Installation Instructions
Original Instructions
440G-EZ Interlocking Safety Switch
Catalog Numbers 440G-EZS21STL05J, 440G-EZS21STL05H
ATTENTION: Read this document and the documents that are
listed in Additional Resources on page 4 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, and requirements of all applicable codes, laws,
and standards.
Only suitably trained personnel must perform activities
including installation, adjustments, commissioning, use,
assembly, disassembly, and maintenance in accordance with
applicable code of practice.
If this equipment is used in a manner that the manufacturer
does not specify, the protection that is provided by the
equipment may be impaired.
Summary of Changes
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 3 table.
Replaced Table 2.
Added IP69K to enclosure ingress rating in Specifications table.
Intended Use
The 440G electromagnetic switch is suitable for monitoring the position of guard
doors. It has a magnetic locking device for process protection only.
ATTENTION: Locking force is not monitored. Locking force is
not a safety-related function.
Mount Multiple Safety Switches
IMPORTANT
Figure 1 - Spacing Requirement [mm (in.)]
Page
2
3
3
260
(10.24)
260 (10.24)
Installation
Installation of the 440G-EZ safety switch must be in accordance with the following
steps and stated specifications and implemented by suitably competent
personnel. The unit is not to be used as a mechanical stop. Guard stops and guides
must be mounted.
Adherence to the recommended maintenance instructions forms part of the
warranty.
ATTENTION: The presence of spare actuators can
compromise the integrity of the safety systems. Personal
injury or death, property damage, or economic loss can result.
Appropriate management controls, working procedures, and
alternative protective measures should be introduced to
control their use and availability.
WARNING: Do not defeat, tamper, remove, or bypass this unit.
Severe injury to personnel could result.
This device must be provided with a 24V DC PELV or SELV
power supply that conforms to the requirements of 414-3 of
IEC 60364-4-41 where provisions have been taken to confirm
that, even if an internal fault is present, the voltage at the
outgoing terminals cannot exceed 60V DC. Improper selection
or installation of the devices affects the integrity of the safety
systems.
When several safety switches are mounted, the
minimum distance between the individual systems
must be followed to avoid mutual interference.
Mounting
The sensor can be mounted in the following ways:
•
•
Surface mount — The sensor is mounted on the fixed part of the protective
device (for example, door frame).
Flush mount — The sensor is mounted in the fixed part of the protective
device (for example, door frame). There must be a suitable recess in the
mounting surface. The thickness of the mounting surface must be
between 1.5…3 mm (0.06…0.12 in.)
For recess dimensions for flush mounting, see Figure 4 on page 4.
IMPORTANT
Install the safety switch horizontally to help increase
protection against manipulation.
440G-EZ Interlocking Safety Switch Installation Instructions
Mount the Sensor
1.
Mount the Actuator
Unscrew the fixing screw (hexagon socket, 2 mm [0.08 in.]) and remove
the cover plate.
1.
2.
Align the actuator to the mounted sensor.
Mount the actuator on the moving part of the protective device (for
example, door) with 4 x M4 screws. Tightening torque: 1 N•m (8.9 lb•in). Use
disposable screws if possible.
• Maximum angle between sensor and actuator when protective device
is closed: 3°
≤3°
3.
Cover drill holes of the actuator with protective caps.
Wiring
2.
Mount the sensor on the fixed part of the protective device with 4 x M4
screws and secure it with four nuts.
• For surface mount: mount the sensor on the fixed part of the
protective device. The screws can be set in the front or the back.
Figure 2 - Device Connection Pin Assignment
(Male Connector, M12, 5-pin, A-coded)
2
1
5
3
4
Pin
Wire Color (1)
Designation
1
Brown
+24V DC
Safety switch voltage supply
2
White
OSSD 1
Safety output
0V DC voltage supply
Description
3
Blue
0V
4
Black
OSSD 2
Safety output
5
Gray
Magnet
Magnet activation 24V DC
(1)
Applies to the extension cables recommended as accessories.
Tightening torque:
1 N•m (8.9 lb•in)
IMPORTANT
Pay attention to tightness of the plug connector.
