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
Installation and Wiring
Chapter 3
General Considerations
The 440G-LZ guard locking switch is designed for use on guards that are engineered to be rigid without sag. A separately mounted latch (e.g. magnetic or mechanical) and mechanical stop are required.
It can be used on Full Body Access guards that do not require escape release, emergency release or remote release guards, and in any situation where the alignment tolerance falls within the stated specification.
Installation must be in accordance with the present manual and must be carried out by qualified personnel exclusively. The 440G-LZ guard locking switch is intended to be part of the safety-related control system of a machine. Before installation, a thorough risk assessment must be performed to determine whether the specifications of this device are suitable for all foreseeable operational and environmental characteristics of the application.
Refer to the Specifications section of this manual. Use appropriate screws, bolts, or nuts fitted by tools to mount the switch and actuators to avoid tampering.
Do not over-torque the mounting hardware.
Pair Proximity
ATTENTION: For the switch, actuator and actuator mounting bracket:
• Only use the designated mounting holes.
• Never drill or use to support other structures such as a conduit, cable ways, or other hardware.
During installation, make sure you observe the following restriction: you must maintain a minimum distance between each pair of switches you mount. Make sure to maintain a minimum distance of 120 mm (4.72 in.) between any two switches and actuators, as indicated in the following illustrations.
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 13
Chapter 3 Installation and Wiring
120 mm
120 mm
Orientation of Switches
If the recommended minimum proximity dimension is not observed, the units will fault.
Can be used in all mounting orientations.
14 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Installation and Wiring Chapter 3
Align the white triangles.
0.4 Nm
2 x T10 Torx screws
Setting the Actuator Direction of Approach
The actuator can approach the switch from all four directions.

Ensure the white arrow on the actuator aligns with the white arrow on the switch body.
The actuator must be fitted to the actuator mounting bracket in such a manner that the white alignment triangles marked on both the actuator and switch body are in the installed position.
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 15
Ensure the locking bolt enters the actuator mounting bracket first.
Chapter 3 Installation and Wiring
Mounting the Assembled Actuator
Ensure two fasteners are used with at least one fastener fitted close to the actuator bracket bend.
The following drawings show mounting possibilities when attaching to extruded aluminum profile and flat surface guard doors.
Removal of the Actuator Plug
This plug may be broken out from the actuator if a through hole is required to prevent a food trap when mounted on the hazard side of a guard door.
The plug can be broken out by using a screwdriver and twisting until it comes apart.
16 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Installation and Wiring Chapter 3
3 x M5
G
H
Mounting the Switch Body
Setting Actuator to Switch Alignment
Three M5 fasteners (not provided) are required for proper mounting to a rigid guard door frame.
There are three ways to achieve proper alignment.
1. By setting gap
2.5 mm (0.09 in.) [
2. By mounting hole alignment
6.5 mm (0.25 in.) [4…9 mm (0.15…0.35 in.)]
3. Using the alignment provided
“G” 0…5 mm (0…0.19 in.)
”H”
guide
]
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 17
Chapter 3 Installation and Wiring
ATTENTION: After installation, ensure
that there is no possibility of lifting the actuator over the extended locki ng bolt.
ATTENTION: After installation, ensure
there is no possibility of collision when the actuator approaches the switch body.
Actuator RFID Setting
Switches with standard coded actuators
These switches are ready for use and need no special RFID setting.
Switches with unique coded actuators
Before use, the switches must first “learn” a new RFID guard actuator. This task is not performed at the factory, as there are two possible methods:
• “Multi-time” learning: the switch can learn up to eight actuators consecutively.
• “One-time” learning: The switch learns one actuator only, for life, irreversibly.
The “one-time” learning method may be invoked at any time, not just during RFID setting. For example, the switch could “multi-time” learn four different actuators consecutively, then complete a “one-time” learning process that would prevent it from learning any additional actuators.
Learning the First “Multi-Time” Actuator
Connect the switch to 24V DC (see the wiring diagrams on page 21 ensure that the lock command is off.
), and
The Status/Diagnostic LED will blink a number of times corresponding to the number of times a new actuator may be acquired (a total of eight times when the switch is new), then repeat, indicating that the switch has yet to learn a new actuator.
The switch automatically starts the learning process as soon as an actuator is placed in the guard-closed position of the switch.
