Rockwell Automation 440G-EZ User Manual
User Manual
Original Instructions
440G-EZ Interlocking Safety Switch
Catalog Numbers 440G-EZS21STL05J, 440G-EZS21STL05H
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).
Table of Contents
Preface
Who Should Use This Publication?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 1
Safety Information Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Requirements for Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Project Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Mounting, Electrical Installation,
and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 2
Product Overview Structure and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Locking Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Protective Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 3
Project Planning Manufacturer of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operating Entity of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mounting Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mounting Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Control Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OSSDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Course of the OSSD Test Over Time . . . . . . . . . . . . . . . . . . . . . . . 17
Locking Solenoid Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Application Diagnostic Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Thorough-check Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Regular Thorough Check Minimum Requirements . . . . . . . . . . 18
Chapter 4
Installation Mount Multiple Safety Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mount the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Mount the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rockwell Automation Publication 440G-UM003B-EN-P - June 2020 3
Table of Contents
Chapter 5
Wiring Notes on c-UL-us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Device Connection (M12, 5-pin). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Device Connection (M12, 8-pin). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Connect Safety Switches with T-connectors . . . . . . . . . . . . . . . . . . . . . 25
Chapter 6
Commissioning Switch On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Thorough-check Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 7
Maintenance and
Troubleshooting
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Clean the Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Regular Thorough Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Appendix A
Specifications Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Appendix B
Ordering Information Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Appendix C
Replacement Parts/Accessories Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Appendix D
Declaration of Conformity (DoC) EU DoC (excerpt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Complete EU DoC for Download. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4 Rockwell Automation Publication 440G-UM003B-EN-P - June 2020
Preface
This user manual contains the information that is needed during the lifecycle of
the 440G-EZ electromagnetic safety switch.
This user manual must be made available to all people who work with the safety
switch. The structure of this user manual is based on the lifecycle phases of the
safety switch: project planning, mounting, electrical installation, commissioning,
operation, and maintenance.
Who Should Use This Publication?
Terminology
These operating instructions are intended for use by the following:
• Project developers (planners, developers, designers)
•Installers
•Electricians
• Safety experts (such as CE authorized representatives, compliance officers,
and people who test and approve the application)
•Operators
•Maintenance personnel
The following terms and abbreviations are used throughout this manual. For
definitions of terms not listed here, refer to the Allen-Bradley Industrial
Automation Glossary, publication AG-7.1
Term Definition
Dangerous state A status of the machine or facility, where people can be injured. Protective devices help prevent this
risk if the machine is operated within its intended use.
The figures in this document always show the dangerous state of the machine as movement of a
machine part. In practice, there are different dangerous states, such as:
• Machine movements
•Electrical parts
• Visible and invisible beam
• A combination of multiple hazards
.
Summary of Changes
This publication contains updated information in Tab le 3 o n pa ge 31 .
Rockwell Automation Publication 440G-UM003B-EN-P - June 2020 5
Preface
Additional Resources
These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
440G-EZ Interlocking Safety Switch Installation
Instructions, publication 440G-IN019
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Product Certifications website: rok.auto/certifications Provides declarations of conformity, certificates, and
You can view or download publications at rok.auto/literature
Provides installation information for 440G-EZ switches.
Provides general guidelines for installing a
Rockwell Automation® industrial system.
other certification details.
.
6 Rockwell Automation Publication 440G-UM003B-EN-P - June 2020
Safety Information
Chapter 1
Introduction
Intended Use
This chapter contains general safety information about the safety switch.
Further information about specific product use situations can be found in the
relevant chapters.
ATT EN TI ON : Hazard due to lack of effectiveness of the protective device
If non-compliant, it is possible that the dangerous state of the machine may not be
stopped or not stopped in a timely manner.
• Read this publication carefully and make sure that you understand the content
fully before working with the device.
• Follow all safety notes in this publication.
