Rockwell Automation Allen-Bradley Guardmaster 440G-LZ, User Manual

Page 1: ...Guardmaster 440G LZ Guard Locking Switch User Manual ...

Page 2: ...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...

Page 3: ...sing this product Purpose of This Manual 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 Provides an overview of the Guardmaster 440G LZ guard locking switch Conventions Used in This Manual The following conventions are used th...

Page 4: ...tributor or sales representative Terminology OSSD 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 ...

Page 5: ...ty 13 Orientation of Switches 14 Setting the Actuator Direction of Approach 15 Mounting the Assembled Actuator 16 Mounting the Switch Body 17 Setting Actuator to Switch Alignment 17 Actuator RFID Setting 18 LED Error Codes During the Learning Process 19 Proving Basic Lock Function 20 Wiring 21 Connection Systems 21 Chapter4 DescriptionofOperation Description of LEDs During Operation 23 Status Diag...

Page 6: ...racteristics 29 Outputs 30 Environmental and General Protection 31 Certifications 31 Compliance to European Union Directives 32 Overall Dimensions 32 Catalog Numbers 34 AppendixB TypicalInstallations Switch Mounted Parallel to Hinge Axis 35 Switch Mounted Perpendicular to Hinge Axis 36 Switch Mounted to a Sliding Guard 36 EU Declaration of Conformity 37 ...

Page 7: ...eatures 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 Beca...

Page 8: ...ter 440G LZ Assembly Overview 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 Actuator mounting bracket Locking bolt Actuator Switch body Actuator mounting bracket QR Code Alignment guide ...

Page 9: ...Rockwell Automation Publication 440G UM001A EN P November 2013 9 General Description Chapter 1 Actuator Actuator to actuator mounting bracket mounting screws 2 x T10 Torx Alignment guide ...

Page 10: ...10 Rockwell Automation Publication 440G UM001A EN P November 2013 Chapter 1 General Description Notes ...

Page 11: ...vel e PLe applications Safety Certification 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 TÜV Rheinland group has app...

Page 12: ...e 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 ...

Page 13: ...ystem 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...

Page 14: ...tion 440G UM001A EN P November 2013 Chapter 3 Installation and Wiring If the recommended minimum proximity dimension is not observed the units will fault Orientation of Switches Can be used in all mounting orientations 120 mm 120 mm ...

Page 15: ...ctions 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 Ensure the locking bolt enters the actuator mounting bracket first Align the white triangles 0 4 Nm 2 x T10 Torx screws ...

Page 16: ...he actuator bracket bend The following drawings show mounting possibilities when attaching to extruded aluminum profile and flat surface guard doors Removal of the Actuator Plug This plug may be broken out from the actuator if a through hole is 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 com...

Page 17: ... fasteners not provided are required for proper mounting to a rigid guard door frame Setting Actuator to Switch Alignment There are three ways to achieve proper alignment 1 By setting gap G 2 5 mm 0 09 in 0 5 mm 0 0 19 in 2 By mounting hole alignment H 6 5 mm 0 25 in 4 9 mm 0 15 0 35 in 3 Using the alignment guide provided 3 x M5 G H ...

Page 18: ...ime learn four different actuators consecutively then complete a one time learning 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 actuato...

Page 19: ...t 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 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 de...

Page 20: ... 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...

Page 21: ...s facilitate connection 8 Pin Micro M12 8 Pin Cordset 889D F8AB or cable version Color Function Pin White Aux 1 Brown 24V DC 2 Green Lock 3 Yellow Safety B 4 Grey Safety A 5 Pink Safety B 6 Blue Gnd 0V 7 Red Safety A 8 2 24V DC 1 Aux 7 0V 6 Safety B 3 Lock Command 8 Safety A 4 Safety B 5 Safety A Keyway Safety wired Splitter T Port Cat No 898D 438Y D8 2 1 7 6 3 8 4 5 ...

Page 22: ...tion may be found online at ab com product catalogues search for Connection Systems Safety wired Shorting Plug Cat No 898D 418U DM 8 pin Device Patchcords Cat No 1 meter 8 pin 889D F8ABDM 1 2 meters 8 pin 889D F8ABDM 2 5 meters 8 pin 889D F8ABDM 5 10 meters 8 pin 889D F8ABDM 10 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...

Page 23: ...t flash green Off Lock CMD on door closed Closed On Off Locked Slow flash green Off Lock CMD on door closed Closed On On Locked Solid green On Power to Release Versions Guard Status Lock CMD OSSD Input Lock Status LED Status OSSD Status Power on with door open Open Off Off or on Unlocked Blinks 6x green then blinks 1x red followed by fast flash green Off Power on with door closed Closed Off Off Lo...

Page 24: ...put 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 Flashing3xgreen thenred repeats Attempting to lock unlock actuator not aligned Flashing 3x green then red repeating then finally fast flash red Failure to lock unlock Align actuator then cycle power Slow flash red 1 Hz OSSD fault check outputs are no...

Page 25: ...SR Relay 889D F8AX X Pigtail Red Brn Wht Grn Pnk Gry Yel Blu Power In1 In2 Out Logic A2 A1 S11 S21 S12 S22 S32 S42 L12 L11 Y32 S34 13 14 23 24 24VDC IN1 DI IN2 0 1 2 3 4 5 6 7 8 LOGIC Test Out A2 A1 B2 37 B1 47 48 38 L12 L11 X32 17 27 28 18 24VDC EMD 17 18 27 28 37 38 47 48 N C E Stop K1 K2 M K1 K2 Reset 440G LZS 24VDCSupply 24VDCCOM ...

