Rockwell Automation Guardmaster Guard Locking Switch User Manual

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Guardmaster Guard Locking Switch

Catalog Numbers 440G-MZS20SNRJ, 440G-MZS20UNRJ, 440G-MZS20SNLJ, 440GMZS20UNLJ

User Manual

Original Instructions

Guardmaster Guard Locking Switch User Manual

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).

2 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Preface

Who Should Use This Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Purpose of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 1

Product Overview Guardmaster 440G-MZ Safety Switch Overview. . . . . . . . . . . . . . . . . . . . . 7

Guard Locking on Power to Release Versions. . . . . . . . . . . . . . . . . . . . 8

Guard Locking on Power to Lock Versions . . . . . . . . . . . . . . . . . . . . . . 8

Assembly Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Chapter 2

Safety Concept Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 3

Installation General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Correct Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Switch Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Actuator Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pair Proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Environmental Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Mount the Switch and Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Auxiliary Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Padlock Accessory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

OSSD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

GuardLink Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 4

Wiring and System Integration Pin Assignment and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

OSSD Mode Safety Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

GuardLink Mode Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

GuardLink System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Add Device to a Studio 5000 Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Upload Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Manual Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Lock Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

OSSD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

GuardLink Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 3

Table of Contents

Chapter 5

Commission the Safety Switch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

First-time Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Learn Additional Replacement Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Lock the Actuator Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Error Codes during the Commissioning Process . . . . . . . . . . . . . . . . . . . 26

Chapter 6

Device Status and Troubleshooting

Status Indicators during Power-up Routine . . . . . . . . . . . . . . . . . . . . . . . 27

Status Indicators During Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Diagnostic/Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Mounting Holes of the Switch Body Cracked or Broken . . . . . . . . . 30

Chapter 7

Application Examples Wire to GLP Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Circuit Status as Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Safely-limited Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Wire to GLT Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Wire to DI and EMD Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Circuit Status as Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Wire to DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Wire to CR30 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Wire to POINT Guard I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Wire to ArmorBlock Guard I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Wire to MSR55P Back EMF Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Appendix A

Specifications Safety Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Outputs (Guard Door Closed and Locked) . . . . . . . . . . . . . . . . . . . . . . . . . 52

Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Compliance to European Union Directives . . . . . . . . . . . . . . . . . . . . . . . . 53

Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

4 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Preface

Who Should Use This Manual?

Purpose of This Manual

Summary of Changes

Use this manual to design, install, program, or troubleshoot systems that use the Guardmaster® 440G-MZ Guard Locking Safety Switches.

You are required to have a basic understanding of electrical circuitry and familiarity with safety-related control systems. If you do not, obtain the proper training before using this product.

This manual is a reference guide for the Guardmaster 440G-MZ safety switch. It describes the procedures that you use to install, wire, and troubleshoot your switch. This manual accomplishes the following:

• Explains how to install and wire your 440G-MZ safety switch

• Provides an overview of the Guardmaster 440G-MZ safety switch

This publication contains the following new or updated information. This list includes substantive updates only and is not intended to reflect all changes.

Top ic Page

Added FCC and IC certification information 53

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 5

Preface

Ter mi no logy

The Industrial Automation Glossary (publication AG-QR071) contains terms and abbreviations that are used by Rockwell Automation to describe industrial automation systems. Table 1

lists specific terms and abbreviations that are

used in this manual.

Table 1 - Terms and Abbreviations

Term Definition

CLU (Command, Lock, and Unlock)

HI Logic state of being ON or a voltage level to be above the turn-on threshold. LO Logic state of being OFF or a voltage level to be below the turn-off threshold. NC No connection

Operational state

OSSD (Output Signal Switching Device)

PLC A programmable logic controller or a programmable automation controller. Reaction time Describes the time between the true state of the input to the ON state of the output.

Response time

RFID Radio frequency identification

Safe state

Standard coding Same as Low coding as defined in ISO 14119

Tap

Unique coding Same as High coding as defined in ISO 14119

This signal is either static or dynamic. When static, this signal is LO when the system is operational and HI when a demand is placed on the safety system. The signal is dynamic when an unlock or lock command is issued to a GuardLink-enabled guard locking device, such as a 440G-MZ safety switch.

The switch is in operational state when there is no demand on its safety function (that is, the switch is closed and locked).

Typically a pair of solid-state signals pulled up to the DC source supply. The signals are tested for short circuits to the DC power supply, short circuits to the DC common, and short circuits between the two signals.

Describes the time between the trigger of the input to the OFF state of the output. Throughout this manual, the safety outputs may be described as turning off immediately, which means that the safety outputs turn off within the response time.

The switch is in safe state when there is a demand on its safety function (that is, the switch is unlocked).

A connection in a GuardLink® circuit that associates a safety device to the GuardLink circuit.

Additional Resources

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

Resource Description

440G-MZ Guard Locking Switch Installation Instructions, publication 440G-IN018

Guardmaster EtherNet/IP Network Interface User Manual, publication 440R-UM009

Guardmaster DG Safety Relay and GuardLink System User Manual, publication 440R-UM015

EtherNet/IP Network Devices User Manual, publication ENET-UM006

Ethernet Reference Manual, publication ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.

System Security Design Guidelines Reference Manual, publication SECURE-RM001

Industrial Components Preventive Maintenance, Enclosures, and Contact Ratings Specifications, publication IC-TD002

Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control, publication SGI-1.1

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system. Product Certifications website, rok.auto/certifications

. Provides declarations of conformity, certificates, and other certification details.

Provides general guidelines for installing a Rockwell Automation® guard locking switch.

Provides a detailed description of module functionality, configuration, installation procedure, and information on how to use the Guardmaster EtherNet/IP Network Interface (440R-ENETR).

Provides general guidelines for configuring a Rockwell Automation Guardlink safety system.

Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP™ network.

Provides guidance on how to conduct security assessments, implement Rockwell Automation products in a secure system, harden the control system, manage user access, and dispose of equipment.

Provides a quick reference tool for Allen-Bradley industrial automation controls and assemblies.

Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides general guidelines for the application, installation, and maintenance of solid-state control in the form of individual devices or packaged assemblies incorporating solid-state components.

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

6 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Product Overview

Chapter 1

Guardmaster 440G-MZ Safety Switch Overview

This 440G-MZ Guardmaster® safety switch locks a guard door in the closed position and does not release it until the hazardous machine functions that are covered by the guard are in a safe condition. The safety control system allows the hazardous machine functions to operate only when the guard is closed and locked.

The locking bolt drive mechanism and logic confirm that the locking bolt is allowed to extend only when the corresponding actuator is detected within range.

RFID technology enables high precision operation while meeting the requirements to prohibit actuator substitution as described in ISO 14119. The 440G-MZ safety switches are classified as Type 4 interlocking devices with guard locking and the unique coded actuators are classified as having a high level of coding according to ISO 14119.

The 440G-MZ safety switch features two OSSD outputs or a single-wire safety output when connected in a GuardLink® system. These safety outputs are enabled only when the locking bolt is sensed in its extended position. This action only happens when the guard is both closed and locked.

