved.
Actuator
Hole
14mm
Y
Locking bolt
9mm
X
The Z position can be carefully selected to offset the anticipated door sag or door drop. Simultaneously, be sure that the alignment is such that it is not possible to lift the door up and off the locking bolt. Also make sure that there is no possibility that the actuator would collide with the switch when the guard door is being closed. It is essential to check the alignment periodically throughout the use of the guard locking switch.
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 57
Appendix B Typical Installations
Switch Mounted
Perpendicularly to
Hinge Axis
The Z (height) position is adjusted by sliding the actuator bracket up/down on the profile. If the setting gap is centered between the minimum of 0 mm and the maximum of 5 mm
(0.20
in.), a tolerance to misalignment of ±2.5 mm
(0.10 in.) is achieved.
The X and Y positions can be adjusted using spacers underneath the switch and appropriate selection of the three pairs of actuator bracket holes, once the bracket is centered.
The tolerance to misalignment is ±2.5 mm
(0.10 in.).
The Z position can be carefully selected to offset the anticipated door sag or door drop. Simultaneously, be sure that the alignment is such that it prohibits lifting the door up and off the locking bolt. Also check to be sure there is no possibility that the actuator would collide with the switch when closing the guard door. It is essential to check the alignment periodically throughout the use of the guard locking switch.
Min R 300 mm
2 mm
(at min. radius)
Minimum radius when guard hinge axis is perpendicular to the switch body axis
58 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Switch Mounted to a Sliding
Guard Door
The Z (height) position is adjusted by sliding the actuator bracket up/down on the profile. If the setting gap is centered between the minimum of 0 mm and the maximum of 5 mm
(0.20
in.), a tolerance to misalignment of ±2.5 mm
(0.10 in.) is achieved.
The X and Y positions can be adjusted using the slotted holes of the mounting bracket and appropriate selection of the three pairs of actuator bracket holes, once the bracket is centered.
The tolerance to misalignment is +/- 2.5 mm
(0.10 in.).
Y
Mounting bracket
440G-LZAM2
Z
Typical Installations Appendix B
X
EU Declaration of Conformity
For Product Certifications, visit our website at rok.auto/certifications .
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 59
Appendix B Typical Installations
Notes:
60 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Notes:
Typical Installations Appendix B
Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 61
Appendix B Typical Installations
62 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
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Publication 440G-UM001C-EN-P - June 2019
Supersedes Publication 440G-UM001B-EN-P - February 2017 Copyright © 2019 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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