Allen-Bradley Guardmaster Guard Locking Switch User Manual

Guardmaster Guard Locking
Switch
Catalog Numbers 440G-MZS20SNRJ, 440G-MZS20SNRJE,
440G-MZS20UNRJ, 440G-MZS20UNRJE, 440G-MZS20SNLJ,
440G-MZS20SNLJE, 440G-MZS20UNLJ, 440G-MZS20UNLJE
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-UM004F-EN-P - July 2022
Table of Contents
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Purpose of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Product Overview
Guardmaster 440G-MZ Safety Switch Overview. . . . . . . . . . . . . . . . . . . . . 9
Guard Locking on Power to Release Versions . . . . . . . . . . . . . . . . . . . 10
Guard Locking on Power to Lock Versions . . . . . . . . . . . . . . . . . . . . . 10
Assembly Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
Safety Concept
Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 3
Installation
General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Correct Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Switch Orientation and Pair Proximity. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Actuator Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mount the Switch and Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Auxiliary Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Escape Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Padlock Accessory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OSSD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
GuardLink Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Escape Release (GuardLink Mode or OSSD Mode) . . . . . . . . . . . . . . 22
Chapter 4
Wiring and System Integration
Pin Assignment and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OSSD Mode Safety Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GuardLink Mode Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GuardLink System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DG Integration to Studio 5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Upload Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Manual Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lock Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OSSD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
GuardLink Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
3
Table of Contents
Chapter 5
GuardLink System Integration
DG Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
432ES Safety System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Manual Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Discover Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Send Commands to 440G-MZ Safety Switch. . . . . . . . . . . . . . . . . . . . 36
Chapter 6
Commission the Safety Switch
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
First-time Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Learn Additional Replacement Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Lock the Actuator Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Error Codes during the Commissioning Process . . . . . . . . . . . . . . . . . . . 40
Chapter 7
Device Status and
Troubleshooting
Status Indicators during Power-up Routine . . . . . . . . . . . . . . . . . . . . . . . 41
Status Indicators During Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Diagnostic/Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Mounting Holes of the Switch Body Cracked or Broken . . . . . . . . . 44
Chapter 8
Application Examples
Wire to GLP Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Circuit Status as Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Safely-limited Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Wire to GLT Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Wire to DI and EMD Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Circuit Status as Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Wire to DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Wire to CR30 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Wire to POINT Guard I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Wire to ArmorBlock Guard I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Wire to MSR55P Back EMF Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Chapter 9
ControlFLASH Firmware Update Update Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Appendix A
Specifications
4
Safety Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Operating Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Outputs (Guard Door Closed and Locked) . . . . . . . . . . . . . . . . . . . . . . . . . 70
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Table of Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
UKCA Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
5
Table of Contents
Notes:
6
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Preface
Use this manual to design, install, program, or troubleshoot systems that use
the Guardmaster® 440G-MZ Guard Locking Safety Switches.
Who Should Use This
Manual
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-MZ safety switch.
It describes the procedures that you use to install, wire, and troubleshoot your
switch. This manual accomplishes the following:
•
•
Summary of Changes
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
Updated Figure 10
Updated DG Integration to Studio 5000
Added GuardLink System Integration
Updated Table 11
Added ControlFLASH Firmware Update
Updated Declaration of Conformity
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Page
25
26
29
41
65
72
7
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
Additional Resources
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 the 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 can 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
These documents contain additional information concerning related products
from Rockwell Automation.
Resource
440G-MZ Guardmaster Safety Switches Installation Instructions,
publication 440G-IN018
Description
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.
Provides general guidelines for installing a Rockwell Automation® guard locking switch.
Describes how to configure and use EtherNet/IP devices to communicate on the
EtherNet/IP™ network.
Ethernet Reference Manual, publication ENET-RM002
Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
Provides guidance on how to conduct security assessments, implement Rockwell
System Security Design Guidelines Reference Manual,
Automation products in a secure system, harden the control system, manage user access,
publication SECURE-RM001
and dispose of equipment.
Provides a quick reference tool for Allen-Bradley® industrial automation controls and
Industrial Components Preventive Maintenance, Enclosures, and Contact
assemblies.
Ratings Specifications, publication IC-TD002
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
Safety Guidelines for the Application, Installation, and Maintenance of
the form of individual devices or packaged assemblies incorporating solid-state
Solid-State Control, publication SGI-1.1
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Provides declarations of conformity, certificates, and other certification details.
Product Certifications website, rok.auto/certifications.
EtherNet/IP Network Devices User Manual, publication ENET-UM006
You can view or download publications at rok.auto/literature.
8
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
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-UM004F-EN-P - July 2022
9
Chapter 1
Product 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/Unlock Command
Mode
Description
• Unlock: Lock signal (pin 5) is connected to 24V DC.
OSSD
• Lock: Lock signal (pin 5) is connected to 0V DC or has no connection (floating).
GuardLink A lock or unlock command is issued to the switch on the CLU signal from a GuardLink safety primary.
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 startup sequence. In this case, the bolt does
extend. If the guard door is closed when the startup 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/Unlock Command
Mode
Description
Unlock:
Lock signal (pin 5) is connected to 0V DC or has no connection (floating).
OSSD
Lock: Lock signal (pin 5) is connected to 24V DC.
GuardLink A lock or unlock command is issued to the switch on the CLU signal from a GuardLink safety primary.
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 startup sequence. In this case, the bolt does
extend. If the guard door is closed when the startup sequence is interrupted, the
guard door is locked. Use the auxiliary release to unlock the switch.
10
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 1
Assembly Overview
Product Overview
Actuator
Actuator
LINK and DEVICE
status indicators
LINK and DEVICE
status indicators
Standard Model
Escape Release Model
Product Selection
Table 4 - Catalog Number Explanation
440G-MZS
a
Outputs (Safety/Auxiliary)
Code
Description
20
Two safety/no aux
d
Lock Type
Description
Power to Release
Power to Lock
Code
R
L
20
a
S
b
Code
S
U
N
c
R
d
J
e
b
Actuator Code
Description
Standard code
Unique code
Code
N
e
Connection Type
Code
Description
J
M12 5-pin
E
f
c
Auxiliary Type
Description
No auxiliary
f
Special Features
Code
Description
Blank
None
E
Escape release
Table 5 - Complete Switches, including Switch Body and Actuator
Type
Power to Release
Power to Lock
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)
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
Yes
Cat No.
440G-MZS20SNRJ
440G-MZS20UNRJ
440G-MZS20SNLJ
440G-MZS20UNLJ
440G-MZS20SNRJE
440G-MZS20UNRJE
440G-MZS20SNLJE
440G-MZS20UNLJE
Table 6 - Spare Actuators
Description
Standard code actuator (Low level to ISO 14119)
Unique code actuator (High level to ISO 14119)
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Cat. No.