Figure 3 - Device Connection Pin Assignment
(Male Connector, M12, 8-pin, A-coded)
• For flush mount: mount the sensor in the fixed part of the protective
device.
2
3
8
4
1
5
7
6
Pin
Tightening torque:
1 N•m (8.9 lb•in)
3.
4.
2
(1)
(2)
Set cover plate on the sensor.
Tighten the fixing screws to 1 N•m (8.9 lb•in).
Wire Color (1)
Designation
Description
Application diagnostic output (not safe)
1
White
Aux
2
Brown
+24V DC
Safety switch voltage supply
3
Green
Magnet
Magnet activation 24V DC
4
Yellow
OSSD IN2
Safety input (2)
5
Gray
OSSD 1
Safety output
6
Pink
OSSD 2
Safety output
7
Blue
0V
8
Red
OSSD IN1
0V DC voltage supply
Safety input (2)
Applies to the extension cables recommended as accessories.
When used as an individual safety switch or as the first safety switch in a cascade apply 24V DC.
IMPORTANT
Pay attention to tightness of the plug connector.
Rockwell Automation Publication 440G-IN019C-EN-P - November 2020
440G-EZ Interlocking Safety Switch Installation Instructions
Status Indicators
Specifications
The switch has two status indicators:
Attribute
440G-EZS21STL05J, 440G-EZS21STL05H
Functional Safety Data
(Guard door sensing)
• PFHd= 1.5 x 10-8 at 40 °C (104 °F) and 1000 m (3280.8 ft) above
sea level
• Mission time/PTI: 20 years
Table 1 - Status Indicator States
Operating Characteristics
1
Item
1
2
(1)
Name
Color
OSSD
Green/Red
LOCK
Yellow
Open
8-pin
5-pin
(1)
(2)
15 mm (0.59 in.)
Safe switch off distance
45 mm (1.77 in.)
Holding force
500 N
Retaining force
25 N
Maximum actuation frequency
0.5 Hz
Alignment tolerance for locking device
• Vertical: 5 mm (0.2 in.)
• Horizontal: 5 mm (0.2 in.)
2
Aperture angle
3°
Offset tolerance
5 mm (0.2 in.)
• Green when the OSSD pair is in the ON state.
• Red when the OSSD pair is in the OFF state. (1)
Rated voltage
24V DC
Insulation voltage Ui
32V
Turns ON when the magnet is supplied with voltage.
Rated impulse withstand voltage Uimp 1.5 kV
Table 2 - Switch Status During Normal Operation
Door/Guard
Status
4 mm (0.16 in.)
Typical switch on distance
Description
When a load is applied to the application diagnostic output that is too high, the red OSSD status
indicator remains continuously ON. The actual switching behavior of the safety switch is not
affected.
Pins
Safe switch on distance
OSSD Inputs (1)
On or Off
OSSD Indicator
Red
AUX Status
Off
OSSD Outputs
Off
Closed
On
Green
On (2)
On (2)
Open
Off
Red
Off
Off
Closed
Off
Red
Off
Off
Open
—
Red
—
Off
Closed
—
Green
—
On (2)
OSSD input only available for use with 8-pin version.
The AUX output and OSSD outputs are OFF if the device is in a fault state.
Maintenance
Supply voltage when an individual
safety switch is connected
24V DC (19.2…28.8 V DC) Class 2 supply
Supply voltage UV when a cascade is
connected
• Sensor: 24V DC (22.8…28.8 V DC) Class 2 supply
• Magnet: 24V DC (21.6…28.8 V DC) Class 2 supply
Power consumption
• Locking active: 350 mA
• Locking deactivated: 50 mA
Switching frequency
≤0.5 Hz
Type of output
OSSD
Maximum Output current
≤100 mA
Diagnostic output
≤25 mA, short-circuit protected
Cable capacitance
400 nF (for OUT A and OUT B)
Response time
50 ms
Enable time
100 ms
Risk time
100 ms
Power up delay
2.5 s
Muting time when supply voltage is
interrupted
4 ms
Environmental
Operating temperature
-20…+55 °C (-4…+131 °F)
Frequency
Description
Storage temperature
-25…+70 °C (-13…+158 °F)
• Ensure the alignment of the actuator to the switch and the correct operation
of the switching circuit.
