Guardmaster® 440G-LZ Guard Locking Switch User Manual
Contents
1. sayin i Connections Systems The following connection system components facilitate connection 24V OV Safety A MI n Te Safety wired Splitter T Port Male M12 Female M12 1 1 2 2 2 3 3 4 4 5 5 12345678 Female M12 Rockwell Automation Publication 440G UM001A EN P November 2013 21 Chapter 3 Installation and Wiring Safety wired Shorting Plug Cat No 898D 418U DM 1 2 Nee a a T pin 4 055523 Pin 5 8 pin Device Patchcords 1 meter amp pin Ve 2 meters 8 pin 5 meters 8 pin 10 meters 8 pin Note Add the letter S to above cat nos for stainless steel connectors e g 889DS F8ABDM 1 Note Add the letter S to above cat nos for stainless steel connectors e g 889DS F5ACDM 1 O 5 pin Patchcords Cat No 1 meter 5 pin 889D F5ACDM 1 2 meters 5 pin 889D F5ACDM 2 5 meters 5 pin 889D F5ACDM 5 10 meters 5 pin 889D F5ACDM 10 5 pin Cordsets Cat No meters 5 pin 889D F5AC 2 5 meters 5 pin 889D F5AC 5 10 meters 5 pin 889D F5AC 10 Note Add the letter S to above cat nos for stainless steel connectors e g 889DS F5AC 1 More detailed information may be found online at ab com product catalogues search for Connection Systems 22 Rockwell Automation Publication 440G UM001A EN P November 2013 Status Diagnostic LEDs During Operation Chapter 4 Description of Operation Duri2. November 2013 31 AppendixA Specifications Compliance to European Union Directives Overall Dimensions 32 This product bears the CE Mark and is approved for installations within the European Union and EEA regions It has been designed and tested to meet the following directives Machine Safety and EMC For a complete list of standards used including Machine Safety Directive and EMC Directive see EU Declaration of Conformity on page 37 of this manual Switch Body 9 525 0 37 129 54 2x55 0 22 dia 9 5 0 37 225 0 88 134 5 5 29 Rockwell Automation Publication 440G UM001A EN P November 2013 Switch Mounting Bracket 440G LZAM2 100 3 93 22 75 0 89 2 15 5 2 0 61 2x 6 35 2x 0 25 Specifications Appendix A 1 R6_3 40 1 57 6 35 2 E 0 25 2x 15 2x 33 2x 0 59 nf Pex 1 s 4x R6 1mm 145 5 5 72 3x 5 5 3x 0 22 xas da 315 3x 0 22 x 0 8 6H 2x 1 24 Rockwell Automation Publication 440G UM001A EN P November 2013 33 AppendixA Specifications Cat Nos Complete switches including switch body actuator and actuator mounting bracket Cat No Connection 6 in pigtail with M12 8 pin Quick Type Actuator Coding 10mlead Disconnect Standard 440G LZS21SPRA 440G LZS21SPRB 440G LZS21SPRH Low level to EN 150 14119 2013 Unique 440G LZS21UPRA 440G LZS21UPRB 440G LZS21UPRH High level t
3. Rockwell Automation Publication 440G UM001A EN P November 2013 5 Table of Contents Specifications Typical Installations Appendix A oio dri RC boa laca Pd Rb ad 0958 da 2454 29 uv d UT se n ka kO Nake eie k df ac dum dH RU aC a 29 Operating Characteristics ccc cece cece cette teen eens 29 CULO UES ants ye e San bel 30 Environmental and General 31 COIT 440101 31 Compliance to European Union Directives 32 Overall 0 32 Catalog 34 Appendix Switch Mounted Parallel to Hinge lt 35 Switch Mounted Perpendicular to Hinge Axis 36 Switch Mounted to a Sliding Guard 36 EU Declaration of 37 Rockwell Automation Publication 440G UM001A EN P November 2013 Guardmaster 440G LZ Overview Rockwell Automation Publication 440G UM001A EN P November 2013 Chapter General Description This Guardmaster 440G LZ guard locking switch functions by extending a locking bolt from the switch through a hole in the actuator thus preventing the opening of a guard The locking bolt drive mechanism and logic ensure that the locking bolt is allowed to ex
4. for and on behalf of the above named manufacturer Place and date of issue Milwaukee WI USA 11 Nov 2013 Name function Daniel L Nachtigall Technical Leader Product Certification Engineering Signature 09 ctu Rockwell Automation Publication 440G UM001A EN P November 2013 37 AppendixB Typical Installations Rockwell Automation 2 Directive Catalogue number Series Description Directive Catalogue number Series Description ue e 440G LZ2 Guard locking RFID non contact safety switches Accessories 889D F8AB Cordset for use with sensors with Micro M12 connector 889D FSABDM Patchcord for use with sensors with Micro M12 connector 1 Ifno series number is given then all series are covered 2 Yes Product is certified to this directive N R This directive is not required for this product NOMENCLATURE 4400 17521 U P R H Designates Product Type 440G LZS21 Guard locking RFID non contact safety switch w 2 safety outputs and 1 auxiliary output Designates Actuator Coding Type U Unique S Standard code Designates Lock Mode Power to release L Power to lock Designates Connection Type H 8 pin micro M12 connector pigtail A 3 meter cable B 10 meter cable 38 Rockwell Automation Publication 440G UM001A EN P November 2013 Rockwell Automation Support Rockwell Automation provides technical information on the web to as