18 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Installation and Wiring Chapter 3
Learning Sequence as Indicated by the Status/Diagnostic LEDs
Actuator present Blinking green, 1 Hz rate
Verifying actuator Blinking green/red, 1 Hz rate (15 sec)
Programming switch (15 sec) Blinking green/red, 4 Hz rate (15 sec)
Program finalization Blinking green (remaining number of times
a new actuator may be acquired, 15 sec)
Ready state (learning process is complete) Solid green (Power-to-release)
Solid red (Power-to-lock)
Learning Additional “Multi-Time” Actuators
Mount the new actuator on the guard and repeat the above process., introducing the actuator to the switch as previously described. During program finalization, the LED will blink green a number of times corresponding to the number of remaining learnable actuators.
Note: Once a new actuator is learned by a unique coded switch, any previous actuator is no longer usable by that switch.
“One-time” Learning Process
Proceed just as in the “multi-time” teaching process described above, with the following exception: at the programming finalizing (last) stage, withdraw the actuator from the switch, until the LED turns solid red, then immediately reposition the actuator near the switch. This process must be executed within 15 seconds.
The LED blinks, then turns solid to indicate that the learning process is complete.
Power-to-release Solid green
Power-to-lock Solid red
Note: For power-to-release switches, you will need to execute a manual release in order to withdraw the actuator away from the switch as described above.
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 19
Chapter 3 Installation and Wiring
Status/Diagnostic LED Error Codes During the Learning Process
Proving Basic Lock Function
The following code sequences persist until a Power On/Off cycle is completed.
Status/Diagnostic LED Flashes (4 Hz) Error Code
Green OSSD inputs not valid
Red-red-red-green Cannot learn a standard actuator
Red-red-red-green-green Actuator already learned
Red-red-red-green-green-green Bad RFID; actuator moved out of range
Red-red-red-green-green-green-green Exceeded learning eight actuators
Red-red-red-green-green-green-green-
Unit locked: cannot learn another actuator
green
To prove basic lock function and to verify correct actuator alignment, it may be necessary to extend the locking bolt. The locking bolt cannot be extended by mechanical means; you must proceed electrically. The following basic connections are required:
Pin 2 (brown wire) must be connected to 24V DC
Pin 7 (blue wire) must be connected to 0V (GND)
In the case of a power-to-release switch, the locking bolt will extend when the guard is shut and the actuator is aligned. Connect Pin 3 (green wire) to 24V DC to unlock the switch and withdraw the locking bolt.
If power is removed from a power-to-release switch in the locked position, the locking bolt will remain in its extended position (switch locked). Use the manual auxiliary release to unlock the switch.
In the case of a power-to-lock switch, connect Pin 3 (green wire) to 24V DC to lock the switch (i.e. extend the locking bolt). Disconnecting Pin 3 will unlock the switch.
If power is removed from a power-to-lock switch in the locked position, the switch unlocks.
In either type of lock, the locking bolt never extends in the absence of the actuator.
20 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Wiring
2
1
7
6
3 8
4
5
8-Pin Micro (M12)
8-Pin Cordset 889D-F8AB-* or cable version
Installation and Wiring Chapter 3
3 Lock Command
8 Safety A+
4 Safety B+
5 Safety A
Color Function Pin
White Aux 1
Brown 24V DC+ 2
Green Lock 3
Yellow Safety B+ 4
Grey Safety A 5 Pink Safety B 6 Blue Gnd/0V 7
Red Safety A+ 8
2 24V DC+
Keyway
1 Aux 7 0V
6 Safety B
Connections Systems
The following connection system components facilitate connection:
Safety-wired Splitter/T-Port Cat. No 898D-438Y-D8
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 21
Chapter 3 Installation and Wiring
PWR OSSD 1+
OSSD 2+
NA
Pin 1 Pin 2 Pin 3 Pin 4
NA
Pin 5
Safety-wired Shorting Plug Cat. No 898D-418U-DM
2
5
3
1
4
8-pin Device Patchcords Cat. No.
1 meter, 8-pin 889D-F8ABDM-1
2 meters, 8-pin 889D-F8ABDM-2
5 meters, 8-pin 889D-F8ABDM-5
10 meters, 8-pin 889D-F8ABDM-10
Note: Add the letter “S” to above cat. nos. for stainless steel connectors; e.g. 889DS-F8ABDM-1
5-pin Patchcords Cat. No.