The locking bolt drive mechanism uses a bi-stable solenoid. As a result, the switch consumes little electrical power, with peak currents occurring (only briefly) on startup and after each movement of the locking bolt.

Because of its bi-stable drive, not only does the device consume minimal power, but it also does not produce heat while it is locked or unlocked.

Although the locking bolt drive uses a bi-stable solenoid, the device logic and functionality are configured to replicate the functionality of a Power to Release or Power to Lock solenoid-operated switch (depending on type).

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 7

Chapter 1 Product Overview

Actua tor

LINK and DEVICE

status indicators

Guard Locking on Power to Release Versions

With a Power to Release switch, the locking bolt extends when the guard is closed with the actuator inserted in the switch and a lock command is issued to the switch:

Table 2 - Lock Command

Mode Description

OSSD The lock signal (pin 5) is connected to 0V DC

GuardLink® A lock command is issued to the switch on the CLU signal from a GuardLink safety master.

IMPORTANT If power is removed from a Power to Release switch in the locked position, the

locking bolt remains in its extended position (switch locked). Use the auxiliary release to unlock the switch.

ATTENTION: Under normal operating conditions, the locking bolt does not extend in the absence of the actuator. The only exception is when power is removed from a switch in the first 4 seconds of the start-up sequence. In this case, the bolt does extend. If the guard door is closed when the start-up sequence is interrupted, the guard door is locked. Use the auxiliary release to unlock the switch.

Guard Locking on Power to Lock Versions

With a Power to Lock switch, the locking bolt extends when the guard is closed with the actuator inserted in the switch and a lock command is issued to the switch:

Table 3 - Lock Command

Mode Description

OSSD The lock signal (pin 5) is connected to 24V DC

GuardLink A lock command is issued to the switch on the CLU signal from a GuardLink safety master.

IMPORTANT If power is removed from a Power to Lock switch or a fault occurs while in the

locked position, the bolt retracts and the switch unlocks.

Assembly Overview

8 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 1 Product Overview

Product Selection

Table 4 - Catalog Number Explanation

440G-MZS 20 S N R J

abc de

abcde

Outputs (Safety/

Auxiliary)

Code Description Code Description Code Description Code Description Code Description

20 Two safety/no aux SStandard code N No auxiliary R Power to Release J M12 5-pin

Actuator Code Auxiliary Type Lock Type Connection Type

U Unique code L Power to Lock

Table 5 - Complete Switches, including Switch Body and Actuator

Type Actuator Coding Escape Release Cat No.

Power to Release

Power to Lock

Standard (Low level to ISO 14119)

Unique (High level to ISO 14119)

Standard (Low level to ISO 14119) 440G-MZS20SNLJ

Unique (High level to ISO 14119)

440G-MZS20SNRJ 440G-MZS20UNRJ

440G-MZS20UNLJ

Table 6 - Spare Actuators

Description Cat. No.

Standard code actuator (Low level to ISO 14119)

Unique code actuator (High level to ISO 14119) 440G-MZAU

440G-MZAS

Table 7 - Accessories

Description Cat. No.

L-shaped

Actuator mounting bracket

Z-shaped

Switch mounting bracket 440G-MZAM3

Padlock accessory

440G-MZAM1

440G-MZAM2

440G-MZAL

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 9

Chapter 1 Product Overview

Package Contents

The box includes the following components:

Description Photo

Switch Body

Actuator

Installation Instructions:

publication 440G-IN018

10 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Safety Concept

Chapter 2

Safety Standards

Safety Certification

The Guardmaster® 440G-MZ safety switch satisfies applicable requirements in the following standards that are related to functional safety and machinery assembly:

• IEC 60947-5-3

•IEC 61508

•IEC 62061

•EN ISO 13849-1

• ISO 14119

•UL 508

The 440G-MZ safety switch 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, and Performance Level e (PLe) Category 4 in compliance with ISO 13849-1.

Safety requirements are based on the standards applicable at the time of certification.

The TÜV Rheinland group has approved the 440G-MZ safety switch for use in safety-related applications where PLe is required for the door position monitoring and guard locking functions.

The 440G-MZ safety switch must be installed in accordance with the applicable regulation and standards.

While the 440G-MZ safety switch can be used for SIL 3, PLe, and Category 4 applications, the installation must comply with guard requirements (for example, ISO 13854 and ISO 13857), and in some cases minimum (safe) distance requirements (for example, ISO 13855).

The installed system, including the safety control system and the means by which the machine stops, must achieve the needed safety performance. The 440G-MZ safety switch is one element in the safety system.

Additional guidance on guards, guard locking and guard interlock can be found in:

• EN ISO 12100

•EN ISO 13854

•EN ISO 13855

•EN ISO 13857

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 11

• EN ISO 14119

• EN ISO TR 24119

• EN ISO 14120

• Application-specific C-level standards

Chapter 2 Safety Concept

Notes:

12 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Installation

Chapter 3

General Considerations

Correct Use

Installation must be in accordance with the present manual and implemented by qualified personnel exclusively. The 440G-MZ safety switch is intended to be part of the safety-related control system of a machine.

ATTENTION: 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. A functional test of the system is necessary to validate that it works as expected (see Functional Testing on page 17 Guard locking switches that use the Power to Lock principle (Cat. No. 440G-MZS20*NLJ*) must only be used after a risk assessment has shown that the use of a Power to Release principle (Cat. No. 440G-MZS20*NRJ*) is inappropriate. This assessment is necessary since the guard can be immediately opened after a loss of power supply or upon deactivation of the unlocking signal.

Review the following requirements and guidelines for proper use of the safety switch to achieve optimal performance.

• The 440G-MZ safety switch is designed for use on medium- and fullsized guards including guards where whole-body access to the safeguarded area is possible.

• The switch is not to be used as a mechanical stop. Check that a separate door stop is used.

• A separately mounted latch (for example, magnetic or mechanical) is recommended to maintain proper alignment of the actuator. The locking bolt must be free to enter and withdraw from the actuator without binding.

• Use appropriate screws, bolts, or nuts that are fitted by tools to mount the switch and actuator to avoid tampering.

• Do not over torque the mounting hardware.

• A minimum distance of 100 mm (3.94in.) must separate adjacent switches, see Pair Proximity on page 14

• The 440G-MZ safety switch is designed for use in a NEC Class 2 circuit. Connect the 440G-MZ safety switch to a dedicated Class 2 power supply or use electronic circuit protection (for example, 1692-ZRCLSS) to achieve NEC Class 2 compliance.

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.

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 13

Chapter 3 Installation

100 (3.94)

Switch Orientation

Actuator Orientation

Can be used in all mounting orientations.

The actuator can approach the switch from three directions (Figure 1).

Figure 1 - Three Directions of Approach

Pair Proximity

The flexible actuator can move in multiple axes to accommodate guard door misalignment (Figure 2

). For optimal performance, verify that the locking bolt can enter and withdraw from the tongue actuator without binding. A separately mounted door latch is recommended to avoid door misalignment.