440G-MZAS
440G-MZAU
11
Chapter 1
Product Overview
Table 7 - Accessories
Description
Cat. No.
L-shaped
440G-MZAM1
Z-shaped
440G-MZAM2
Actuator mounting bracket
Package Contents
Switch mounting bracket
440G-MZAM3
Padlock accessory
440G-MZAL
Auxiliary release tool
440G-MZAT
Replacement screw
440G-MZRSC
Replacement button
440G-MZRBU
The box includes the following components:
Description
Switch Body
Standard Model
Escape Release Model
OR
Actuator
Documentation
12
Installation Instructions:
publication 440G-IN018
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
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:
•
•
•
•
•
•
Safety Certification
EN 60947-5-3
EN 61508
EN 62061
EN ISO 13849-1
ISO 14119
UL 508
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-UM004F-EN-P - July 2022
13
Chapter 2
Safety Concept
Notes:
14
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter
3
Installation
General Considerations
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 21).
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.
Correct Use
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 Switch Orientation and Pair Proximity on page 16.
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-UM004F-EN-P - July 2022
15
Chapter 3
Installation
Switch Orientation and
Pair Proximity
The switch can be mounted with the actuator opening in any orientation.
As shown in Figure 1, a minimum of 100 mm (3.94 in.) must separate a pair of
switches to help achieve correct operation.
Figure 1 - Minimum Distance between Switches [mm (in.)]
100
(3.94)
100
(3.94)
IMPORTANT
Actuator Orientation
If the minimum separation distance is not observed, the electromagnetic fields
interact causing crosstalk. Crosstalk can result in nuisance faults and false
operation.
The actuator can approach the switch from three directions (Figure 2).
Figure 2 - Three Directions of Approach
2
3
1
The flexible actuator can move in multiple axes to accommodate guard door
misalignment (Figure 3). 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 3 - Actuator Function
16
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 3
Environmental
Considerations
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.
The 440G-MZ safety switch is constructed of stainless-steel materials and
plastics that are resistant to various machining fluids, oils, and food industry
soils and cleaners.
IMPORTANT
Mount the Switch and
Actuator
To help prevent adverse effects that can occur with long-term exposure to
cleaners used in CIP (clean-in-place) applications, thoroughly rinse the
switch with water after cleaning.
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 must 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
Max screw torque
2 N•m (17.7 lb•in)
IMPORTANT
Do not use a washer with the screw at the base of the switch body. The use of 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 must 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-UM004F-EN-P - July 2022
17
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 examples show the switch and
actuator mounted to a hinged or sliding guard door.
Standard Model
•
Mount the switch on the inside of a hinged door
Actuator
Switch
mounting
bracket
•
Switch
mounting
bracket
Mount the switch on the outside of a hinged door
Actuator
Z-shaped Actuator
Mounting Bracket
Z-shaped Actuator
Mounting Bracket
•
Mount the switch on a sliding door
Actuator
18
L-shaped Actuator
Mounting Bracket
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
L-shaped Actuator
Mounting Bracket
Chapter 3
Installation
Escape Release Models
•
Mount the escape release switch on a sliding door
Actuator
•
L-shaped Actuator
Mounting Bracket
L-shaped Actuator
Mounting Bracket
Mount the escape release switch on a hinged door
Actuator
Z-shaped Actuator
Mounting Bracket
Z-shaped Actuator
Mounting Bracket
Auxiliary Release
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.
ATTENTION: For infrequent use only. The auxiliary release is not intended for
routine access or maintenance. It is intended to be used in exceptional cases only,
such as when power is lost and an emergency release is unavailable.
• Do not operate the machine while the auxiliary tool is attached to the switch.
• To help prevent accumulation of debris inside the switch, return the screw that is
removed in step 1 on page 20 immediately after using the auxiliary release tool and
tighten the screw to 0.56 N•m (5 lb•in).
Figure 5 - Auxiliary Release Operation — Standard Model [mm (in.)]
5 (0.2)
Top View
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
19
Chapter 3
Installation
Figure 6 - Auxiliary Release Operation — Escape Release Model [mm (in.)]
2
1
1.
2.
3.
4.
3…6
Remove screw.
Engage 2…3 threads of the auxiliary release tool into the release key.
Use the tool to pull the release forward to retract the locking bolt.
Reset the release key by pushing the key back to the original position.
The actuator can now be removed from the switch.
A built-in spring assists with reset of the release key.
5. Open the guard door. If the guard door does not open, repeat step 3 and
step 4.
6. Unscrew the auxiliary release tool and replace the screw that was
removed in step 1.
Escape Release
The escape release is used to open a locked safety guard from inside the
safe-guarded area without tools.
ATTENTION: Do not remove the M4 screw that seals the opening at the top of
the switch.
Figure 7 - Actuate the Escape Release
1
2
3
1.
Actuate the escape release by pushing the red button to the end stop.
This action turns the safety outputs OFF and causes a fault condition.
2. Reset the escape release by pulling out the red button to the original
position. The actuator can now be removed from the switch.
A built-in spring assists with reset of the escape release.
3. Open the guard door. If the guard door does not open, repeat step 1
and step 2.
IMPORTANT
• The escape release meets the requirements of Cat. B according to
EN ISO 13849.
• The escape release must only be accessible from inside the safe-guarded
area. The installation must not allow access to the escape release from
outside the safe-guarded area.
• A manual functional test of the escape release is required after installation
and after any maintenance or change of components.
Operation of the escape 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.
20
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 3
Padlock Accessory
Installation
The padlock accessory (Figure 8) 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 accommodates up to three nominal 6.35 mm (0.25 in.) locks.
Figure 8 - 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.
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
yellow (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.
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
21
Chapter 3
Installation
GuardLink Mode
1.
2.
3.
4.
5.
6.
7.
8.
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.
Confirm that the guard door is open.
Test to confirm that the machine cannot start.
Send a lock command to the 440G-MZ safety switch over the link.
Test again to confirm that the machine cannot start.
Close the guard door.
Send a lock command to the switch over the link.
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.
Escape Release (GuardLink Mode or OSSD Mode)
1.
2.
3.
4.
5.
22
Confirm that the guard is mechanically closed and locked and that the
device status indicator is steady green.
Actuate the escape release by pressing the red button (see Escape
Release on page 20).
Confirm that the OSSD safety outputs turn OFF and the safety switch
faults (the device status indicators are flashing red).
Reset the escape release by pulling out the red button to the original
position.
Confirm that the actuator can be removed from the switch and the
guard door can be opened.
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter
4
Wiring and System Integration
Pin Assignment and
Function
The 440G-MZ safety switch is available with a 5-pin DC Micro M12 quickdisconnect 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
Pin
Color
1
2
3
4
5
Brown
White
Blue
Black
Gray
4
Function
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 I/O™ is the 2 m (6.5 ft) catalog number 889DF5NCDM-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-UM004F-EN-P - July 2022
23
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 9 - 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
20ms/Div
GuardLink Mode Safety
Signals
24
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.