5. position is adjusted by sliding the actuator bracket up down on the profile If the setting gap is centered between the minimum of 0 mm and the maximum of 5 mm a tolerance to misalignment of 2 5 mm is achieved The X and Y positions can be adjusted using the slotted holes of the mounting bracket and appropriate selection of the three pairs of actuator bracket holes once the bracket is centered The tolerance to misalignment is 2 5 mm 2mm at min radius Minimum radius when guard hinge axis is perpendicular to the switch body axis Mounting bracket 440G LZAM2 36 Rockwell Automation Publication 440G UM001A EN P November 2013 Typical Installations Appendix B Rockwell Automation EU Declaration of Conformity Identification of the product Guard Locking Safety Switch Name and address of the manufacturer Name and address of the authorised representative Rockwell Automation Inc Rockwell Automation B V 2 Executive Drive Rivium Promenade 160 Chelmsford MA 01824 2909 LM Capelle aan den Ijssel USA The Netherlands This declaration of conformity is issued under the sole responsibility of the manufacturer Object of the declaration Allen Bradley Guardmaster 440G LZ21 Series reference the attached list of catalogue numbers The object of the declaration described above is in conformity with the relevant EU harmonisation legislation 2004 108 EC EMC Directive EMC 2006 42 EC Machinery D
6. technical documents contact your local Rockwell Automation distributor or sales representative Terminology 05SD Output Signal Switching Device Typically designates a pair of solid state signals pulled up to the DC source supply The signals are usually tested for short circuits to the DC power supply short circuits to the DC common and short circuits between the two signals Standard coding Same as Low coding as defined in EN ISO 14119 2013 Unique coding Same as High coding as defined in EN ISO 14119 2013 4 Rockwell Automation Publication 440G UM001A EN P November 2013 General Description Safety Concept Installation and Wiring Description of Operation Table of Contents Important User Information 2 Preface Who Should Use This 3 Purpose of This Manual 3 Conventions Used in This 3 Additional 3 TCM MIN OOO Se uwe n bel xen utes Kine b e inb e be GYAN 4 Chapter 1 Guardmaster 440G LZ kk kk kk kk 7 Assembly 8 Packaging CODETODIS eae ae ae eae 8 Chapter 2 Safety Standards Applied to Guardmaster 440G LZ 11 kiya n d n n ley LEUR 11 Safety Certif
7. 001A EN P November 2013 Installation and Wiring Chapter 3 Setting the Actuator The actuator can approach the switch from all four directions Direction of Approach Ensure the white arrow on the actuator aligns with the white arrow on the switch body The actuator must be fitted to the actuator mounting bracket in such a manner that the white alignment triangles marked on both the actuator and switch body are in the installed position Align the white triangles 2x T10 Torx screws Ensure the locking bolt enters the actuator mounting bracket first Rockwell Automation Publication 440G UM001A EN P November 2013 15 Chapter 3 Installation and Wiring Mounting the Assembled Actuator Ensure two fasteners are used with at least one fastener fitted close to the actuator bracket bend The following drawings show mounting possibilities when attaching to extruded aluminum profile and flat surface guard doors Always use 2 fasteners with at least one fastener near the actuator Q sie of 8 Ss Removal of the Actuator Plug This plug may be broken out from the actuator if a through hole is 16 required to prevent a food trap when mounted on the hazard side of a guard door The plug can be broken out by using a screwdriver and twisting until it comes apart On Rockwell Automation Publication 440G UM001A EN P November 2013 Mounting the Switch Body Setting Actuator to Switch Alignment In
8. 01A EN P November 2013 25 Chapter 4 Description of Operation Guardmaster 440G LZ Wiring Point to Point with Unlock request with Point 1 0 24V DC Supply Safety Fault Unlock Reset Reset Request c pe Ij o P K1 Pigtail N C ecc 1 j K 1734 IB8S M 24V DC COM Unlock Signal COM COM 1734 85 Guardmaster 440G LZ Wiring E Stops with Speed Monitoring Guard Locking and Servo Drive with GLP Relay 24V DC Class 2 Supply E Stop Gate 800FM MT44 Drive Status pA Unlock 800F MX025 to PLC Reset amp Request Reset E Gate Lock Safety 440G LZS21SPRA Brn Yel jer li Wht Blu Reset SLS S H Request o ae y Stop Start SLS 22 gt j fromPIC 511 512 521 522 1 13 23 534 ene NA Locic 7 sii 0 512 0 0 CE NS MEZ K 300 1 DI 5 440R GL2S2P 440R D22R2 X X XX X KX Safe Torque off STO Connector With Wiring Header Gate Open Unlocked RS E Stop 800F MX02S Safety Input 2 872C D8NP18 E5 2 24V DC COM 26 Rockwell Automation Publication 440G UM001A EN P November 2013 Description of Operation Chapter 4 Troubleshooting Series Circuit 24 24V DC Power Supply RTN Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 1606 XL120D a E m Lock Unlock Lock Unlock Lock Unlock Lock Unlock Lock Unlock Re