Figure 2 - Actuator Function

If a pair of 440G-MZ safety switches are mounted too close to one another, the two electromagnetic fields interact causing crosstalk, which can result in nuisance faults and false operation.

A minimum of 100 mm (3.94 in.) must separate a pair of switches to help achieve correct operation (Figure 3 on page 14

Figure 3 - Minimum Distance between Switches [mm (in.)]

IMPORTANT If the minimum separation distance is not observed, the electromagnetic fields

14 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

interact causing crosstalk. Crosstalk can result in nuisance faults and false operation.

Chapter 3 Installation

3 x M5

2 x M5

Environmental Considerations

Mount the Switch and Actuator

The 440G-MZ safety switch is rated for IP69K in accordance with ISO 20653 and IP69 per IEC 60529. This rating involves a short-term test that is made with high-pressure water jets at 80 °C (176 °F). The test is passed if no water enters the enclosure of the switch that contains the electrical components and the switch function is not impaired.

This rating does not promise protection from any liquids other than water and does not promise the mechanical longevity from continuous or frequent exposure.

ATTENTION: Do not defeat, tamper, remove, or bypass this unit. Severe injury to personnel could result. The presence of spare actuators can compromise the integrity of the safety systems. Personal injury or death, property damage, or economic loss can result. Appropriate management controls, working procedures, and alternative protective measures should be introduced to control their use and availability.

Three M5 fasteners (not provided) are required for proper mounting of the switch to a rigid guard door frame (Figure 4

). Two M5 fasteners (not provided)

are required to mount the actuator.

Figure 4 - Required Mounting Hardware for Switch and Actuator

IMPORTANT Do not use a washer with the screw at the base of the switch body. Using a

washer causes the plastic to crack. Loctite 242 thread-locking adhesive is known to cause stress cracks in the plastic housing of the 440G-MZ safety switch and should not be used. Lab tests

have determined that Loctite 425, a cyanoacrylate adhesive, does not cause cracking and can be considered if the faster cure time is acceptable in the application.

Check the manufacturer specifications of any thread-locking compound used to secure the screws. It is recommended to use a cyanoacrylate-type compound. Other compounds can cause stress cracks in the plastic feet of the switch.

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 15

Chapter 3 Installation

Switch

mounting

bracket

Switch

mounting

bracket

Actuator

Z-shaped Actuator Mounting Bracket

L-shaped Actuator Mounting Bracket

Actuator

Typical Applications

The 440G-MZ safety switch can be mounted on the inside or outside of a hinged or sliding guard door. The following shows three examples of the switch and actuator mounted to a hinged or sliding guard door.

• Mount the switch on the inside of a hinged door

• Mount the switch on outside of a hinged door

• Mount the switch on a sliding door

16 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 3 Installation

5 (0.2)

Top View

Up to three nominal

6.35 mm (0.25 in.) locks

Auxiliary Release

Padlock Accessory

Operation of the auxiliary release causes a fault condition.

To reset the switch, cycle the power or issue a RESET command over the link in a GuardLink® safety system.

Figure 5 - Auxiliary Release Operation [mm (in.)]

The padlock accessory (Figure 6) can be inserted through the actuator opening of the 440G-MZ safety switch to help prevent the locking of the guard door and restarting of the machine while an operator is inside the safeguarded area. The padlock accessory can accommodate up to three nominal 6.35 mm (0.25 in.) locks.

Figure 6 - Padlock Accessory (Cat. No. 440G-MZAL)

Functional Testing

A manual functional test must be made:

•After installation

• After any maintenance or change of component

• If the guard is used infrequently

- Less than once a month for SIL 3, cat. 3 or cat. 4, PLe

- Less than once a year for SIL 2, cat. 3, PLd

ATTENTION: During the functional test, verify that there are no persons in the danger area and that the machine startup does not cause a hazard.

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 17

Chapter 3 Installation

OSSD Mode

1. Confirm that the guard door is open.

2. Connect the 24V DC power to pin 1 and ground (0V) to pin 3. The switch conducts a self-testing routine at the end of which the device status indicator is steady red (if lock signal is set to UNLOCK) or flashing amber (if lock signal is set to LOCK).

3. Test to confirm that the machine cannot start.

4. Confirm the lock signal at pin 5 is set to LOCK (0V for PTR and 24V for PTL types).

5. Test again to confirm that the machine cannot start.

6. Close the guard door and then confirm that the guard is mechanically locked and the device status indicator is steady green.

7. Test to confirm that the machine can start.

8. Change the lock signal at pin 5 to UNLOCK (24V for PTR and 0V for PTL types).

9. Confirm the machine stops, the guard door is mechanically unlocked, and the machine cannot restart.

GuardLink Mode

1. To begin a functional test of the 440G-MZ safety switch when connected in a GuardLink system, all other devices on the link must be in the operational state.

2. Confirm that the guard door is open.

3. Test to confirm that the machine cannot start.

4. Send a lock command to the 440G-MZ safety switch over the link.

5. Test again to confirm that the machine cannot start.

6. Close the guard door.

7. Send a lock command to the switch over the link.

8. Confirm that the switch is mechanically locked and the Device status indicator is steady green.

A flashing green status indicator on the device indicates that another device on the link is tripped. To proceed, verify that all other devices on the link are in operational state.

9. Test to confirm that the machine can start.

10. Send an unlock command to this 440G-MZ safety switch only over the link.

11. Confirm that the machine stops, the guard door is mechanically unlocked, and the machine cannot restart.

18 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Wiring and System Integration

Chapter 4

Pin Assignment and Function

The 440G-MZ safety switch is available with a 5-pin DC Micro M12 quickdisconnect connector. Table 8

shows the pin assignments and their functions and typical mating cordsets. Other cordsets are available at DC Micro Cordsets

and Patchcords.

Table 8 - 5-pin Micro (M12)

Pin Color

1 Brown +24V +24V 2 White Safety A Safety In 3Blue 0V 0V 4 Black Safety B Safety Out 5 Gray Lock Command CLU

(1) The recommended cordset is catalog number 889D-F5AC-2 (2 m [6.5ft]). For additional lengths, replace the 2 with 5 [5 m

(16.4 ft)] or 10 [10 m (32.8 ft)] for standard cable lengths. The recommended patchcord for use with GuardLink® and ArmorBlock® Guard Safety I/O is the 2 m (6.5 ft) catalog number 889D-F5ACDM-2. Replace the 2 with 0M3 [0M3 (0.98 ft)], 1 [1 m (3.28 ft)], 5 [5 m (16.4 ft)], or 10 [10 m (32.8 ft)] for standard cable lengths.