Page 26: ... K2 Unlock Request Unlock Signal E Stop 800FM MT44 800F MX02S Reset GLP 440R GL2S2P A2 S12 S22 L11 L12 L61 51 P12 P22 A1 X14 X24 S54 S44 AP Y32 Reset Gate Lock Request Gate Unlock Request Y32 DI 440R D22R2 S32 A1 13 S21 S11 S22 S12 S34 S42 L12 14 872C D8NP18 E5 2 24V DC Class 2 Supply 24V DC COM 0 1 4 5 6 7 8 9 SL2 2 3 0 1 3 4 5 6 7 8 9 SL1 2 LOGIC 0 1 2 3 4 5 6 7 9 8 E Stop 800FM MT44 800F MX02S ...

Page 27: ... indicate series inputs are not 24V Actuator 5 is in sensing range and guard is locked Guard 5 functions properly Series inputs are 0V OSSDs are de energized to 0V Green LED is flashing to indicate series inputs are not 24V OSSDs are OFF Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Actuator 1 Actuator 2 Actuator 3 Switch 1 Switch 2 Switch 3 RTN 24V DC Power Supply 24 1606 XL120D Green Pink Grey Br...

Page 28: ...anual Release Safety A Safety B Occurs every 25 ms Occurs every 25 ms Occurs every 11 sec 300 μs 300 μs 600 μs 600 μs Occurs every 11 sec The manual release is provided to allow you to unlock the guard door in the event of unforeseen and uncommon circumstances Ifpower issuppliedtotheswitchandthelatter is in its locked state invoking the auxiliary release will cause the switch to enter a fault cond...

Page 29: ...yData Guarddoorsensingand lock monitoring PFHD 9 1 x 10 10 Dual channel interlock may be suitable for use in applications up to PLe in accordance with ISO13849 1 andforuseuptoSIL3systems in accordance with IEC 62061 depending on application characteristics Mission time PTI 20 years 440G LZS21 PR Power to release 440G LZS21 PL Power to lock Switch function OSSDs enable when guard closed and locked ...

Page 30: ...erating cycles 0 2 Hz Dwell time between subsequent locking unlocking 2 5 s Response time Off 100msfirstswitch 50msforeachadditional switch Risk time according to IEC 60947 5 3 100 ms Start up time availability 5 s Usage category IEC 60947 5 2 DC 13 24V 200 mA Insulation voltage Ui IEC 60947 5 1 75 V Impulse withstand voltage Uimp IEC 60947 5 1 1 kV Pollution degree IEC 60947 5 1 3 Manual auxiliar...

Page 31: ... to EN ISO 14119 2013 Operating temperature C F 0 55º 14 131º Storage temperature C F 25 75º 13 167º Operating humidity 5 95 relative Enclosure ingress rating NEMA 3 4x 12 13 IP66 IP67 IP69K Shock and vibration IEC 68 2 27 30 g 11 ms IEC 68 2 6 10 55 Hz Hygienic ISO 14159 2004 and EN 1672 2005 for part of the machine defined as food splash area Washdown Suitable for sodium hydroxide based washdown...

Page 32: ...ctives 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 Overall Dimensions Switch Body Actuator and Actuator Mounting Bracket 25 0 98 50 1 97 22 5 0 89 45 1 77 8 0 31 10 0 39 22 9 0 90 140 5 51 10 0 39 9 5 0 37 9 525 0 37 dia 22 5 0 88 134 5 5 29 33 1 29 2 x 5 5 0 22 dia 65 2...

Page 33: ... Specifications Appendix A Switch Mounting Bracket 440G LZAM2 6 35 0 25 54 2 12 40 1 57 R6 1 3 3x 5 5 3x 0 22 145 5 5 72 4x R6 1 mm 2x 15 2x 0 59 2x 33 2x 1 3 6x M5 x 0 8 6H 2x 31 5 2x 1 24 3 x 5 5 3x 0 22 2x 15 5 2x 0 61 18 5 0 73 2x 6 35 2x 0 25 22 75 0 89 100 3 93 ...

Page 34: ... 440G LZS21SPRH Unique High level to EN ISO 14119 2013 440G LZS21UPRA 440G LZS21UPRB 440G LZS21UPRH Power to Lock Standard Low level to EN ISO 14119 2013 440G LZS21SPLA 440G LZS21SPLB 440G LZS21SPLH Unique High level to EN ISO 14119 2013 440G LZS21UPLA 440G LZS21UPLB 440G LZS21UPLH Type Coding Cat No Power to Release Standard Low level EN ISO 14119 2013 440G LZASPR Unique High level EN ISO 14119 2...

Page 35: ...e guard door is being closed It is essential to check the alignment periodically throughout the use of the guard locking switch 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 The Z height position is adjusted by sliding t...

Page 36: ...ime 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 Y X Z 2 mm at min radius Minimum radius when guard hinge axis is perpendicular t...

Page 37: ...ntrol circuit devices and switching elements Requirements for proximity devices with defined behaviour under fault conditions PDF EN 60204 1 2006 A1 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 Ge...

Page 38: ...1 If no 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 440G LZS21 U P R H 1 2 3 4 5 1 Designates Product Type 440G LZS21 Guard locking RFID non contact safety switch w 2 safety outputs and 1 auxiliary output 2 Designates Actuator Coding Type U Unique S Standard code 3 Designates Sensor...

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Page 40: ... offer TechConnectSM 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 gettin...