Rockwell Automation Allen-Bradley 440GMZS20UNLJ User Manual

Guardmaster Guard Locking

Switch

Catalog Numbers 440G-MZS20SNRJ, 440G-MZS20UNRJ,

440G-MZS20SNLJ, 440GMZS20UNLJ

User Manual

Original Instructions

Guardmaster Guard Locking Switch User Manual

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).

2 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Table of Contents

Product Overview

Safety Concept

Preface

Who Should Use This Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Purpose of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 1

Guardmaster 440G-MZ Safety Switch Overview. . . . . . . . . . . . . . . . . . . . . 7

Guard Locking on Power to Release Versions . . . . . . . . . . . . . . . . . . . . 8

Guard Locking on Power to Lock Versions . . . . . . . . . . . . . . . . . . . . . . 8

Assembly Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Chapter 2

Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installation

Chapter 3

General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Correct Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Switch Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Actuator Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pair Proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Mount the Switch and Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Auxiliary Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Padlock Accessory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

OSSD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

GuardLink Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 4

Wiring and System Integration

Pin Assignment and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

OSSD Mode Safety Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

GuardLink Mode Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

GuardLink System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Add Device to a Studio 5000 Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Upload Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Manual Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Lock Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

OSSD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

GuardLink Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 3

4

Table of Contents

Chapter 5

Commission the Safety Switch

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

First-time Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Learn Additional Replacement Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Lock the Actuator Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Error Codes during the Commissioning Process . . . . . . . . . . . . . . . . . . . 26

Device Status and

Troubleshooting

Chapter 6

Status Indicators during Power-up Routine . . . . . . . . . . . . . . . . . . . . . . . 27

Status Indicators During Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Diagnostic/Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Mounting Holes of the Switch Body Cracked or Broken . . . . . . . . . 30

Application Examples

Specifications

Chapter 7

Wire to GLP Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Circuit Status as Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Safely-limited Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Wire to GLT Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Wire to DI and EMD Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Circuit Status as Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Wire to DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Wire to CR30 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Wire to POINT Guard I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Wire to ArmorBlock Guard I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Wire to MSR55P Back EMF Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Appendix A

Safety Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Outputs (Guard Door Closed and Locked) . . . . . . . . . . . . . . . . . . . . . . . . . 52

Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Compliance to European Union Directives . . . . . . . . . . . . . . . . . . . . . . . . 53

Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Preface

Who Should Use This

Manual?

Purpose of This Manual

Summary of Changes

Use this manual to design, install, program, or troubleshoot systems that use the Guardmaster® 440G-MZ 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.

This manual is a reference guide for the Guardmaster 440G-MZ safety switch.

It describes the procedures that you use to install, wire, and troubleshoot your switch. This manual accomplishes the following:

• Explains how to install and wire your 440G-MZ safety switch

• Provides an overview of the Guardmaster 440G-MZ safety switch

This publication contains the following new or updated information. This list includes substantive updates only and is not intended to reflect all changes.

Topic

Added FCC and IC certification information

Page

53

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 5

Preface

Terminology

The Industrial Automation Glossary (publication AG-QR071 ) contains terms and abbreviations that are used by Rockwell Automation to describe industrial automation systems.

Table 1

lists specific terms and abbreviations that are used in this manual.

Table 1 - Terms and Abbreviations

Term

CLU (Command, Lock, and Unlock)

HI

LO

NC

Operational state

OSSD (Output Signal

Switching Device)

PLC

Reaction time

Response time

RFID

Safe state

Standard coding

Tap

Unique coding

Definition

This signal is either static or dynamic. When static, this signal is LO when the system is operational and HI when a demand is placed on the safety system. The signal is dynamic when an unlock or lock command is issued to a GuardLink-enabled guard locking device, such as a 440G-MZ safety switch.

Logic state of being ON or a voltage level to be above the turn-on threshold.

Logic state of being OFF or a voltage level to be below the turn-off threshold.

No connection

The switch is in operational state when there is no demand on its safety function (that is, the switch is closed and locked).

Typically a pair of solid-state signals pulled up to the DC source supply. The signals are tested for short circuits to the DC power supply, short circuits to the DC common, and short circuits between the two signals.

A programmable logic controller or a programmable automation controller.

Describes the time between the true state of the input to the ON state of the output.

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, which means that the safety outputs turn off within the response time.

Radio frequency identification

The switch is in safe state when there is a demand on its safety function (that is, the switch is unlocked).

Same as Low coding as defined in ISO 14119

A connection in a GuardLink® circuit that associates a safety device to the GuardLink circuit.

Same as High coding as defined in ISO 14119

6

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource

440G-MZ Guard Locking Switch Installation Instructions, publication 440G-IN018

Description

Provides general guidelines for installing a Rockwell Automation® guard locking switch.

Guardmaster EtherNet/IP Network Interface User Manual, publication 440R-UM009

Provides a detailed description of module functionality, configuration, installation procedure, and information on how to use the Guardmaster EtherNet/IP Network Interface

(440R-ENETR).

Guardmaster DG Safety Relay and GuardLink System User Manual, publication 440R-UM015

Provides general guidelines for configuring a Rockwell Automation Guardlink safety system.

EtherNet/IP Network Devices User Manual, publication

Ethernet Reference Manual, publication ENET-RM002

ENET-UM006

Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP network.

Describes basic Ethernet concepts, infrastructure components, and infrastructure features.

System Security Design Guidelines Reference Manual, publication SECURE-RM001

Industrial Components Preventive Maintenance, Enclosures, and Contact

Ratings Specifications, publication IC-TD002

Provides guidance on how to conduct security assessments, implement Rockwell

Automation products in a secure system, harden the control system, manage user access, and dispose of equipment.

Provides a quick reference tool for Allen-Bradley industrial automation controls and assemblies.

Safety Guidelines for the Application, Installation, and Maintenance of

Solid-State Control, publication SGI-1.1

Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides general guidelines for the application, installation, and maintenance of solid-state control in the form of individual devices or packaged assemblies incorporating solid-state components.

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

Provides general guidelines for installing a Rockwell Automation industrial system.

Product Certifications website, rok.auto/certifications .

Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at rok.auto/literature .

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter

1

Product Overview

Guardmaster 440G-MZ

Safety Switch Overview

This 440G-MZ Guardmaster® safety switch locks a guard door in the closed position and does not release it until the hazardous machine functions that are covered by the guard are in a safe condition. The safety control system allows the hazardous machine functions to operate only when the guard is closed and locked.

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 ISO 14119. The

440G-MZ safety switches are classified as Type 4 interlocking devices with guard locking and the unique coded actuators are classified as having a high level of coding according to ISO 14119.

The 440G-MZ safety switch features two OSSD outputs or a single-wire safety output when connected in a GuardLink® system. These safety outputs are enabled only when the locking bolt is sensed in its extended position. 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.

Although the locking bolt drive uses a bi-stable solenoid, 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-UM004C-EN-P - August 2020 7

8

Chapter 1 Product Overview

Assembly Overview

Guard Locking on Power to Release Versions

With a Power to Release switch, the locking bolt extends when the guard is closed with the actuator inserted in the switch and a lock command is issued to the switch:

Table 2 - Lock Command

Mode

OSSD

Description

The lock signal (pin 5) is connected to 0V DC

GuardLink® A lock command is issued to the switch on the CLU signal from a GuardLink safety master.

IMPORTANT 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 auxiliary release to unlock the switch.

ATTENTION: Under normal operating conditions, the locking bolt does not extend in the absence of the actuator. The only exception is when power is removed from a switch in the first 4 seconds of the start-up sequence. In this case, the bolt does extend. If the guard door is closed when the start-up sequence is interrupted, the guard door is locked. Use the auxiliary release to unlock the switch.

Guard Locking on Power to Lock Versions

With a Power to Lock switch, the locking bolt extends when the guard is closed with the actuator inserted in the switch and a lock command is issued to the switch:

Table 3 - Lock Command

Mode

OSSD

GuardLink

Description

The lock signal (pin 5) is connected to 24V DC

A lock command is issued to the switch on the CLU signal from a GuardLink safety master.