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 4
GuardLink System
Integration
Wiring and System Integration
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.
This anomaly is present with Dual GuardLink (DG) safety relay with firmware revision
1.001 only. The anomaly was fixed with DG firmware revision 1.021.
Figure 10 on page 25 shows the basic components of a GuardLink system with
a DG safety relay primary. The 440G-MZ safety switch, with embedded
GuardLink technology, connects to the link with a passive tap (as shown in
Figure 10 on page 25) or a passive power tap (catalog number 440S-PF5D4).
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 10 - GuardLink System Components
440G-MZ
5
1
1
INPUT
LNK2
S12 S22 S32 S42
A1 A2 S11 S21
2 3
8
B
C
4
8
7
4
5 6
8
9 0 1
7
4
5 6
7
6
5
4
5
6
3
Reset
Sel./Save
. 0.2
Time
X1 X2 X3 X4
13 14 23 24
LNK2
5
INPUT
Config/Set
DG
8
12.14
5 6
9 0 1
4
1
INPUT
.4.6.
A
2 3
7
9
2 3
9 0 1
2
1
INPUT
PWR/Fault
OUT
IN 1
IN 2
OUT X
IN X
Reset
FB
NS
8.10.
MS
LNK1
IP: 192. 168. 1. ABC
A1 A2
LNK1
440G-MZ
8
Item
Description
Cat. No.
1
5-pin device patchcord (1)
889D-F5NCDM-x (2) (3)
2
Cordset
3
Terminator
889D-F4NE-y (4)
898D-418U-DM2
4
GuardLink passive tap
440S-PF5D (5) (6)
5
4-pin link patchcords
889D-F4NEDM-x (3) (7)
6
GuardLink-enabled tap
7
8
9
EtherNet/IP™ Network Interface
DG Safety Relay
CIP Safety EtherNet/IP Interface
440S-SF5D (6)
440R-ENETR
440R-DG2R2T
432ES-IG3
(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
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
25
Chapter 4
Wiring and System Integration
DG Integration to Studio
5000
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 primary. 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.
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 11.
Figure 11 - 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 12.
Figure 12 - Manual Method
1
2
1. Right-click the GuardLink and select Add Device.
2. Select the correct catalog number from the device list
26
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 4
Lock Command
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.
Function
440G-MZS20*MR*
Power to Release
440G-MZS20*ML*
Power to Lock
Value
24V = Unlock
0V = Lock
24V = Lock
0V = Unlock
Catalog codes for both types are explained in Table 4 on page 11.
GuardLink Mode
In a GuardLink system, the GuardLink safety primary (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 primary inserts a short delay between commands to each
successive device to minimize the momentary inrush current to the solenoids.
The device closest to the primary receives the command first. The device
furthest away from the primary receives the command last.
See publication 440R-UM015 for more information.
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
27
Chapter 4
Wiring and System Integration
Notes:
28
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter
5
GuardLink System Integration
The 440G-MZ safety switch can be used in either of the two available
GuardLink® systems:
1. The DG safety relay system
2. The 432ES-IG3 CIP Safety™ EtherNet/IP™ system
Implementation is slightly different, but firmware revision 2 or later enhances
performance with the 432ES safety system.
DG Integration
The DG integration system has two significant concepts:
1. The DG relay plays a part of the safety function.
2. The DG relay provides non-safety rated information to the machine
control system.
ATTENTION: For information on a known anomaly, see rok.auto/knowledgebase
article: Unlocked 440G-MZ safety switch on GuardLink does not respond to lock
command on power-up. This anomaly is present with a Dual GuardLink (DG) safety
relay with firmware revision 1.001 only. The anomaly is corrected with DG firmware
revision 1.021.
Figure 10 on page 25 shows the basic components of a GuardLink system with
a DG safety relay primary. The 440G-MZ safety switch with embedded
GuardLink technology, connects to the link with a passive tap (as shown in
Figure 10 on page 25) or a passive power tap (catalog number 440S-PF5D4).
Different types and versions of GuardLink-enabled and passive taps can
connect 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 connect to a GuardLink safety system.
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
29
Chapter 5
GuardLink System Integration
432ES Safety System
Integration
The 432ES safety system integration is a solution that uses CIP Safety over
EtherNet/IP. The 432ES safety system conveys safety-rated status information
over an EtherNet/IP connection, as compared to the DG solution, which
provides non-safety rated status information to the machine control system.
This integration requires the 432ES safety system to communicate with a
safety-rated controller. At the time of release of the 432ES safety system, the
safety controller must be one of the following GuardLogix® controllers (where
x is the amount of memory in the controller):
•
•
•
1756-L8xS
5069-L3xERS
5069-L3xERMS
In addition, the controller must run Studio 5000® version 34.01 or later and
communication must be with FTLinx 6.30 or later.
The 440G-MZ safety switch appears as an icon on the Studio 5000 controller
tree and has its own Module Profile [Add-on Profile (AOP)]. The Module Profile
provides a significant number of status, diagnostic, and fault tags to help
contribute to the maintaining machine uptime.
The 440G-MZ safety switch module profile is included in the 432ES-IG3 safety
system module profile, which is available at rok.auto/pcdc.
The AOP for the 440G-MZ safety switch is considered a standard (non-safety
rated) AOP. The Main Routine can use the controller tags for status and
diagnostic information. None of the controller tags for the 440G-MZ safety
switch must be used as part of a safety function.
The 440G-MZ safety switch devices can be added to the controller tree in one of
two ways:
•
•
30
Manual method: Select each device individually.
Discover modules: When the switches are installed, they can be
discovered and loaded onto the controller tree.
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 5
GuardLink System Integration
Manual Method
With the manual method, a 440G-MZ safety switch can be added to the
controller tree.
1. Right-click the desired channel.
2. Click New Module
Figure 13 - Logix Designer Application
3. Click the 440G-MZ safety switch that you want to add to the GuardLink
channel.
4. Click Create.
5.
Figure 14 - Select Module
6. Enter a name. This field is required.
7. Type a description, if desired. This field is optional.
8. Select the node. Nodes must be numbered in consecutive order. Each
device must correspond to its node location.
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
31
Chapter 5
GuardLink System Integration
The nodes can be assigned in any order at the time of creation. For
example, this device can be assigned to node 3, but eventually, there
must be devices that are assigned to nodes 0, 1 and 2.
9. Click Change to adjust the Module Definition, if necessary.
Figure 15 - New Module
10. Select the series of the 440G-MZ safety switch. The 432ES safety system
operates with Series A and Series B. You must select the proper Series
letter. Series A provides basic locked/unlocked status. Series B provides
additional diagnostic information.