9. Allen Bradley Cua norte Guardmaster 440G LZ Guard Locking Switch User Manual dia i amp E Rockwell Allen Bradley Rockwell Software Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI INO01 EN P available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable 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
10. ICatlOD ciu voe ee S oe ox acl a ak44 11 Chapter 3 General Considerations 13 PAP OXI A m 13 Orientation of Switches i 4 3 2444 4440 245020424 nay nn 14 Setting the Actuator Direction of 15 Mounting the Assembled 16 Mounting the Switch 17 Setting Actuator to Switch Alignment 17 Actuator REID Settings dE ERES Eq oun b 20 18 LED Error Codes During the Learning Process 19 Proving Basic Lock 20 tro 21 Connection Systems 21 hapter 4 Description of LEDs During Operation 23 Status Diagnostic LED During Troubleshooting 24 Auxiliar OUt FUNCHON eiue dte teer do D a 11253352300 24 Guardmaster 440G LZ Wiring with GSR Relay 25 Guardmaster 440G LZ Wiring with Point I O 26 Guardmaster 440G LZ Wiring with GLP Relay 26 Guardmaster 440G LZ Troubleshooting Series Circuit 27 Unit Response 27 OSSD Output Test 5 28 Auxiliary Manual cece KK KK KK KK KK KK 28
11. ce a new actuator is learned by a unique coded switch any previous actuator is no longer usable by that switch One time Learning Process Proceed just as in the multi time teaching process described above with the following exception at the programming finalizing last stage withdraw the actuator from the switch until the LED turns solid red then immediately reposition the actuator near the switch This process must be executed within 15 seconds The LED blinks then turns solid to indicate that the learning process is complete Power to release Solid green Power to lock Solid red Note For power to release switches you will need to execute a manual release in order to withdraw the actuator away from the switch as described above Rockwell Automation Publication 440G UM001A EN P November 2013 19 Chapter 3 Installation and Wiring Status Diagnostic LED Error Codes During the Learning Process Proving Basic Lock Function 20 The following code sequences persist until a Power On Off cycle is completed Status Diagnostic LED Flashes 4 Hz Error Code Green OSSD inputs not valid Red red red green Cannot learn a standard actuator Red red red green green Actuator already learned Red red red green green green Bad RFID actuator moved out of range Red red red green green green green Exceeded learning eight actuators Red red red green green green green Unit locked cannot learn another actuator green To
12. 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 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 IMPORTANT Identifies information that is critical for successful application and understanding of the product It is recommended that you save this user manual for future use 2 Rockwell Automation Publication 440G UM001A EN P November 2013 Who Should Use This Manual Purpose of This Manual Conventions Used in This Manual Additional Resources Rockwell Automation Publication 440G UM001A EN P November 2013 Prefac
13. ck monitoring functions The 440G LZ must be installed in accordance with the applicable regulation and standards While the 440G LZ can be used for SIL 3 PLe and Category 4 applications the installer must comply with guard requirements e g EN ISO13854 and EN ISO 13857 and in some cases also minimum safe distance requirements e g EN ISO 13855 Rockwell Automation Publication 440G UM001A EN P November 2013 11 Chapter 2 12 The installed system including the safety control system and the means by which the machine stops must achieve the needed safety performance The 440G LZ is one element in the safety system Additional guidance on guards guard locking and guard interlocking may be found in EN ISO 12100 EN ISO 13854 EN ISO 13855 EN ISO 13857 EN ISO 14119 EN ISO TR 24119 EN ISO 14120 Application specific C Level standards Rockwell Automation Publication 440G UM001A EN P November 2013 General Considerations Pair Proximity Chapter 3 Installation and Wiring The 440G LZ guard locking switch is designed for use on guards that are engineered to be rigid without sag A separately mounted latch e g magnetic or mechanical and mechanical stop are required It can be used on Full Body Access guards that do not require escape release emergency release or remote release guards and in any situation where the alignment tolerance falls within the stated specification Installation must be in acc