IMPORTANT If power is removed from a Power to Lock switch or a fault occurs while in the locked position, the bolt retracts and the switch unlocks.

ATTENTION: Under normal operating conditions, the locking bolt does not extend in the absence of the actuator. The only exception is when power is removed from a switch in the first 4 seconds of the start-up sequence. In this case, the bolt does extend. If the guard door is closed when the start-up sequence is interrupted, the guard door is locked. Use the auxiliary release to unlock the switch.

Actuator

LINK and DEVICE status indicators

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter 1 Product Overview

Product Selection

Table 4 - Catalog Number Explanation

440G-MZS 20 a

S b

N c

R d

J e a

Outputs (Safety/

Auxiliary)

Code Description

20 Two safety/no aux b

Actuator Code

Code Description

S Standard code

U Unique code c

Auxiliary Type

Code Description

N No auxiliary d

Lock Type

Code Description

R Power to Release

L Power to Lock e

Connection Type

Code Description

J M12 5-pin

Table 5 - Complete Switches, including Switch Body and Actuator

Type

Power to Release

Power to Lock

Actuator Coding

Standard (Low level to ISO 14119)

Unique (High level to ISO 14119)

Standard (Low level to ISO 14119)

Unique (High level to ISO 14119)

Escape Release

No

Table 6 - Spare Actuators

Description

Standard code actuator (Low level to ISO 14119)

Unique code actuator (High level to ISO 14119)

Cat No.

440G-MZS20SNRJ

440G-MZS20UNRJ

440G-MZS20SNLJ

440G-MZS20UNLJ

Cat. No.

440G-MZAS

440G-MZAU

Table 7 - Accessories

Description Cat. No.

L-shaped 440G-MZAM1

Actuator mounting bracket

Z-shaped 440G-MZAM2

Switch mounting bracket

Padlock accessory

440G-MZAM3

440G-MZAL

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 9

Chapter 1 Product Overview

Package Contents

The box includes the following components:

Description Photo

Switch Body

Actuator

Installation Instructions: publication 440G-IN018

10 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter

2

Safety Concept

Safety Standards

The Guardmaster® 440G-MZ safety switch satisfies applicable requirements in the following standards that are related to functional safety and machinery assembly:

• IEC 60947-5-3

• IEC 61508

• IEC 62061

• EN ISO 13849-1

• ISO 14119

• UL 508

Safety Certification

The 440G-MZ 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 test interval of 20 years, and Performance Level e (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 440G-MZ safety switch for use in safety-related applications where PLe is required for the door position monitoring and guard locking functions.

The 440G-MZ safety switch must be installed in accordance with the applicable regulation and standards.

While the 440G-MZ safety switch can be used for SIL 3, PLe, and Category 4 applications, the installation must comply with guard requirements (for example, ISO 13854 and ISO 13857), and in some cases minimum (safe) distance requirements (for example, ISO 13855).

The installed system, including the safety control system and the means by which the machine stops, must achieve the needed safety performance. The

440G-MZ 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

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 11

Chapter 2 Safety Concept

Notes:

12 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter

3

Installation

General Considerations

Correct Use

Installation must be in accordance with the present manual and implemented by qualified personnel exclusively. The 440G-MZ 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.

A functional test of the system is necessary to validate that it works as expected

(see Functional Testing on page 17

).

Guard locking switches that use the Power to Lock principle (Cat. No.

440G-MZS20*NLJ*) must only be used after a risk assessment has shown that the use of a Power to Release principle (Cat. No. 440G-MZS20*NRJ*) is inappropriate.

This assessment is necessary since the guard can be immediately opened after a loss of power supply or upon deactivation of the unlocking signal.

Review the following requirements and guidelines for proper use of the safety switch to achieve optimal performance.

• The 440G-MZ safety switch is designed for use on medium- and fullsized guards including guards where whole-body access to the safeguarded area is possible.

• The switch is not to be used as a mechanical stop. Check that a separate door stop is used.

• 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 actuator without binding.

• Use appropriate screws, bolts, or nuts that are fitted by tools to mount the switch and actuator to avoid tampering.

• Do not over torque the mounting hardware.

• A minimum distance of 100 mm (3.94 in.) must separate adjacent switches, see

Pair Proximity on page 14 .

• The 440G-MZ safety switch is designed for use in a NEC Class 2 circuit.

Connect the 440G-MZ safety switch 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.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 13

Chapter 3 Installation

Switch Orientation

Can be used in all mounting orientations.

Actuator Orientation

The actuator can approach the switch from three directions (

Figure 1

).

Figure 1 - Three Directions of Approach

2

3

1

The flexible actuator can move in multiple axes to accommodate guard door misalignment (

Figure 2

). For optimal performance, verify that the locking bolt can enter and withdraw from the tongue actuator without binding. A separately mounted door latch is recommended to avoid door misalignment.

Figure 2 - Actuator Function

Pair Proximity

14

If a pair of 440G-MZ safety switches are mounted too close to one another, the two electromagnetic fields interact causing crosstalk, which can result in nuisance faults and false operation.

A minimum of 100 mm (3.94 in.) must separate a pair of switches to help achieve correct operation (

Figure 3 on page 14 ).

Figure 3 - Minimum Distance between Switches [mm (in.)]

100 (3.94)

IMPORTANT If the minimum separation distance is not observed, the electromagnetic fields interact causing crosstalk. Crosstalk can result in nuisance faults and false operation.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Environmental

Considerations

Mount the Switch and

Actuator

Chapter 3 Installation

The 440G-MZ safety switch is rated for IP69K in accordance with ISO 20653 and IP69 per IEC 60529. 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 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.

ATTENTION: Do not defeat, tamper, remove, or bypass this unit. Severe injury to personnel could result.

The presence of spare actuators can compromise the integrity of the safety systems. Personal injury or death, property damage, or economic loss can result.

Appropriate management controls, working procedures, and alternative protective measures should be introduced to control their use and availability.

Three M5 fasteners (not provided) are required for proper mounting of the switch to a rigid guard door frame (

Figure 4 ). Two M5 fasteners (not provided)

are required to mount the actuator.

Figure 4 - Required Mounting Hardware for Switch and Actuator

2 x M5

3 x M5

IMPORTANT Do not use a washer with the screw at the base of the switch body. Using a washer causes the plastic to crack.

Loctite 242 thread-locking adhesive is known to cause stress cracks in the plastic housing of the 440G-MZ safety switch 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.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 15

Chapter 3 Installation

Typical Applications

The 440G-MZ safety switch can be mounted on the inside or outside of a hinged or sliding guard door. The following shows three examples of the switch and actuator mounted to a hinged or sliding guard door.

• Mount the switch on the inside of a hinged door

Actuator

Switch mounting bracket

• Mount the switch on outside of a hinged door

Switch mounting bracket

Actuator

Z-shaped Actuator

Mounting Bracket

• Mount the switch on a sliding door

Z-shaped Actuator

Mounting Bracket

Actuator

L-shaped Actuator

Mounting Bracket

L-shaped Actuator

Mounting Bracket

16 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Auxiliary Release

Chapter 3 Installation

Operation of the auxiliary release causes a fault condition.

To reset the switch, cycle the power or issue a RESET command over the link in a GuardLink® safety system.

Figure 5 - Auxiliary Release Operation [mm (in.)]

5 (0.2)

Top View

Padlock Accessory

The padlock accessory (

Figure 6 ) can be inserted through the actuator opening

of the 440G-MZ safety switch to help prevent the locking of the guard door and restarting of the machine while an operator is inside the safeguarded area. The padlock accessory can accommodate up to three nominal 6.35 mm (0.25 in.) locks.

Figure 6 - Padlock Accessory (Cat. No. 440G-MZAL)

Up to three nominal

6.35 mm (0.25 in.) locks

Functional Testing

A manual functional 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, cat. 3 or cat. 4, PLe

- Less than once a year for SIL 2, cat. 3, PLd

ATTENTION: During the functional test, verify that there are no persons in the danger area and that the machine startup does not cause a hazard.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 17

Chapter 3 Installation

OSSD Mode

1.