1 meter, 5-pin 889D-F5ACDM-1
2 meters, 5-pin 889D-F5ACDM-2
5 meters, 5-pin 889D-F5ACDM-5
10 meters, 5-pin 889D-F5ACDM-10
Note: Add the letter “S” to above cat. nos. for stainless steel connectors; e.g. 889DS-F5ACDM-1
5-pin Cordsets
Cat. No.
2 meters, 5-pin 889D-F5AC-2
5 meters, 5-pin 889D-F5AC-5
10 meters, 5-pin 889D-F5AC-10
Note: Add the letter “S” to above cat. nos. for stainless steel connectors; e.g. 889DS-F5AC-1
More detailed information may be found online at ab.com/product
catalogues/ (search for “Connection Systems”).
22 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Description of Operation
Chapter 4
Status/Diagnostic LEDs During Operation
During operation, the LEDs indicate the status of the Guardmaster 440G-LZ guard locking switch as follows:
Power -to-Lock Versions
Power on and lock CMD off
Lock CMD on, door open
Lock CMD on, door closed
Lock CMD on, door closed
Power -to­Release Versions
Power on with door open
Power on with door closed
Guard Status
Open or closed
Open On Off or onUnlocked Fast flash green Off
Closed On Off Locked Slow flash green Off
Closed On On Locked Solid green On
Guard Status
Open Off Off or onUnlocked Blinks 6x green,
Closed Off Off Locked Blinks 6x green,
Lock
OSSD
CMD
Input
Off Off or onUnlocked Blinks 6x green
Lock
OSSD
CMD
Input
Lock Status
Lock Status
LED Status
then solid red
LED Status
then blinks 1x red, followed by fast flash green
then blinks 1x red, followed by slow flash green
OSSD Status
Off
OSSD Status
Off
Off
Power on with door open, and OSSD input active
Unlock CMD on, and door closed or open
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 23
Closed Off On Locked Blinks 6x green,
then blinks 1x red, followed by solid green
Open or closed
On Off or onUnlocked Solid red Off
On
Chapter 4 Description of Operation
Status/Diagnostic LEDs During Troubleshooting
This section explains the meaning of the various LEDs during troubleshooting.
LED Status Switch Status
Off Not powered
Solid green Door shut, locked, and OSSDs are ON.
Fast flash, green (4 Hz) Waiting to lock, actuator is not within range
Slow flash, green (1 Hz) Door shut, locked. OSSDs are OFF because there’s no safety
input signal.
Solid red (PTL versions) Door open or shut, not locked. No lock signal.
Solid red (PTR versions) Door open or shut, not locked. Unlock signal is ON.
Flashing 3x green, then red - repeats Attempting to lock/unlock, actuator not aligned.
Flashing 3x green, then red ­repeating, then finally fast flash red
Slow flash, red (1 Hz) OSSD fault, check outputs are not shorted to GND, 24V DC,
Fast flash, red (4 Hz) General fault. Cycle power to reset.
Failure to lock/unlock. Align actuator, then cycle power.
or each other. Cycle power to reset.
Auxiliary Out Function
The Auxiliary Out only changes state when the door is shut and locked, regardless of OSSD status.