14. coverable Actuator 1 is in sensing range Actuator 2 is in sensing range Actuator 3 is in sensing Actuator 4 is in sensing range Actuator 5 is in sensing range OSSDs Fault and guard is locked and guard is locked range and guard islocked and guard is locked Guard and guard is locked Guard 5 are OFF Guard 1 functions properly Guard 2 functions properly Guard 3 has a fault 4 functions properly Series functions properly OSSDs are energized to 24V OSSDs are energized 24V See Diagnostic table inputs are OV OSSDs are Series inputs are OV OSSDs Green LED is ON Green LED is ON Red LED is flashing de energized to OV Green are de energized to OV Green LED is flashing to indicate LED is flashing to indicate series inputs are not 24V series inputs are not 24V Unit Response Times When Connected in Series RT 24V DC Power 1606 XL120D Ts s III WI NESE Switch 1 Switch 3 RA BEE d command Initial Conditions Switch 1 receives Switch 2 drops the 24 volts Switch 3 drops the 24 volts All switches are Unlock command red and yellow from red and yellow from locked guard can then switch 1 OSSD outputs switch 3 OSSD outputs be opened Green LED flashes Green LED flashes 0 ms 100 ms 150 ms 200 ms Switch 1 guardis Switch 1 OSSD Switch 2 OSSD inputs red Switch 3 OSSD inputs red closed outputs are and yellow transition to and yellow
15. e Read this preface to become familiar with the rest of the manual It provides information concerning who should use this manual e the purpose of this manual e related documentation e conventions used in this manual Use this manual if you are responsible for designing installing programming or troubleshooting systems that use the Guardmaster 440G LZ guard locking switch You should have a basic understanding of electrical circuitry and familiarity with safety related systems If you do not obtain the proper training before using this product This manual is a reference guide for the Guardmaster 440G LZ guard locking switch It describes the procedures you use to install wire and troubleshoot your switch This manual Explains how to install and wire your 440G LZ e Provides an overview of the Guardmaster 440G LZ guard locking switch The following conventions are used throughout this manual e Bulleted lists such as this one provide information not procedural steps Numbered lists provide sequential steps or hierarchical information The following document offers additional information about related Rockwell Automation products Resource Description Allen Bradley Industrial Automation Glossary Glossary of industrial automation terms and publication AG 7 1 abbreviations Preface You can view and download publications http www rockwellautomation com literature To order paper copies of
16. e C 1 2 2 Standards Safety Classification Guard door sensing and lock monitoring Functional Safety Data Guard door sensing and lock monitoring 440G LZS21 PR 440G LZS21 PL Switch function Torque for M5 mounting of switch and actuator mounting bracket Locking bolt insertion for assured locking and holding force Approach speed Locking bolt alignment tolerance X Y Z Holding force Fmax EN ISO 14119 Holding force Fzh EN ISO 14119 Maximum output current each output Quiescent power consumption Locked or Unlocked 60947 5 3 IEC 60947 5 1 IEC 61508 EN ISO 13849 1 IEC 62061 EN ISO14119 UL 508 PLe Category 4 per ISO 13849 1 SIL 3 per IEC 61508 and IEC 62061 9 1 10770 Dual channel interlock may be suitable for use in applications up to PLe in accordance with 150 13849 1 and for use up to SIL 3 systems in accordance with IEC 62061 depending on application characteristics Mission time PTI 20 years Power to release Power to lock OSSDs enable when guard closed and locked 2 Nm max Minimum of 5 mm 0 19 in maximum of 10 mm 0 39 in Minimum of 2 mm s Maximum of 2 5 mm 1 690 N 1 300 N 200 mA 2 5 W Rockwell Automation Publication 440G UM001A EN P November 2013 29 AppendixA Specifications Peak current during turn on or after Lock 400 mA Unlock operation Duration of peak current at turn on or after 100 ms Lock Unlock operation Maximum number