Confirm that the guard door is open.

2. Connect the 24V DC power to pin 1 and ground (0V) to pin 3. The switch conducts a self-testing routine at the end of which the device status indicator is steady red (if lock signal is set to UNLOCK) or flashing amber (if lock signal is set to LOCK).

3. Test to confirm that the machine cannot start.

4. Confirm the lock signal at pin 5 is set to LOCK (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 device status indicator is steady green.

7. Test to confirm that the machine can start.

8. Change the lock signal at pin 5 to UNLOCK (24V for PTR and 0V for PTL types).

9. Confirm the machine stops, the guard door is mechanically unlocked, and the machine cannot restart.

GuardLink Mode

1.

To begin a functional test of the 440G-MZ safety switch when connected in a GuardLink system, all other devices on the link must be in the operational state.

2. Confirm that the guard door is open.

3. Test to confirm that the machine cannot start.

4. Send a lock command to the 440G-MZ safety switch over the link.

5. Test again to confirm that the machine cannot start.

6. Close the guard door.

7. Send a lock command to the switch over the link.

8. Confirm that the switch is mechanically locked and the Device status indicator is steady green.

A flashing green status indicator on the device indicates that another device on the link is tripped. To proceed, verify that all other devices on the link are in operational state.

9. Test to confirm that the machine can start.

10. Send an unlock command to this 440G-MZ safety switch only over the link.

11. Confirm that the machine stops, the guard door is mechanically unlocked, and the machine cannot restart.

18 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Pin Assignment and

Function

Chapter

4

Wiring and System Integration

The 440G-MZ safety switch is available with a 5-pin DC Micro M12 quick-

disconnect connector. Table 8

shows the pin assignments and their functions and typical mating cordsets. Other cordsets are available at DC Micro Cordsets and Patchcords .

Table 8 - 5-pin Micro (M12)

(1)

2

5

1

3

4

Function

Pin

1

2

3

4

5

Color

Brown

White

Blue

Black

Gray

OSSD Mode

+24V

Safety A

0V

Safety B

Lock Command

GuardLink® Mode

+24V

Safety In

0V

Safety Out

CLU

(1) The recommended cordset is catalog number 889D-F5AC-2 (2 m [6.5 ft]). For additional lengths, replace the 2 with 5 [5 m

(16.4 ft)] or 10 [10 m (32.8 ft)] for standard cable lengths.

The recommended patchcord for use with GuardLink® and ArmorBlock® Guard Safety I/O is the 2 m (6.5 ft) catalog number

889D-F5ACDM-2. Replace the 2 with 0M3 [0M3 (0.98 ft)], 1 [1 m (3.28 ft)], 5 [5 m (16.4 ft)], or 10 [10 m (32.8 ft)] for standard cable lengths.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 19

Chapter 4 Wiring and System Integration

OSSD Mode Safety Signals

In OSSD mode, safety outputs Safety A and Safety B are OFF (0V) when the switch is in safe state (that is, the switch is unlocked). When the switch is in operational state (that is, closed and locked), safety outputs Safety A and Safety

B are ON (24V) and 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.

IMPORTANT To prohibit nuisance tripping, mask the OSSD input channels of the safety system with an On to Off delay of at least 1 ms.

Figure 7 - Output Test Pulses

OSSD test pulses into a 10K resistive load.

Safety OSSD A

Safety OSSD B

5V/Div

580 μs

26 ms

2ms/Div

Safety OSSD A

Safety OSSD B

5V/Div

189 ms

GuardLink Mode Safety

Signals

GuardLink System

Integration

20ms/Div

When the 440G-MZ safety switch is connected in a GuardLink system, the safety signals are Safety In and Safety Out. These signals are dynamic signals in operational state and two-way communication signals in the safe state.

ATTENTION: For information on a known anomaly, see Knowledgebase Article

Unlocked 440G-MZ switch on GuardLink doesn't respond to lock command on power up

.

Figure 8 on page 21 shows the basic components of a GuardLink system with a

DG safety relay master. The 440G-MZ safety switch, with embedded

GuardLink technology, connects to the link with a passive tap (as shown in

Figure 8 on page 21 ) or a passive power tap (catalog number 440S-PF5D4).

20 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter 4 Wiring and System Integration

Different types and versions of GuardLink enabled and passive taps can be connected in any order and can be mixed on the same link. For more information about the configuration a GuardLink safety system, see publication 440R-UM015 .

Both the Power to Release and Power to Lock versions of the 440G-MZ safety switch can be connected to a GuardLink safety system.

Figure 8 - GuardLink System Components

440G-MZ 440G-MZ

2

7

A1 A2

LNK1

MS

LNK1

LNK2

NS

0 1

0 1

0 1

A

B

C

S12 S22 S32 S42

A1 A2 S11 S21

PWR/Fault

OUT

IN 1

IN 2

OUT X

IN X

Reset

FB

DG

.14

Config/Set

Reset

Sel./Save

.2.4.6

Time

X1 X2 X3 X4

13 14 23 24

LNK2

8

4

INPUT

1

5 6

INPUT

1

5

1

4

INPUT

5 6

INPUT

1

3

Item

2

1

3

4

5

6

7

8

Description

5-pin device patchcord

Cordset

Terminator

GuardLink passive tap

4-pin link patchcords

GuardLink enabled tap

(1)

EtherNet/IP™ Network Interface

DG Safety Relay

Cat. No.

889D-F5NCDMx (2) (3)

889D-F4NEy (4)

898D-418U-DM2

440S-PF5D

(5) (6)

889D-F4NEDMx

(3)

(7)

440S-SF5D

(6)

440R-ENETR

440R-DG2R2T

(1) Optional: Device can be connected directly to the passive tap.

(2) 10 m (32.8 ft) length, max.

(3) Replace x with 0M3 (300 mm [0.98 ft]), 0M6 (600 mm [1.97 ft]), 1 (1 m [3.3 ft]), 2 (2 m [6.6 ft]), 5 (5 m [16.4 ft]), or 10 (10 m

[32.8 ft]) for standard cable lengths.

(4) Replace y in order number with 2 (2 m [6.6 ft]), 5 (5 m [16.4 ft]), 10 (10 m [32.8 ft]), 15 (15 m [49.2 ft]), 20 (20 m [65.6 ft]), or

30 (30 m [98.4 ft]) for standard cable lengths.

(5) A passive power tap (Cat. No. 440S-PF5D4) can also be used.

(6) Mounting brackets sold separately. Cat. No. 440S-GLTAPBRK1 (pack of 1) or Cat. No. 440S-GLTAPBRK5 (pack of 5).

(7) 30 m (98.4 ft) length, max

Add Device to a Studio 5000

Project

Information about how to add a 440G-MZ safety switch to a GuardLink system in a Studio 5000® project can be found in the user manual for the GuardLink safety master. See publication 440R-UM009 for information about using the upload method or manual method to add a 440G-MZ safety switch in a

GuardLink circuit controlled by a Guardmaster® DG safety relay.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 21

Chapter 4 Wiring and System Integration

Upload Method

After the upload is complete, the position and type of connected 440G-MZ

safety switches is shown in the Module Definition tab as shown in Figure 9

.

Figure 9 - Upload Method

Manual Method

With the manual method, a 440G-MZ safety switch can be added to a

GuardLink circuit in steps as shown in

Figure 10 .

Figure 10 - Manual Method

1

2

1.

Right-click the GuardLink and select Add Device.

2. Select the correct catalog number from the device list

22 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Lock Command

Chapter 4 Wiring and System Integration

OSSD Mode

Table 9

shows the lock command function. The lock command is a 24V logic signal with a current of less than 2 mA. The function of the logic signal is dependent on the catalog number.

Table 9 - Lock Command Function

Cat. No.

