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 |
|
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Who Should Use This Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 5 |
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Purpose of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 5 |
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Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
5 |
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Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
6 |
|
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
6 |
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Chapter 1 |
|
Product Overview |
Guardmaster 440G-MZ Safety Switch Overview . . . . . . . . . . . . . . . . . . . . . |
7 |
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Guard Locking on Power to Release Versions . . . . . . . . . . . . . . . . . . . . |
8 |
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Guard Locking on Power to Lock Versions . . . . . . . . . . . . . . . . . . . . . . |
8 |
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Assembly Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
8 |
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Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
9 |
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Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
10 |
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Chapter 2 |
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Safety Concept |
Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11 |
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Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11 |
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Chapter 3 |
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Installation |
General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
13 |
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Correct Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
13 |
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Switch Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
14 |
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Actuator Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
14 |
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Pair Proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
14 |
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Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
15 |
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Mount the Switch and Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
15 |
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Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
16 |
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Auxiliary Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
17 |
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Padlock Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
17 |
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Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
17 |
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OSSD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
18 |
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GuardLink Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
18 |
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Chapter 4 |
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Wiring and System Integration |
Pin Assignment and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
19 |
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OSSD Mode Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
20 |
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GuardLink Mode Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
20 |
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GuardLink System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
20 |
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Add Device to a Studio 5000 Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
21 |
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Upload Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
22 |
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Manual Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
22 |
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Lock Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
23 |
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OSSD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
23 |
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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
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Chapter 7 |
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Application Examples |
Wire to GLP Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
31 |
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Circuit Status as Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
32 |
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Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
32 |
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Safely-limited Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
32 |
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Wire to GLT Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
33 |
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Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
33 |
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Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
34 |
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Wire to DI and EMD Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
35 |
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Circuit Status as Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
35 |
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Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
36 |
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Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
36 |
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Wire to DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
37 |
|
Wire to CR30 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
38 |
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Wire to POINT Guard I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
40 |
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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 |
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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 |
Who Should Use This
Manual?
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
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 |
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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 |
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locking device, such as a 440G-MZ safety switch. |
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HI |
Logic state of being ON or a voltage level to be above the turn-on threshold. |
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LO |
Logic state of being OFF or a voltage level to be below the turn-off threshold. |
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NC |
No connection |
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Operational state |
The switch is in operational state when there is no demand on its safety function (that |
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is, the switch is closed and locked). |
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OSSD (Output Signal |
Typically a pair of solid-state signals pulled up to the DC source supply. The signals are |
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tested for short circuits to the DC power supply, short circuits to the DC common, and |
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Switching Device) |
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short circuits between the two signals. |
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PLC |
A programmable logic controller or a programmable automation controller. |
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Reaction time |
Describes the time between the true state of the input to the ON state of the output. |
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Response time |
Describes the time between the trigger of the input to the OFF state of the output. |
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Throughout this manual, the safety outputs may be described as turning off |
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immediately, which means that the safety outputs turn off within the response time. |
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RFID |
Radio frequency identification |
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Safe state |
The switch is in safe state when there is a demand on its safety function (that is, the |
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switch is unlocked). |
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Standard coding |
Same as Low coding as defined in ISO 14119 |
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Tap |
A connection in a GuardLink® circuit that associates a safety device to the GuardLink |
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circuit. |
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Unique coding |
Same as High coding as defined in ISO 14119 |
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 |
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|
|
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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
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.
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
Table 4 - Catalog Number Explanation
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440G-MZS |
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20 |
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S |
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N |
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R |
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J |
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a |
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b |
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c |
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d |
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e |
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a |
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b |
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c |
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d |
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e |
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Outputs (Safety/ |
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Actuator Code |
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Auxiliary Type |
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Lock Type |
Connection Type |
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Auxiliary) |
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Code |
Description |
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Code |
Description |
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Code |
Description |
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Code |
Description |
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Code |
Description |
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20 |
Two safety/no aux |
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S |
Standard code |
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N |
No auxiliary |
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R |
Power to Release |
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J |
M12 5-pin |
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U |
Unique code |
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L |
Power to Lock |
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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 |
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Power to Lock |
Standard (Low level to ISO 14119) |
440G-MZS20SNLJ |
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|
||||
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
The box includes the following components:
Description Photo
Switch Body
Actuator
Installation Instructions:
publication 440G-IN018
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Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 |
Chapter 2
Safety Concept
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
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 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.
Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 |
13 |
Chapter 3 |
Installation |
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
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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Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 |
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.
Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 |
15 |
Chapter 3 |
Installation |
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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Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 |
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
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
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 |
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.
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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Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 |
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.
Rockwell Automation Publication 440G-UM004C-EN-P - January 2021 |
19 |