17. et mounting screws 2 x T10 Torx h Alignment guide Rockwell Automation Publication 440G UM001A EN P November 2013 Chapter 1 General Description Notes 10 Rockwell Automation Publication 440G UM001A EN P November 2013 Safety Standards Applied to the Guardmaster 440G LZ Guard Locking Switch Introduction Safety Certification Chapter 2 Safety Concept The Guardmaster 440G LZ satisfies applicable requirements in the following standards related to functional and machinery assembly e IEC 60947 5 1 2003 A1 2009 e IEC 60947 5 3 1999 A 2005 e IEC 61508 2010 SIL 3 e IEC 62061 2005 SIL 3 e EN ISO 13849 1 2008 AC 2009 Performance Level Category 4 e EN ISO 14119 2013 e UL508 17th Edition dated 3 19 2013 This section describes the safety performance level concept and explains how the Guardmaster 440G LZ meets the requirements for SIL 3 Cat 4 or Performance Level e PLe applications The Guardmaster 440G LZ 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 Performance Level PLe and Category 4 in compliance with ISO 13849 1 Safety requirements are based on the standards applicable at the time of certification The TUV Rheinland group has approved the Guardmaster 440G LZ for use in safety related applications where Performance Level e is required for the door position and lo
18. g process that would prevent it from learning any additional actuators Learning the First Multi Time Actuator Connect the switch to 24V DC see the wiring diagrams on page 21 and ensure that the lock command is off The Status Diagnostic LED will blink a number of times corresponding to the number of times a new actuator may be acquired a total of eight times when the switch is new then repeat indicating that the switch has yet to learn a new actuator The switch automatically starts the learning process as soon as an actuator is placed in the guard closed position of the switch Rockwell Automation Publication 440G UM001A EN P November 2013 Installation and Wiring Chapter 3 Learning Sequence as Indicated by the Status Diagnostic LEDs Actuator present Blinking green 1 Hz rate Verifying actuator Blinking green red 1 Hz rate 15 sec Programming switch 15 sec Blinking green red 4 Hz rate 15 sec Program finalization Blinking green remaining number of times a new actuator may be acquired 15 sec Ready state learning process is complete Solid green Power to release Solid red Power to lock Learning Additional Multi Time Actuators Mount the new actuator on the guard and repeat the above process introducing the actuator to the switch as previously described During program finalization the LED will blink green a number of times corresponding to the number of remaining learnable actuators Note On
19. irective MD References to the relevant harmonised standards used or references to the specifications in relation to which conformity is declared EN 60947 1 2007 Low voltage switchgear and controlgear Part 1 General rules EN 6094 7 5 3 1999 41 2005 Low voltage switchgear and controlgear Part 5 3 Control circuit devices and switching elements Requirements for proximity devices with defined behaviour under fault conditions PDF EN 60204 1 2006 41 2009 Safety of Machinery Electrical equipment of machines General requirements IEC 61508 Part 1 7 2010 Functional Safety of electrical programmable electronic safety related Systems EN ISO 13849 1 2008 Safety related parts of control systems Part 1 General principles of design EN 62061 2005 Safety of Machinery Functional safety of safety related electrical electronic and programmable electronic control systems EN ISO 14119 2013 Safety of Machinery Interlocking devices associated with guards Principles for design and selection Notified Body TUV Rheinland IndustrieService GmbH 51105 Koln Germany performed EU Type Examination and issued the certificate 968 EZ 616 00 13 Additional information Person authorised to compile the Authorised representative see details above technical file MD Product Safety Function MD Interlocking devices suitable for use in safety related applications up to PLe EN ISO 13849 1 and SIL SIL CL EN 61508 EN 62061 Signed
20. ng operation the LEDs indicate the status of the Guardmaster 440G LZ guard locking switch as follows Power to Lock Lock OSSD Versions CMD Status Power on and lock Open or Off Offor Unlocked Blinks 6x green Off CMD off closed on then solid red Lock CMD on door Offor Unlocked Fast flash green Off open on Lock CMD on door Closed Off Locked Slow flash green Off closed Lock CMD on door Closed Locked Solid green On closed Power to Lock OSSD Release Versions CMD Status Power on with Off Offor Unlocked Blinks 6x green Off door open on then blinks 1x red followed by fast flash green Power on with Closed Off Off Locked Blinks green door closed then blinks 1x red followed by slow flash green Power on with Closed Off Locked Blinks 6x green door open and then blinks 1x OSSD input active red followed by solid green Unlock on Open or Off or Unlocked Solid red Off and door closed or closed on open Rockwell Automation Publication 440G UM001A EN P November 2013 23 Chapter 4 Description of Operation Status Diagnostic LEDs During Troubleshooting Auxiliary Out Function 24 This section explains the meaning of the various LEDs during troubleshooting LED Status Switch Status Off Not powered Solid green Door shut locked and OSSDs are ON Fast flash green 4 Hz Waiting to lock actuator is not within range Slow flash green 1 Hz Door sh
