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

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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	Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
Troubleshooting	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

Who Should Use This

Publication?

Terminology

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 availableto 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.

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

•Maintenancepersonnel

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 Table 3 on page 31.

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Preface

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource	Description
440G-EZ Interlocking Safety Switch Installation	Provides installation information for 440G-EZ switches.
Instructions, publication 440G-IN019
Industrial Automation Wiring and Grounding Guidelines,	Provides general guidelines for installing a
publication 1770-4.1	Rockwell Automation® industrial system.
Product Certifications website: rok.auto/certifications	Provides declarations of conformity, certificates, and
	other certification details.

You can view or download publications at rok.auto/literature.

6	Rockwell Automation Publication 440G-UM003B-EN-P - June 2020

Chapter 1

Introduction

Intended Use

Safety Information

This chapter contains general safety information about the safety switch.

Further information about specific product use situations can be found in the relevant chapters.

ATTENTION: 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)

•Vacuumorhighpressure

•High UV load

•In the vicinity of low-frequency RFID devices

•In the vicinity of magnetic fields

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Chapter 1 Safety Information

ATTENTION: 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.

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Chapter 2

Structure and Function

Product Features

Product Overview

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

12 3

4

	6	5
Item	Description
1	Locking solenoid
2	Sensor surface
3	Cover plate
4	Plug connector IN
5	LOCK light-emitting diode (LED)
6	OSSD LED

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Chapter 2 Product Overview

Figure 2 - Actuator Overview

1

2

3

Item Description

1 Anchor plate

2 Protective 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

ATTENTION: 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.

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Product Overview	Chapter 2

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

	1		2
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. (1)
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.

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Chapter 2 Product Overview

Notes:

12	Rockwell Automation Publication 440G-UM003B-EN-P - June 2020

Chapter 3

Manufacturer of the

Machine

Project Planning

ATTENTION: 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.

Operating Entity of the

Machine

ATTENTION: 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.

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Chapter 3 Project Planning

Assembly

ATTENTION: 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).

• Flushmount (1): 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

1.5…3 mm (0.06…0.12 in.).

(1) For the recess dimensions for flush mounting, see Figure 12 on page 34

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