Rockwell Automation SensaGuard 440N-Z21SS2 Series Installation Instructions Manual

Installation Instructions

WARNING

SensaGuard™ Rectangular Flat Pack - 440N-Z21SS2*

IMPORTANT: SAVE THESE INSTRUCTIONS FOR FUTURE USE.

ENGLISH:

GERMAN:

FRENCH:

ITALIAN:

SPANISH:

PORTUGUESE:

POLISH:

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Installation Instructions

Installation must be in accordance with the following steps and
stated specifications and should be carried out by suitable
competent personnel. The unit is not to be used as a mechanical
stop. Guard stops and guides must be fitted. Adherence to the
recommended maintenance instructions forms part of the
warranty.

This device is intended to be part of the safety related control
system of a machine. Before installation, a risk assessment should
be performed to determine whether the specifications of this
device are suitable for all foreseeable operational and
environmental characteristics of the machine to which it is to be
fitted. Refer to Technical Specifications below for certification
information and ratings.

The presence of spare actuators compromise the

ATTENTION

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.

Do not defeat, tamper, remove or bypass this unit.
Severe injury to personnel could result. The sensor
MUST be connected to a Class 2 SELV 24V DC,
+10%/-15% power supply.

Operating Characteristics

Sensing Distance

Assured Make 15 mm

Assured OFF 35 mm

Typical Misalignment (±7 mm in both axes)

Repeat Accuracy 10% of sensing range

Max. output current (all outputs) 200 mA

Input Current 50 mA (no load supply current)

Operational Current, Min. ≥1 mA DC

Off-state Current <0.5 mA DC

Max. no. of switches, connected in series

Operating Voltage

Unlimited. See Unit Response Time
section on page 5.

24V DC +10%/-15%
Class 2 SELV power supply

Frequency of operating cycle 1 Hz

Response Time (Off)

54 ms first switch,
18 ms for each additional switch

Case Material Valox® DR 48

Actuator Materia l Valox® DR 48

Outputs
(guard door closed, actuator in place)

Outputs Description Status

Safety 2 x PNP, 0.2 A max. ON (+24V DC)

Auxiliary 1 x PNP, 0.2 A max. OFF (0V DC)

Environmental

Technical Specifications

Type 4 Interlocking Device per ISO 14119 (Low Coding)

Safety Classification

Standards

Certifications TÜV, CE Marked for all applicable directives, cULus

Functional Safety Data

PLe, Cat 4 per ISO 13849-1
SIL CL3 per IEC 62061 and IEC 61508

CSA 22.2 No. 14, ISO13849-1, ISO 14119, IEC 60947-5-3,
IEC 61508, IEC 62061, and UL508

-9

: 1.12 - 10

PFH

D

Operating Temperature [C (F)] -10…+55° (14…131°)

Operating Humidity 5…95% relative

Washdown Rating NEMA 3, 4X, 12, 13, IP69k

Shock & Vibration

Radio Frequency

IEC 68-2-27 30 g, 11 ms/IEC 68-2-6
10…55 Hz

IEC 61000-4-3
IEC 61000-4-6

Protection

24.99

(0.984)

88.14
(3.47)

10.66
(0.42)

7.11

(0.28)

6.78

(0.267)

4.57

(0.18)

Ø5.08
(Ø0.2)

4.57

(0.18)

68.31

(2.689)

18.54
(0.73)

72.9

(2.87)

77.98
(3.07)

20.65

(0.813)

24.99

(0.984)

88.14
(3.47)

20.65

(0.813)

4.57

(0.18)

18.54
(0.73)

10.67
(0.42)

13.41

(0.528)

9.96

(0.392)

QD

CONNECTOR

VERSION

M12 x 1

¯ 9.7

(¯ 0.38)

4.57

(0.18)

Ø5.08
(Ø0.2)

4.57

(0.18)

77.98
(3.07)

62.53

(2.462)

57.96

(2.282)

82.55
(3.25)

Short-circuit Incorporated

Current Limitation Incorporated

Overload Incorporated

False Pulse Incorporated

Tra nsi ent Noi se In cor por ated

Reverse Polarity Incorporated

Overvoltage Incorporated

Thermal Shutdown/Restart Incorporated

Electrical Life

10 x 10

Dimensions [mm (in.)]

6

Mode of Operation

Status indicators:

• “Status/Diag” LED illuminates green: Door/guard closed,
safety outputs active.

• “Status/Diag” LED illuminates red: Door/guard open,
safety outputs off.