11. If you select Series A, the major revision is 1. If you select Series B, the
major revision is 2. Enter the minor revision of the firmware of the
safety switch.
12. Select the desired level of Electronic Keying:
• Compatible: Default. Verifies the product and major revision.
• Exact: Verifies the product, major, and minor revision.
• Disabled: Does not use keying. Only use this level for
troubleshooting purposes.
13. The connection option is limited to Data. This option is standard
non-safety rated data.
14. Click OK.
15.
32
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 5
GuardLink System Integration
Figure 16 - Module Definition
Follow the prompts and accept the changes.
16. The 440G-MZ safety switch is added to the CH0 GuardLink Channel.
17. The Module Properties window shows three pages: General,
Connection, and Module Info.
18.
Figure 17 - Module Properties
Discover Modules
To use the Discover Modules feature, install and power the safety switches.
1.
The controller must be online in either Rem Run, Rem Prog, or Rem
Test mode.
2. The controller can be either Safety Unlocked or Safety Locked.
3. Right-click the desired channel.
4. Click Discover Modules.
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Chapter 5
GuardLink System Integration
Figure 18 - Logix Designer Application
5. The discovery of node 0 shows that the device is tap 440S-SF8D,
whereas the controller tree shows that the device is 440G-MZS20SNRJ.
To correct this issue, delete the 440G-MZ safety switch from the
controller tree. Use Discover Modules to create the proper device, the
440S-SF8D.
6. Uncheck the Close on Create checkbox. This action keeps the window
open and allows faster creation of multiple devices. This example shows
seven devices to create.
7. Click the Create button of any device.
Figure 19 - Discover Modules
8. Type in a unique name. This field is required and must be unique.
9. Type in an optional description.
10. The node number does not need to be changed, as the number reflects
the discovered position.
11. The Module Definition is discovered and does not require changing.
12. To accept the new module, click OK.
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Chapter 5
GuardLink System Integration
Figure 20 - New Module
13. Consider whether you want to inhibit the module connection. If no
logic code was previously created for this device, leave the box
unchecked. If a logic code exists, check this box.
14. Click Yes to create the module.
Figure 21 - Inhibit Module
15. The Select Module Type window reappears and shows that node 1 exists
in the project.
16. The 440G-MZ shows in the controller tree.
17. Click Create to add the next device.
Repeat the process to add the remaining switches.
Delete node o and reenter it as a 440S-SF8D.
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Chapter 5
GuardLink System Integration
Figure 22 - Select Module Type
18. The Controller Organizer for CH0 shows the current tree with node 0
corrected and all switches listed in the Controller Organizer.
19. The 440G-MZ safety switches have the input tags showing operating
and diagnostic information. The class is standard, none of the tags are
safety-rated, and must not be used as part of a safety function.
20. The 440G-MZ safety switch has three output tags: Lock the switch,
Unlock the switch, and Reset the switch if there is an internal
recoverable fault.
21.
Send Commands to 440G-MZ Safety Switch
The following screen capture shows examples of sending commands to a
440G-MZ safety switch. The example uses momentary commands; the
duration of the command must accommodate network delays.
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Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 5
GuardLink System Integration
1.
A momentary icon on an HMI sends a Lock command to the 440G-MZ
safety switch, named Guard_000. The 440G-MZ safety switch remains
locked, even though the lock command is momentary. A momentary
icon is used as the lock command must be turned off before it can be
turned on again.
2. A momentary icon on an HMI sends an Unlock command to the 440GMZ safety switch, named Guard_000. The 440G-MZ safety switch
remains unlocked, even though the unlock command was momentary.
A momentary icon is used as the unlock command must be turned off
before it can be turned on again.
3. A momentary icon on an HMI sends a Reset Device command to the
440G-MZ safety switch, named Guard_000. A momentary icon is
needed as the Reset Device command must be turned off before it can
be turned on again.
Figure 23 - Send Command
4.
1
2
3
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Chapter 5
GuardLink System Integration
Notes:
38
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Chapter
6
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 first
time learn, this process can be repeated up to seven more times with
unique coded replacement actuators.
IMPORTANT
Setup
When the switch learns a new actuator, it no longer recognizes previously
learned actuators.
The 440G-MZ safety switch can be configured 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 24.
Figure 24 - Wiring
Brown
White
Black
Gray
Blue
DEVICE
LINK
+24V DC
NC
NC
NC
Gnd 0V
889D-F5NC-x
or
889D-F5BC-x
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Chapter 6
Commission the Safety Switch
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).
First-time Learn
Table 10 - Commissioning Process for Unique Coded Switches
Step
State
Approximate Duration
Status Indicators
1
Actuator Present
15 s
2
3
Verifying Actuator
Programming Switch
15 s
15 s
4
Program Finalization
15 s
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)
5
Run Mode (2)
—
Steady red
(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 21).
Learn Additional
Replacement Actuators
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
Lock the Actuator Code
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
Error Codes during the
Commissioning Process
When the switch learns a new actuator, it no longer recognizes previously
learned actuators.
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.
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
40
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
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter
7
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 startup 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
State
Steady green
Flashing green @ 1 Hz (1)
Device
Flashing yellow @ 1 Hz
Steady red
Flashing red @ 1 Hz
Off
Link (2)
Steady green
Steady red
Flashing red @ 1 Hz
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 PTR switch is locked, high pressure is affecting the actuator,
and an unlock command is issued.
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.
(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).
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Chapter 7
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 helps prevent
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 43) 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)
04 (04)
31 (1F)
32 (20)
33 (21)
38 (26)
40 (28)
42
Description
Recommended Action
No diagnostic
No action required.
Input voltage is approaching Evaluate input voltage. Input voltage must be 20.4…26.4V under all
minimum (20.4V DC)
electrical load conditions.
A lock command has been sent to the device but the guard door is open
Ready to lock
or ajar. Check the actuator alignment or close the guard door.
actuator alignment. Check the wiring for the lock feedback
Device is attempting to lock Check
input.
Device is attempting to
Check for load on actuator or bolt. Check the wiring for the lock
unlock
feedback input.
Unique coded switch has not been paired with an actuator yet. Insert a
Actuator not paired
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
Guard door open
to lock.
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 7
Device Status and Troubleshooting
Fault Codes
Table 13 - Fault Codes
Decimal
(Hex)
00 (00)
05 (05)
07 (07)
08 (08)
09 (09)
10 (0A)
15 (0F)
31 (1F)
32 (20)
40 (28)
41 (29)
42 (2A)
43 (2B)
44 (2C)
56 (38)
57 (39)
58 (3A)
59 (3B)
255 (FF)
Description
Recommended Action
No fault.
No action required.
Evaluate input voltage. Input voltage must be 20.4…26.4V under all
Power error
electrical load conditions.
