Allen-Bradley 440N-Z21W1PB Installation Manual

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Page 1

Installation Instructions

Original Instructions

Magnetically Coded Non-contact Switch (MC2)

Catalog Numbers

440N-Z21W1PA, 440N-Z21W1PB, 440N-Z21W1PH

IMPORTANT Save these instructions for future reference.

Topi c Page

Specifications 1

Summary of Changes 1

Introduction 1

Mounting Information 2

LED Operation and Diagnostics 2

Connection Information 3

Power Supply Requirements 3

Safety Ratings 3

Maintenance 3

Declaration of Conformity 3

Approved Monitoring Relay Units 3

Troubleshooting 4

Application Wiring Examples 5

Summary of Changes

Updated the Approved Monitoring Relay Un its on page 3.

Introduction

Installation must be in accordance with the following instructions and specifications and implemented by suitable competent personnel. Adherence to the recommended maintenance instructions forms part of the warranty.

This unit is not to be used as a mechanical stop. Guard stops and guides must be fitted.

This device is intended to be part of the safety-related control system of a machine. Before installation, a risk assessment must be performed to determine whether the specifications of this device are suitable for all foreseeable operational and environmental characteristics. Refer to

for Certification information and ratings.

Ta b l e 1

ATT EN TI ON : The presence of spare actuators 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 measure 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.

Table 1 - Specifications

Attribute 440N-Z21W1PA, 440N-Z21W1PB, 440N-Z21W1PH

Safety Standards

Safety Classification Dual contacts suitable for Cat.3 or 4 systems

Functional Safety Data Usable for ISO 13849-1:2006 and IEC 62061. Data other than B10d is based on: Usage rate of 10p/10mins., day, 360 days/year, representing 51840 operations per year.

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

Operating Characteristics (at rated temperature range)

Sensing distance horizontal plane of operation 10 mm (0.39 in.)

Sensing distance vertical plane of operation 6 mm (0.23 in.)

Typical misalignment

Operational Current ≤ 30 mA + 1 Aux

Maximum # of switches, connected in series Monitoring Relay Unit dependent

Operating Voltage 24V DC +10% / -15%

Physical Characteristics

Case Material Molded ABS

Actuator M aterial Molded A BS

Color Red

Outputs

Safety Output (Solid State Relay) 2 x N.C. 50 mA

Auxiliary 1 x PNP N.O. 200 mA

Response Time

Switch response time 5 ms

Series response time 5 ms

Maximum Frequency of Ope ration 1 Hz

Environmental

Operating Temperature -10…+55 °C (14…131 °F)

Operating Humidity 5…95% relative

Washdown rating / Enclosure type rating IEC 60529, IP69

ISO 14119, IEC 60947-5-3, ISO 13849-1 when used with approved safety relay

B10d: > 2x106 operations min. PFHD: < 3x10 MTTFd: > 380 years Dual channel interlock may be suitable for pe rformance

24 hrs/

levels PLe or PLd (according to ISO13849-1:2006 and for use in SIL 2 or SIL 3 systems (according to IEC 62061) depending on application chara cteristics.

Make, Minimum

± 4 mm (0.16 in.) (see Figure 3 on page2 Misalignment Curve)

-7

for

Page 2

Magnetically Coded Non-contact Switch (MC2)

5.5

(0.22)

16.5

(0.65)

4.2

(0.17) Ø

20.0

(0.79)

29.0

(1.14)

(2.1)

48.0 (1.89)

22.0 (0.87)

5.5

(0.22)

16.5

(0.65)

4.2

(0.17) Ø

20.0

(0.79)

29.0

(1.14)

48.0 (1.89)

22.0 (0.87)

To obtain maximum switching distance center switches ± 4 mm (0.16 in.)

To prevent damage, it is recommended that a 2 mm (0.08 in.) gap be maintained between the actuator and sensor.

Distance 8…14 mm (0.31…0.55 in.)

Actuator Sensor

To prevent damage, it is recommended that a 2 mm (0.08 in.) gap be maintained between the actuator and sensor.

Actuator

Sensor

-4 -8 -12 -16 -20

442-8121620

-4 -8 -12 -16 -20

442-8121620

2mm Gap

-4 -8 -12 -16 -20442-8121620

paG mm2paG mm2

2mm Gap

Table 1 - Specifications (Continued)

Shock & Vibration

E.M.C. EN 61000-6-2, EN 60947-5-3

Protection

Safety Output Short-Circuit Protection Provided by the approved safety relays

Auxiliary Overload Protection Internal resettable fuse

24V Supply Reverse Polarity Protection Incorporated

Electrical Life 1 x 10

IEC 680068-2-27 30 g, 11 ms IEC 680068-2-6 10…55 Hz

cycles

Figure 1 - Approximate Dimensions [mm (in.)]

Figure 2 - Sensor Alignment

Figure 3 - Misalignment Curve

Mounting Information

Use non-removable screws, bolts, or nuts to mount the switch and actuator. Do not over torque the mounting hardware. It is re commended to use M3 screws and washers throughout.

Maximum torque is 1 N•m (8.86 in•lb). Use nonmagnetic mounting hardware.