• “Status/Diag” LED flashes red: Unit failure. See Diagnostic
section on page 4.

• “Status/Diag” LED flashes green: Safety inputs off.

• “Status/Diag” LED flashes amber: Sensor is approaching
max. sensing distance. (-N and -N9 models only)

2

Mounting Information

Use non-removable screws, bolts, or nuts to mount the switch and
actuator. Do not over torque the mounting hardware.

Position the switch and actuator so they are aligned with each
other.

Mount the switch and actuator to removable guard, door, or gate.
Keep the switch and actuator within the sensing range shown in
the sensing/misalignment curve.

Nut Torque Specification

Switch/Actuator: 2.26 N•m (20 in•lb)

Minimum Distance Between Sensors

200.00 mm

5

10

15

20

25

30

35

SIDE
LOBES

Sensing Distance* (mm)

0

SIDE
LOBES

ASSURED
SENSING
DIS TANC E

* when the actuator approaches the sensor in the x-direction or
from above (z-direction) and is misaligned in the y-direction

Sensor Actuator

Misalignment (mm)

Assured Make: 15 mm
Assured OFF: 35 mm

x

z

y

Sensor

Actuator

Actuator

IMPORTANT

5

10

15

20

25

30

35

Sensing Distance** (mm)

0

23

23

50

40

30

20

30

0

10

20

10

40

50

50

40

30

20

30

0

10

20

10

40

50

Misalignment (mm)

** when the actuator approaches the sensor in the
x-direction and is misaligned in the z-direction.

Sensor Actuator

ASSURED
SENSING
DISTANCE

Assured Make: 15 mm
Assured OFF: 35 mm

x

Sensor Actuator

zz

Misalignment Curve

Wiring Diagram

Allow a minimum spacing of 9 mm (0.35 in.) if the
actuator and sensor faces approach laterally (from
the y-direction). This will prevent false triggering
due to the side lobe areas.

To ensure proper functioning of margin indication
(non-safety), z-direction approach is not
recommended for -N and -N9 models.

3

8-Pin Unit

Pin Number Wire Color Signal

1 White Aux. Outputs

2Brown+24V

3GreenNA

4 Yellow OSSD 2, +24V Input

5 Grey OSSD 1

6 Pink OSSD 2

7Blue0V

8 Red OSSD 1, +24V Input

Recommended mating cable, 2 m (6.5 ft)—889D-F8AB-2.
Replace the 2 with 5 (5 m) or 10 (10 m) for standard cable lengths.

Green

1

2

3

8

476

Red

Yellow

5

Brown

White

Blue

Pink

Grey

5-Pin Unit

15

2

4

3

IMPORTANT

Pin Number Signal

1+24V

2 OSSD 1

30V

4 OSSD 2

5Aux.

Recommended cordset, 2m (6.5 ft) - 889D-F5AC-2. Replace the
2 with 5 (5 m) or 10 (10 m) for standard cable lengths.

Note: If the user does not require the Auxiliary signal, a 4-pin
cordset (889D-F4AC-2) can be used.

Recommended patchcord for use with ArmorBlock® Guard
Safety I/O, 2 m (6.5 ft) - 889D-F4ACDM-2. Replace the 2 with

0M3 (0.3 m), 1 (1 m), 5 (5 m), or 10 (10 m) for standard cable
lengths.

Note: Do not use a 5-pin patchcord with the ArmorBlock.

Diagnostic

Unit Indicators (per IEC 60073)

State Status Troubleshooting

Off Not Powered NA

Red Not Safe, OSSD not active NA

Green Safe, OSSD active NA

Device

Output

LED

Green Flash

Red Flash

Amber Flash

(-N & -N9

models only)

Refer to Technical Specifications (page 1) for
certification information and ratings.

Power up test or OSSD

inputs not valid

1 Hz Flash Recoverable Fault

4 Hz Flash Non-recoverable

Fau lt

1 Hz Flash margin indicator

Safe, OSSD active

Check 24V DC or OSSD

inputs (yellow and red wire)

Recoverable fault —check

OSSD outputs are not

shorted to GND, 24V DC or

each other. Cycle power.