Power-to-Lock Versions Lock CMD Lock Status Auxiliary Out
Door open On or off Unlocked On
Lock CMD on, door closed On Locked Off
Power-to-Release Versions Lock CMD Lock Status Auxiliary Out
Door open On or off Unlocked On
Lock CMD off, door closed On Locked Off
24 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Guardmaster 440G-LZ Wiring
889D-F8AX-X
Pigtail
Red
Brn
Wht
Grn
Pnk Gry
Ye l
Blu
Power
In1 In2 Out Logic
A2
A1
+-
S11
S21
S12
S22
S32
S42
L12
L11
Y32
S34
13
14
23
24
24VDC
IN1
DI
IN2
0
1
2 3
4
56
7
8
LOGIC
Test Out
A2A1
+-
B2 37B1 47 4838
L12 L11 X32 17
27
2818
24VDC
EMD
171827
28
373847
48
N/C
E-Stop
K1
K2
M
K1
K2
Reset
440G-LZS
24V DC Supply
24V DC COM
with GSR Relay
Description of Operation Chapter 4
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 25
Chapter 4 Description of Operation
1734-IB8S
I0 I4 I5I1
I2 I6 I7I3
COM COM COMCOM
T0 T2 T3MT1
1734-OB8S
O0 O4 O5O1
O2 O6 O7O3
COM COM COMCOM
889D-F8AX-X
Pigtail
COM COM COM COM
M
K1
K2
Safety Reset
Faul t Reset
N/C
Red
Brn
Wht
Grn
Pnk
Gry
Yel
Blu
24V DC Supply
24V DC COM
K1
K2
Unlock Request
Unlock Signal
E-Stop 800FM-MT44 800F-MX02S
Reset
GLP
440R-GL2S2P
A2S12 S22
L11
L12
L61
51
P12 P22
A1X14 X24 S54
S44
AP
Y32
Reset & Gate Lock Request
Gate Unlock Request
Y32
DI
440R-D22R2
S32
A1 13
S21S11 S22S12 S34
S42
L12
14
872C-D8NP18-E5 (2)
24V DC, Class 2 Supply
24V DC COM
0
1
4
5
6
7
8
9
SL2
2
3
0
1
3
4
5
6
7
8
9
SL1
2
LOGIC
0
1
2 3
4
5
6
7
9
8
E-Stop 800FM-MT44 800F-MX02S
0
1
2 3
4
56
7
8
LOGIC
Brn
Brn
Blk
Blk
Blu
Blu
23
24
Safety Status
to PLC
L11 A2
Brn Red Yel
Grn
Wht Blu Gr y Pnk
Reset
440G‐LZS21SPRA
SLS Request to PLC
+24V DC
COM
Status
Safety Input 1
Safety C ommon
Safety Input 2
K 300
Safe Torque-o (STO) Connector With Wiring Header
Drive Status to PLC
Stop/Start/SLS from PLC
Gate Open
- Unlocked
Guardmaster 440G-LZ Wiring with Point I/O
Point to Point I/O with Unlock request.
Guardmaster 440G-LZ Wiring with GLP Relay
26 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
E-Stops with Speed Monitoring, Guard Locking and Servo Drive
Troubleshooting Series
Actuator 1
Actuator 2
Actuator 3
Switch 1
Switch 2
Switch 3
RTN
24V DC
Power
Supply
+24
1606-
XL120D
Green
Pink
Grey
Brown
Red
Yel
White
A2
440R-N23132
Initial Conditions: All switches are locked
Switch 1 receives Unlock command (guard can then be opened).
Lock/unlock
command
Switch 2 drops the 24 volts (red and yellow) from switch 1 OSSD outputs. Green LED ashes.
Switch 3 drops the 24 volts (red and yellow ) from switch 3 OSSD outputs. Green LED ashes.
Pink
Grey
Red
Yel
White
Green
Blue
Pink Grey
Red
Yel
White
S11 41332313S12S52
S21 S22 42342414A1S34
200 ms150 ms100 ms0 ms
650 ms625 ms600 ms0 ms
Switch 1 guard is closed
Switch 1 OSSD outputs are energized.
Switch 2 OSSD inputs (red and yellow) transition to 24V DC from switch 1 OSSD outputs. Switch 2 OSSD outputs are energized.
Switch 3 OSSD inputs (red and yellow) transition to 24V DC from switch 2 OSSD outputs. Switch 3 OSSD outputs are energized.
Green
Brown
Blue
Brown
Blue
Switch 1
Switch 2
Switch 3
Circuit
+24
24V DC
Power
Supply
1606-
XL120D
RTN
Switch 1 Switch 2 Switch 3 Switch 4 Switch 5
Description of Operation Chapter 4
Green
Yellow
White
Red
Lock/Unlock Lock/UnlockLock/UnlockLock/UnlockLock/Unlock
Recoverable
Actuator 1 is in sensing range and guard is locked.
Fault
Guard 1 functions properly. OSSDs are energized to 24V. Green LED is ON.
Unit Response Times When Connected in Series
Blue
Brown
Grey
Pink
Green
White
+24V +24V +24V +24V
Actuator 2 is in sensing range and guard is locked. Guard 2 functions properly. OSSDs are energized to 24V. Green LED is ON.
Brown
Yellow
Grey
Red
Blue
Pink
Green
Actuator 3 is in sensing range and guard is locked. Guard 3 has a fault. See Diagnostic table. Red LED is ashing.