• Check for signs of abuse or interference.
• Inspect the switch casing and actuator for damage and replace if needed.
Relative humidity
50% at 70 °C (158 °F) (IEC 60947-5-2)
Every week
Enclosure ingress rating
IP67, IP69K
EMC
IEC EMC: EN IEC 61326-3-1, EN IEC 60947-5-2, EN IEC 60947-5-3
•
•
•
•
•
Vibration resistance
1 mm/10…55 Hz (IEC 60068-2-6)
Shock resistance
30 g, 11 ms (IEC 60068-2-27)
At least every
6 months
Isolate all power.
Remove the lid and end cover.
Inspect all terminals for tightness.
Clean out any accumulation of fine dirt.
Check for any sign of wear of damage, for instance, actuator wear, cam
assembly wear, contact oxidization and replace if needed.
• Replace cover and tighten screws to specified settings.
• Reinstate the power and check for correct operation.
• Reapply tamper evident varnish or similar compound for mountings.
Repair
If there is any malfunction or damage, make no attempts at repair. Replace before
machine operation is allowed.
IMPORTANT
Do not dismantle the unit.
Outputs
Safety outputs
2 x OSSDs, 2 x PNP, max
100 mA, short-circuit protected and overload-proof
Auxiliary output
25 mA max, short-circuit protected (resistive load)
Switching voltage
• ON State: 19.2…28.8 V DC
• OFF State: 0…2 V DC
Switching current
• ON State: ≤100 mA
• OFF State: ≤500 µA
Test pulse duration
300 µs
Weight
Sensor
510 g (18 oz)
Actuator
210 g (7.4 oz)
Material
Sensor housing
Anodized aluminum
Actuator housing
Fiberglass-reinforced PVC
Anchor plate
Nickel-plated steel
Rockwell Automation Publication 440G-IN019C-EN-P - November 2020
3
Approximate Dimensions
Figure 6 - Sensor [mm (in.)]
122 (4.8)
Figure 4 - Flush Mounting [mm (in.)]
44 (1.73)
15.2
(0.60)
14.4 (0.57)
42
(1.65)
22
(0.87) 22
(0.87)
28
(1.10)
4.5
(0.18)
44
(1.73)
44
(1.73)
5.7
(0.22)
Ø5 (0.20) x 4
L
Figure 5 - Actuator [mm (in.)]
(1)
120 (4.72)
16.8
(0.66)
16.8
(0.66)
10
(0.39)
44
60
(1.73) (2.36)
12.5
(0.49)
32 (1.26)
83.5 (3.29)
6.5
(0.26)
14.4
(0.57)
Ø42
(1.65)
16.3 (0.64)
5.5
24 (0.22) 34
(1.34)
(0.94)
14.5
(0.57)
(1)
120 (4.73)
L = 150±2 mm (5.91±0.79 in.)
Additional Resources
These documents contain additional information concerning related products from
Rockwell Automation.
44 (1.73)
60
(2.36)
44
(1.73)
Resource
Description
440G-EZ Interlocking Safety Switch User
Manual, publication 440G-UM003
Provides information that is needed during
the lifecycle of the 440G-EZ safety switch.
Industrial Automation Wiring and Grounding Provides general guidelines for installing a
Rockwell Automation industrial system.
Guidelines, publication 1770-4.1
Product Certifications website:
rok.auto/certifications
4x
4.5 (0.18)
32
(1.26)
Provides declarations of conformity,
certificates, and other certification details.
You can view or download publications at rok.auto/literature.
Waste Electrical and Electronic Equipment (WEEE)
At the end of life, this equipment should be collected separately from any unsorted municipal waste.
Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec.
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Publication 440G-IN019C-EN-P - November 2020 | Supersedes Publication 440G-IN019B-EN-P- June 2020
Copyright © 2020 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
10005248682 Ver 02
8025119/19G3/2020-11-03
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