Rockwell Automation 440G-LZ User Manual
Guardmaster® 440G-LZ Guard Locking Switch
User Manual
Important User Information
IMPORTANT
Solid-state equipment has operational characteristics differing from those of electromechanical equipment.
Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication
SGI-IN001_-EN-P
http://www.rockwellautomation.com/literature/
equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide
variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy
themselves that each intended application of this equipment is acceptable.
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.
available from your local Rockwell Automation sales office or online at
) describes some important differences between solid-state
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.
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.
Identifies information that is critical for successful application and understanding of the product.
It is recommended that you save this user manual for future use.
2 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Read this preface to become familiar with the rest of the manual.
It provides information concerning:
• who should use this manual
• the purpose of this manual
• related documentation
• conventions used in this manual
Preface
Who Should Use This Manual
Purpose of This Manual
Conventions Used in This
Manual
Use this manual if you are responsible for designing, installing,
programming, or troubleshooting systems that use the Guardmaster
440G-LZ guard locking switch.
You should have a basic understanding of electrical circuitry and
familiarity with safety-related systems. If you do not, obtain the proper
training before using this product.
This manual is a reference guide for the Guardmaster 440G-LZ guard
locking switch. It describes the procedures you use to install, wire, and
troubleshoot your switch. This manual:
• Explains how to install and wire your 440G-LZ
• Provides an overview of the Guardmaster 440G-LZ guard locking
switch
The following conventions are used throughout this manual:
• Bulleted lists such as this one provide information, not procedural
steps.
• Numbered lists provide sequential steps or hierarchical
information.
Additional Resources
The following document offers additional information about related
Rockwell Automation products:
Resource Description
Allen-Bradley Industrial Automation Glossary,
publication AG-7.1
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 3
Glossary of industrial automation terms and
abbreviations
Preface
Terminology
You can view and download publications at http://
www.rockwellautomation.com/literature/ . To order paper copies of
technical documents, contact your local Rockwell Automation distributor
or sales representative.
OSSD Output Signal Switching Device. Typically designates a pair of solid state
signals pulled up to the DC source supply. The signals are usually tested for
short circuits to the DC power supply, short circuits to the DC common, and
short circuits between the two signals.
Standard coding Same as Low coding as defined in EN/ISO 14119:2013
Unique coding Same as High coding as defined in EN/ISO 14119:2013
4 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
General Description
Safety Concept
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Preface
Who Should Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conventions Used in This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 1
Guardmaster 440G-LZ Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Packaging Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 2
Safety Standards Applied to Guardmaster 440G-LZ. . . . . . . . . . . . . 11
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation and Wiring
Description of Operation
Chapter 3
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pair Proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Orientation of Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Setting the Actuator Direction of Approach . . . . . . . . . . . . . . . . . . . . 15
Mounting the Assembled Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mounting the Switch Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setting Actuator to Switch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . 17
Actuator RFID Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LED Error Codes During the Learning Process . . . . . . . . . . . . . . . . . . 19
Proving Basic Lock Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chapter 4
Description of LEDs During Operation . . . . . . . . . . . . . . . . . . . . . . . . . 23
Status/Diagnostic LED During Troubleshooting . . . . . . . . . . . . . . . . 24
Auxiliary Out Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Guardmaster 440G-LZ Wiring with GSR Relay . . . . . . . . . . . . . . . . . . 25
Guardmaster 440G-LZ Wiring with Point I/O . . . . . . . . . . . . . . . . . . . 26
Guardmaster 440G-LZ Wiring with GLP Relay . . . . . . . . . . . . . . . . . . 26
Guardmaster 440G-LZ Troubleshooting Series Circuit . . . . . . . . . . 27
Unit Response Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OSSD Output Test Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Auxiliary/Manual Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 5
Table of Contents
Appendix A
Specifications
Typical Installations
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Safety Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Operating Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Environmental and General Protection. . . . . . . . . . . . . . . . . . . . . . . . . 31
Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Compliance to European Union Directives . . . . . . . . . . . . . . . . . . . . . 32
Overall Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Catalog Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Appendix B
Switch Mounted Parallel to Hinge Axis . . . . . . . . . . . . . . . . . . . . . . . . . 35
Switch Mounted Perpendicular to Hinge Axis . . . . . . . . . . . . . . . . . . 36
Switch Mounted to a Sliding Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
General Description
Chapter 1
Guardmaster 440G-LZ
Overview
This Guardmaster 440G-LZ guard locking switch functions by extending a
locking bolt from the switch through a hole in the actuator, thus
preventing the opening of a guard.