Brown
Yellow
White
Red
Grey
Pink
Blue
Green
White
0V
Actuator 4 is in sensing range and guard is locked. Guard 4 functions properly. Series inputs are 0V. OSSDs are de-energized to 0V. Green LED is ashing to indicate series inputs are not 24V.
Yellow
Red
Blue
Brown
Grey
Pink
Green
0V0V 0V
Actuator 5 is in sensing range and guard is locked. Guard 5 functions properly. Series inputs are 0V. OSSDs are de-energized to 0V. Green LED is ashing to indicate series inputs are not 24V.
Brown
Yellow
White
Red
Grey
Pink
Blue
0V 0V
OSSDs are OFF
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 27
Chapter 4 Description of Operation
Safety A
Safety B
Occurs every 25 ms
Occurs every 25 ms
Occurs every 11 sec
300 μs
300 μs
˂ 600 μs
˂ 600 μs
Occurs every 11 sec
OSSD Output Test Pulses
Auxiliary/Manual Release
The Guardmaster 440G-LZ guard locking switch uses test pulses to check for OSSD output faults. This process is illustrated graphically as follows:
The manual release is provided to allow you to unlock the guard door in the event of unforeseen and uncommon circumstances.
< 2.5 (0.098) dia.
If power is supplied to the switch and the latter is in its locked state, invoking the auxiliary release will cause the switch to enter a fault condition (blinking red LED).
To reset the switch, simply cycle the power.
28 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Specifications

Appendix A

Introduction
Safety Ratings
This appendix provides the specifications for the Guardmaster 440G-LZ guard locking switch.
Note: The holding force Fzh is in accordance to EN/ISO 14119:2013, clause 5.7.4. Additional validation was performed in accordance with IEC 60947-5-1:2009, clause C.1.2.2.
Standards IEC 60947-5-3, IEC 60947-5-1, IEC 61508, EN/
ISO 13849-1, IEC 62061, EN/ISO14119, UL 508
Safety Classification: Guard door sensing and lock monitoring
Functional Safety Data: Guard door sensing and lock monitoring
PLe Category 4 per ISO 13849-1, SIL 3 per IEC 61508 and IEC 62061
PFHD: 9.1 x 10 Dual channel interlock may be suitable for use
in applications up to PLe (in accordance with ISO 13849-1) and for use up to SIL 3 systems (in accordance with IEC 62061), depending on application characteristics. Mission time/PTI: 20 years
-10
Operating Characteristics
440G-LZS21*PR* Power-to-release
440G-LZS21*PL* Power-to-lock
Switch function OSSDs enable when guard closed and locked
Torque for M5 mounting of switch and actuator mounting bracket
Locking bolt insertion for assured locking and holding force
Approach speed Minimum of 2 mm/s
Locking bolt alignment tolerance X, Y, Z Maximum of +/- 2.5 mm
Holding force Fmax (EN/ISO 14119) 1,690 N
Holding force Fzh (EN/ISO 14119) 1,300 N
Maximum output current (each output) 200 mA
Quiescent power consumption, Locked or Unlocked
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 29
2 Nm max.
Minimum of 5 mm (0.19 in.), maximum of 10 mm (0.39 in.)
2.5 W
Appendix A Specifications
Peak current, during turn-on or after Lock/ Unlock operation
Duration of peak current, at turn-on or after Lock/Unlock operation
Maximum number of switches connectable in series
Operating voltage Ue 24V DC + 10% / -15% Class 2 SELV
Maximum frequency of operating cycles 0.2 Hz
Dwell time between subsequent locking/ unlocking
Response time (Off) 100 ms first switch, +50 ms for each additional
Risk time (according to IEC 60947-5-3) 100 ms
Start-up time (availability) 5 s
Usage category (IEC 60947-5-2) DC-13 24V 200 mA
Insulation voltage Ui (IEC 60947-5-1) 75 V
Impulse withstand voltage Uimp (IEC 60947-5-1)1 kV
Pollution degree (IEC 60947-5-1) 3
400 mA
100 ms
Unlimited, See Chapter 4, Unit Response Times
2.5 s
switch
Outputs (Guard Closed and Locked)
Manual (auxiliary) release Built-in
Emergency release No
Escape release No
Protection class (IEC 61140) Class II
* See nomenclature section below, and cat. nos. section on page 34.