440G-MZS20*M R *

Function

Power to Release

440G-MZS20*M L * Power to Lock

Value

24V = Unlock

0V = Lock

24V = Lock

0V = Unlock

Catalog codes for both types are explained in

Table 4 on page 9 .

GuardLink Mode

In a GuardLink system, the GuardLink safety master (for example a DG safety relay) issues lock and unlock commands to the 440G-MZ safety switch via the

GuardLink Control, Lock, and Unlock (CLU) signal. This signal is either static or dynamic. When static, this signal is LO when the system is operational and

HI when a demand is placed on the safety system. The signal is dynamic when an unlock or lock command is issued to the 440G-MZ safety switch.

When multiple guard locking devices are installed in a GuardLink system, the

GuardLink safety master inserts a short delay between commands to each successive device to minimize the momentary inrush current to the solenoids.

The device closest to the master receives the command first. The device furthest away from the master receives the command last.

See publication 440R-UM015 for more information.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 23

Chapter 4 Wiring and System Integration

Notes:

24 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Setup

Chapter

5

Commission the Safety Switch

The 440G-MZ 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 must 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 firsttime 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.

The 440G-MZ safety switch can be set up in OSSD mode or GuardLink® mode.

IMPORTANT If the 440G-MZ safety switch is connected in a GuardLink system, verify that the

GuardLink is powered ON and the switch is unlocked to insert the actuator and initiate the teach process.

During commissioning, connect the switch as shown in Figure 11

.

Figure 11 - Wiring

DEVICE

LINK

Brown

White

Black

Gray

Blue

+24V DC

NC

NC

NC

Gnd 0V

889D-F5NC-x

or

889D-F5BC-x

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 25

Chapter 5 Commission the Safety Switch

First-time Learn

Apply power to the switch without the actuator present. After the switch completes the power-sequence (approximately 8 seconds), the status indicator flashes green eight times, indicating the total number of times a new actuator can be learned. This status indicator sequence repeats until an actuator is inserted in the switch (in the guard closed position).

Table 10 - Commissioning Process for Unique Coded Switches

Step

2

1

3

4

State

Actuator Present

Verifying Actuator

Programming Switch

Program Finalization

Approximate Duration

15 s

15 s

15 s

15 s

Status Indicators

Flashing 8x green, repeating

(1)

Steady red (learning a replacement actuator)

Flashing red/green, slow

Flashing red/green, fast

Flashing green (number of times a new actuator can be learned)

Steady red 5 Run Mode

(2) —

(1) Out of box condition only.

(2) When teaching an actuator, the switch must be unlocked to insert the actuator. At the end of the finalization step, the switch remains unlocked and in the safe state.

IMPORTANT After teaching a new actuator, a power cycle is required to complete the process.

Perform a functional test of the switch to validate that it works as expected (see

Functional Testing on page 17

).

Learn Additional

Replacement Actuators

Lock the Actuator Code

The switch automatically starts a new teach process when a unique coded replacement actuator is inserted in the switch (in the guard closed position).

IMPORTANT When the switch learns a new actuator, it no longer recognizes previously learned actuators.

If the actuator is removed from the switch and then reinserted into the switch

during the 15-second Program Finalization stage (see Step 4 in Table 10 ), this

action 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, the switch cannot learn additional replacement actuators for the remaining life of the switch. If the actuator is lost or damaged, the switch must 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

26 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter

6

Device Status and Troubleshooting

Status Indicators during

Power-up Routine

When power is applied to the switch, the DEVICE status indicator is steady red for 2.5 seconds, then the DEVICE and LINK status indicators flash red/green for 1 second, and then the DEVICE status indicator is steady red for 3 seconds.

At the conclusion of the start-up sequence, the state of the status indicators is determined by whether there is a demand on the safety function and the status

of the lock signal. See Table 11 .

Status Indicators During

Run Mode

Table 11

shows the status of the 440G-MZ safety switch during run mode.

Table 11 - Switch Status Indication During Run Mode

Indicator

Device

Link

(2)

State

Steady green

Flashing green @ 1 Hz

(1)

Flashing amber @ 1 Hz

Steady red

Flashing red @ 1 Hz

Off

Steady green

Steady red

Description

The switch is in the operational state with no demand on the safety function (that is, closed and locked).

The switch is in the operational state with no demand on the safety function, but the link is in the safe state due to a demand on another device in the link.

The switch is ready to be locked, or attempting to lock. The lock command is set to LOCK but the door is in the open position or slightly ajar. Check that the door is closed.

The switch is in the safe state due to a demand on the safety function (that is, unlocked).

The switch is in the fault state.

Indicates no communication to the DG safety relay over the link.

The switch is wired directly to I/O and is not part of a GuardLink® system.

The link is in the operational state. This switch and all other devices on the link are in the operational state.

The link is in the safe state due to a demand or fault on this switch or another device in the link.

The link is faulted.

Flashing red @ 1 Hz

(1) This state occurs when connected to a GuardLink system only

(2) The Link status indicator is only used when the 440G-MZ safety switch is connected in a GuardLink system. It is OFF when the

440G-MZ safety switch is connected directly to an I/O device or safety relay (OSSD mode).

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 27

Chapter 6 Device Status and Troubleshooting

Diagnostic/Fault Codes

When connected in a GuardLink system, the 440G-MZ safety switch communicates information about its current state with diagnostic and fault codes.

Diagnostic codes ( Table 12 ) warn that a condition exists which prevents the

switch from transitioning to the operational state (for example, the switch is a unique coded switch that must be commissioned), or causes the switch to fault

(for example, the input voltage is approaching the minimum value) if not addressed.

Fault codes ( Table 13 on page 29 ) provide information about why the switch is

in the faulted state (as indicated by the DEVICE status indicator flashing red.)

When a fault is present, perform the recommended action, if stated. Issue a

RESET command to the 440G-MZ safety switch over the link to clear the fault.

IMPORTANT When a Power to Lock switch faults in the locked position, the bolt retracts and the switch unlocks.

Diagnostic Codes

Table 12 - Diagnostic Codes

Decimal

(Hex)

00 (00)

Description Recommended Action

04 (04)

31 (1F)

32 (20)

33 (21)

38 (26)

40 (28)

No diagnostic No action required.

Input voltage is approaching minimum (20.4V DC)

Evaluate input voltage. Input voltage must be 20.4…26.4V under all electrical load conditions.

Ready to lock

A lock command has been sent to the device but the guard door is open or ajar. Check the actuator alignment or close the guard door.

Device is attempting to lock

Device is attempting to unlock

Actuator not paired

Guard door open

Check actuator alignment. Check the wiring for the lock feedback input.

Check for load on actuator or bolt. Check the wiring for the lock feedback input.

Unique coded switch has not been paired with an actuator yet. Insert a unique coded actuator (Cat. No. 440G-MZAU) to start the commissioning process.

The actuator is not detected (RFID is not present). Close the guard door to lock.

28 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter 6 Device Status and Troubleshooting

Fault Codes

Table 13 - Fault Codes

Decimal

(Hex)

00 (00)

Description Recommended Action

05 (05)

No fault.

Power error

No action required.

Evaluate input voltage. Input voltage must be 20.4…26.4V under all electrical load conditions.

07 (07)

Failure to detect device type

(OSSD or GuardLink)

Check wiring and cycle power to the switch. If error persists, replace the switch.

08 (08) Internal memory (ROM) fault Internal memory fault. Reset the device. If error persists, replace it.

09 (09) Runtime memory (RAM) fault Internal memory fault. Reset the device. If error persists, replace it.

10 (0A) Internal memory (CPU) fault Internal memory fault. Reset the device. If error persists, replace it.

15 (0F) No response on GuardLink Check GuardLink wiring and connections.

31 (1F) GuardLink application fault GuardLink system fault. Reset the device. If error persists, replace it.

32 (20) Product application fault Product Application fault. Reset the device. If error persists, replace it.

40 (28)

Unique code actuator is locked

A new actuator cannot be learned because the current actuator is locked.