The locking bolt drive mechanism and logic ensure that the locking bolt
is allowed to extend only when the corresponding actuator is detected
within range.
The appropriate actuator is detected by RFID coding.
This version of the Guardmaster 440G-LC guard locking switch features
OSSD outputs that are enabled only when the locking bolt is sensed in its
extended position in the actuator, which happens only when the guard is
both closed and locked.
The locking bolt drive mechanism uses a bi-stable solenoid; as a result,
the switch consumes very little electrical power, with peak currents
occurring only briefly, upon start-up and after each movement of the
locking bolt.
Because of its bi-stable drive, not only does the device consume minimal
power, but it does not produce heat whether in its locked or unlocked
condition.
Despite the bi-stable design of the locking bolt drive, the device logic and
functionality are configured to replicate the functionality of a power-torelease or power-to-lock solenoid-operated switch (depending on type).
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 7
Chapter 1 General Description
Locking bolt
Act uato r
Switch body
Actu ator
mounting bracket
QR Code
Alignment guide
Guardmaster 440G-LZ
Assembly Overview
Packaging Contents
The box includes the following components:
Switch body including connection lead: 3 m or 10 m flying lead or
pigtail equipped with M12 QD connector
Actuator mounting bracket
8 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
General Description Chapter 1
Actuator
Actuator-to-actuator mounting bracket mounting screws: 2 x T10
To r x
Alignment guide
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 9
Chapter 1 General Description
Notes:
10 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Safety Concept
Chapter 2
Safety Standards Applied to
the Guardmaster 440G-LZ
Guard Locking Switch
Introduction
Safety Certification
The Guardmaster 440G-LZ satisfies applicable requirements in the
following standards related to functional and machinery assembly:
• IEC 60947-5-1: 2003+A1: 2009
• IEC 60947-5-3: 1999/A: 2005
• IEC 61508:2010 SIL 3
• IEC 62061:2005 SIL 3
• EN/ISO 13849-1:2008/AC: 2009 Performance Level e (PLe), Category
4
• EN/ISO 14119:2013
• UL 508 17
This section describes the safety performance level concept and explains
how the Guardmaster 440G-LZ meets the requirements for SIL 3, Cat. 4 or
Performance Level “e” (PLe) applications.
The Guardmaster 440G-LZ is certified for use in safety applications up to
and including SIL 3 according to IEC 61508 and IEC 62061 with a proof test
interval of 20 years, Performance Level PLe and Category 4 in compliance
with ISO 13849-1.
th
Edition dated 3/19/2013
Safety requirements are based on the standards applicable at the time of
certification.
The TÜV Rheinland group has approved the Guardmaster 440G-LZ for use
in safety-related applications where Performance Level “e” is required for
the door position and lock monitoring functions.
The 440G-LZ must be installed in accordance with the applicable
regulation and standards.
While the 440G-LZ can be used for SIL 3, PLe and Category 4 applications,
the installer must comply with guard requirements (e.g. EN/ISO13854
and EN/ISO 13857) and in some cases also minimum (safe) distance
requirements (e.g. EN/ISO 13855).
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 11
Chapter 2
The installed system, including the safety control system and the means
by which the machine stops, must achieve the needed safety
performance. The 440G-LZ is one element in the safety system.
Additional guidance on guards, guard locking and guard interlocking
may be found in:
• EN/ISO 12100
• EN/ISO 13854
• EN/ISO 13855
• EN/ISO 13857
• EN/ISO 14119
• EN/ISO TR 24119
• EN/ISO 14120
• Application specific C-Level standards
12 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
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