Nomenclature for Complete Switches
440G-LZS21
abc
S Standard Coding R Power-to-Release A 3 m Cable
U Unique Coding L Power-to-Lock B 10 Cable
Outputs Description/Status
Safety 2 x PNP, 0.2 A max. / ON (+24V DC)
P
abc
H M12 8-pin
Auxiliary 2 x PNP, 0.2 A max. / OFF (+0V DC)
30 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Specifications Appendix A
Environmental
General
Operating temperature [C (F)] 0…55º (+14…131º)
Storage temperature [(C (F)] -25…75º (+13…167º)
Operating humidity 5…95%, relative
Enclosure ingress rating NEMA 3, 4x, 12, 13, IP66, IP67, IP69K
Shock and vibration IEC 68-2-27 30 g, 11 ms/IEC 68-2-6 10…55 Hz
Hygienic ISO 14159:2004 and EN 1672-2005 (for part of
the machine defined as “food splash area”)
Washdown Suitable for sodium hydroxide-based
washdown fluids
Radio frequency / EMC IEC-60947-5-3, FCC-1 (Parts 18 & 15), R&TTE
Materials ABS, locking bolt and mounting bracket 304
stainless steel
Weight switch/actuator Switch 400 g, actuator 22 g,
actuator mounting bracket 60 g
Connection Flying lead or pigtail with M12 8-pin QD
connector (stainless steel)
Protection
Certifications
Short-circuit protection Incorporated
Current limitation Incorporated
Overload protection Incorporated
Reverse polarity protection Incorporated
Overvoltage protection Incorporated (up to 60V max.)
Thermal shutdown/restart Incorporated
See the Product Certification link at http://
www.rockwellautomation.com/rockwellautomation/certification/ for
Declaration of Conformity, Certificates, and other certification details.
UL Listed Industrial Control Equipment, Certified for US and Canada
CE Marked for all applicable directives
C-Tick Marked
TÜV Certified for Functional Safety up to SIL 3 Category 4 for use in
safety applications up to and including SIL 3, in accordance with IEC 61508 and EN 62061, Performance Level “e” and Category 4 in accordance with ISO 13849-1, both for guard positioning and for lock monitoring according to EN/ISO 14119:2013.
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 31
Appendix A Specifications
25
(0.98)
50
(1.97)
22.5
(0.89)
45 (1.77)
8
(0.31)
10
(0.39)
22.9
(0.90)
140 (5.51)
10
(0.39)
9.5
(0.37)
9.525
(0.37) dia.
22.5
(0.88)
134.5 (5.29)
33
(1.29)
2 x 5.5
(0.22) dia.
Compliance to European Union Directives
Overall Dimensions
This product bears the CE Mark and is approved for installations within the European Union and EEA regions. It has been designed and tested to meet the following directives (Machine Safety and EMC).
For a complete list of standards used (including Machine Safety Directive and EMC Directive), see EU Declaration of Conformity on page 37
of this
manual.
Switch Body
Actuator and Actuator Mounting Bracket
(1.57)
65
(2.56)
25.4 (1.0)
7
(0.28)
25 (0.98)
6 x 6.35
(0.25) dia.
12.5 (0.5)
40
47
(1.85)
51.5 (2.03)
40 (1.57)
3
(0.12)
32 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Switch Mounting Bracket 440G-LZAM2
40 (1.57)
Specifications Appendix A
+1
R6
-3
2x 6.35 (2x 0.25)
100 (3.93)
22.75 (0.89)
18.5 (0.73)
2x 15.5 (2x 0.61)
145.5 (5.72)
3x 5.5 (3x 0.22)
3 x 5.5 (3x 0.22)
2x 15 (2x 0.59)
54 (2.12)
2x 33 (2x 1.3)
2x 31.5 (2x 1.24)
6.35 (0.25)
4x R6 ± 1 mm
6x M5 x 0.8-6H
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 33
Appendix A Specifications
Cat. Nos.
Complete switches, including switch body, actuator and actuator mounting bracket
Cat. No.
