Allen-Bradley 440N-Z21W1PB Installation Manual

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

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 ISO13849-1:2006 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)
53
(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
0
0
0
-4 -8 -12 -16 -20
442-8121620
4
8
12
16
0
-4 -8 -12 -16 -20
442-8121620
4
8
12
16
20
24
20
24
2mm Gap
2mm Gap
0
0
0
-4 -8 -12 -16 -20442-8121620
4
8
12
16
0
-4 -8 -12 -16 -20442-8121620
4
8
12
16
20
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
6
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
8
1
5
2
3

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
Aux - OFF
LED - Flashing Green
Aux - OFF
AuxAuxAuxAuxAux
Actuator
Actuator
Actuator
Actuator
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
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
0V
S52 41
34 42
K1
K2
L1
L2 L3
MC2
Red
Grey
Pink
Yellow
Brown (2)
Blue (7)
Red (8)
Gray (5)
Yellow (4)
Pink (6)
Green (3) White (1)
+24V
0V
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
Page 6
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
S5
2CM2CM2CM
Actuator
S4
Actuator in place Flashing LED Green Actuator in place Flashing LED Green
Actuator
S3
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
K2
L1 L2 L3
K1
K2
24 24
13
Gray
S12 23
S52
Red
S11
MSR127TP
A1
M
K1
24 24
S34 14A2 S21
Pink
S22 24
Yellow
+24V
6 Rockwell Automation Publication 440N-IN003B-EN-P - April 2018
0V
Page 7
Figure 8 - Multiple Switches, Manual Reset, Monitored Output MSR210P
+24V
MC2
Magnetically Coded Non-contact Switch (MC2)
MC2
+24v
0v
Safety A
Safety A
Safety B
Red (8)
Blue (7)
GSR DI
L11
Gray (5)
L12
Yellow (4)
S21S11
Brown (2)
A1
A2
0V
Aux
Safety B
Not
Pink (6)
S22 S32 S42S12 23
S34
Green (3)
White (1)
Connected
13
14 24Y32
Fuses
+24v
0v
Safety A
Safety A
Safety B
Safety B
Aux
Not
Connected
Red (8)
Blue (7)
Brown (2)
K1
K2
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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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 information on its website at
http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page
Allen-Bradley, Guardmaster, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.
.
Publication 440N-IN003B-EN-P - April 2018 72697 Ver 03
Supersedes Publication 440N-IN003A-EN-P - August 2008 Copyright © 2018 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
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