21. ning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Rockwell Automation Allen Bradley and POINT I O are trademarks of Rockwell Automation Inc Guardmaster is a registered trademark of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are the property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 440G UM001A EN P November 2013 Copyright 2013 Rockwell Automation Inc All rights reserved
22. o EN Power to 150 14119 2013 Release Standard 440G LZS21SPLA 440G L S21SPLB 440G LZS21SPLH Low level to EN ISO 14119 2013 Unique 440G LZS21UPLA 440G LZS21UPLB 440G LZS21UPLH High level to EN Power to Lock 0 14119 2013 Spare actuators and actuator mounting bracket Standard 440G LZASPR Low level EN ISO 14119 2013 Unique 440G LZAUPR Power to Release High level EN ISO 14119 2013 Standard 440G LZASPL Low level EN ISO 14119 2013 Unique 440G LZAUPL High level EN ISO 14119 2013 Power to Lock Actuator mounting bracket 440G LZAM1 Accessories Description Cat No Switch body mounting bracket 440G LZAM2 34 Rockwell Automation Publication 440G UM001A EN P November 2013 Switch Mounted Parallel to Hinge Axis Typical Installations The X and Y positions can be adjusted using the slotted holes of the mounting bracket and appropriate selection of the three pairs of actuator bracket holes once the bracket is centered The tolerance to misalignmentis Mounting 2 5 mm 440G LZAM2 5 29 The 2 height position is adjusted by sliding the actuator bracket up down the profile If the setting Actuator Locking bolt gap is centered between the Hole 9mm minimum of 0 mm and the 14mm gee maximum of 5 mm a tolerance to misalignment of 2 5 mm is achieved The Z position should be carefully selected to offset the anticipated door sag o
23. of switches connectable Unlimited See Chapter 4 Unit Response Times series Operating voltage Ue 24V DC 10 15 Class 2 SELV Maximum frequency of operating cycles 0 2 Hz Dwell time between subsequent locking 2 55 unlocking Response time Off 100 ms first switch 50 ms for each additional switch Risk time according to IEC 60947 5 3 100 ms Start up time availability 55 Usage category IEC 60947 5 2 DC 13 24V 200 mA Insulation voltage Ui IEC 60947 5 1 75 Impulse withstand voltage Uimp IEC 60947 5 1 kV 1 Pollution degree IEC 60947 5 1 3 Manual auxiliary release Built in Emergency release No Escape release No Protection class IEC 61140 Class Il See nomenclature section below and cat nos section on page 34 Nomenclature for Complete Switches 440G LZS21 P b c a b C Standard Coding Power to Release 3 Cable M12 8 pin Outputs Guard Closed and Locke d Outputs Description Status Safety 2 x PNP 0 2 max ON 24V DC Auxiliary 2 x PNP 0 2 A max OFF 0V DC 30 Rockwell Automation Publication 440G UM001A EN P November 2013 Environmental General Protection Certifications Operating temperature C F Storage temperature C F Operating humidity Enclosure ingress rating Shock and vibration Hygienic Washdown Radio frequency EMC Materials Weight switch actuator Connection Short circuit protection Current limitation Overload
24. ordance with the present manual and must be carried out by qualified personnel exclusively The 440G LZ guard locking switch is intended to be part of the safety related control system of a machine 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 Refer to the Specifications section of this manual Use appropriate screws bolts or nuts fitted by tools to mount the switch and actuators to avoid tampering Do not over torque the mounting hardware ATTENTION For the switch actuator and actuator mounting bracket Only use the designated mounting holes e Never drill or use to support other structures such as a conduit cable ways or other hardware During installation make sure you observe the following restriction you must maintain a minimum distance between each pair of switches you mount Make sure to maintain a minimum distance of 120 mm 4 72 in between any two switches and actuators as indicated in the following illustrations Rockwell Automation Publication 440G UM001A EN P November 2013 13 Chapter 3 Installation and Wiring _ 20 _ mm If the recommended minimum proximity dimension is not observed the units will fault Orientation of Switches Can be used in all mounting orientations 14 Rockwell Automation Publication 440G UM
