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.
Table of Contents Preface Who Should Use This Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Resources . . . . . . . . . . . . . . . .
Table of Contents Chapter 5 Commission the Safety Switch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First-time Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Learn Additional Replacement Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . Lock the Actuator Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preface Use this manual to design, install, program, or troubleshoot systems that use the Guardmaster® 440G-MZ Guard Locking Safety Switches. Who Should Use This Manual? 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. Purpose of This Manual This manual is a reference guide for the Guardmaster 440G-MZ safety switch.
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.
Chapter 1 Product Overview 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.
Chapter 1 Product 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 OSSD GuardLink® Description The lock signal (pin 5) is connected to 0V DC A lock command is issued to the switch on the CLU signal from a GuardLink safety master.
Chapter 1 Product Selection Product Overview Table 4 - Catalog Number Explanation 440G-MZS a Outputs (Safety/ Auxiliary) Code Description 20 Two safety/no aux 20 a S b N c R d J e b c d e Actuator Code Auxiliary Type Lock Type Connection Type Code Description S Standard code U Unique code Code Description N No auxiliary Code Description R Power to Release L Power to Lock Code Description J M12 5-pin Table 5 - Complete Switches, including Switch Body and Actuator Type Power to Release P
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 - August 2020
Chapter 2 Safety Concept Safety Standards The Guardmaster® 440G-MZ safety switch satisfies applicable requirements in the following standards that are related to functional safety and machinery assembly: • • • • • • Safety Certification 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)
Chapter 2 Safety Concept Notes: 12 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
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.
Chapter 3 Installation Switch Orientation Can be used in all mounting orientations. Actuator Orientation 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.
Chapter 3 Environmental Considerations 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.
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.
Chapter 3 Auxiliary Release 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.
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.
Chapter 4 Wiring and System Integration 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.
Chapter 4 Wiring and System Integration OSSD Mode Safety Signals In OSSD mode, safety outputs Safety A and Safety B are OFF (0V) when the switch is in safe state (that is, the switch is unlocked). When the switch is in operational state (that is, closed and locked), safety outputs Safety A and Safety B are ON (24V) and contain test pulses. The test pulses are used to detect short circuits to 24V, to 0V and cross faults (from Safety A to Safety B).
Chapter 4 Wiring and System Integration Different types and versions of GuardLink enabled and passive taps can be connected in any order and can be mixed on the same link. For more information about the configuration a GuardLink safety system, see publication 440R-UM015. Both the Power to Release and Power to Lock versions of the 440G-MZ safety switch can be connected to a GuardLink safety system. Figure 8 - GuardLink System Components 440G-MZ 440G-MZ 1 1 1 1 2 INPUT 4 MS LNK1 LNK2 NS IP: 192.
Chapter 4 Wiring and System Integration Upload Method After the upload is complete, the position and type of connected 440G-MZ safety switches is shown in the Module Definition tab as shown in Figure 9. Figure 9 - Upload Method Manual Method With the manual method, a 440G-MZ safety switch can be added to a GuardLink circuit in steps as shown in Figure 10. Figure 10 - Manual Method 1 2 1. Right-click the GuardLink and select Add Device. 2.
Chapter 4 Lock Command Wiring and System Integration OSSD Mode Table 9 shows the lock command function. The lock command is a 24V logic signal with a current of less than 2 mA. The function of the logic signal is dependent on the catalog number. Table 9 - Lock Command Function Cat. No. Function 440G-MZS20*MR* Power to Release 440G-MZS20*ML* Power to Lock Value 24V = Unlock 0V = Lock 24V = Lock 0V = Unlock Catalog codes for both types are explained in Table 4 on page 9.
Chapter 4 Wiring and System Integration Notes: 24 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Chapter 5 Commission the Safety Switch The 440G-MZ safety switch is available with standard coded actuators or unique coded actuators. • • Switches with standard coded actuators are ready for use and do not require commissioning. Switches with unique coded actuators must be commissioned before use. The actuator teach process is not performed at the factory and must be performed when the switch is first put into use.
Chapter 5 Commission the Safety Switch Apply power to the switch without the actuator present. After the switch completes the power-sequence (approximately 8 seconds), the status indicator flashes green eight times, indicating the total number of times a new actuator can be learned. This status indicator sequence repeats until an actuator is inserted in the switch (in the guard closed position).