(1)

Function

OSSD Mode GuardLink® Mode

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 19

Chapter 4 Wiring and System Integration

OSSD Mode Safety Signals

In OSSD mode, safety outputs Safety A and Safety B are OFF (0V) when the switch is in safe state (that is, the switch is unlocked). When the switch is in operational state (that is, closed and locked), safety outputs Safety A and Safety B are ON (24V) and contain test pulses. The test pulses are used to detect short circuits to 24V, to 0V and cross faults (from Safety A to Safety B). This description of the test pulses is provided for informational purposes; you cannot modify them.

IMPORTANT To prohibit nuisance tripping, mask the OSSD input channels of the safety

system with an On to Off delay of at least 1 ms.

Figure 7 - Output Test Pulses

OSSD test pulses into a 10K resistive load.

Safety OSSD A

Safety OSSD B

5V/Div

580 μs

26 ms

2ms/Div

GuardLink Mode Safety Signals

GuardLink System Integration

Safety OSSD A

Safety OSSD B

5V/Div

189 ms

20ms/Div

When the 440G-MZ safety switch is connected in a GuardLink system, the safety signals are Safety In and Safety Out. These signals are dynamic signals in operational state and two-way communication signals in the safe state.

ATTENTION: For information on a known anomaly, see Knowledgebase Article

Unlocked 440G-MZ switch on GuardLink doesn't respond to lock command on power up

Figure 8 on page 21 shows the basic components of a GuardLink system with a

DG safety relay master. The 440G-MZ safety switch, with embedded GuardLink technology, connects to the link with a passive tap (as shown in

Figure 8 on page 21

) or a passive power tap (catalog number 440S-PF5D4).

20 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 4 Wiring and System Integration

INPUT

LNK2

LNK1

A2A1

LNK2

LNK1

IP: 192. 168. 1. ABC

S12 S22 S32 S42 A1 A2 S11 S21

X1 X2 X3 X4 13 14 23 24

OUT IN 1

IN X Reset

Cong/Set

Sel./Save

Reset

Time

OUT X

IN 2

PWR/Fault

INPUTINPUT INPUT

4 6

5 5

440G-MZ 440G-MZ

Different types and versions of GuardLink enabled and passive taps can be connected in any order and can be mixed on the same link. For more information about the configuration a GuardLink safety system, see publication 440R-UM015

Both the Power to Release and Power to Lock versions of the 440G-MZ safety switch can be connected to a GuardLink safety system.

Figure 8 - GuardLink System Components

Add Device to a Studio 5000 Project

Item Description Cat. No.

5-pin device patchcord

(1)

2Cordset

889D-F5NCDM-x

889D-F4NE-y

(2) (3)

(4)

3 Terminator 898D-418U-DM2 4 GuardLink passive tap

5 4-pin link patchcords 6 GuardLink enabled tap

440S-PF5D

889D-F4NEDM-x

440S-SF5D

(5) (6)

(3) (7)

(6)

7 EtherNet/IP™ Network Interface 440R-ENETR

8DG Safety Relay

(1) Optional: Device can be connected directly to the passive tap. (2) 10 m (32.8 ft) length, max. (3) Replace x with 0M3 (300 mm [0.98 ft]), 0M6 (600 mm [1.97 ft]), 1 (1 m [3.3 ft]), 2 (2 m [6.6 ft]), 5 (5 m [16.4 ft]), or 10 (10 m

[32.8 ft]) for standard cable lengths.

(4) Replace y in order number with 2 (2 m [6.6 ft]), 5 (5 m [16.4 ft]), 10 (10 m [32.8 ft]), 15 (15 m [49.2 ft]), 20 (20 m [65.6 ft]), or

30 (30 m [98.4 ft]) for standard cable lengths. (5) A passive power tap (Cat. No. 440S-PF5D4) can also be used. (6) Mounting brackets sold separately. Cat. No. 440S-GLTAPBRK1 (pack of 1) or Cat. No. 440S-GLTAPBRK5 (pack of 5). (7) 30 m (98.4 ft) length, max

440R-DG2R2T

Information about how to add a 440G-MZ safety switch to a GuardLink system in a Studio 5000® project can be found in the user manual for the GuardLink safety master. See publication 440R-UM009

for information about using the upload method or manual method to add a 440G-MZ safety switch in a GuardLink circuit controlled by a Guardmaster® DG safety relay.

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 21

Chapter 4 Wiring and System Integration

Upload Method

After the upload is complete, the position and type of connected 440G-MZ safety switches is shown in the Module Definition tab as shown in Figure 9

Figure 9 - Upload Method

Manual Method

With the manual method, a 440G-MZ safety switch can be added to a GuardLink circuit in steps as shown in Figure 10

Figure 10 - Manual Method

1. Right-click the GuardLink and select Add Device.

2. Select the correct catalog number from the device list

22 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 4 Wiring and System Integration

Lock Command

OSSD Mode

Table 9 shows the lock command function. The lock command is a 24V logic

signal with a current of less than 2 mA. The function of the logic signal is dependent on the catalog number.

Table 9 - Lock Command Function

Cat. No. Function Value

440G-MZS20*MR* Power to Release

440G-MZS20*ML*Power to Lock

Catalog codes for both types are explained in Table 4 on page 9

24V = Unlock 0V = Lock

24V = Lock 0V = Unlock

GuardLink Mode

In a GuardLink system, the GuardLink safety master (for example a DG safety relay) issues lock and unlock commands to the 440G-MZ safety switch via the GuardLink Control, Lock, and Unlock (CLU) signal. This signal is either static or dynamic. When static, this signal is LO when the system is operational and HI when a demand is placed on the safety system. The signal is dynamic when an unlock or lock command is issued to the 440G-MZ safety switch.

When multiple guard locking devices are installed in a GuardLink system, the GuardLink safety master inserts a short delay between commands to each successive device to minimize the momentary inrush current to the solenoids. The device closest to the master receives the command first. The device furthest away from the master receives the command last.

See publication 440R-UM015

for more information.

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 23

Chapter 4 Wiring and System Integration

Notes:

24 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 5

Commission the Safety Switch

The 440G-MZ safety switch is available with standard coded actuators or unique coded actuators.

• Switches with standard coded actuators are ready for use and do not require commissioning.

• Switches with unique coded actuators must be commissioned before use. The actuator teach process is not performed at the factory and must be performed when the switch is first put into use. After the firsttime learn, this process can be repeated up to seven more times with unique coded replacement actuators.

IMPORTANT When the switch learns a new actuator, it no longer recognizes previously

learned actuators.

Setup

The 440G-MZ safety switch can be set up in OSSD mode or GuardLink® mode.

IMPORTANT If the 440G-MZ safety switch is connected in a GuardLink system, verify that the

GuardLink is powered ON and the switch is unlocked to insert the actuator and initiate the teach process.

During commissioning, connect the switch as shown in Figure 11

Figure 11 - Wiring

DEVICE

LINK

Brown

White

Black

Gray

Blue

889D-F5NC-x or 889D-F5BC-x

+24V DC NC

NC Gnd 0V

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 25

Chapter 5 Commission the Safety Switch

First-time Learn

Apply power to the switch without the actuator present. After the switch completes the power-sequence (approximately 8 seconds), the status indicator flashes green eight times, indicating the total number of times a new actuator can be learned. This status indicator sequence repeats until an actuator is inserted in the switch (in the guard closed position).