Sensor is reaching max.

sensing distance; realign

sensor with actuator

4

Troubleshooting

Yel

Red

Brown

Gray

Pink

Blue

24VDC

Power

Supply

1606

-XL120D

Switch 1

+24

RTN

Switch 2

White

White

Yel

Red

Brown

Gray

Pink

Blue

Actuator 1

Actuator 2

Switch 3

White

Yel

Red

Brown

Gray

Pink

Blue

Actuator 3

Switch 4

White

Yel

Red

Brown

Gray

Pink

Blue

Actuator 4

Switch 5

White

Yel

Red

Brown

Gray

Pink

Blue

Actuator 5

+24 V
+24 V

+24 V
+24 V

+0 V
+0 V

+0 V
+0 V

+0 V
+0 V

Actuator 2 is in sensing range.
Switch
2 is functioning properly
OSSDs are energize to 24 V
Green LED is ON.

Actuator 3 is in sensing range.
Switch
3 has fault.
See Table Above—Red LED is flashing

Actuator 1 is in sensing range.
Switch
1 is functioning properly
OSSDs are energize to 24 V
Green LED is ON.

Actuator 4 is in sensing range.
Switch
4 is functioning properly.
Series inputs are 0 V.
OSSDs are de-energized to 0V .
Green LED is Flashing to indicate
Series inputs are not 24V.

Actuator 5 is in sensing range.
Switch
5 is functioning properly .
Series inputs are 0V .
OSSDs are de-energized to 0V.
Green LED is Flashing to indicate
Series inputs are not 24V.

OSSD’s are OFF

Recoverable fault

IMPORTANT

Yel

Red

White

Gray

Pink

Blue

24V DC

Power

Supply

1606

Sensor 1

+24

RT

Sensor 2

Brown

Brown

Gray

Pink

White

Yel

Red

Blue

Sensor 3

Brown

Yel

Red

White

Gray

Pink

Blue

A1

S21

S11 41332313S12S52

42342414A2S34S22

MSR127TP

Actuator 1

Actuator 2

Actuator 3

Initial Conditions:
All actuators are in sensing
distance.

Actuator 1 is moved out of
sensing range.

Sensor 2 drops the 24 volts
(red and yellow) from Sensor 1
OSSD outputs.
Green LED flashes.

Sensor 3 drops the 24 volts
(red and yellow) from Sensor 2
OSSD outputs.
Green LED flashes.

0 ms

54 ms 72 ms 90 ms

Actuator 1 is out of sensing
range.
Actuator 2 and 3 are in
sensing range.

Actuator 1 is moved into sensing
range.
Sensor 1 OSSD outputs are
energized.

Sensor 2 OSSD inputs (red and yellow)
transition to 24V DC from Sensor 1
OSSD outputs.
Sensor 2 OSSD outputs are energized

Sensor 3 OSSD inputs (red and
yellow) transition to 24V DC from
Sensor 2 OSSD outputs.
Sensor 3 OSSD outputs are
energized.

0 ms

360 ms 378 ms 396 ms

OFF

ON

IMPORTANT

Series Circuit

Refer to Technical Specifications (page 1) for
certification information and ratings.

Unit Response Time (does not include safety control system response time)

5

Refer to Technical Specifications (page 1) for
certification information and ratings.

Application Wiring Examples

K1

+24V DC

MSR127RP with 1 sensor, monitored manual reset, driving 100S or 700S safety controllers.

A1 S11

S52 S121323 33

41

S21

S22

S34A214 24 34 42

MSR127RP

Reset

GND

Blue

Gray

Pink

Yellow

Red

Brown

SensaGuard

Unit 1

K2

+24V DC

GND

MSR127RP with 3 sensors in series, monitored manual reset, driving 100S or 700S safety controllers

Blue

Gray

Pink

Yellow

Red

Brown

SensaGuard

Unit 1

SensaGuard

Unit 2

SensaGuard

Unit 3

K1

A1 S11

S52 S121323 33

41

S21 S22 S34 A2 14 24 34 42

MSR127RP

Reset

K2

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

MSR127RP with 3 sensors and 1 440L light curtain in series, monitored manual reset, driving 100S or 700S safety relays.
Note: Light curtain must be last (farthest from MSR127).

GND

A1 S11

S52 S121323 33

41

S21 S22 S34 A2 14 24 34 42

MSR127RP

Reset

K1

K2

+24V DC

Blue

Gray

Pink

Yellow

Red

Brown

SensaGuard

Unit 1

SensaGuard

Unit 2

SensaGuard

Unit 3

GuardShield

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Brown

A1 S11

S52 S121323 33

41

S21

S22

S34A214 24 34 42

MSR127TP

GND

MSR127RP with 1 sensor, automatic reset, driving 100S or 700S safety controllers

+24V DC

SensaGuard

Unit 1

K1

K2

Blue

Gray

Pink

Yellow

Red

Brown

MSR127TP with 3 sensors in series, automatic reset, driving 100S or 700S relays.