41 (29)

42 (2A)

43 (2B)

44 (2C)

56 (38)

Invalid actuator detected Cannot teach a standard actuator to a unique coded switch.

No learns left

Actuator relearn

Teaching is not possible. The switch has learned 8 actuators and cannot learn any more actuators.

Switch cannot learn a previously learned actuator. Use a new actuator.

Actuator teach fault

Bolt detection fault

Actuator moved out of range during teach process or the switch has detected an invalid RFID tag.

Keep actuator within sensing range during learn process.

During operational state, the device failed to detect the bolt. On escape release models, this fault can be caused by engaging the escape release. It can also occur if the auxiliary release was actuated.

Inspect the bolt. Disengage the escape release mechanism (if applicable). Reset the device if the fault is not cleared.

57 (39)

58 (3A)

59 (3B)

255 (FF)

Failure to lock

Failure to unlock

Actuator detection fault

Internal fault

Device attempted to lock for specified lock attempt length, but lock status input did not indicate that the device locked.

Check guard door and actuator alignment.

Device attempted to unlock for specified unlock attempt length, but lock status input did not indicate that the device unlocked.

Check the device. Verify that door is not applying a side load on the locking bolt.

During operational state, the device failed to detect the RFID tag in the actuator. Inspect the actuator and RFID tag for signs of damage. Fault reset the device. If the error persists, replace the actuator.

An internal device fault has occurred. Reset the device. If error persists, replace it.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 29

Chapter 6 Device Status and Troubleshooting

Troubleshooting Mounting Holes of the Switch Body Cracked or Broken

The mounting hole 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 required to mount the switch body properly. Do not over torque the screws.

IMPORTANT Do not use a washer with the screw at the base of the switch body. Using a washer causes the plastic to crack.

Loctite 242 thread-locking adhesive is known to cause stress cracks in the plastic housing of the 440G-MZ safety switch 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.

30 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter

7

Application Examples

The following application and wiring examples are intended to show how the

440G-MZ safety switch products can be applied. If you are the user or the designer, you may require variations to these examples to meet your specific requirements.

Wire to GLP Safety 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 12

, the GLP safety relay allows the gate to be unlocked when the motor is running at a Safely-limited Speed.

Figure 12 - GLP and 440G-MZ Safety Switch Schematic

+24V DC, Class 2, PELV

Reset

& Lock

Request

SLS

Request

to PAC

440G-MZS20*NR*

Unlock

Request

800FM-MT44

Reset

Safety

Status to PAC

K300

Status to PAC

Stop/Start/SLS

from PAC

Kinetix® 300 Drive

Brown

889D-F5NC-X

X 1 4 X 2 4

Gry

51 A1 S 4 4 S 5 4 Y32 L12

LOGIC SL1 SL2

GLP 3 5 8

440R-GL2S2P

S 1 2 S 2 2 L61 A2 AP P12 P22 L 1 1

Blue

Blue

872C-D8NP18-E5

Blue

Black

800FM-MT44

S11 S12 S21 S22 A1 13 23

DI

LOGIC

4

440R-D22R2

S32 S42 L11 L12 A2 14

S34

24 Y32

Safe Torque-off

(STO)

Connector with

Wiring Header

4

5

6

1

2

3

+24V DC

COM

Status

Safety Input 1

Safety COM

Safety Input 2

24V DC COM

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 31

Chapter 7 Application Examples

Circuit Status as Shown

The gate is open and unlocked. The motor is off. The GLP safety relay is ready for reset. The GLP safety relay 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 safety relay turns ON, which makes an SLS request to the PAC. The PAC commands the Kinetix® drive to bring the motor to a safe slow speed. 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.

32 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter 7 Application Examples

Wire to GLT Safety Relay

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 GLT safety relay.

In this example shown in

Figure 13

, the GLT safety relay sends an immediate command to the drive to turn OFF. After 8 seconds, the GLT safety relay 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.

Figure 13 - GLT and 440G-MZ Safety Switch Schematic

+24V DC, Class 2, PELV

440G-MZ

Safety Gate Gate

Unlock

Request

Reset and

Gate Lock

Request

L1 L2 L3

PowerFlex

525

11 +24V DC

R S T

1 Stop

2 Start

440G-MZS20*NR*

Power to Release

No aux

4 Gnd

889D-F5NC-X

Brown (+24)

Gray - Lock Cmd

White - OSSD 1

Black - OSSD 2

Blue (Gnd)

24V DC Com

S 5 4 A1 S 1 1 S 1 2 51 S 4 4 Y32

LOGIC RANGE TIME

3 4 8

GLT

440R-GL2S2T

S12 S22 L61 A2 L11 L12

B2

14 24

Gate control power supply

Gate control circuit

S1

S2

U V W

M

Circuit status as shown: The gate is open and unlocked. The motor is off. The

GLT safety relay is ready for reset. The GLT safety relay 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 PowerFlex® 525 drive 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-UM004C-EN-P - August 2020 33

Chapter 7 Application 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 GLT safety relay turns OFF, which commands the PowerFlex® drive to bring the motor to a stop. After the configured time delay (8 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.

34 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Wire to DI and EMD

Safety Relay

Chapter 7 Application Examples

The 440G-MZ safety switch can be connected to the DI and EMD safety relays.

The DI safety relay 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 14

, 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 14 - DI Safety Relay with EMD Safety Relay and 440G-MZ Safety Switch Schematic

+24V DC, Class 2, PELV

Brown

Reset

Brown = +24V DC

White = OSSD 1

Black = OSSD 2

Blue = 24V DC COM

Gray = Lock CMD

L1 L2 L3

440G-MZS20*NR*

E-stop

Gray

Unlock

Blue

K1

K2

White Black

Power

In 1

In 2

Out

Logic

A1

DI

A2 S11 S21 S12 S22 S32 S42

Test Out

LOGIC

2

IN1 IN 2

L12 L11 Y32 S34 13 14 23 24

A1 A2

EMD

B1

RANGE

2

B2 37

TIME

8

L12 L11 X32 17

38 47 48

37 38 47 48

17 18 27 28

18 27 28

M

K1 K2

24V DC COM

Circuit Status as Shown

The E-stop is released. The gate is open and unlocked. K1 and K2 are OFF. The

DI safety relay is configured for two inputs with monitored manual reset. The

EMD safety relay 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.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 35

Chapter 7 Application Examples

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 safety relay (L11) to the

EMD safety relay (L12) also turns off immediately, and the EMD starts the offdelay timer. After 8 seconds, X32 goes to 24V. The unlock switch is enabled, and the gate can be unlocked. While the gate is unlocked, the DI safety relay 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.

36 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Wire to DG Safety Relay

Chapter 7 Application Examples

The 440G-MZ 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 15

shows four 440G-MZ safety switches that are connected on two

GuardLink circuits from one DG safety relay. The DG safety 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 15 - DG Safety Relay with 440G-MZ Safety Switch Schematic

+24V DC, Class 2, PELV

440G-MZS20*NR* 440G-MZS20*NR*

889D-F5NCDM-X

440S-PFSD

889D-F5NCDM-X

440S-PFSD

889D-F4NE-X

Brown

Blue

440G-MZS20*NR* 440G-MZS20*NR*

889D-F5NCDM-X

440S-PFSD

889D-F5NCDM-X

440S-PFSD

889D-F4NE-X

Brown

Blue

Control

Status

Machine

Control

System

440R-ENETR

+

A

B

C

S12 S22 S11 S21 A1

Control

Status

TIME

DG

0

440R-DG2R2T

S32 S42 X2 X1 A2

13 23 X4

14 24 X3

K1 K2

24V DC Com

L1 L2 L3

K1

K2

M

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 37

Chapter 7 Application Examples

Wire to CR30 Safety Relay

The CR30 safety relay is a software configurable safety relay that can easily interface with the 440G-MZ safety switch. Version 10 and later of the

Connected Components Workbench™ software has a locking function that is useful for guard locking applications.