Failure to detect device type Check wiring and cycle power to the switch. If the error persists,
(OSSD or GuardLink)
replace the switch.
Internal memory (ROM) fault Internal memory fault. Reset the device. If the error persists, replace it.
Runtime memory (RAM) fault Internal memory fault. Reset the device. If the error persists, replace it.
Internal memory (CPU) fault Internal memory fault. Reset the device. If the error persists, replace it.
No response on GuardLink Check GuardLink wiring and connections.
system fault. Reset the device. If the error persists, replace
GuardLink application fault GuardLink
it.
Application fault. Reset the device. If the error persists,
Product application fault Product
replace it.
Unique code actuator is A new actuator cannot be learned because the current actuator is
locked
locked.
Invalid actuator detected Cannot teach a standard actuator to a unique coded switch.
Teaching is not possible. The switch has learned 8 actuators and
No learns left
cannot learn any more actuators.
Actuator relearn
Switch cannot learn a previously learned actuator. Use a new actuator.
Actuator moved out of range during the teach process or the switch
Actuator teach fault
has detected an invalid RFID tag.
Keep actuator within sensing range during learn process.
During the operational state, the device failed to detect the bolt. On
escape release models, this fault can be caused by engaging the
Bolt detection fault
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.
Device attempted to lock for specified lock attempt length, but lock
Failure to 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.
Failure to unlock
Check the device. Verify that the 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 detection fault 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 the error
Internal fault
persists, replace it.
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Chapter 7
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 must 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.
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Chapter
8
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 can require variations to these examples to meet your specific
requirements.
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 25, the GLP safety relay allows the gate to be unlocked when the motor is
running at a Safely-limited Speed.
Wire to GLP Safety Relay
Figure 25 - GLP and 440G-MZ Safety Switch Schematic
+24V DC, Class 2, PELV
Reset
& Lock
Request
SLS
Request
to PAC
K300
Status
to PAC
440G-MZS20*NR*
Unlock
Request
Reset
800FM-MT44
Safety
Status
to PAC
Kinetix® 300 Drive
Gry
X14 X24 51
LOGIC
SL1
SL2
GLP 3
5
8
S11 S12 S21 S22 A1 13 23
S34
LOGIC
DI
4
440R-D22R2
S12 S22 L61 A2 AP P12 P22 L11
S32 S42 L11 L12 A2 14 24 Y32
Black
440R-GL2S2P
White
Brown
A1 S44 S54 Y32 L12
Safe Torque-off
(STO)
Connector with
Wiring Header
1
Blue
2
3
Black
Brown
889D-F5NC-X
4
Brown
800FM-MT44
Blue
Stop/Start/SLS
from PAC
Black
5
6
+24V DC
COM
Status
Safety Input 1
Safety COM
Safety Input 2
Blue
872C-D8NP18-E5
24V DC COM
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Chapter 8
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.
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Chapter 8
Application Examples
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.
Wire to GLT Safety Relay
In this example shown in Figure 26, 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 the adequate time delay for the machine to achieve a safe state
before unlocking the gate.
Figure 26 - GLT and 440G-MZ Safety Switch Schematic
+24V DC, Class 2, PELV
440G-MZ
L1 L2 L3
Safety Gate
Reset and
Gate Lock
Request
Gate
Unlock
Request
PowerFlex
525
R S T
11 +24V DC
1 Stop
2 Start
440G-MZS20*NR*
Power to Release
No aux
S11 S12
S54 A1
S44 Y32 B2
LOGIC
RANGE
TIME
3
4
8
L11 L12
14
GLT
889D-F5NC-X
51
4 Gnd
Gate control
power supply
440R-GL2S2T
S12 S22
L61 A2
Brown (+24)
24
Gate control
circuit
S1
S2
Gray - Lock Cmd
White - OSSD 1
Black - OSSD 2
U V W
M
Blue (Gnd)
24V DC Com
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.
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47
Chapter 8
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.
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Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 8
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.
Wire to DI and EMD
Safety Relay
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 27, 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 the adequate
time delay for the machine to achieve a safe state before unlocking the gate.
Figure 27 - 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
440G-MZS20*NR*
L1 L2 L3
Gray
Unlock
K1
E-stop
Blue
K2
White Black
A1
Power
In 1
In 2
Out
Logic
A2
S11
S21
S12
Test Out
DI LOGIC
S22
S32
S42
IN 2
IN1
A1
A2
B1
B2
37
EMD RANGE TIME
2
2
38
47
37 38
L11
Y32
S34
13
14
K1
23
24
L12
L11
X32
48
27
28
M
8
17 18
L12
48
47
17
18
27
28
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.
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Chapter 8
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.
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Chapter 8
Wire to DG Safety Relay
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 28 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 28 - DG Safety Relay with 440G-MZ Safety Switch Schematic
+24V DC, Class 2, PELV
440G-MZS20*NR*
889D-F5NCDM-X
440S-PFSD
440G-MZS20*NR*
889D-F5NCDM-X
440S-PFSD
Brown
889D-F4NE-X
Machine
Control
System
440S-PFSD
Black
S12 S22 S11 S21 A1
A
Control
Status
TIME
DG
0
B
C
889D-F5NCDM-X
L1 L2
+
13
23
L3
X4
K1
K2
440R-DG2R2T
S32 S42 X2
440S-PFSD
440R-ENETR
X1
A2
14
24 X3
M
Black
889D-F5NCDM-X
White
Control
Status
440G-MZS20*NR*
White
440G-MZS20*NR*
Blue
Brown
889D-F4NE-X
Blue
K1 K2
24V DC Com
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Chapter 8
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 29 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 29 - CR30 Safety Relay with 440G-MZ Safety Switch Schematic
+24V DC, Class 2, PELV
L1 L2L3
Safety Gate
PowerFlex
525
11 +24V DC
Lock
440G-MZS20*NR*
Power to Release
No aux
Unlock
R S T
1 Stop
2 Start
Reset
R5
Motor Not Running
t081=2
R6
00
01
02
CR30
889D-F5NC-X
03
04
A1 A2 12 13 14
Brown (+24)
Black - OSSD 2
White - OSSD 1
Gray - Lock Cmd
05 06 07 08 09 10 11
440C-CR30-22BBB
15
4 Gnd
Gate control
power supply
16 17 18 19 20 21
Gate control
circuit
S1
S2
U VW
M
Blue (Gnd)
24V DC Com
Figure 30 on page 53 shows an example CR30 safety relay configuration that
works with the schematic in Figure 29.