Position the switch and actuator so they are aligned with each other.

Mounting for Maximum Misalignment

Mount the Sensor to the fixed part of the guard and the Actuator to the movable section. Keep the Sensor and Actuator within the sensing range detailed as shown in Figure 3

Minimum distance between sensors is 50 mm (1.97 in.).

2 Rockwell Automation Publication 440N-IN003B-EN-P - April 2018

IMPORTANT To obtain maximum switching distance, center the switches

± 4 mm (0.24 in.).

LED Operation and Diagnostics

Table 2 - Unit Indicators (per IEC 60073)

State Status Troubleshooting

Off Not powered

Off O verload Check AUX connections

Device

Output LED

Red Actuator not present

Green Actuator present —

Green

flashing

Actuator present

Actuation not present on other

switches or wiring fault

Check supply, check wiring to

controller A

If actuator present check

misalignment.

Check wiring to controller.

actuators on other switches

Check

Page 3

Magnetically Coded Non-contact Switch (MC2)

+24V Aux

Gnd

Safety B Safety A

Not

connected

Safety A

Safety B

476

Connection Information

Table 3 - Wiring Diagram

Pin Wire Color Signal

1 White PNP Aux

2Brown+24V

3 Green Not connected

4 Yellow S afety B

5 Gray Safety A

6PinkSafety B

7Blue0V

8RedSafety A

Recommended Mating Cable

The standard cable lengths are 2 m, 5 m, and 10 m. Use catalog number 889D-F8AB-2 [2 m (6.5 ft)] for the standard length or replace the 2 with 5 [5 m (16.4 ft)] or 10 [10 m (32.8 ft)] for remaining options.

IMPORTANT When the MC2 is used with any MSR100 series relay, for the

diagnostic function to operate correctly the red and gray wires (Safety A) must be connected to S11 and S12.

Power Supply Requirements

24V DC + 10°/-15° has to be supplied by a power supply that complies with IEC/EN 60204 and IEC/EN 61558-1. Such a power supply meets the electrical safety requirements and maintains the minimum power of

20.4V DC during 20 ms even in the event of voltage dips.

When using an approved relay with a MC2 and the same power supply is utilized for all devices, the relay will provide surge protection for the MC2. If a separate power supply is used for the MC2, then extra protection will be required.

Safety Ratings

An MC2 can achieve up to Cat 4/PLe, SIL CL3 when individually monitored by an approved Monitoring Relay Unit (see 9.1) that itself achieves Cat 4/PLe SIL CL3.

Two or more MC2 sensors connected in series with an approved relay, achieves up to CAT3/PLd/SIL CL2.

Repair

If there is any malfunction or damage, no attempts at repair should be made. The unit should be replaced before machine operation is allowed.

Declaration of Conformity

This is to declare that the products shown in this document conform with the Essential Health and Safety Requirements (EHSRs) of the European Machinery Directive (98/37/ED Machinery Directive, 2004/ 108/EC EMC Directive). These products also conform to EN60947-5-3, EN 1088, EN ISO 12100 parts 1 & 2, EN 60204-1 and have Third Party Approval.

For a comprehensive certificate, visit: https://

www.rockwellautomation.com/global/certification/overview.page

Approved Monitoring Relay Units

MC2 can only be used with the approved relays. Use of other devices not listed is at your own risk.

Only 24V DC MSR Relays or MSR Relays configured for 24V DC operation are compatible with MC2.

Table 4 - Approved Monitoring Relay Unit List and Max Number of Series MC2s

Monitoring Relay

Series

GSR Series -5% -10% -15%

GSR CI 440R-S13R2 8 10 10

GSR DI 440R-D22R2 8 10 10

GSR SI 440R-S12R2 8 10 10

GSR DIS 440R-D22S2 8 10 10

CR30 440C-CR30 8 10 10

MSR Series

MSR30RT/RTP 440R-N23197/440R-N23198 10 10 10

MSR 100 Series

MSR124RT

MSR126T/R 440R-N23117/440R-N23123 10 10 10

MSR126.1T/.1R 440R-N23114/440R-N23120 10 10 10

MSR127T/TP 440R-N23126/440R-N23132 10 10 10

MSR127R/RP 440R-N23129/440R-N23135 10 10 10

MSR131RTP 440R-C23139 10 10 10

MSR138DP 440R-M23151 10 10 10

MSR138.1DP 440R-M23084 10 10 10

MSR142RTP 440R-G23216 10 8 -

MSR178DP 440R-M23227 10 10 10

Catalog Number

440R-G23110/440R-G23108/

440R-G23107

Max Number of

24V DC Supply Voltage

10 10 10

MC2 Units

in Series

Maintenance

Every six months check the correct operation of the switching circuit. Also check for signs of abuse or tampering. Inspect the switch casing for damage.