MSR127TP

+24V DC

GND

Blue

Gray

Pink

Yellow

Red

Brown

SensaGuard

Unit 1

K1

A1 S11

S52 S121323 33

41

S21 S22 S34 A2 14 24 34 42

K2

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

SensaGuard

Unit 3

SensaGuard

Unit 2

MSR127TP with 3 sensors and 1 440L light curtain in series, automatic reset, driving 100S or 700S safety contactors.

Note: Light curtain must be last (farthest from MSR127)

MSR127TP

GND

A1 S11

S52 S121323 33

41

S21 S22 S34 A2 14 24 34 42

K1

K2

+24V DC

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Brown

GuardShield

SensaGuard

Unit 1

SensaGuard

Unit 3

SensaGuard

Unit 2

IMPORTANT

Refer to Technical Specifications (page 1) for
certification information and ratings.

6

Application Wiring Examples

A1

S11

S21

S12

S22

S32

L11 Y32L121314

S42

2324S34

A2

DI
440R-D22R2

0

1

2
3

4

56

7

8

LOGIC

K1

K2

SensaGuard

SensaGuard

+24V DC

K1

K2

Reset

889D-F4AC-*

889D-F5AC-*

24V Com

Brown

Blue

Black

White

Brown

Blue

Grey

Black

White

Gate
Open

889D-F5AC-*

K1

K2

S11

S12

S21

S22

S34 A1 13

L11 A2 142324Y32

SI
440R-S12R2

RESET

0

MM

AM

24V DC

24V DC Com

Brown

Blue

White

Black

SensaGuard Integrated Latch

Reset

Gate
Open

Grey

IMPORTANT

889D-F8AB-*

A1

S11

S21

S12

S22

S32

L11 Y32L121314

S42

2324S34

A2

DI
440R-D22R2

0

1

2
3

4

56

7

8

LOGIC

K1

K2

K1

K2

S11

S12

S21

S22

S34 A1 13

L11 A2 142324Y32

SI
440R-S12R2

RESET

0

MM

AM

SensaGuard

SensaGuard

+24V DC

K1

K2

Reset

889D-F8AB-*

889D-F8AB-*

24V Com
Note: The Green wire is connected to the housing of the Stainless Steel
SensaGuard only; it has no connection for plastic SensaGuard.

Brown

Yel lo w

Yel lo w

Red

Red

Blue

Pink

Grey

Pink

Grey

Brown

Blue

Green

White

Green

White

Gates
Open

24V DC

24V DC Com

Brown

Yellow

Red

Blue

White

Pink

SensaGuard Integrated Latch

Reset

Gate
Open

Grey

Green

Refer to Technical Specifications (page 1) for
certification information and ratings.

7

List of Recommended Safety Control Interfaces

GSR DI, GSR DIS, GSR SI, CR30, MSR126, MSR127, MSR131, MSR138, MSR211, MSR221, MSR121, MSR320, SmartGuard™, 1791DS/ES
CompactBlock™ Guard Safety I/O, 1732DS/ES ArmorBlock Guard Safety I/O. Relay must have OSSD (light curtain) inputs.

Check the machine is
isolated and stopped
whenever the interlocked
guard door is open.

IMPORTANT: After
installation and
commissioning, the
actuator, switch and switch
lid fixing screws should be
coated with tamper evident
varnish or similar compound.

Maintenance

Monthly

Check the correct operation of the switching circuit. Also check for signs of abuse or tampering. Inspect the switch casing for damage.

Repair

If there is any malfunction or damage, no attempts at repair should be made. The unit should be replaced before machine operation is
allowed.

Declaration of Conformity

This is to declare that the products shown in this document conform with the Essential Health and Safety Requirements (EHSRs) of the
European Machinery Directive. These products also conform to EN60947-5-3, EN ISO 14119, and have Third Party Approval.

For a comprehensive certificate please visit: www.ab.com/safety.

Allen-Bradley, CompactBlock, Rockwell Software, and SensaGuard are trademarks of Rockwell Automation, Inc.

Rockwell Automation maintains current product environmental information on its website at

http//www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page

Publication 440N-IN008B-EN-P — December 2014 — 10000979555 Ver 00 PN-243696

Supersedes Publication 440N-IN0008A-EN-P — May 2012 Copyright © 2014 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.