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Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 8
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 30 - CR30 Configuration in Connected Components Workbench
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
53
Chapter 8
Application Examples
Wire to POINT Guard I/O
Module
Figure 31 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 31 - 1734 Module and 440G-MZ Safety Switch Schematic
440G-MZ
1734-AENT
Safety Gate
1734-IB8S
1734-OB8S
Ethernet I/P
to GuardLogix®
PLC and HMI
440G-MZS20*NR*
Power to Release
No aux
0
1
I0
I1
I4
I5
O0
2
3
I2
I3
I6
I7
O2
O3
4
5
COM
COM
COM
COM
COM
COM
6
7
T0
T1M
T2
T3M
COM
COM
24V DC Com
O4
O1
O6
COM
COM
O5
O7
COM
COM
+24V DC
889D-F5NC-X
K1
K2
K1
K2
Black - OSSD 2
White - OSSD 1
Blue (Gnd)
Gray - Lock Cmd
Brown (+24)
Figure 32 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 32 - 1734-AENTR Module Properties - General
54
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 8
Application Examples
Figure 33 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 33 - 1734-IB8S Module Properties - General
Figure 34 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. Set
the On->Off delay time to 6 ms to filter out the test pulses from the 440G-MZ
safety switch.
Points 2 and 3 monitor the status of the output contactors, K1 and K2. The Type
must be set to Single. Set Mode to Safety Pulse Test. Safety pulse testing is
used to detect potential faults in the monitoring circuit.
Figure 34 - 1734-IB8S Module Properties - Input Configuration
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
55
Chapter 8
Application Examples
Figure 35 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 35 - 1734-IB8S Module Properties - Test Output
Figure 36 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 36 - 1734-OB8S Module Properties - General
56
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 8
Application Examples
Figure 37 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 37 - Module Properties - Output Configuration
Figure 38 on page 58 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.
Rung
0
1
2
3
4
5
6
7
8
9
10
11
12
Description
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.
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.
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.
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-UM004F-EN-P - July 2022
57
Chapter 8
Application Examples
Figure 38 - 1734 Example Studio 5000 Program
58
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 8
Wire to ArmorBlock
Guard I/O Module
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 39.
Figure 39 - ArmorBlock Schematic
1732ES-IB12XOB4
889D-F5NCDM-X
889D-E5NC-10
889D-E5NC-10
White (2) A1
K1
A2 Blue (3)
100S Contactors or
700S or 700-HPS Relays
K2
Black (4)
K1
White (2)
Brown (1)
Black(4) A1
Gray (5)
K2
A2 Gray (5)
Figure 40 shows the General tab of the ArmorBlock module properties. The
Input Status must be set to Combined Status - Muting and the Output Data
must be set to Combined.
Figure 40 - Module Properties - General
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
59
Chapter 8
Application Examples
Figure 41 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 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-MZ safety switch.
Points 4 and 5 monitor the status of the output contactors K1 and K2. These
points must also be set to Single and Safety Pulse Test. The Test Source must
agree with the Test Output tab.
Figure 41 - Module Properties - Input Configuration
Figure 42 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 42 - Module Properties - Test Output
60
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 8
Application Examples
Figure 43 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 43 - Module Properties - Output Configuration
Figure 44 on page 62 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.
Rung
0
1
2
3
4
5
6
7
8
9
10
11
12
Description
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.
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.
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.
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-UM004F-EN-P - July 2022
61
Chapter 8
Application Examples
Figure 44 - Example Studio 5000 Program
62
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 8
Wire to MSR55P Back EMF
Safety Relay
Application Examples
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 45 - MSR55P Back EMF Relay Schematic
+24V DC Class 2 PELV
L1L2 L3
Reset
Vm -Monitoring
voltage
t s - time Setting
(delay)
Unlock
Status
to PAC
S11S21 S22 S12 A1 L12 Y32 S34
2
440G-MZS20*NR*
Power to Release
No aux
A1 11 23 33 43 53
A3 X1 X2 X3
Vm
440R-S35014
440R-D22S2
S32 S42 L11 A2 34 44 14 24
1 Stop
4 Gnd
7
3
DIS
Safety Gate
PowerFlex
525
2 Start
MSR55P
LOGIC
R S T
ts
Gate Control
Power Supply
A2 12 24 34 44 54 ON ERR A4 L1 L2 L3
Gate control
circuit
S1
S2
889D-F5NC-X
Fuses*
Brown (+24)
Black - OSSD 2
White - OSSD 1
Gray - Unlock Request
Blue (Gnd)
UVW
ON status
ON status
Error status
M
3~
24V DC Com
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
63
Chapter 8
Application Examples
Notes:
64
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter
9
ControlFLASH Firmware Update
The firmware is issued as a Device Management Kit (.dmk file). A DMK is a
digitally signed file that contains the firmware. ControlFLASH™ authenticates
the origin of the DMK and then validates its contents. This validation provides
enhanced protection against malicious threats.
You can use ControlFLASH Plus® to update the firmware of the 440G-MZ
Series B (or later), when connected to the 432ES-IG3 GuardLink® EtherNet/IP™
interface. In the example in Figure 46, the 440G-MZ at Node 0 on CH2 is going
to be updated.
Update Firmware
To update the firmware, the 440G-MZ must have a network connection to the
controller.
1.
2.
3.
4.
5.
The controller must be online (Rem Run, Rem Prog, or Rem Test).
The controller must be Safety Unlocked.
To open its Module Properties, double-click the 432ES-IG3.
Navigate to the Connection page.
Check the Inhibit Module checkbox. Notice that the 432ES Status is
now Inhibited. All devices have a Status of Waiting.
6. Click Apply, and then click Yes to confirm in the follow-up window.
Figure 46 - Inhibit Module
7. Double-click the 440G-MZ on CH2.
8. Navigate to the Connection page.
9. Check the Inhibit Module checkbox. Notice that the 440G-MZ status is
now Inhibited. All other devices have a Waiting status.
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
65
Chapter 9
ControlFLASH Firmware Update
10. Click Apply, and then click Yes to confirm in the follow-up window.
Figure 47 - Inhibit the Node
11. Click the Start Menu icon.
12. Scroll down to find FLASH Programming Tools. Expand and click
ControlFLASH Plus.
Figure 48 - Start Menu
12
11
13. If the 440G-MZ is not listed, click the Network icon to open the
Network Browser.
Figure 49 - ControlFLASH Plus Devices
14. In the Network Browser, expand the Ethernet path. Select the desired
channel in which the 440G-MZ resides. Do not select the device itself.
15. Click OK.
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Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Chapter 9
ControlFLASH Firmware Update
Figure 50 - Network Browser
The window is populated with all devices on the selected channel, along with
its address and firmware in the devices. In this case, there is only one device on
channel 0.
16. If you have downloaded the DMK file, select Latest on Computer. If you
have not downloaded the DMK file, select Latest from Download
Center to go to the PCDC website to download the firmware.
17. If you downloaded the firmware and the message still shows No
Firmware Found, add the location to the list of firmware locations.