The 440G electromagnetic safety switch is a transponder safety switch with a
locking function, which is controlled without contact by actuators and is suitable
for the following applications:
• Monitoring of movable physical guards
• Locking device for process protection
The safety switch must only be used within the limits of the prescribed and
specified technical data and operating conditions.
Incorrect use, improper modification of, or tampering with the safety switch
invalidates any warranty from Rockwell Automation; in addition, any
responsibility and liability of Rockwell Automation for damage and secondary
damage that this action causes is excluded.
The safety switch is not suitable for the ambient conditions such as, but not
limited, to the following:
• Applications in which the dangerous state cannot be ended immediately
(stopping time)
• Radioactivity (exception: natural radioactivity)
•Vacuum or high pressure
• High UV load
• In the vicinity of low-frequency RFID devices
• In the vicinity of magnetic fields
Rockwell Automation Publication 440G-UM003B-EN-P - June 2020 7
Chapter 1 Safety Information
ATT EN TI ON : Improper use of the safety switch
If a voltage drop occurs, the locking device unlocks regardless of whether the
dangerous state of the machine has ended.
This safety switch has a simple electromagnetic locking device. There is no locking
device monitoring.
• Do not use the safety switch as a safety locking device according to EN 14119.
• Do not use the safety switch in applications in which the dangerous state
cannot be ended immediately (stopping/run-down time).
IMPORTANT Passing metal chips may impair the function of the safety switch.
Requirements for Qualified Personnel
Only qualified safety personnel can configure, mount, connect, commission, and
service the safety switch.
Project Planning
For project planning, a person is considered competent when they have expertise
and experience in the selection and use of protective devices on machines and is
familiar with the relevant technical rules and national work safety regulations.
Mechanical Mounting, Electrical Installation, and Commissioning
For the task, a person is considered qualified when they have the expertise and
experience in the relevant field and is sufficiently familiar with the application of
the protective device on the machine to be able to assess whether it is in an
operationally safe state.
Operation and Maintenance
For operation and maintenance, a person is considered competent when they
have the expertise and experience in the relevant field and is sufficiently familiar
with the application of the protective device on the machine and the machine
operator has instructed them in its operation.
8 Rockwell Automation Publication 440G-UM003B-EN-P - June 2020
Product Overview
123
4
65
Chapter 2
Structure and Function
Product Features
The safety switch is an interlocking device with a locking device consisting of a
non-contact sensor with locking solenoid and a coded actuator. The actuator has
a low coding level.
If the protective device is closed, the actuator is led to the sensor. When the
actuation field is reached, the actuator code is read out and evaluated by RFID. If
the code is valid, the safe output signal switching device (OSSD) switches.
If the locking solenoid is supplied with power, the locking device is active.
Figure 1 - Sensor Overview
Item Description
1 Locking solenoid
2 Sensor surface
3Cover plate
4Plug connector IN
5 LOCK light-emitting diode (LED)
6OSSD LED
Rockwell Automation Publication 440G-UM003B-EN-P - June 2020 9
Chapter 2 Product Overview
123
Figure 2 - Actuator Overview
Item Description
1 Anchor plate
2Protective cap
3Actuator surface
Product Models
The safety switch is available in different models. The following is an overview of
unique features of the models:
• One cable with M12 plug connector (5-pin)
• One cable with M12 plug connector (8-pin)
Locking Principle
ATT EN TI ON : Hazard due to lack of effectiveness of the protective device.
If a voltage drop occurs, the locking device unlocks regardless of whether the
dangerous state of the machine has ended.
• Do not use the safety switch in applications where the dangerous state cannot
be ended immediately (stopping/run-down time).
Power to Lock Principle
• Lock locking device: voltage at locking device input
• Unlock locking function: no voltage at locking device input
If voltage is interrupted, the locking device is unlocked and the protective device
can be opened immediately.
The locking device is not monitored, which means that the safety switch does not
check whether the anchor plate is applied to the solenoid.