Chapter 6 Device Status and Troubleshooting Status Indicators during Power-up Routine When power is applied to the switch, the DEVICE status indicator is steady red for 2.5 seconds, then the DEVICE and LINK status indicators flash red/green for 1 second, and then the DEVICE status indicator is steady red for 3 seconds. At the conclusion of the start-up sequence, the state of the status indicators is determined by whether there is a demand on the safety function and the status of the lock signal.
Chapter 6 Device Status and Troubleshooting Diagnostic/Fault Codes When connected in a GuardLink system, the 440G-MZ safety switch communicates information about its current state with diagnostic and fault codes.
Chapter 6 Device Status and Troubleshooting Fault Codes Table 13 - Fault Codes Decimal (Hex) 00 (00) Description 05 (05) Power error 07 (07) 41 (29) Failure to detect device type (OSSD or GuardLink) Internal memory (ROM) fault Runtime memory (RAM) fault Internal memory (CPU) fault No response on GuardLink GuardLink application fault Product application fault Unique code actuator is locked Invalid actuator detected 42 (2A) No learns left 43 (2B) Actuator relearn 44 (2C) Actuator teach fault 56
Chapter 6 Device Status and Troubleshooting Troubleshooting Mounting Holes of the Switch Body Cracked or Broken The mounting hole of the switch body can crack when washers are used to mount the switch or when an incompatible thread locking compound is used to secure the mounting hardware. Three M5 fasteners are required to mount the switch body properly. Do not over torque the screws. IMPORTANT Do not use a washer with the screw at the base of the switch body. Using a washer causes the plastic to crack.
Chapter 7 Application Examples The following application and wiring examples are intended to show how the 440G-MZ safety switch products can be applied. If you are the user or the designer, you may require variations to these examples to meet your specific requirements. The GLP safety relay is designed to operate with Power to Release (PTR) switches. To use a Power to Lock (PTL) switch, you must use an interposing relay on the lock command at GLP terminal 51.
Chapter 7 Application Examples Circuit Status as Shown The gate is open and unlocked. The motor is off. The GLP safety relay is ready for reset. The GLP safety relay has a Logic setting of 3: (Safely-limited Speed with Logic IN OFF), a Safely-limited Speed (SLS1) setting of 5 (5 Hz) and a maximum (SLS2) speed setting of 8 (2000 Hz). The safety outputs (X14 & X24), the single wire safety output (L11), and the auxiliary output (Y32) are OFF.
Chapter 7 Application Examples The GLT safety relay is designed to operate with PTR switches. To use a PTL switch, you must use an interposing relay on the lock command at terminal 51 of the GLT safety relay. Wire to GLT Safety Relay In this example shown in Figure 13, the GLT safety relay sends an immediate command to the drive to turn OFF. After 8 seconds, the GLT safety relay turns off its safety outputs and unlocks the gate.
Chapter 7 Application Examples Stopping Normal production stops are performed by pressing Stop. Access through the safety gate is initiated by pressing the Gate Unlock Request. The Y32 output of the GLT safety relay turns OFF, which commands the PowerFlex® drive to bring the motor to a stop. After the configured time delay (8 seconds) expires, the GLT safety outputs turn off, and the gate becomes unlocked.
Chapter 7 Application Examples The 440G-MZ safety switch can be connected to the DI and EMD safety relays. The DI safety relay monitors the safety outputs of the safety switch and the EMD enables the gate to be unlocked after a configured delay time expires. Wire to DI and EMD Safety Relay B1 is connected to B2 to allow for retriggering. If you open and close the E-stop and press Reset before the delay expires, the EMD timer resets.
Chapter 7 Application Examples Starting With the Unlock switch open, close the gate. Press Reset to lock the gate and turn on the K1…K4 safety contactors. Stopping Stopping is initiated by pressing the E-stop. K1 and K2 contactors turn off immediately. The single wire safety signal from the DI safety relay (L11) to the EMD safety relay (L12) also turns off immediately, and the EMD starts the offdelay timer. After 8 seconds, X32 goes to 24V. The unlock switch is enabled, and the gate can be unlocked.
Chapter 7 Wire to DG Safety Relay Application Examples The 440G-MZ safety switch can be used in GuardLink® applications. The GuardLink system: • • • Is designed to operate with Power to Release switches. Uses taps to connect a series of devices to one relay. Provides control and status information between the machine control system and the safety system. Figure 15 shows four 440G-MZ safety switches that are connected on two GuardLink circuits from one DG safety relay.