Table 10 - Commissioning Process for Unique Coded Switches

Step State Approximate Duration Status Indicators

1 Actuator Present 15 s

2 Verifying Actuator 15 s Flashing red/green, slow 3 Programming Switch 15 s Flashing red/green, fast

4 Program Finalization 15 s

(1) Out of box condition only. (2) When teaching an actuator, the switch must be unlocked to insert the actuator. At the end of the finalization step, the switch

remains unlocked and in the safe state.

IMPORTANT After teaching a new actuator, a power cycle is required to complete the

Run Mode

(2)

process.

—Steady red

Flashing 8x green, repeating

Steady red (learning a replacement actuator)

Flashing green (number of times a new

actuator can be learned)

(1)

Perform a functional test of the switch to validate that it works as expected (see

Functional Testing on page 17

Learn Additional Replacement Actuators

Lock the Actuator Code

Error Codes during the Commissioning Process

The switch automatically starts a new teach process when a unique coded replacement actuator is inserted in the switch (in the guard closed position).

IMPORTANT When the switch learns a new actuator, it no longer recognizes previously

learned actuators.

If the actuator is removed from the switch and then reinserted into the switch during the 15-second Program Finalization stage (see Step 4 in Table 10

), this action triggers the switch to LOCK the actuator code. This action can be performed during any of the eight unique coded actuator learn cycles.

IMPORTANT After a unique coded actuator is locked using this method, the switch cannot

learn additional replacement actuators for the remaining life of the switch. If the actuator is lost or damaged, the switch must be replaced.

The following indicator patterns repeat until a Power Off/On cycle is completed.

Status/Diagnostic Indicator Error Code

Flashing 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-green Unit locked: cannot learn another actuator

26 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Device Status and Troubleshooting

Chapter 6

Status Indicators during Power-up Routine

Status Indicators During Run Mode

When power is applied to the switch, the DEVICE status indicator is steady red for 2.5 seconds, then the DEVICE and LINK status indicators flash red/green for 1 second, and then the DEVICE status indicator is steady red for 3 seconds. At the conclusion of the start-up sequence, the state of the status indicators is determined by whether there is a demand on the safety function and the status of the lock signal. See Table 11

Table 11 shows the status of the 440G-MZ safety switch during run mode.

Table 11 - Switch Status Indication During Run Mode

Indicator State Description

Steady green

Flashing green @ 1 Hz

Device

(2)

Link

(1) This state occurs when connected to a GuardLink system only (2) The Link status indicator is only used when the 440G-MZ safety switch is connected in a GuardLink system. It is OFF when the

440G-MZ safety switch is connected directly to an I/O device or safety relay (OSSD mode).

Flashing amber @ 1 Hz

Steady red

Flashing red @ 1 Hz The switch is in the fault state.

Off

Steady green

Steady red

Flashing red @ 1 Hz The link is faulted.

The switch is in the operational state with no demand on the safety function (that is, closed and locked).

The switch is in the operational state with no demand on the safety

(1)

function, but the link is in the safe state due to a demand on another device in the link.

The switch is ready to be locked, or attempting to lock. The lock command is set to LOCK but the door is in the open position or slightly ajar. Check that the door is closed.

The switch is in the safe state due to a demand on the safety function (that is, unlocked).

Indicates no communication to the DG safety relay over the link. The switch is wired directly to I/O and is not part of a GuardLink® system.

The link is in the operational state. This switch and all other devices on the link are in the operational state.

The link is in the safe state due to a demand or fault on this switch or another device in the link.

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 27

Chapter 6 Device Status and Troubleshooting

Diagnostic/Fault Codes

When connected in a GuardLink system, the 440G-MZ safety switch communicates information about its current state with diagnostic and fault codes.

Diagnostic codes (Table 12

) warn that a condition exists which prevents the switch from transitioning to the operational state (for example, the switch is a unique coded switch that must be commissioned), or causes the switch to fault (for example, the input voltage is approaching the minimum value) if not addressed.

Fault codes (Table 13 on page 29

) provide information about why the switch is in the faulted state (as indicated by the DEVICE status indicator flashing red.) When a fault is present, perform the recommended action, if stated. Issue a RESET command to the 440G-MZ safety switch over the link to clear the fault.

IMPORTANT When a Power to Lock switch faults in the locked position, the bolt retracts

and the switch unlocks.

Diagnostic Codes

Table 12 - Diagnostic Codes

Decimal

(Hex)

00 (00) No diagnostic No action required.

04 (04)

31 (1F) Ready to lock

32 (20) Device is attempting to lock

33 (21)

38 (26) Actuator not paired

40 (28) Guard door open

Description Recommended Action

Input voltage is approaching

minimum (20.4V DC)

Device is attempting to

unlock

Evaluate input voltage. Input voltage must be 20.4…26.4V under all electrical load conditions.

A lock command has been sent to the device but the guard door is open or ajar. Check the actuator alignment or close the guard door.

Check actuator alignment. Check the wiring for the lock feedback input.

Check for load on actuator or bolt. Check the wiring for the lock feedback input.

Unique coded switch has not been paired with an actuator yet. Insert a unique coded actuator (Cat. No. 440G-MZAU) to start the commissioning process.

The actuator is not detected (RFID is not present). Close the guard door to lock.

28 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Fault Codes

Table 13 - Fault Codes

Chapter 6 Device Status and Troubleshooting

Decimal

(Hex)

00 (00) No fault. No action required.

05 (05) Power error

07 (07)

08 (08) Internal memory (ROM) fault Internal memory fault. Reset the device. If error persists, replace it. 09 (09) Runtime memory (RAM) fault Internal memory fault. Reset the device. If error persists, replace it.

10 (0A) Internal memory (CPU) fault Internal memory fault. Reset the device. If error persists, replace it. 15 (0F) No response on GuardLink Check GuardLink wiring and connections.

31 (1F) GuardLink application fault GuardLink system fault. Reset the device. If error persists, replace it.

32 (20) Product application fault Product Application fault. Reset the device. If error persists, replace it.

40 (28)

41 (29) Invalid actuator detected Cannot teach a standard actuator to a unique coded switch.

42 (2A) No learns left

43 (2B) Actuator relearn Switch cannot learn a previously learned actuator. Use a new actuator.

44 (2C) Actuator teach fault

56 (38) Bolt detection fault

57 (39) Failure to lock

58 (3A) Failure to unlock

59 (3B) Actuator detection fault

255 (FF) Internal fault

Description Recommended Action

Evaluate input voltage. Input voltage must be 20.4…26.4V under all electrical load conditions.

Failure to detect device type

(OSSD or GuardLink)

Unique code actuator is

locked

Check wiring and cycle power to the switch. If error persists, replace the switch.