18. Click the Settings icon.
Figure 51 - Browse to Locate Firmware Kits
19. Navigate to the Firmware Locations tab. This tab shows the list of
directory locations that ControlFLASH Plus checks. You can either
move the dmk file to one of these locations, or you can add a directory.
20. Click to add a location, if desired.
Figure 52 - Browse to Locate Firmware Kits
21. Check the box of the device that you want to flash.
22. Click Next.
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
67
Chapter 9
ControlFLASH Firmware Update
Figure 53 - Use File Manager to Locate Firmware Kits
23. Click Flash.
Figure 54 - Flash
24. The upgrade is successful. Click Close.
25. Click Done.
Go to the Connection page for the 44G-MZ Module Profile, clear the Inhibit
Module checkbox, and click Apply.
Return to the Connection page for the 432ES Module Profile, clear the Inhibit
Module checkbox, and click Apply.
Figure 55 - Success
68
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Appendix
A
Specifications
This appendix provides the specifications and safety ratings for the 440G-MZ
safety switch.
Safety Ratings
Attribute
Value
Standards
IEC 60947-5-3, IEC 61508, ISO 13849-1, IEC 62061, ISO 14119, UL 508
Safety classification
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
Functional safety
• 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
Certifications
CE Marked for all applicable EU directives, UKCA marked for all applicable regulations, cULus Listed,
TÜV Certified
(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.
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
69
Appendix A
Specifications
Operating Characteristics
Outputs (Guard Door Closed
and Locked)
Environmental
70
Attribute
Value
Torque for M5 mounting of switch and actuator
mounting bracket
2 N•m (17.7 lb•in) max
Torque, auxiliary release access screw (escape
release model)
0.56 N•m (5 lb•in)
Locking bolt alignment tolerance X, Y, Z
±5 mm (0.2 in.) max
Door radius, min
457.2 mm (18 in.)
Holding force Fmax (ISO 14119)
3250 N
Holding force Fzh (ISO 14119)
2500 N
Output current, max (each output)
200 mA
Quiescent power consumption, locked or unlocked
1.5 W
Lock signal current
1 mA
Peak current and duration, at turn on or after lock/
unlock operation
150 mA for approximately 800 ms following lock/unlock operation.
Steady state current, max
• OSSD mode: 40 mA
• GuardLink mode: 50 mA
Operating voltage Ue
24V DC +10%/-15% Class 2 PELV
Operating cycle frequency, max
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)
8s
Utilization category (IEC 60947-5-2)
DC-13 24V 200 mA
Insulation voltage Ui (IEC 60947-5-1)
75V
Impulse withstand voltage Uimp (IEC 60947-5-1)
1 kV
Pollution degree (IEC 60947-5-1)
3
Auxiliary release
Built-in
Escape release
Built-in (select models)
Protection class (IEC 61140)
Class II
Mechanical life
500,000 cycles
Attribute
Value
Safety outputs (OSSD mode) 2 x PNP, 0.2 A max / ON (+24V DC)
Attribute
Value
Operating temperature
0…55 °C (32…131 °F)
Storage temperature
-25…+75 °C (-13…+167 °F)
Operating humidity
5…95%, non-condensing
Enclosure ingress rating
• IP65
• IP66
• IP67
• IP69
• IP69K
Shock and vibration
• IEC 60068-2-27 30 g (1.06 oz), 11 ms
• IEC 60068-2-6 10…55 Hz, 1 mm (0.04 in.)
Radio frequency/EMC
IEC 60947-5-3, FCC-1 (Parts 18 and 15), RED
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Appendix A
General
Attribute
Specifications
Value
Switch
• Housing: ABS
• Front brace and escape release: SS304 (machined), SS316 (cast)
Actuator
• Housing and housing cover: SS304
• Spring: SS302
• Grommet: Nitrile rubber
• Screws: Stainless-steel
• Tongue: SS410
Materials
Brackets
High-strength low alloy steel
Accessories
• Padlock: SS410
• Button: Aluminum, powder painted
• Auxiliary release tool: SS304 with SS201 key ring
• Screw: Steel
Weight [kg (lb)]
• Switch: 0.75 (1.7)
• Switch with escape release: 1.59 (3.5)
• 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)
• Button: 0.025 (0.06)
• Auxiliary release tool: 0.018 (0.04)
• Screw: 0.014 (0.03)
Protection Type
• Short-circuit
• Current limitation
• Overload
• Reverse polarity
• Overvoltage (up to 60V max)
• Thermal shutdown/restart
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
71
Appendix A
Specifications
Declaration of Conformity
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
UKCA marked for all applicable regulations
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 must not cause harmful interference, and
b. This device must accept any interference received, including
interference that may cause undesired operation.
Changes and Modifications that are 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.
CE Conformity
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.
UKCA Conformity
Rockwell Automation declares that the products that are shown in this
document are in compliance with UK Electromagnetic Compatibility
regulations (2016 No.1091), Supply of Machinery Safety regulations
(2008 No. 1597) and have Third-party Approval.
72
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Appendix A
Approximate Dimensions
Specifications
Figure 56 - Switch Body — Standard Model [mm (in.)]
2 x Ø5.5
(0.22)
33
(1.3)
45.2
(1.78)
153 (6.02)
134.5 (5.3)
22.5
(0.89)
6
(0.24)
14.9 (0.59)
176.8 (6.96)
15
33 (1.3) (0.59)
15 (0.59)
5.9
(0.23)
39.5
50
47.5
25.3 (1.97)(1.87)(1.56)
(1)
Ø5.1
(0.2)
22.6
(0.89)
134.5 (5.3)
153 (6.02)
182.7 (7.19)
0.3
(0.01)
Figure 57 - Switch Body — Escape Release Model [mm (in.)]
25.7
(1.01)
111.1 (4.37)
2 x 32 (1.26)
Ø31
(1.22)
2x
32 (1.26)
45.2 (1.78)
Ø20
(0.79)
3.2 (0.13) REF
53.1
(2.09)
68.3
(2.69)
46.6 (1.83)
60.6 (2.39)
79.6 (3.13)
4x
12.8 (0.5)
197.1
(7.76)
Figure 58 - Actuator [mm (in.)]
65 (2.56)
15
(0.59)
14
(0.55)
Ø32.9 (1.3)
10
7.3 (0.28) (0.39) 14
(0.55)
25.6 (1.01)
30
(1.18)
20
12.8 (0.5) (0.79) 10
(0.39)
7.5
Ø12.4
(0.3)
(0.49)
30
(1.18)
6 x Ø6.3 (0.25)
4 x Ø6.5
(0.26)
50 (1.97)
32.5
(1.28)
23.8
(0.94)
40
(1.57)
23.7
(0.93)
3 (0.12)
4
(0.16)
9.9
(0.39)
59.3
(2.33)
12.5
(0.49)
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
73
Appendix A
Specifications
Figure 59 - Actuator on Z Bracket [mm (in.)]