Chapter 7 Application Examples Wire to CR30 Safety Relay The CR30 safety relay is a software configurable safety relay that can easily interface with the 440G-MZ safety switch. Version 10 and later of the Connected Components Workbench™ software has a locking function that is useful for guard locking applications. Figure 16 shows an example schematic. The CR30 safety relay monitors the motor running signal from the PowerFlex 525 drive.
Chapter 7 Application Examples The safety switch OSSD outputs drive the Safe Torque Off (STO) signals of the PowerFlex 525 drive. The STO is enabled after the gate is locked and the Reset is pressed. The PowerFlex 525 drive STO inputs can tolerate the pulse test that is generated by the CR30 outputs. The Lock_Ctrl_1 block controls the unlock command to the safety switch. The unlock Stop Time delay is set to 5 seconds, and the ULR Latch (Unlock Request) is set to ON.
Chapter 7 Application Examples Wire to POINT Guard I/O Module Figure 18 shows a wiring example of a 440G-MZ Power to Release safety switch that is connected to a 1734 POINT Guard I/O™ module.
Chapter 7 Application Examples Figure 20 shows the 1734-IB8S General tab. Set the Module Definition with the following settings: • • • Input Data: Safety Output: Test Input Status: Pt. Status-Power-Muting-Test Output Figure 20 - 1734-IB8S Module Properties - General Figure 21 shows the Input Configuration tab of the 1734-IB8S switch module properties. In this example, Points 0 and 1 monitor the OSSD outputs of the 440G-MZ safety switch. The Type is set to Single and the Mode must be set to Safety.
Chapter 7 Application Examples Figure 22 shows the Test Output tab of the 1734-IB8S module properties. In this example, Points 0 and 1 are set to Pulse Test as these points help check the integrity of the contactors K1 and K2, to be sure they are off before the logic program energizes the contactors. Points 2 and 3 are set to Standard. Point 2 is the LOCK command. Point 3 applies power to the safety switch.
Chapter 7 Application Examples Figure 24 shows the Output Configuration tab of the 1734-OB8S switch module properties. Points 0 and 1 drive the output contactors K1 and K2. For both points, Type is set to Dual, and the Mode is set to Safety Pulse Test. Figure 24 - Module Properties - Output Configuration Figure 25 on page 44 shows an example program. A Dual Channel Input Stop function block monitors the 440G-MZ safety switch, and a Configurable Redundant Output function block controls two contactors.
Chapter 7 Application Examples Figure 25 - 1734 Example Studio 5000® Program 44 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Chapter 7 Wire to ArmorBlock Guard I/O Module Application Examples The 440G-MZ safety switch can be connected to a 1732ES/1732DS ArmorBlock Guard I/O™ module by using a catalog number 889D-F5NCDM-x 5-wire patchcord. An example schematic is shown in Figure 26.
Chapter 7 Application Examples Figure 28 shows the Input Configuration tab of the ArmorBlock module properties. In this example, Points 0 and 1 monitor the OSSD outputs of the safety switch. The Type should be set to Single, and the Mode must be set to Safety. Points 4 and 5 monitor the status of the output contactors K1 and K2. These points should also be set to Single and Safety Pulse Test. The Test Source must agree with the Test Output tab.
Chapter 7 Application Examples Figure 31 on page 48 shows an example program. A Dual Channel Input Stop function block monitors the 440G-MZ safety switch, and a Configurable Redundant Output function block controls two contactors. This example can be used as a starting point for implementation; you must incorporate additional logic that is based on the risk assessment for the machine.
Chapter 7 Application Examples Figure 31 - Example Studio 5000 Program 48 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Chapter 7 Wire to MSR55P Back EMF Safety Relay Application Examples A PowerFlex 525 drive controls the speed and direction of the motor. The MSR55P safety relay allows access to the hazard after the motor has achieved its standstill settings. The DI safety relay monitors the guard locking switch and the E-stop push button. The DI safety relay enables the drive to restart after the gate is closed and locked and the E-stop is released.
Chapter 7 Application Examples Notes: 50 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Appendix A Specifications This appendix provides the specifications and safety ratings for the 440G-MZ safety switch.
Appendix A Specifications Outputs (Guard Door Closed and Locked) Environmental General Attribute Value Safety outputs (OSSD mode) 2 x PNP, 0.2 A max / ON (+24V DC) Attribute Value Operating temperature 0…55 °C (32…131 °F) Storage temperature -25…+75 °C (-13…+167 °F) Operating humidity 5…95%, noncondensing Enclosure ingress rating • • • • • Shock and vibration • IEC 60068-2-27 30 g (1.06 oz), 11 ms • IEC 60068-2-6 10…55 Hz, 1 mm (0.04 in.