Rockwell Automation Publication 440N-IN003B-EN-P - April 2018 3

IMPORTANT For up-to-date information, visit http://

ab.rockwellautomation.com/sensors-Switches/safetyinterlock-switches/magnetically-coded-non-contactinterlock-switches

Page 4

Magnetically Coded Non-contact Switch (MC2)

S11 S21

Safety A Safety B

24V

Aux

Safety A Safety B

24V

Aux

Safety A Safety B

24V

Aux

Safety A Safety B

24V

Aux

Safety A Safety B

24V

Aux

S12 S22

LED - Flashing GreenLED - Red

Aux - ON

LED - Red

Aux - ON

LED - Green

Aux - OFF

LED - Flashing Green

Aux - OFF

AuxAuxAuxAuxAux

Actuator

S11

Open Circuit between two MC2s

S21

Safety A

Safety B

24V

Aux

Safety A

Safety B

24V

Aux

Safety A

Safety B

24V

Aux

Safety A

Safety B

24V

Aux

Safety A

Safety B

24V

Aux

S12 S22

LED - Flashing GreenLED - Flashing Green

Aux - OFF

LED - Green

Aux - OFF

LED - Green

Aux - OFF

LED - Flashing Green

Aux - OFF

AuxAuxAuxAuxAux

Actuator Actuator ActuatorActuatorActuator

Troubleshooting

Figure 4 - Series Circuit — Two Guards Open

The auxiliary contacts close at the same time as the first safety contact opens

Figure 5 - S eries Circuit — Open Circuit on Channel A

The auxiliary contacts close at the same time as the first safety contact opens

4 Rockwell Automation Publication 440N-IN003B-EN-P - April 2018

Page 5

Application Wiring Examples

3313A1

S11

S12 23

S34 14A2 S21 S22 24

MSR127TP

+24V

S52 41

34 42

L2 L3

MC2

Red

Grey

Pink

Yellow

Brown (2)

Blue (7)

Red (8)

Gray (5)

Yellow (4)

Pink (6)

Green (3) White (1)

+24V

Safety A+

Safety A-

Safety B+

Safety B-

Aux

Not Connected

Figure 6 - Single Switch, Automatic Reset, Monitored Outputs MSR127TP

Magnetically Coded Non-contact Switch (MC2)

IMPORTANT To maintain the correct diagnostic operation, the red wire (QD

pin 8) must be connected to S11.

Rockwell Automation Publication 440N-IN003B-EN-P - April 2018 5

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Magnetically Coded Non-contact Switch (MC2)

Figure 7 - Multiple Switches, Automatic Reset, Monitored Output MSR127TP

Connected

Green (3)

Not Aux

White (1)

Safety B-

Pink (6)

Safety B+

Yellow (4)

Safety A-

Actuator

2CM2CM2CM

Actuator

Actuator in place Flashing LED Green Actuator in place Flashing LED Green

Actuator

Actuator NOT in place LED Red

Actuator

2S1S

2CM2CM

Actuator

Actuator in place LED Green Actuator in place LED Green

Safety A+ 0v +24v

Connected Not

Aux Safety B-

Safety B+ Safety A-

Safety A+ 0v +24v

Connected Not

Aux Safety B-

Safety B+ Safety A-

Safety A+ 0v +24v

Connected Not

Aux Safety B-

Safety B+ Safety A-

Safety A+ 0v +24v

Connected Not

Aux Safety B-

Safety B+ Safety A-

Safety A+ 0v +24v

Gray(5)

Red (8)

Blue (7)

Brown (2)

Green (3)

White (1)

Pink (6)

Yellow (4)

Gray(5)

Red (8)

Blue (7)

Brown (2)

Green (3)

White (1)

Pink (6)

Yellow (4)

Gray(5)

Red (8)

Blue (7)

Brown (2)

Green (3)

White (1)

Pink (6)

Yellow (4)

Gray(5)

Red (8)

Blue (7)

Brown (2)

Green (3)

White (1)

Pink (6)

Yellow (4)

Gray(5)

Red (8)

Blue (7)

Brown (2)

Red

Gray

Red

Gray

Red

Gray

Gray Red

Yellow

Pink

Yellow

Pink

Yellow

Pink

Yellow

Pink

Fuses

Indication

L1 L2 L3

24 24

Gray

S12 23

S52

Red

S11

MSR127TP

24 24

S34 14A2 S21

Pink

S22 24

Yellow

+24V

6 Rockwell Automation Publication 440N-IN003B-EN-P - April 2018

Page 7

Figure 8 - Multiple Switches, Manual Reset, Monitored Output MSR210P

+24V

MC2

Magnetically Coded Non-contact Switch (MC2)

MC2

+24v

Safety A

Safety B

Red (8)

Blue (7)

GSR DI

L11

Gray (5)

L12

Yellow (4)

S21S11

Brown (2)

Aux

Safety B

Not

Pink (6)

S22 S32 S42S12 23

S34

Green (3)

White (1)

Connected

14 24Y32

Fuses

+24v

Safety A

Safety B

Aux

Not

Connected

Red (8)

Blue (7)

Brown (2)

RESET

K2K1

Gray (5)

Pink (6)

Yellow (4)

White (1)

Green (3)

Rockwell Automation Publication 440N-IN003B-EN-P - April 2018 7

Page 8

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Magnetically Coded Non-contact Switch (MC2)

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