Installation. Rockwell Automation Allen-Bradley 440GMZS20UNLJ, Allen-Bradley 440G-MZS20SNLJ, Allen-Bradley 440G-MZS20UNRJ, Allen-Bradley 440G-MZS20SNRJ
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Chapter
3
Installation
General Considerations
Correct Use
Installation must be in accordance with the present manual and implemented by qualified personnel exclusively. The 440G-MZ safety switch is intended to be part of the safety-related control system of a machine.
ATTENTION: Before installation, a thorough risk assessment must be performed to determine whether the specifications of this device are suitable for all foreseeable operational and environmental characteristics of the application.
A functional test of the system is necessary to validate that it works as expected
(see Functional Testing on page 17
).
Guard locking switches that use the Power to Lock principle (Cat. No.
440G-MZS20*NLJ*) must only be used after a risk assessment has shown that the use of a Power to Release principle (Cat. No. 440G-MZS20*NRJ*) is inappropriate.
This assessment is necessary since the guard can be immediately opened after a loss of power supply or upon deactivation of the unlocking signal.
Review the following requirements and guidelines for proper use of the safety switch to achieve optimal performance.
• The 440G-MZ safety switch is designed for use on medium- and fullsized guards including guards where whole-body access to the safeguarded area is possible.
• The switch is not to be used as a mechanical stop. Check that a separate door stop is used.
• A separately mounted latch (for example, magnetic or mechanical) is recommended to maintain proper alignment of the actuator. The locking bolt must be free to enter and withdraw from the actuator without binding.
• Use appropriate screws, bolts, or nuts that are fitted by tools to mount the switch and actuator to avoid tampering.
• Do not over torque the mounting hardware.
• A minimum distance of 100 mm (3.94 in.) must separate adjacent switches, see
• The 440G-MZ safety switch is designed for use in a NEC Class 2 circuit.
Connect the 440G-MZ safety switch to a dedicated Class 2 power supply or use electronic circuit protection (for example, 1692-ZRCLSS) to achieve NEC Class 2 compliance.
ATTENTION: For the switch, actuator, and actuator mounting bracket:
• Only use the designated mounting holes.
• Never drill or use to support other structures such as a conduit, cable ways, or other hardware.
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 13
Chapter 3 Installation
Switch Orientation
Can be used in all mounting orientations.
Actuator Orientation
The actuator can approach the switch from three directions (
).
Figure 1 - Three Directions of Approach
2
3
1
The flexible actuator can move in multiple axes to accommodate guard door misalignment (
). For optimal performance, verify that the locking bolt can enter and withdraw from the tongue actuator without binding. A separately mounted door latch is recommended to avoid door misalignment.
Figure 2 - Actuator Function
Pair Proximity
14
If a pair of 440G-MZ safety switches are mounted too close to one another, the two electromagnetic fields interact causing crosstalk, which can result in nuisance faults and false operation.
A minimum of 100 mm (3.94 in.) must separate a pair of switches to help achieve correct operation (
Figure 3 - Minimum Distance between Switches [mm (in.)]
100 (3.94)
IMPORTANT If the minimum separation distance is not observed, the electromagnetic fields interact causing crosstalk. Crosstalk can result in nuisance faults and false operation.
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Environmental
Considerations
Mount the Switch and
Actuator
Chapter 3 Installation
The 440G-MZ safety switch is rated for IP69K in accordance with ISO 20653 and IP69 per IEC 60529. This rating involves a short-term test that is made with high-pressure water jets at 80 °C (176 °F). The test is passed if no water enters the enclosure of the switch that contains the electrical components and the switch function is not impaired.
This rating does not promise protection from any liquids other than water and does not promise the mechanical longevity from continuous or frequent exposure.
ATTENTION: Do not defeat, tamper, remove, or bypass this unit. Severe injury to personnel could result.
The presence of spare actuators can compromise the integrity of the safety systems. Personal injury or death, property damage, or economic loss can result.
Appropriate management controls, working procedures, and alternative protective measures should be introduced to control their use and availability.
Three M5 fasteners (not provided) are required for proper mounting of the switch to a rigid guard door frame (
Figure 4 ). Two M5 fasteners (not provided)
are required to mount the actuator.