Appendix A Specifications Visit rok.auto/certifications for Declaration of Conformity, Certificates, and other certification details. Certifications • • • • • UL Listed Industrial Control Equipment, Certified for US and Canada CE Marked for all applicable directives RCM Marked TÜV Certified for Functional Safety up to SIL 3 Category 4 for use in safety applications up to and including SIL 3.
Appendix A Specifications Approximate Dimensions Figure 33 - Switch Body [mm (in.)] 2 x Ø5.5 (0.22) 33 (1.3) 45.2 (1.78) 153 (6.02) 134.5 (5.3) 22.5 (0.89) 6 (0.24) 14.9 (0.59) 176.8 (6.96) 15 33 (1.3) (0.59) 15 (0.59) 5.9 (0.23) 39.5 50 47.5 25.3 (1.97)(1.87)(1.56) (1) Ø5.1 (0.2) 22.6 (0.89) 134.5 (5.3) 153 (6.02) 182.7 (7.19) 0.3 (0.01) Figure 34 - Actuator [mm (in.)] 14 (0.55) Ø32.9 (1.3) 10 7.3 (0.28) (0.39) 14 (0.55) 25.6 (1.01) 65 (2.56) 15 (0.59) 30 (1.18) 6 x Ø6.3 (0.25) 4 x Ø6.5 (0.
Appendix A Specifications Figure 36 - Actuator on L Bracket [mm (in.)] 83.5 (3.3) 55.4 (2.2) 33.8 (1.3) 32.5 (1.27) 27.6 (1.1) 7.2 (0.28) 2 x 12.8 (0.5) 65 (2.6) REF 2 x 50 (1.96) 65 (2.6) 23.3 (0.9) 2 x Ø8.5 (0.33) 4 x Ø6.3 (0.24) 7.5 (0.3) 45.3 (1.8) 50 (1.96) 7.5 (0.3) 7.2 (0.28) 12.8 (0.5) 2 x Ø8.5 (0.33) 32.5 (1.27) 37.2 (1.4) 59.3 (2.3) 65 40 (1.6) (2.6) 27.6 (1.1) 2 x Ø8.5 (0.33) 27 (1.06) 45.3 (1.8) REF 23.7 (0.9) 60.5 (2.4) 60.5 (2.
Appendix A Specifications Figure 38 - Padlock Accessory [mm (in.)] 4.7 (0.2) 102.7 (4.04) 2 x Ø4.7 (0.2) 15.5 (0.6) 3 x Ø7.4 (0.3) 17.5 (0.7) 20 (0.79) 35 (1.4) 3 x 10 (0.39) REF 45 (1.8) 8 x R2 (0.1) 2 x 7.8 (0.3) 63.8 (2.5) 74.8 (2.9) 85.8 (3.
Index A abbreviation 6 accessories 9 actuator dimension 54 spare 9 actuator code lock 26 allowable approach direction 14 application ArmorBlock Guard I/O 45 CR30 safety relay 38 DG safety relay 37 DI safety relay 35 EMD safety relay 35 GLP safety relay 31 GLT safety relay 33 MSR55P back EMF safety relay 49 POINT Guard I/O 40 approximate dimension 54 ArmorBlock Guard I/O application 45 assembly overview 8 assignment pin 19 auxiliary release 17 C CE Marked 53 certification 53 safety 11 characteristic operati
Index L L bracket dimension 55 learn additional replacement actuator 26 first-time 26 license-exempt RSS standard Industry Canada 53 lock actuator code 26 lock command 23 M mount switch body 15 mounting holes cracked/broken 30 MSR55P back EMF safety relay application 49 N notice FCC 53 O operating characteristic 51 operational state 6 orientation switch 14 OSSD 6 OSSD mode safety signal 20 output specification 52 output signal switching device 6 overview assembly 8 P package content 10 padlock accessor
Index T tap 6 terminology 6 testing functional 17 GuardLink mode 18 OSSD mode 18 time reaction 6 response 6 troubleshooting 30 TÜV Certified 53 U UL Listed 53 unique coding 6 use correct 13 W wiring 19, 25 Z Z bracket dimension 54 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 59
Index Notes: 60 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020
Guardmaster Guard Locking Switch User Manual Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 61
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