Figure 16 shows an example schematic. The CR30 safety relay monitors the

motor running signal from the PowerFlex 525 drive. When the motor is not running, the safety gate can be unlocked, and the PowerFlex 525 drive goes to a

Safe Torque Off state.

Figure 16 - CR30 Safety Relay with 440G-MZ Safety Switch Schematic

+24V DC, Class 2, PELV

Safety Gate

440G-MZS20*NR*

Power to Release

No aux

889D-F5NC-X

Brown (+24)

Black - OSSD 2

White - OSSD 1

Gray - Lock Cmd

Blue (Gnd)

24V DC Com

Lock

Unlock

PowerFlex

525

11 +24V DC

R S T

1 Stop

L1 L2 L3

Reset

2 Start

0 0 0 1 0 2 0 3 0 4

CR30

A1 A2 12 13 14

05

Motor Not Running

R5

R6

06 07 08 09 10 11

440C-CR30-22BBB

15 16 17 18 19 20 21 t081=2

4 Gnd

Gate control power supply

Gate control circuit

S1

S2

U V W

M

Figure 17 on page 39 shows an example CR30 safety relay configuration that

works with the schematic in

Figure 16 .

38 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter 7 Application Examples

The safety switch OSSD outputs drive the Safe Torque Off (STO) signals of the

PowerFlex 525 drive. The STO is enabled after the gate is locked and the Reset is pressed. The PowerFlex 525 drive 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 5 seconds, and the ULR Latch (Unlock Request) is set to ON. When an unlock request is made, the command is issued 5 seconds after the motor stops running, and the unlock request is latched ON.

Figure 17 - CR30 Configuration in CCW

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 39

Chapter 7 Application Examples

Wire to POINT Guard I/O

Module

Figure 18

shows a wiring example of a 440G-MZ Power to Release safety switch that is connected to a 1734 POINT Guard I/O™ module.

Figure 18 - 1734 Module and 440G-MZ Safety Switch Schematic

440G-MZ

440G-MZS20*NR*

Power to Release

No aux

889D-F5NC-X

Safety Gate

Ethernet I/P to GuardLogix®

PLC and HMI

1 7 3 4 A E N T

0 1

2

4

3

5

24V DC Com

6 7

+24V DC

1734-IB8S 1 7 3 4 O B 8 S

I0

I2

I1

I3

I4

I6

I5

I7

O0 O1

O2 O3

O4 O5

O6 O7

COM COM

T0 T1M

COM

T2

COM COM COM COM COM

T3M

COM COM COM COM

K1 K2

K1 K2

Black - OSSD 2

White - OSSD 1

Blue (Gnd)

Gray - Lock Cmd

Brown (+24)

Figure 19 shows the General tab of the 1734-AENTR module properties.

The Input Status can be set to Rack Optimization, Enhanced Rack

Optimization, or Combined Status - Power - Muting as these settings are 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 19 - 1734-AENTR Module Properties - General

40 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter 7 Application Examples

Figure 20 shows the 1734-IB8S General tab. Set the Module Definition with the

following settings:

• Input Data: Safety

• Output: Test

• Input Status: Pt. Status-Power-Muting-Test Output

Figure 20 - 1734-IB8S Module Properties - General

Figure 21

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-MZ safety switch. The Type is set to Single and the Mode must be set to Safety.

Points 2 and 3 monitor the status of the output contactors, K1 and K2. The Type should be set to Single. Set Mode to Safety Pulse Test. Safety pulse testing is used to detect potential faults in the monitoring circuit.

Figure 21 - 1734-IB8S Module Properties - Input Configuration

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 41

Chapter 7 Application Examples

Figure 22

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. By setting it to Standard, you can programmatically turn these points OFF and ON, in case a nonrecoverable fault occurs with the switch.

Figure 22 - 1734-IB8S Module Properties - Test Output

Figure 23

shows the General tab of the 1734-OB8S module properties. Set the

Module Definition with the following settings:

• Input Data: None

• Output: Safety

• Input Status: Pt. Status

Figure 23 - 1734-OB8S Module Properties - General

42 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter 7 Application Examples

Figure 24 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 24 - Module Properties - Output Configuration

Figure 25 on page 44 shows an example program. A Dual Channel Input Stop

function block monitors the 440G-MZ safety switch, 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.

9

10

11

12

Rung Description

0

With the Test Data output setup set as Standard, an HMI input can cycle power ON and OFF to the

440G-MZ safety switch to recover from a fault, if necessary. Upon powerup, the N.C. contact automatically applies power to the 440G-MZ safety switch.

2

1

The Dual Channel Input Stop monitors the outputs of the 440G-MZ safety switch. The DCS block is set for automatic start on powerup (cold start) and automatic restart each time the switch is locked.

The output of the DCS in Rung 1 provides a tag that shows the input 440G-MZ input status is OK. This tag is used in Rung 4 to enable the Configurable Output to be reset.

3

4

5

A momentary contact from an HMI input starts a short on delay timer. HMI input must be held long enough for the timer to expire. This timer is intended to help prevent inadvertent reset. The preset value can be adjusted to suit the application.

When the timer is done, the OSF_Storage_Bit is set. When the HMI_CROUT_Actuate button in Rung 4 is released, the OSF_Storage_Bit goes LO and the OSF_Output_Bit goes HI.

When the OSF_Output_Bit goes HI, the CROUT_Actuate tag is set. The CROUT_Actuate tag is self-sealing because the OSF_Output_Bit is HI only momentarily.

6

7

8

The GMZ_Crout block is set for negative feedback. The CROUT block output cannot go HI unless the external contactor status at Feedback 1 and 2 is HI.

The two CROUT outputs turn ON the ArmorBlock® outputs, which energize the external contactors.

From an HMI input, you can lock or unlock the 440G-MZ safety switch. The HMI input must be a maintained switch.

Notify the HMI if a fault is present on the DCS block.

An HMI input can reset the DCS if a fault is present.

Notify the HMI if a fault is present on the CROUT block.

An HMI input can reset the CROUT if a fault is present.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 43

Chapter 7 Application Examples

Figure 25 - 1734 Example Studio 5000® Program

44 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Wire to ArmorBlock

Guard I/O Module

Chapter 7 Application Examples

The 440G-MZ safety switch can be connected to a 1732ES/1732DS ArmorBlock

Guard I/O™ module by using a catalog number 889D-F5NCDM-x 5-wire patchcord. An example schematic is shown in

Figure 26

.

Figure 26 - ArmorBlock Schematic

1732ES-IB12XOB4

889D-F5NCDM-X

889D-E5NC-10 889D-E5NC-10

Brown (1)

K1

K2

White (2)

Black (4) Gray (5)

White (2) A1

K1

A2 Blue (3)

100S Contactors or

700S or 700-HPS Relays

Black(4) A1

K2

A2 Gray (5)

Figure 27

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 27 - Module Properties - General

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 45

Chapter 7 Application Examples

Figure 28

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 should be set to Single, and the Mode must be set to

Safety.

Points 4 and 5 monitor the status of the output contactors K1 and K2. These points should also be set to Single and Safety Pulse Test. The Test Source must agree with the Test Output tab.

Figure 28 - Module Properties - Input Configuration

46

Figure 29 shows the Test Output tab of the ArmorBlock Module Properties. In

this example, Points 0 and 1 are set to Standard, which allows the program to control these points. Point 0 applies power to the 440G-MZ safety switch. By setting it to standard, you can programmatically turn this point off and on if the 440G-MZ safety switch has a fault condition. Point 1 is the lock/unlock command. In this example, the 440G-MZ safety switch 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 29 - Module Properties - Test Output

Figure 30 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 30 - Module Properties - Output Configuration

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter 7 Application Examples

Figure 31 on page 48 shows an example program. A Dual Channel Input Stop

function block monitors the 440G-MZ safety switch, 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.

9

10

11

12

Rung Description

0

With the Test Data output setup set as Standard, an HMI input can cycle power ON and OFF to the

440G-MZ safety switch to recover from a fault, if necessary. Upon powerup, the N.C. contact automatically applies power to the 440G-MZ safety switch.