Connection
6 in. pigtail with M12 8-pin Quick
Type Actuator Coding
Standard
3 m lead 10 m lead
440G-LZS21SPRA 440G-LZS21SPRB 440G-LZS21SPRH
Disconnect
(Low level to EN/ ISO 14119:2013)
Unique
440G-LZS21UPRA 440G-LZS21UPRB 440G-LZS21UPRH
(High level to EN/
Power-t o-
ISO 14119:2013)
Release
Standard
440G-LZS21SPLA 440G-LZS21SPLB 440G-LZS21SPLH
(Low level to EN/ ISO 14119-2013)
Unique
440G-LZS21UPLA 440G-LZS21UPLB 440G-LZS21UPLH
(High level to EN/
Power-to -Lock
ISO 14119:2013)
Spare actuators and actuator mounting bracket
Type Coding Cat. No.
Standard
440G-LZASPR
(Low level EN/ISO 14119:2013)
Power-to -Relea se
Unique
(High level EN/ISO 14119:2013)
Standard
440G-LZAUPR
440G-LZASPL
(Low level EN/ISO 14119:2013)
Unique
440G-LZAUPL
(High level EN/ISO 14119:2013)
Power-to -Lock
Actuator mounting bracket 440G-LZAM1
Accessories
Description Cat. No.
Switch body mounting bracket 440G-LZAM2
34 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Typical Installations
Mounting bracket
440G-LZAM2
X
Z
Y
Y
X
Actuator Hole 14mm
Locking bolt
9mm
Appendix B
Switch Mounted Parallel to Hinge Axis
The X and Y positions can be adjusted using the slotted holes of the mounting bracket and appropriate selection of the three pairs of actuator bracket holes, once the bracket is centered.
The tolerance to misalignment is ±2.5 mm.
The Z (height) position is adjusted by sliding the actuator bracket up/ down on the profile. If the setting gap is centered between the minimum of 0 mm and the maximum of 5 mm, a tolerance to misalignment of ±2.5 mm is achieved.
The Z position should be carefully selected to offset the anticipated door sag or door drop. At the same time, ensure that the alignment is such that it is not possible to lift the door up and off the locking bolt. Also make sure that there is no possibility that the actuator would collide with the switch when the guard door is being closed. It is essential to check the alignment periodically throughout the use of the guard locking switch.
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 35
Appendix B Typical Installations
2 mm (at min. radius)
Minimum radius when guard hinge axis is perpendicular to the switch body axis
Min R 300 mm
Mounting bracket
440G-LZAM2
X
Z
Y
Switch Mounted Perpendicularly to Hinge Axis
The Z (height) position is adjusted by sliding the actuator bracket up/ down on the profile. If the setting gap is centered between the minimum of 0 mm and the maximum of 5 mm, a tolerance to misalignment of ±2.5 mm is achieved.
The X and Y positions can be adjusted using spacers underneath the switch and appropriate selection of the three pairs of actuator bracket holes, once the bracket is centered.
The tolerance to misalignment is ±2.5 mm.
The Z position should be carefully selected to offset the anticipated door sag or door drop. At the same time, ensure that the alignment is such that it prevents lifting the door up and off the locking bolt. Also check to ensure there is no possibility that the actuator would collide with the switch when closing the guard door. It is essential to check the alignment periodically throughout the use of the guard locking switch.
Z
Y
X
Switch Mounted to a Sliding Guard Door
36 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
The Z (height) position is adjusted by sliding the actuator bracket up/ down on the profile. If the setting gap is centered between the minimum of 0 mm and the maximum of 5 mm, a tolerance to misalignment of ±2.5 mm is achieved.
The X and Y positions can be adjusted using the slotted holes of the mounting bracket and appropriate selection of the three pairs of actuator bracket holes, once the bracket is centered.
The tolerance to misalignment is +/- 2.5 mm.
Typical Installations Appendix B
EU Declaration of Conformity
Identification of the product:
Guard Locking Safety Switch
Name and address of the manufacturer:
Rockwell Automation, Inc. 2 Executive Drive Chelmsford, MA 01824 USA
Name and address of the authorised representative:
Rockwell Automation B.V. Rivium Promenade 160 2909 LM Capelle aan den Ijssel The Netherlands
This declaration of conformity is issued under the sole responsibility of the manufacturer.