A new actuator cannot be learned because the current actuator is locked.

Teaching is not possible. The switch has learned 8 actuators and cannot learn any more actuators.

Actuator moved out of range during teach process or the switch has detected an invalid RFID tag. Keep actuator within sensing range during learn process.

During operational state, the device failed to detect the bolt. On escape release models, this fault can be caused by engaging the escape release. It can also occur if the auxiliary release was actuated. Inspect the bolt. Disengage the escape release mechanism (if applicable). Reset the device if the fault is not cleared.

Device attempted to lock for specified lock attempt length, but lock status input did not indicate that the device locked. Check guard door and actuator alignment.

Device attempted to unlock for specified unlock attempt length, but lock status input did not indicate that the device unlocked. Check the device. Verify that door is not applying a side load on the locking bolt.

During operational state, the device failed to detect the RFID tag in the actuator. Inspect the actuator and RFID tag for signs of damage. Fault reset the device. If the error persists, replace the actuator.

An internal device fault has occurred. Reset the device. If error persists, replace it.

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 29

Chapter 6 Device Status and Troubleshooting

Troubleshooting

Mounting Holes of the Switch Body Cracked or Broken

The mounting hole of the switch body can crack when washers are used to mount the switch or when an incompatible thread locking compound is used to secure the mounting hardware. Three M5 fasteners are required to mount the switch body properly. Do not over torque the screws.

IMPORTANT Do not use a washer with the screw at the base of the switch body. Using a

washer causes the plastic to crack. Loctite 242 thread-locking adhesive is known to cause stress cracks in the plastic housing of the 440G-MZ safety switch and should not be used. Lab tests

have determined that Loctite 425, a cyanoacrylate adhesive, does not cause cracking and can be considered if the faster cure time is acceptable in the application.

30 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 7

800FM-MT44

GLP

A2 11L22S21S

L12

L61

P12 P22

45S44S

42X41X

Y32

S11

S12 S21 S22

S32 S42 L11 L12

S34

A1 13

A2 142324 Y32

440R-D22R2

LOGIC

LOGIC SL1 SL2

440R-GL2S2P

SLS Request to PAC

Reset & Lock Request

Unlock Request

800FM-MT44

872C-D8NP18-E5

Blue

Brown Brown

Black

+24V DC

COM

Status

Safety Input 1

Safety CO M

Safety Input 2

Kinetix® 300 Drive

Safe Torque-o (STO) Connector with Wiring H eader

Safety Status to PAC

K300 Status to PAC

Stop/Start/SLS from PAC

Brown

White

Black

Blue

Gry

+24V DC, Class 2, PELV

24V DC COM

440G-MZS20*NR*

889D-F5NC-X

Reset

Application Examples

The following application and wiring examples are intended to show how the 440G-MZ safety switch products can be applied. If you are the user or the designer, you may require variations to these examples to meet your specific requirements.

Wire to GLP Safety Relay

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 31

The GLP safety relay is designed to operate with Power to Release (PTR) switches. To use a Power to Lock (PTL) switch, you must use an interposing relay on the lock command at GLP terminal 51. In the example shown in

Figure 12

, the GLP safety relay allows the gate to be unlocked when the motor is

running at a Safely-limited Speed.

Figure 12 - GLP and 440G-MZ Safety Switch Schematic

Chapter 7 Application Examples

Circuit Status as Shown

The gate is open and unlocked. The motor is off. The GLP safety relay is ready for reset. The GLP safety relay has a Logic setting of 3: (Safely-limited Speed with Logic IN OFF), a Safely-limited Speed (SLS1) setting of 5 (5 Hz) and a maximum (SLS2) speed setting of 8 (2000 Hz). The safety outputs (X14 & X24), the single wire safety output (L11), and the auxiliary output (Y32) are OFF.

IMPORTANT Start the GLP logic configuration from “0” to configure X14 and X24 for use as

safety outputs.

Starting

Close the gate and press Reset to lock the gate and turn on the GLP safety outputs. Press Start to turn the motor ON.

Safely-limited Speed

A normal production stop is performed by pressing Stop. Access through the safety gate is initiated by pressing Gate Unlock Request. The Y32 output of the GLP safety relay turns ON, which makes an SLS request to the PAC. The PAC commands the Kinetix® drive to bring the motor to a safe slow speed. When the proximity sensors detect the speed has dropped below the Safely-limited Speed (5 Hz), the gate becomes unlocked. The operator can enter the machine cell, as the motor continues to run at the safe slow speed. After you leave the cell and close the gate, press Reset to lock the gate and return the machine to production speeds.

The circuit meets the safety requirements up to Category 3, Performance Leveld in accordance with ISO 13849-1 and SIL CL 2 in accordance with IEC 62061.

32 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 7 Application Examples

Blue (Gnd)

Brown (+24)

24V DC Com

Gate Unlock Request

Reset and Gate Lock Request

GLT

440R-GL2S2T

A2S12 S22B2L61

L12

A145S

44S21S11S

L11

Y32

LOGIC

TIME

RANGE

Gate control

power supply

Gate control

circuit

S1 S2

1 Stop

PowerFlex

525

2 Start

4 Gnd

11 +24V DC

440G-MZS20*NR*

Power to Release

No aux

14 24

Gray - Lock Cmd

White - OSSD 1 Black - OSSD 2

889D-F5NC-X

Safety Gate

440G-MZ

UVW

L1 L2 L3

+24V DC, Class 2, PELV

3 4

RS T

Wire to GLT Safety Relay

The GLT safety relay is designed to operate with PTR switches. To use a PTL switch, you must use an interposing relay on the lock command at terminal 51 of the GLT safety relay.

In this example shown in Figure 13

, the GLT safety relay sends an immediate command to the drive to turn OFF. After 8 seconds, the GLT safety relay turns off its safety outputs and unlocks the gate. The risk assessment must determine adequate time delay for the machine to achieve a safe state before unlocking the gate.

Figure 13 - GLT and 440G-MZ Safety Switch Schematic

Circuit status as shown: The gate is open and unlocked. The motor is off. The GLT safety relay is ready for reset. The GLT safety relay has a Logic setting of 3: (Category 1 Stop), a Range setting of 4 (10 seconds) and a Time setting of 8 (80%). The Y32 output turns OFF immediately; 8 seconds later, the safety outputs turn OFF.

The safety outputs (14 and 24) and the single wire safety output (L11) are OFF and the auxiliary output (Y32) is ON.

IMPORTANT Start the GLT logic configuration from 0 to configure 14 and 24 for use with

Starting

Close the gate. Press Reset and Gate Lock Request to lock the gate and turn on the GLT safety outputs. Press Start to turn the motor ON.

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 33

pulse testing; the PowerFlex® 525 drive can operate with pulse tested inputs to S1 and S2.