1

The Dual Channel Input Stop monitors the outputs of the 440G-MZ safety switch. The DCS block is set for automatic start on powerup (cold start) and automatic restart each time the switch is locked.

2

3

4

The output of the DCS in Rung 1 provides a tag that shows the input 440G-MZ input status is OK. This tag is used in Rung 4 to enable the Configurable Output to be reset.

A momentary contact from an HMI input starts a short on delay timer. HMI input must be held long enough for the timer to expire. This timer is intended to help prevent inadvertent reset. The preset value can be adjusted to suit the application.

When the timer is done, the OSF_Storage_Bit is set. When the HMI_CROUT_Actuate button in Rung 4 is released, the OSF_Storage_Bit goes LO and the OSF_Output_Bit goes HI.

5

6

7

When the OSF_Output_Bit goes HI, the CROUT_Actuate tag is set. The CROUT_Actuate tag is self-sealing because the OSF_Output_Bit is HI only momentarily.

The GMZ_Crout block is set for negative feedback. The CROUT block output cannot go HI unless the external contactor status at Feedback 1 and 2 is HI.

The two CROUT outputs turn ON the ArmorBlock outputs, which energize the external contactors.

8

From an HMI input, you can lock or unlock the 440G-MZ safety switch. The HMI input must be a maintained switch.

Notify the HMI if a fault is present on the DCS block.

An HMI input can reset the DCS if a fault is present.

Notify the HMI if a fault is present on the CROUT block.

An HMI input can reset the CROUT if a fault is present.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 47

Chapter 7 Application Examples

Figure 31 - Example Studio 5000 Program

48 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Chapter 7 Application Examples

Wire to MSR55P Back EMF

Safety Relay

A PowerFlex 525 drive controls the speed and direction of the motor. The

MSR55P safety relay allows access to the hazard after the motor has achieved its standstill settings. The DI safety relay monitors the guard locking switch and the E-stop push button.

The DI safety relay enables the drive to restart after the gate is closed and locked and the E-stop is released.

Figure 32 - MSR55P Back EMF Relay Schematic

+24V DC Class 2 PELV

L1L2 L3

R S T

Reset

Unlock

Vm -Monitoring

voltage ts - time Setting

(delay)

Status

to PAC

PowerFlex

525

1 Stop

2 Start

Safety Gate

440G-MZS20*NR*

Power to Release

No aux

889D-F5NC-X

Brown (+24)

Black - OSSD 2

White - OSSD 1

Gray - Unlock Request

Blue (Gnd)

24V DC Com

S11S21 S22 S12 A1 L12 Y32 S34

LOGIC

2

DIS

440R-D22S2

S32 S42 L11 A2 34 44 14 24

A1 11 23 33 43 53

MSR55P

440R-S35014

A3 X1 X2

Vm

X3

7

3 t s

A2 12 24 34 44 54 ON ERR A4 L1 L2 L3

ON status

ON status

Error status

Fuses*

4 Gnd

Gate Control

Power Supply

S1

S2

Gate control

circuit

U V W

M

3~

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 49

Chapter 7 Application Examples

Notes:

50 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Appendix

A

Specifications

This appendix provides the specifications and safety ratings for the 440G-MZ safety switch.

Safety Ratings

Attribute

Standards

Safety classification

Functional safety

Value

IEC 60947-5-3, IEC 61508, ISO 13849-1, IEC 62061, ISO 14119, UL 508

Type 4 interlocking device with guard locking per ISO 14119 with low (standard) and high (unique) coding per ISO 14119

Suitable for use in applications up to and including PLe Cat 4 per ISO 13849-1, SIL CL 3 per IEC 62061, and SIL 3 per IEC 61508

• OSSD mode

(1)

Proof test interval = 20 years

PFHd = 3.17E-09

PFD = 3.67E-04

• GuardLink® mode

(2)

Proof test interval = 20 years

PFHd = 2.93E-09

PFD = 3.59E-04

CE Marked for all applicable EU directives, c-UL-us, TÜV Certifications

(1) This data is given for the 440G-MZ safety switch when used in OSSD mode (connected to a safety I/O or safety logic device).

(2) This data is given for the 440G-MZ safety switch when used in a GuardLink safety system.

Operating Characteristics

Attribute

Torque for M5 mounting of switch and actuator mounting bracket

Locking bolt alignment tolerance X, Y, Z

Holding force F max

(ISO 14119)

Value

2 N•m (17.7 lb•in) max

±5 mm (0.2 in.) max

3250 N

Holding force F zh

(ISO 14119)

Output current, max (each output)

Quiescent power consumption, locked or unlocked

Lock signal current

Peak current and duration, at turn on or after lock/ unlock operation

2500 N

200 mA

1.5 W

1 mA

150 mA for approximately 800 ms following lock/unlock operation.

Steady state current, max

Operating voltage Ue

Operating cycle frequency, max

• OSSD mode: 40 mA

• GuardLink mode: 50 mA

24V DC +10% / -15% Class 2 PELV

0.2 Hz

Dwell time between subsequent locking/unlocking 2.5 s

Response time (Off) (IEC 60947-5-3) 275 ms

Start up time (availability)

Utilization category (IEC 60947-5-2)

Insulation voltage U i

(IEC 60947-5-1)

Impulse withstand voltage U imp

(IEC 60947-5-1)

8 s

DC-13 24V 200 mA

75V

1 kV

Pollution degree (IEC 60947-5-1)

Auxiliary release

Protection class (IEC 61140)

Mechanical life

3

Built in

Class II

500,000 cycles

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 51

Appendix A Specifications

Outputs (Guard Door Closed and Locked)

Attribute Value

Safety outputs (OSSD mode) 2 x PNP, 0.2 A max / ON (+24V DC)

Environmental

Attribute

Operating temperature

Storage temperature

Operating humidity

Enclosure ingress rating

Shock and vibration

Radio frequency/EMC

Value

0…55 °C (32…131 °F)

-25…+75 °C (-13…+167 °F)

5…95%, noncondensing

• IP65

• IP66

• IP67

• IP69

• IP69K

• IEC 60068-2-27 30 g (1.06 oz), 11 ms

• IEC 60068-2-6 10…55 Hz, 1 mm (0.04 in.)

IEC 60947-5-3, FCC-1 (Parts 18 and 15), RED

General

Attribute

Materials

Weight [kg (lb)]

Protection Type

Value

Switch

Actuator

• Housing - ABS

• Front brace – SS304 (machined), SS316 (cast)

• Housing and housing cover – SS304

• Spring – SS302

• Grommet – nitrile rubber

• Screws - stainless steel

• Tongue – SS410

Brackets High-strength low alloy steel

Padlock Accessory SS410

• Switch 0.75 (1.7)

• Actuator 0.27 (0.6)

• Actuator L mounting bracket 0.27 (0.6)

• Actuator Z bracket 0.54 (1.2)

• Switch L bracket 1 (2.2)

• Short-circuit

• Current limitation

• Overload

• Reverse polarity

• Overvoltage

• Thermal shutdown/restart

52 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Certifications

Appendix A Specifications

Visit rok.auto/certifications 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

• RCM 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 monitoring and for guard locking according to ISO 14119.

• FCC Notice (for U.S. Customers)

This device complies with Part 15 of the FCC Rules. Operation is subject to the following conditions: a. This device many not cause harmful interference, and b. This device must accept any interference received, including interference that may cause undesired operation.

Changes and Modifications not expressly approved by

Rockwell Automation can void your authority to operate this equipment under Federal Communications Commissions rules.

• This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts de licence. L'exploitation est autorisée aux deux conditions suivantes : (1) l'appareil ne doit pas produire de brouillage, et (2) l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d'en compromettre le fonctionnement.

Compliance to European

Union Directives

This product bears the CE marking and is approved for installations within the

European Union and EEA regions. It has been designed and tested to meet the

Machine Safety and EMC directives.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 53

Appendix A Specifications

Approximate Dimensions

Figure 33 - Switch Body [mm (in.)]

