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

Device Status and

Troubleshooting

Chapter 6

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.

Topic	Page
Added FCC and IC certification information	53

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

5

Preface

Terminology

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,	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
	and Unlock)	dynamic when an unlock or lock command is issued to a GuardLink-enabled guard
		locking device, such as a 440G-MZ safety switch.
	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	The switch is in operational state when there is no demand on its safety function (that
		is, the switch is closed and locked).
	OSSD (Output Signal	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
	Switching Device)
		short circuits between the two signals.
	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	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.
	RFID	Radio frequency identification
	Safe state	The switch is in safe state when there is a demand on its safety function (that is, the
		switch is unlocked).
	Standard coding	Same as Low coding as defined in ISO 14119
	Tap	A connection in a GuardLink® circuit that associates a safety device to the GuardLink
		circuit.
	Unique coding	Same as High coding as defined in ISO 14119

Additional Resources

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

	Resource			Description
	440G-MZ Guard Locking Switch Installation Instructions,			Provides general guidelines for installing a Rockwell Automation® guard locking switch.
	publication 440G-IN018
	Guardmaster EtherNet/IP Network Interface User Manual,			Provides a detailed description of module functionality, configuration, installation
				procedure, and information on how to use the Guardmaster EtherNet/IP Network Interface
	publication 440R-UM009
				(440R-ENETR).
	Guardmaster DG Safety Relay and GuardLink System User Manual,			Provides general guidelines for configuring a Rockwell Automation Guardlink safety system.
	publication 440R-UM015
	EtherNet/IP Network Devices User Manual, publication ENET-UM006			Describes how to configure and use EtherNet/IP devices to communicate on the
				EtherNet/IP™ network.
	Ethernet Reference Manual, publication ENET-RM002			Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
	System Security Design Guidelines Reference Manual,			Provides guidance on how to conduct security assessments, implement Rockwell
				Automation products in a secure system, harden the control system, manage user access,
	publication SECURE-RM001
				and dispose of equipment.
	Industrial Components Preventive Maintenance, Enclosures, and Contact			Provides a quick reference tool for Allen-Bradley industrial automation controls and
	Ratings Specifications, publication IC-TD002			assemblies.
	Safety Guidelines for the Application, Installation, and Maintenance of			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
	Solid-State Control, publication SGI-1.1			the form of individual devices or packaged assemblies incorporating solid-state
				components.
	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.

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

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

Chapter 1

Guardmaster 440G-MZ

Safety Switch Overview

Product 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

Assembly Overview

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.

Actuator

LINK and DEVICE status indicators

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

a

b

c

d

e

a

b

c

d

e

Outputs (Safety/

Actuator Code

Auxiliary Type

Lock Type

Connection Type

Auxiliary)

Code

Description

Code

Description

Code

Description

Code

Description

Code

Description

20

Two safety/no aux

S

Standard code

N

No auxiliary

R

Power to Release

J

M12 5-pin

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	Standard (Low level to ISO 14119)		440G-MZS20SNRJ
		Unique (High level to ISO 14119)	No	440G-MZS20UNRJ
	Power to Lock	Standard (Low level to ISO 14119)		440G-MZS20SNLJ
		Unique (High level to ISO 14119)		440G-MZS20UNLJ

Table 6 - Spare Actuators

Description	Cat. No.
Standard code actuator (Low level to ISO 14119)	440G-MZAS
Unique code actuator (High level to ISO 14119)	440G-MZAU

Table 7 - Accessories

	Description		Cat. No.
		L-shaped	440G-MZAM1
	Actuator mounting bracket
		Z-shaped	440G-MZAM2
	Switch mounting bracket		440G-MZAM3
	Padlock accessory		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

Chapter 2

Safety Concept

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 14119
•	EN ISO 13854	• EN ISO TR 24119
•	EN ISO 13855	•	EN ISO 14120
•	EN ISO 13857	•	Application-specific C-level standards

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

11

Chapter 2

Safety Concept

Notes:

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

Chapter 3

Installation

General Considerations

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.

Correct Use

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 mediumand 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.

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Chapter 3

Installation

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

2

3

1

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.)]

100 (3.94)

IMPORTANT If the minimum separation distance is not observed, the electromagnetic fields interact causing crosstalk. Crosstalk can result in nuisance faults and false operation.

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Environmental

Considerations

Mount the Switch and

Actuator

Chapter 3

Installation

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

2 x M5

3 x M5

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.

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Chapter 3

Installation

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

Actuator

Switch	Switch
mounting	mounting
bracket	bracket

•Mount the switch on outside of a hinged door

Z-shaped Actuator

Mounting Bracket

Actuator

Z-shaped Actuator

Mounting Bracket

•Mount the switch on a sliding door

Actuator	L-shaped Actuator	L-shaped Actuator
	Mounting Bracket	Mounting Bracket

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Auxiliary Release

Chapter 3

Installation

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.)]

5 (0.2)

Top View

Padlock Accessory

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)

Up to three nominal 6.35 mm (0.25 in.) locks

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.

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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.

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Pin Assignment and

Function

Chapter 4

Wiring and System Integration

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) (1)

		5	2
		3			1
Pin	Color					Function
			OSSD Mode				GuardLink® Mode
1	Brown			+24V			+24V
2	White			Safety A			Safety In
3	Blue			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.

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