Chapter 7 Application Examples

Stopping

Normal production stops are performed by pressing Stop. Access through the safety gate is initiated by pressing the Gate Unlock Request. The Y32 output of the GLT safety relay turns OFF, which commands the PowerFlex® drive to bring the motor to a stop. After the configured time delay (8 seconds) expires, the GLT safety outputs turn off, and the gate becomes unlocked. After you leave the cell and close the gate, press Reset to lock the gate and return the machine to a production state.

The circuit meets the safety requirements up to Category 3, Performance Leveld in accordance with ISO 13849-1 and SIL CL 2 in accordance with IEC

62061.

34 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 7 Application Examples

Power

n1 In 2 O

gic

L12

L11

IN1

LOGIC

Test O

L12

L11

X32

EMD

E-stop

Reset

nlock

S11

S21

S12

S22 S32 S42

Y32 S34

TIME

RANGE

Brown

Blue

Gray

White Black

Brown = +24V DC White = OSSD 1 Black = OSSD 2 Blue = 24V DC COM Gray = Lock CMD

L1 L2L3

440G-MZS20*NR*

+24V DC, Class 2, PELV

24V DC COM

Wire to DI and EMD Safety Relay

The 440G-MZ safety switch can be connected to the DI and EMD safety relays. The DI safety relay monitors the safety outputs of the safety switch and the EMD enables the gate to be unlocked after a configured delay time expires.

B1 is connected to B2 to allow for retriggering. If you open and close the E-stop and press Reset before the delay expires, the EMD timer resets.

Upon initial power-up, the safety switch must be cycled for the DI to recognize the safety switch OSSD signals.

In the example shown in Figure 14

, an E-stop initiates the machine shutdown. After an eight-second delay, the safety switch is allowed to be unlocked and the hazards that remain are turned OFF. A selector switch is required to maintain the gate in an unlock state. The risk assessment must determine adequate time delay for the machine to achieve a safe state before unlocking the gate.

Figure 14 - DI Safety Relay with EMD Safety Relay and 440G-MZ Safety Switch Schematic

Circuit Status as Shown

The E-stop is released. The gate is open and unlocked. K1 and K2 are OFF. The DI safety relay is configured for two inputs with monitored manual reset. The EMD safety relay is configured for 8-second off-delay; Range setting of 2 is 10

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 35

s, Time setting of 8 is 80% of the range. The X32 terminal is ON because the EMD safety outputs are OFF.

Chapter 7 Application Examples

Starting

With the Unlock switch open, close the gate. Press Reset to lock the gate and turn on the K1…K4 safety contactors.

Stopping

Stopping is initiated by pressing the E-stop. K1 and K2 contactors turn off immediately. The single wire safety signal from the DI safety relay (L11) to the EMD safety relay (L12) also turns off immediately, and the EMD starts the offdelay timer. After 8 seconds, X32 goes to 24V. The unlock switch is enabled, and the gate can be unlocked. While the gate is unlocked, the DI safety relay cannot turn the safety outputs back ON. After you leave the cell and close the gate, open the unlock switch to lock the gate, and release the E-stop.

The circuit can meet the safety requirements up to Category 4, Performance Level e in accordance with ISO 13849-1 and SIL CL 3 in accordance with IEC62061.

36 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 7 Application Examples

L2 L3

Status

Control

Machine

Control System

24V DC Com

S32 X3

14S42

13 23

S11

S22

440R-DG2R2T

440R-ENETR

Status

TIME

S12

S21

440S-PFSD

440S-PFSD 440S-PFSD

889D-F5NCDM-X 889D-F5NCDM-X

889D-F5NCDM-X889D-F5NCDM-X

440G-MZS20*NR* 440G-MZS20*NR*

+24V DC, Class 2, PELV

Brown

Blue

White

Black

889D-F4NE-X

Brown

Blue

White

Black

Wire to DG Safety Relay

The 440G-MZ safety switch can be used in GuardLink® applications. The GuardLink system:

• Is designed to operate with Power to Release switches.

• Uses taps to connect a series of devices to one relay.

• Provides control and status information between the machine control system and the safety system.

Figure 15

shows four 440G-MZ safety switches that are connected on two GuardLink circuits from one DG safety relay. The DG safety relay can accommodate up to 32 devices on each input. The devices can be a mix of many different safety devices. When guard locking devices are included in the GuardLink system, the lock/unlock command must come from the machine control system through the 440R-ENETR module.

See publication 440R-UM015 for further details.

Figure 15 - DG Safety Relay with 440G-MZ Safety Switch Schematic

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 37

Chapter 7 Application Examples

CR30

4030001020

A1 15 20 21160618A2

071908 10 11

12 13 14

24V DC Com

Reset

440C-CR30-22BBB

Unlock

Motor Not Running

Lock

Gate control

power supply

Gate control

circuit

4 Gnd

S1 S2

1 Stop

11 +24V DC

PowerFlex

525

2 Start

t081=2

Blue (Gnd)

Brown (+24)

440G-MZS20*NR*

Power to Release

No aux

Gray - Lock Cmd

White - OSSD 1

Black - OSSD 2

889D-F5NC-X

Safety Gate

+24V DC, Class 2, PELV

L1 L2L3

VUW

Wire to CR30 Safety Relay

The CR30 safety relay is a software configurable safety relay that can easily interface with the 440G-MZ safety switch. Version 10 and later of the Connected Components Workbench™ software has a locking function that is useful for guard locking applications.

Figure 16

shows an example schematic. The CR30 safety relay monitors the motor running signal from the PowerFlex 525 drive. When the motor is not running, the safety gate can be unlocked, and the PowerFlex 525 drive goes to a Safe Torque Off state.

Figure 16 - CR30 Safety Relay with 440G-MZ Safety Switch Schematic

Figure 17 on page 39 shows an example CR30 safety relay configuration that

works with the schematic in Figure 16

38 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 7 Application Examples

The safety switch OSSD outputs drive the Safe Torque Off (STO) signals of the PowerFlex 525 drive. The STO is enabled after the gate is locked and the Reset is pressed. The PowerFlex 525 drive STO inputs can tolerate the pulse test that is generated by the CR30 outputs.

The Lock_Ctrl_1 block controls the unlock command to the safety switch. The unlock Stop Time delay is set to 5 seconds, and the ULR Latch (Unlock Request) is set to ON. When an unlock request is made, the command is issued 5 seconds after the motor stops running, and the unlock request is latched ON.

Figure 17 - CR30 Configuration in CCW

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 39

Chapter 7 Application Examples

Wire to POINT Guard I/O Module

Figure 18 shows a wiring example of a 440G-MZ Power to Release safety switch

that is connected to a 1734 POINT Guard I/O™ module.

Figure 18 - 1734 Module and 440G-MZ Safety Switch Schematic

440G-MZ

440G-MZS20*NR*

Power to Release

No aux

889D-F5NC-X

Black - OSSD 2

White - OSSD 1

Blue (Gnd)

Gray - Lock Cmd

Brown (+24)

Safety Gate

Ethernet I/P

to GuardLogix®

PLC and HMI

24V DC Com

+24V DC

263

I2T0I3

COM COM

1734-IB8S S8BO-4371TNEA-4371

T1M

I6T2I7

COM COM

O2 O3

COM COM

T3M

COM COM COM COM

O6 O7

COM COM

Figure 19 shows the General tab of the 1734-AENTR module properties.