Figure 4 - Required Mounting Hardware for Switch and Actuator
2 x M5
3 x M5
IMPORTANT Do not use a washer with the screw at the base of the switch body. Using a washer causes the plastic to crack.
Loctite 242 thread-locking adhesive is known to cause stress cracks in the plastic housing of the 440G-MZ safety switch and should not be used. Lab tests have determined that Loctite 425, a cyanoacrylate adhesive, does not cause cracking and can be considered if the faster cure time is acceptable in the application.
Check the manufacturer specifications of any thread-locking compound used to secure the screws. It is recommended to use a cyanoacrylate-type compound. Other compounds can cause stress cracks in the plastic feet of the switch.
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 15
Chapter 3 Installation
Typical Applications
The 440G-MZ safety switch can be mounted on the inside or outside of a hinged or sliding guard door. The following shows three examples of the switch and actuator mounted to a hinged or sliding guard door.
• Mount the switch on the inside of a hinged door
Actuator
Switch mounting bracket
• Mount the switch on outside of a hinged door
Switch mounting bracket
Actuator
Z-shaped Actuator
Mounting Bracket
• Mount the switch on a sliding door
Z-shaped Actuator
Mounting Bracket
Actuator
L-shaped Actuator
Mounting Bracket
L-shaped Actuator
Mounting Bracket
16 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Auxiliary Release
Chapter 3 Installation
Operation of the auxiliary release causes a fault condition.
To reset the switch, cycle the power or issue a RESET command over the link in a GuardLink® safety system.
Figure 5 - Auxiliary Release Operation [mm (in.)]
5 (0.2)
Top View
Padlock Accessory
The padlock accessory (
Figure 6 ) can be inserted through the actuator opening
of the 440G-MZ safety switch to help prevent the locking of the guard door and restarting of the machine while an operator is inside the safeguarded area. The padlock accessory can accommodate up to three nominal 6.35 mm (0.25 in.) locks.
Figure 6 - Padlock Accessory (Cat. No. 440G-MZAL)
Up to three nominal
6.35 mm (0.25 in.) locks
Functional Testing
A manual functional test must be made:
• After installation
• After any maintenance or change of component
• If the guard is used infrequently
- Less than once a month for SIL 3, cat. 3 or cat. 4, PLe
- Less than once a year for SIL 2, cat. 3, PLd
ATTENTION: During the functional test, verify that there are no persons in the danger area and that the machine startup does not cause a hazard.
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 17
Chapter 3 Installation
OSSD Mode
1.
Confirm that the guard door is open.
2. Connect the 24V DC power to pin 1 and ground (0V) to pin 3. The switch conducts a self-testing routine at the end of which the device status indicator is steady red (if lock signal is set to UNLOCK) or flashing amber (if lock signal is set to LOCK).
3. Test to confirm that the machine cannot start.
4. Confirm the lock signal at pin 5 is set to LOCK (0V for PTR and 24V for
PTL types).
5. Test again to confirm that the machine cannot start.
6. Close the guard door and then confirm that the guard is mechanically locked and the device status indicator is steady green.
7. Test to confirm that the machine can start.
8. Change the lock signal at pin 5 to UNLOCK (24V for PTR and 0V for PTL types).
9. Confirm the machine stops, the guard door is mechanically unlocked, and the machine cannot restart.
GuardLink Mode
1.
To begin a functional test of the 440G-MZ safety switch when connected in a GuardLink system, all other devices on the link must be in the operational state.
2. Confirm that the guard door is open.
3. Test to confirm that the machine cannot start.
4. Send a lock command to the 440G-MZ safety switch over the link.
5. Test again to confirm that the machine cannot start.
6. Close the guard door.
7. Send a lock command to the switch over the link.
8. Confirm that the switch is mechanically locked and the Device status indicator is steady green.
A flashing green status indicator on the device indicates that another device on the link is tripped. To proceed, verify that all other devices on the link are in operational state.
9. Test to confirm that the machine can start.
10. Send an unlock command to this 440G-MZ safety switch only over the link.
11. Confirm that the machine stops, the guard door is mechanically unlocked, and the machine cannot restart.
18 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

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