25. protection Reverse polarity protection Overvoltage protection Thermal shutdown restart Specifications Appendix A 0 55 14 131 25 759 13 167 5 95 relative NEMA 3 4x 12 13 IP66 IP67 IP69K IEC 68 2 27 30 0 11 ms IEC 68 2 6 10 55 Hz ISO 14159 2004 and EN 1672 2005 for part of the machine defined as food splash area Suitable for sodium hydroxide based washdown fluids IEC 60947 5 3 FCC 1 Parts 18 amp 15 R amp TTE ABS locking bolt and mounting bracket 304 stainless steel Switch 400 0 actuator 22 g actuator mounting bracket 60 g Fying lead or pigtail with M12 8 pin QD connector stainless steel Incorporated Incorporated Incorporated Incorporated Incorporated up to 60V max Incorporated See the Product Certification link at http www rockwellautomation com rockwellautomation certification for Declaration of Conformity Certificates and other certification details ULListed Industrial Control Equipment Certified for US and Canada CE Marked for all applicable directives e C Tick Marked e T V Certified for Functional Safety up to SIL 3 Category 4 for use in safety applications up to and including SIL 3 in accordance with IEC 61508 and EN 62061 Performance Level e and Category 4 in accordance with ISO 13849 1 both for guard positioning and for lock monitoring according to EN ISO 14119 2013 Rockwell Automation Publication 440G UM001A EN P
26. prove basic lock function and to verify correct actuator alignment it may be necessary to extend the locking bolt The locking bolt cannot be extended by mechanical means you must proceed electrically The following basic connections are required Pin 2 brown wire must be connected to 24V DC e Pin7 blue wire must be connected to OV GND In the case of a power to release switch the locking bolt will extend when the guard is shut and the actuator is aligned Connect Pin 3 green wire to 24V DC to unlock the switch and withdraw the locking bolt If power is removed from a power to release switch in the locked position the locking bolt will remain in its extended position switch locked Use the manual auxiliary release to unlock the switch In the case of a power to lock switch connect Pin 3 green wire to 24V DC to lock the switch i e extend the locking bolt Disconnecting Pin 3 will unlock the switch If power is removed from a power to lock switch in the locked position the switch unlocks In either type of lock the locking bolt never extends in the absence of the actuator Rockwell Automation Publication 440G UM001A EN P November 2013 Installation and Wiring Chapter 3 Wiring 3 Lock Command 2 24V DC 8 Safety A Keyway 4 Safety B 1 Aux 7 0V 5 Safety A 8 Pin Micro M12 6 Safety B Pi DAV DG 8 Pin Cordset Lock 3 889D F8AB or cable version Safety B 4 Safety A Safety 6
27. r door drop At the same time ensure that the alignment is such that it is not possible to lift the door up and off the locking bolt Also make sure that there is no possibility that the actuator would collide with the switch when the guard door is being closed It is essential to check the alignment periodically throughout the use of the guard locking switch Rockwell Automation Publication 440G UM001A EN P November 2013 35 AppendixB Typical Installations Switch Mounted Perpendicularly to Hinge Axis Switch Mounted to a Sliding Guard Door The Z height position is adjusted by sliding the actuator bracket up down on the profile If the setting gap is centered between the minimum of 0 mm and the maximum of 5 mm a tolerance to misalignment of 2 5 mm is achieved The X and Y positions can be adjusted using spacers underneath the switch and appropriate selection of the three pairs of actuator bracket holes once the bracket is centered The tolerance to misalignment is 2 5 mm The Z position should be carefully selected to offset the anticipated door sag or door drop At the same time ensure that the alignment is such that it prevents lifting the door up and off the locking bolt Also check to ensure there is no possibility that the actuator would collide with the switch when closing the guard door It is essential to check the alignment periodically throughout the use of the guard locking switch The Z height
28. sist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local Allen Bradley distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 11 440 646 3434 Outside United States Use the Worldwide Locator at http www rockwellautomation com support americas Canada phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure they are fully operational when shipped from the manufacturing facility However if your product is not functio
