Rockwell Automation Guardmaster Guard Locking Switch User Manual
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
Table of Contents
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.
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.
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)
No
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 (3.94in.) 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
1
2
3
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
Actuator
Z-shaped Actuator
Mounting Bracket
Z-shaped Actuator
Mounting Bracket
L-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
5
4
3
1
2
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 [6.5ft]). 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
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