10 Rockwell Automation Publication 440G-UM003B-EN-P - June 2020
Product Overview Chapter 2
21
Protective Functions
The safety switch has the following internal protective functions:
• Short-circuit protection at all outputs
• Cross-circuit monitoring at OSSDs
• Overload protection on OSSDs
• Supply voltage reverse polarity protection
Status Indicators
The safety switch displays important status information with the status
indicators.
Figure 3 - Status Indicators
Item Name Color Description
1 OSSD Green/Red Green when the OSSD pair is in the ON state.
Red when the OSSD pair is in the OFF state.
2 LOCK Yellow Turns ON when the magnet is supplied with voltage.
(1) 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.
(1)
Rockwell Automation Publication 440G-UM003B-EN-P - June 2020 11
Chapter 2 Product Overview
Notes:
12 Rockwell Automation Publication 440G-UM003B-EN-P - June 2020
Project Planning
Chapter 3
Manufacturer of the Machine
Operating Entity of the Machine
ATT EN TI ON : Failure to comply with obligations of manufacturer.
Hazard due to lack of effectiveness of the protective device.
• Conduct a risk assessment before using the safety switch.
• Do not tamper with, open, or modify the components of the safety switch.
• Do not repair defective devices – they must be replaced instead.
• Make sure that switch-on commands, which bring about a dangerous state of
the machine, are not enabled until the protective device is closed.
• Make sure that a stop command is triggered when the protective device is
opened during the dangerous machine state.
• The safety switches must not be defeated (that is, contacts jumpered), rotated
away, removed, or rendered ineffective in any other way. If necessary, put
measures in place to reduce possibilities for defeat.
ATT EN TI ON : Failure to comply with obligations of the operating entity.
Hazard due to lack of effectiveness of the protective device.
• Modifications to the machine and modifications to the mechanical mounting of
the safety switch necessitate a new risk assessment. The results of this risk
assessment may require the operating entity of the machine to fulfill the
obligations of the manufacturer.
• Apart from during the procedures described in this document, the components
of the safety switch must not be opened or modified.
• Do not perform repair work on the components. Improper repair of the safety
switch can lead to a loss of the protective function.
• Verify that there is no bypassing by replacement actuators. Restrict access to
actuators.
Rockwell Automation Publication 440G-UM003B-EN-P - June 2020 13
Chapter 3 Project Planning
Assembly
ATT EN TI ON : Bypassing the protective device.
Hazard due to lack of effectiveness of the protective device.
Avoid incentives to manipulate the safety switch by taking at least one of the
following measures:
• Cover the sensor and the actuator with additional equipment or protect them
against access.
• If possible use permanent mounting methods for actuators (for example, glue,
safety screws, or rivets).
Mounting Location
• Select the mounting location so that the sensor and actuator are accessible
for maintenance work and are protected against damage.
• Select a mounting location for the sensor that is as far away from the door
hinge as possible.
• If necessary, fit an additional stop for the moving protective device.
Distance
When several safety switches are mounted to the machine, they must be mounted
at a minimum distance to one another see Mount Multiple Safety Switches on
page 19
Alignment
The safety switch can be mounted in any alignment. When mounted
horizontally, the anchor plate with rotating bearings increases the manipulation
protection. When mounted horizontally, if the movable physical guard triggers
the actuator, the magnet holds the actuator. As the anchor plate has rotating
bearings, the gravitational force rotates the actuator surface away from the sensor
surface and the OSSDs go into the OFF state.
Mounting Methods
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
device (for example, door frame). There must be a suitable recess in the
mounting surface. The thickness of the mounting surface must be
1.5…3 mm (0.06…0.12 in.).
(1)
: The sensor is mounted in the fixed part of the protective
(1) For the recess dimensions for flush mounting, see Figure 12 on page 34
14 Rockwell Automation Publication 440G-UM003B-EN-P - June 2020
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