2 x Ø5.5

(0.22)

33

(1.3)

2 x 30.1 (1.19)

2 x 32.5 (1.28)

3 x 27.6 (1.1)

6 x Ø 8.5 (0.33)

14.6 (0.6)

153 (6.02)

134.5 (5.3)

22.5

(0.89)

40.5

(1.6)

Ø5.1

(0.2)

6

(0.24)

45.2

(1.78)

33 (1.3)

15

(0.59)

22.6

(0.89)

25.3

(1)

50 39.5

(1.97) 47.5

(1.87)

(1.56)

0.3

(0.01)

14.9 (0.59)

176.8 (6.96)

15 (0.59)

134.5 (5.3)

153 (6.02)

182.7 (7.19)

Figure 34 - Actuator [mm (in.)]

14

(0.55)

10

(0.39) 14

(0.55)

30

(1.18)

15

(0.59)

65 (2.56)

Ø32.9 (1.3)

7.3 (0.28)

25.6 (1.01)

6 x Ø6.3 (0.25)

4 x Ø6.5

(0.26)

30

(1.18)

50 (1.97)

7.5

(0.3)

12.8 (0.5)

20

(0.79) 10

(0.39)

Ø12.4

(0.49)

32.5

(1.28)

23.7

(0.93)

4

(0.16)

9.9

(0.39)

59.3

(2.33)

23.8

(0.94)

40

(1.57)

3 (0.12)

12.5

(0.49)

74.2 (2.9)

Figure 35 - Actuator on Z Bracket [mm (in.)]

7.2 (0.28)

2 x 25.6 (1) 7.5

(0.29)

72.1 (2.8) REF

3 x 50 (2) 65 (2.6)

REF

6 x Ø 6.3 (0.2)

5.9

(0.23)

30.3 (1.2)

59.3

(2.3)

104.3 (4.1)

124.3 (4.9)

74.2 (2.9)

65

(2.6)

76.6 (3.01)

REF

30.3 (0.33)

29.3 (1.2)

46.8

(1.8)

6 x Ø 8.5 (0.33)

40 (1.6)

2 x Ø 8.5 (0.33)

40 (1.6)

46.8

(1.8)

4 x Ø 7.1 (0.3)

6 x Ø 6.3 (0.2)

124.3 (4.9) REF

54 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Appendix A Specifications

83.5 (3.3)

55.4 (2.2)

33.8 (1.3)

Figure 36 - Actuator on L Bracket [mm (in.)]

32.5 (1.27)

7.2

(0.28)

2 x 12.8 (0.5)

27.6

(1.1)

65 (2.6)

REF

2 x 50 (1.96)

45.3

(1.8)

4 x Ø 6.3 (0.24)

7.5 (0.3)

65 (2.6) 50 (1.96)

23.3

(0.9)

2 x Ø 8.5 (0.33) 7.5

(0.3)

2 x Ø 8.5 (0.33)

32.5 (1.27)

45.3 (1.8)

REF

60.5 (2.4) REF

Figure 37 - Switch on L Bracket [mm (in.)]

47.8 (1.9)

34.4 (1.4)

27.6 (1.1)

2 x Ø 8.5 (0.33)

27 (1.06)

60.5 (2.4)

22.5 (0.9)

37.2

(1.4)

59.3 (2.3)

7.2 (0.28)

12.8 (0.5)

40

(1.6)

65

(2.6)

23.7 (0.9)

5.3 (0.2)

3 x Ø 5.2 (0.2)

2 x 80 (3.1)

134.5

(5.3)

80

(3.1)

160 (6.3)

REF

182 (7.2)

REF

33 (1.3) 6

(0.24)

42.2

(1.7)

25.3 (1)

30.4 (1.2)

60.5 (2.4)

REF

2 x Ø 8.5 (0.33)

68.8 (2.7)

REF

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 55

Appendix A Specifications

Figure 38 - Padlock Accessory [mm (in.)]

2 x Ø 4.7 (0.2)

45

(1.8)

35

(1.4)

17.5

(0.7)

2 x 7.8 (0.3)

15.5 (0.6)

102.7 (4.04)

3 x Ø 7.4 (0.3)

63.8 (2.5)

74.8 (2.9)

85.8 (3.4)

4.7 (0.2)

3 x 10 (0.39) REF

20

(0.79)

8 x R2 (0.1)

56 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

A

abbreviation

6

accessories

9

actuator

dimension

54

spare

9

actuator code lock

26

allowable approach direction

14

application

ArmorBlock Guard I/O

45

CR30 safety relay

38

DG safety relay

37

DI safety relay

35

EMD safety relay

35

GLP safety relay

31

GLT safety relay

33

MSR55P back EMF safety relay

49

POINT Guard I/O

40

approximate dimension

54

ArmorBlock Guard I/O application

45

assembly overview

8

assignment pin

19

auxiliary release

17

C

CE Marked

53

certification

53

safety

11

characteristic

CLU

6 operating

51

code

diagnostic

28

fault

29

coding

standard 6

unique

6

command lock

23

command, lock, and unlock

6

commission safety switch

25

commissioning process error codes

26

complete switch

9

compliance

European Union Directive

53

concept safety

11

content

package

10

correct use

13

CR30 safety relay application

38

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

D

device status

27

DG safety relay application

37

DI safety relay application

35

diagnostic code

28

dimension approximate

54

direction allowable approach

14

E

EMD safety relay

application

35

environmental

52

error codes commissioning process

26

European Union Directive compliance

53

example application

31

F

fault code

29

FCC notice

53

first-time learn

26

functional testing

17

GuardLink mode 18

OSSD mode

18

G

general specification

52

GLP safety relay application

31

GLT safety relay application

33

guard locking

Power to Lock

8

Power to Release

8

GuardLink safety signal

20

system integration

20

I

Industry Canada

license-exempt RSS standard

53

ingress protection

15

installation

13

integration

GuardLink system

20

Index

57

Index

58

L

L bracket learn dimension

55

additional replacement actuator 26

first-time

26

license-exempt RSS standard

Industry Canada

53

lock

actuator code

26

lock command

23

M

mount switch body

15

mounting holes cracked/broken

30

MSR55P back EMF safety relay application

49

N

notice

FCC

53

O

operating characteristic

51

operational state

6

orientation switch

14

OSSD

6

OSSD mode safety signal

20

output specification

52

output signal switching device

6

overview assembly

8

P

package content

10

padlock accessory

17

dimension

56

pair proximity

14

pin assignment

19

POINT Guard I/O application

40

Power to Lock guard locking

8

Power to Release guard locking

8

power-up routine status indicator

27

product selection

9

protection ingress

15

proximity pair

14

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

R

rating safety

51

RCM Marked

53

reaction time

6

release auxiliary

17

replacement actuator learn

26

response time

6

RSS standard

Industry Canada license-exempt

53

run mode status indicator

27

S

safe state

6

safety certification

11

concept

11

rating

51

signal

GuardLink 20

OSSD

20

standard

11

selection

product

9

setup

25

spare actuator

9

specification

51

environmental

52

general

52 operating characteristic

51

output

52

standard safety

11

standard coding

6

state

operational 6

safe

6

status device

27

status indicator power-up routine

27

run mode

27

switch commission

25

complete

9

orientation

14

setup

25

switch body dimension

54

mount

15

mounting holes cracked/broken

30

system integration

GuardLink

20

T

tap

6

terminology

6

testing functional

17

GuardLink mode 18

OSSD mode

18

time reaction

6

response

6

troubleshooting

30

TÜV Certified

53

U

UL Listed

53

unique coding

6

use correct

13

W

wiring

19

, 25

Z

Z bracket dimension

54

Index

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 59

Index

Notes:

60 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

Guardmaster Guard Locking Switch User Manual

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 61

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Publication 440G-UM004C-EN-P - August 2020

Supersedes Publication 440G-UM004B-EN-P - July 2020 Copyright © 2020 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.