The Input Status can be set to Rack Optimization, Enhanced Rack Optimization, or Combined Status - Power - Muting as these settings are used by the Dual Channel Input Stop (DCS) logic block to verify that the 1734-IB8S switch is operational. The Output Data must be set to Test, as the test outputs are used to generate test pulses for the output contactors, K1 and K2.

Figure 19 - 1734-AENTR Module Properties - General

40 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 7 Application Examples

Figure 20 shows the 1734-IB8S General tab. Set the Module Definition with the

following settings:

• Input Data: Safety

•Output: Test

• Input Status: Pt. Status-Power-Muting-Test Output

Figure 20 - 1734-IB8S Module Properties - General

Figure 21 shows the Input Configuration tab of the 1734-IB8S switch module

properties.

In this example, Points 0 and 1 monitor the OSSD outputs of the 440G-MZ safety switch. The Type is set to Single and the Mode must be set to Safety.

Points 2 and 3 monitor the status of the output contactors, K1 and K2. The Type should be set to Single. Set Mode to Safety Pulse Test. Safety pulse testing is used to detect potential faults in the monitoring circuit.

Figure 21 - 1734-IB8S Module Properties - Input Configuration

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 41

Chapter 7 Application Examples

Figure 22 shows the Test Output tab of the 1734-IB8S module properties.

In this example, Points 0 and 1 are set to Pulse Test as these points help check the integrity of the contactors K1 and K2, to be sure they are off before the logic program energizes the contactors.

Points 2 and 3 are set to Standard. Point 2 is the LOCK command. Point 3 applies power to the safety switch. By setting it to Standard, you can programmatically turn these points OFF and ON, in case a nonrecoverable fault occurs with the switch.

Figure 22 - 1734-IB8S Module Properties - Test Output

Figure 23 shows the General tab of the 1734-OB8S module properties. Set the

Module Definition with the following settings:

• Input Data: None

• Output: Safety

• Input Status: Pt. Status

Figure 23 - 1734-OB8S Module Properties - General

42 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 7 Application Examples

Figure 24 shows the Output Configuration tab of the 1734-OB8S switch module

properties.

Points 0 and 1 drive the output contactors K1 and K2. For both points, Type is set to Dual, and the Mode is set to Safety Pulse Test.

Figure 24 - Module Properties - Output Configuration

Figure 25 on page 44 shows an example program. A Dual Channel Input Stop

function block monitors the 440G-MZ safety switch, and a Configurable Redundant Output function block controls two contactors. This example can be used as a starting point for implementation; you must incorporate additional logic that is based on the risk assessment for the machine.

Rung Description

With the Test Data output setup set as Standard, an HMI input can cycle power ON and OFF to the

440G-MZ safety switch to recover from a fault, if necessary. Upon powerup, the N.C. contact automatically applies power to the 440G-MZ safety switch.

The Dual Channel Input Stop monitors the outputs of the 440G-MZ safety switch. The DCS block is set

for automatic start on powerup (cold start) and automatic restart each time the switch is locked. The output of the DCS in Rung 1 provides a tag that shows the input 440G-MZ input status is OK. This

tag is used in Rung 4 to enable the Configurable Output to be reset. A momentary contact from an HMI input starts a short on delay timer. HMI input must be held long

enough for the timer to expire. This timer is intended to help prevent inadvertent reset. The preset value can be adjusted to suit the application.

When the timer is done, the OSF_Storage_Bit is set. When the HMI_CROUT_Actuate button in Rung 4 is

released, the OSF_Storage_Bit goes LO and the OSF_Output_Bit goes HI. When the OSF_Output_Bit goes HI, the CROUT_Actuate tag is set. The CROUT_Actuate tag is self-sealing

because the OSF_Output_Bit is HI only momentarily. The GMZ_Crout block is set for negative feedback. The CROUT block output cannot go HI unless the

external contactor status at Feedback 1 and 2 is HI.

7 The two CROUT outputs turn ON the ArmorBlock® outputs, which energize the external contactors.

From an HMI input, you can lock or unlock the 440G-MZ safety switch. The HMI input must be a

maintained switch.

9 Notify the HMI if a fault is present on the DCS block.

10 An HMI input can reset the DCS if a fault is present.

11 Notify the HMI if a fault is present on the CROUT block.

12 An HMI input can reset the CROUT if a fault is present.

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 43

Chapter 7 Application Examples

Figure 25 - 1734 Example Studio 5000® Program

44 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 7 Application Examples

1732ES-IB12XOB4

889D-E5NC-10

100S Contactors or

700S or 700-HPS Relays

889D-E5NC-10

White (2) A1 A2 Blue (3)

Black(4) A1 A2 Gray (5)

889D-F5NCDM-X

Brown (1)

White (2)

Black (4) Gray (5)

Wire to ArmorBlock Guard I/O Module

The 440G-MZ safety switch can be connected to a 1732ES/1732DS ArmorBlock Guard I/O™ module by using a catalog number 889D-F5NCDM-x 5-wire patchcord. An example schematic is shown in Figure 26

Figure 26 - ArmorBlock Schematic

Figure 27 shows the General tab of the ArmorBlock module properties. The

Input Status must be set to Combined Status - Muting and the Output Data must be set to Combined.

Figure 27 - Module Properties - General

Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 45

Chapter 7 Application Examples

Figure 28 shows the Input Configuration tab of the ArmorBlock module

properties. In this example, Points 0 and 1 monitor the OSSD outputs of the safety switch. The Type should be set to Single and the Mode must be set to Safety.

Points 4 and 5 monitor the status of the output contactors K1 and K2. These points should also be set to Single and Safety Pulse Test. The Test Source must agree with the Test Output tab.

Figure 28 - Module Properties - Input Configuration

Figure 29 shows the Test Output tab of the ArmorBlock Module Properties. In

this example, Points 0 and 1 are set to Standard, which allows the program to control these points. Point 0 applies power to the 440G-MZ safety switch. By setting it to standard, you can programmatically turn this point off and on if the 440G-MZ safety switch has a fault condition. Point 1 is the lock/unlock command. In this example, the 440G-MZ safety switch is a PTR type, so 24V unlocks the switch. Points 4 and 5 are used to monitor the contactor outputs and are set to Pulse Test.

Figure 29 - Module Properties - Test Output

Figure 30 shows the Output Configuration tab of the ArmorBlock module

properties. Points 0 and 1 drive the output contactors K1 and K2. The point Types are set to Dual, and the Modes are set to Safety.

Figure 30 - Module Properties - Output Configuration

46 Rockwell Automation Publication 440G-UM004C-EN-P - January 2021

Chapter 7 Application Examples

Figure 31 on page 48 shows an example program. A Dual Channel Input Stop