Object of the declaration:
Allen Bradley / Guardmaster 440G-LZ21 Series
(reference the attached list of catalogue numbers)
The object of the declaration described above is in conformity with the relevant EU harmonisation legislation: 2004/108/EC
EMC Directive
(EMC)
2006/42/EC
Machinery Directive
(MD)
References to the relevant harmonised standards used or references to the specifications in relation to which conformity is declared:
EN 60947-1:2007
Low-voltage switchgear and controlgear – Part 1: General rules
EN 60947-5-3:1999 + A1:2005
Low- voltage switchgear and controlgear – Part 5-3: Control circuit devices and switching elements – Requirements for proximity devices with defined behaviour under fault conditions (PDF)
EN 60204-1:2006 + A1:2009
Safety of Machinery – Electrical equipment of machines – General requirements
IEC 61508: Part 1-7:2010
Functional Safety of electrical /programmable electronic safety related systems
EN ISO 13849-1:2008
Safety related parts of control systems – Part 1: General principles of design
EN 62061:2005
Safety of Machinery – Functional safety of safety related electrical, electronic and programmable electronic control systems
EN ISO 14119:2013
Safety of Machinery – Interlocking devices associated with guards – Principles for design and selection
Notified Body:
TUV Rheinland IndustrieService GmbH 51105 Koln Germany
performed:
EU Type Examination
and issued the certificate:
968/EZ 616.00/13
Additional information:
Person authorised to compile the technical file (MD):
Authorised representative (see details above).
Product Safety Function (MD):
Interlocking devices suitable for use in safety related applications up to PLe (EN ISO 13849-1) and SIL/SIL CL (EN 61508/EN 62061)
Signed for and on behalf of the above named manufacturer:
Place and date of issue:
Milwaukee, WI USA
11-Nov-2013
Name, function:
Daniel L. Nachtigall, Technical Leader – Product Certification Engineering
Signature:
Rockwell Automation Publication 440G-UM001A-EN-P — November 2013 37
Appendix B Typical Installations
Catalogue number
Series 1
Description
Directive 2
EMC
MD
440G-LZ21****
Guard locking RFID non-contact safety switches
Yes
Yes
Accessories
889D-F8AB-*
Cordset for use with sensors with Micro (M12) connector
N/R
N/R
889D-F8ABDM-*
Patchcord for use with sensors with Micro (M12) connector
N/R
N/R
1) If no series number is given, then all series are covered
2) Yes = Product is certified to this directive. N/R = This directive is not required for this product
NOMENCLATURE:
440G-LZS21
U P R
H
1 2 3 4 5
1
Designates Product Type 440G-LZS21 – Guard locking RFID non-contact safety switch w/2 safety outputs and 1 auxiliary output
2
Designates Actuator Coding Type U – Unique S – Standard code
3
Designates Sensor Type P – Plastic Switch
4
Designates Lock Mode R – Power to release L – Power to lock
5
Designates Connection Type H – 8 pin micro (M12) connector pigtail A – 3 meter cable B – 10 meter cable
38 Rockwell Automation Publication 440G-UM001A-EN-P — November 2013
Power, Control and Information Solutions Headquarters
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel : (1) 414.382.2000, Fa x: (1) 414.382.4444 Europe/Middle East/Africa: Rockwell Automation NV, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacic: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel : (852) 2887 4788, Fax: (852) 2508 1846
www.rockwel lautomation.com
Rockwell Automation Support
Rockwell Automation provides technical information on the web to assist you in using its products. At http://www.rockwellautomation.com/support notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at
http://www.rockwellautomation.com/knowledgebase
forums, software updates, and to sign up for product notification updates.
, you can find technical manuals, technical and application
for FAQs, technical information, support chat and
For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer
SM
Tec hCon ne ct Rockwell Automation representative, or visit http://www.rockwellautomation.com/support/
support programs. For more information, contact your local Allen-Bradley distributor or
.
Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.
United States or Canada 1.440.646.3434
Outside United States or Canada
Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/
phone_en.html, or contact your local Rockwell Automation representative.
New Product Satisfaction Return
Rockwell Automation tests all of its products to ensure they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.
United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to
obtain one) to your distributor to complete the return process.
Outside United States Please contact your local Rockwell Automation representative for the return procedure.
Rockwell Automation, Allen-Bradley, and POINT I/O are trademarks of Rockwell Automation, Inc. Guardmaster is a registered trademark of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are the property of their respective companies.
Publication 440G-UM001A-EN-P– November 2013 Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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