29. stallation and Wiring Chapter 3 Three M5 fasteners not provided are required for proper mounting to a rigid guard door frame There are three ways to achieve proper alignment 1 By setting gap 2 5 mm 0 09 in 0 5 mm 0 0 19 in 2 By mounting hole alignment H 6 5 mm 0 25 4 9 mm 0 15 0 35 11 3 Using the alignment guide provided Rockwell Automation Publication 440G UM001A EN P November 2013 17 Chapter 3 Installation and Wiring Actuator RFID Setting ATTENTION After installation ensure that there is no possibility of lifting the actuator over the extended locking bolt ATTENTION After installation ensure there is no possibility of collision when the actuator approaches the switch body Switches with standard coded actuators These switches are ready for use and need no special RFID setting Switches with unique coded actuators Before use the switches must first learn a new RFID guard actuator This task is not performed at the factory as there are two possible methods e Multi time learning the switch can learn up to eight actuators consecutively e One time learning The switch learns one actuator only for life irreversibly The one time learning method may be invoked at any time not just during RFID setting For example the switch could multi time learn four different actuators consecutively then complete a one time learnin
30. tend only when the corresponding actuator is detected within range The appropriate actuator is detected by RFID coding This version of the Guardmaster 440G LC guard locking switch features OSSD outputs that are enabled only when the locking bolt is sensed in its extended position in the actuator which happens only when the guard is both closed and locked The locking bolt drive mechanism uses a bi stable solenoid as a result the switch consumes very little electrical power with peak currents occurring only briefly upon start up and after each movement of the locking bolt Because of its bi stable drive not only does the device consume minimal power but it does not produce heat whether in its locked or unlocked condition Despite the bi stable design of the locking bolt drive 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 Chapter 1 General Description Guardmaster 440G LZ Assembly Overview Locking bolt hw QR Code Actuator mounting bracket Alignment guide Switch body Packaging Contents The box includes the following components Switch body including connection lead 3 m or 10 m flying lead or pigtail equipped with M12 QD connector 8 Rockwell Automation Publication 440G UM001A EN P November 2013 General Description Chapter 1 Actuator Actuator to actuator mounting brack
31. transition to energized 24V DC from switch 1 OSSD 24V DC from switch 2 outputs Switch 2 OSSD OSSD outputs Switch 3 outputs are energized OSSD outputs are energized 0 ms 600 ms 625 ms 650 ms Rockwell Automation Publication 440G UM001A EN P November 2013 27 Chapter 4 Description of Operation OSSD Output Test Pulses The Guardmaster 440G LZ guard locking switch uses test pulses to check for OSSD output faults This process is illustrated graphically as follows Occurs every 25 ms Occurs every 11 sec Safety A 300 Us lt 600 US Occurs every 25 ms Occurs every 11 sec Safety B 300 us lt 600 us Auxiliary Manual Release The manual release is provided to allow you to unlock the guard door in the event of unforeseen and uncommon circumstances lt 2 5 0 098 dia lf power is supplied to the switch and the latter is in its locked state invoking the auxiliary release will cause the switch to enter a fault condition blinking red LED To reset the switch simply cycle the power 28 Rockwell Automation Publication 440G UM001A EN P November 2013 Introduction Safety Ratings Operating Characteristics Specifications Appendix This appendix provides the specifications for the Guardmaster 440G LZ guard locking switch Note The holding force Fzh is in accordance to EN ISO 14119 2013 clause 5 7 4 Additional validation was performed in accordance with IEC 60947 5 1 2009 claus
32. ut locked OSSDs are OFF because there s no safety input signal Solid red PTL versions Door open or shut not locked No lock signal Solid red PTR versions Door open or shut not locked Unlock signal is ON Flashing 3x green then red repeats Attempting to lock unlock actuator not aligned Flashing 3x green then red Failure to lock unlock Align actuator then cycle power repeating then finally fast flash red Slow flash red 1 Hz OSSD fault check outputs are not shorted to GND 24V DC or each other Cycle power to reset Fast flash red 4 Hz General fault Cycle power to reset The Auxiliary Out only changes state when the door is shut and locked regardless of OSSD status Power to Lock Versions Lock CMD Lock Status Auxiliary Out Door open Unlocked On Lock CMD on door closed Off Power to Release Versions Lock CMD jLockStatus Auxiliary Out Door open Unlocked On Rockwell Automation Publication 440G UM001A EN P November 2013 Description of Operation Chapter 4 Guardmaster 440G LZ Wiring with GSR Relay 24V DC Supply 440G LZS 889D F8AX X Reset 9 v ii 1 al P Pigtail 511 521 512 Test Out 1 B1 B2 37 38 pos 31 6 L NS ur o na Neko Ss G3 Allen Bradley 1 9g 297 10 1 me 17 18 27 1 112 111 X32 24V DC Rockwell Automation Publication 440G UM0
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