74.2 (2.9)
2 x 30.1 (1.19)
2 x 32.5 (1.28)
7.2 (0.28)
7.5
2 x 25.6 (1)
(0.29)
3 x 50 (2)
72.1 (2.8) REF
65 (2.6)
REF
30.3 (1.2)
40 (1.6)
59.3
(2.3)
46.8
(1.8)
3 x 27.6 (1.1)
6 x Ø8.5 (0.33)
14.6 (0.6)
40.5
(1.6)
6 x Ø6.3 (0.2)
104.3 (4.1)
124.3 (4.9)
74.2 (2.9)
65
(2.6)
30.3 (0.33)
6 x Ø6.3 (0.2)
46.8
29.3 (1.2) (1.8)
76.6 (3.01)
REF
4 x Ø7.1 (0.3)
6 x Ø8.5 (0.33)
40 (1.6)
2 x Ø8.5 (0.33)
124.3 (4.9) REF
Figure 60 - Actuator on L Bracket [mm (in.)]
83.5 (3.3)
55.4 (2.2)
33.8 (1.3)
32.5 (1.27)
27.6
(1.1)
7.2
(0.28)
65 (2.6)
REF
2 x 12.8 (0.5)
2 x 50 (1.96)
65 (2.6)
23.3
(0.9)
2 x Ø8.5 (0.33)
4 x Ø6.3 (0.24)
7.5 (0.3)
45.3
(1.8)
50 (1.96)
7.5
(0.3)
2 x Ø8.5 (0.33)
32.5 (1.27)
7.2 (0.28)
12.8 (0.5)
37.2
(1.4)
59.3 (2.3)
40
65
(1.6) (2.6)
27.6 (1.1)
45.3 (1.8)
REF
2 x Ø8.5 (0.33)
27 (1.06)
60.5 (2.4) REF
74
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
23.7 (0.9)
60.5 (2.4)
Appendix A
Specifications
Figure 61 - Switch on L Bracket [mm (in.)]
47.8 (1.9)
34.4 (1.4)
22.5 (0.9)
3 x Ø5.2 (0.2)
2 x 80 (3.1)
80
(3.1)
30.4 (1.2)
5.3 (0.2)
134.5
(5.3)
160 (6.3)
REF
182 (7.2)
REF
33 (1.3)
2 x Ø8.5 (0.33)
6
(0.24)
42.2
(1.7)
60.5 (2.4)
REF
25.3 (1)
68.8 (2.7)
REF
Figure 62 - Padlock Accessory [mm (in.)]
4.7 (0.2)
102.7 (4.04)
2 x Ø4.7 (0.2)
15.5 (0.6)
3 x Ø7.4 (0.3)
17.5
(0.7)
20
(0.79)
35
(1.4)
3 x 10 (0.39) REF
45
(1.8)
8 x R2 (0.1)
2 x 7.8 (0.3)
63.8 (2.5)
74.8 (2.9)
85.8 (3.4)
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
75
Appendix A
Specifications
Notes:
76
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Index
A
abbreviation 8
accessories 12
actuator
dimension 73
spare 11
actuator code
lock 40
allowable approach direction 16
application
ArmorBlock Guard I/O 59
CR30 safety relay 52
DG safety relay 51
DI safety relay 49
EMD safety relay 49
GLP safety relay 45
GLT safety relay 47
MSR55P back EMF safety relay 63
POINT Guard I/O 54
approximate dimension 73
ArmorBlock Guard I/O
application 59
assembly overview 11
assignment
pin 23
auxiliary release 19
C
CE Marked 72
certification 72
safety 13
characteristic
operating 70
CLU 8
code
diagnostic 42
fault 43
coding
standard 8
unique 8
command
lock 27
command, lock, and unlock 8
commission
safety switch 29, 39
commissioning process
error codes 40
complete switch 11
concept
safety 13
content
package 12
correct use 15
CR30 safety relay
application 52
D
device status 41
DG safety relay
application 51
DI safety relay
application 49
diagnostic code 42
dimension
approximate 73
direction
allowable approach 16
E
EMD safety relay
application 49
environmental 70
error codes
commissioning process 40
escape release 20
example
application 45, 65
F
fault code 43
FCC notice 72
first-time learn 40
functional testing 21
GuardLink mode 22
OSSD mode 21
G
general specification 71
GLP safety relay
application 45
GLT safety relay
application 47
guard locking
Power to Lock 10
Power to Release 10
GuardLink
safety signal 24
system integration 25
I
Industry Canada
license-exempt RSS standard 72
ingress protection 17
installation 15
integration
GuardLink system 25
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
77
Index
L
L bracket
dimension 74
learn
additional replacement actuator 40
first-time 40
license-exempt RSS standard
Industry Canada 72
lock
actuator code 40
lock command 27
M
mount
switch body 17
mounting holes
cracked/broken 44
MSR55P back EMF safety relay
application 63
N
notice
FCC 72
O
operating characteristic 70
operational state 8
orientation
switch 16
OSSD 8
OSSD mode
safety signal 24
output
specification 70
output signal switching device 8
overview
assembly 11
P
package content 12
padlock accessory 21
dimension 75
pin assignment 23
POINT Guard I/O
application 54
Power to Lock
guard locking 10
Power to Release
guard locking 10
power-up routine
status indicator 41
product selection 11
protection
ingress 17
proximity
switch 16
R
rating
safety 69
RCM Marked 72
reaction time 8
release
auxiliary 19
escape 20
replacement actuator
learn 40
response time 8
RSS standard
Industry Canada license-exempt 72
run mode
status indicator 41
S
safe state 8
safety
certification 13
concept 13
rating 69
signal
GuardLink 24
OSSD 24
standard 13
selection
product 11
setup 29, 39
spare actuator 11
specification 69
environmental 70
general 71
operating characteristic 70
output 70
standard
safety 13
standard coding 8
state
operational 8
safe 8
status
device 41
status indicator
power-up routine 41
run mode 41
switch
commission 29, 39
complete 11
orientation 16
proximity 16
setup 29, 39
switch body
dimension 73
mount 17
mounting holes
cracked/broken 44
system integration
GuardLink 25
T
tap 8
78
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Index
terminology 8
testing
functional 21
GuardLink mode 22
OSSD mode 21
time
reaction 8
response 8
troubleshooting 44
TÜV Certified 72
U
UKCA Marked 72
UL Listed 72
unique coding 8
use
correct 15
W
wiring 23, 39
Z
Z bracket
dimension 74
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
79
Index
Notes:
80
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
Guardmaster Guard Locking Switch User Manual
Rockwell Automation Publication 440G-UM004F-EN-P - July 2022
81
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