Guardmaster Guard Locking

Switch
Catalog Numbers 440G-MZS20SNRJ, 440G-MZS20UNRJ,
440G-MZS20SNLJ, 440GMZS20UNLJ

User Manual Original Instructions

Guardmaster Guard Locking Switch User Manual

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may
lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or
economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may
be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach
dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc
Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements
for safe work practices and for Personal Protective Equipment (PPE).

2 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Table of Contents

Preface
Who Should Use This Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Purpose of This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Chapter 1
Product Overview Guardmaster 440G-MZ Safety Switch Overview. . . . . . . . . . . . . . . . . . . . . 7
Guard Locking on Power to Release Versions . . . . . . . . . . . . . . . . . . . . 8
Guard Locking on Power to Lock Versions . . . . . . . . . . . . . . . . . . . . . . 8
Assembly Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Chapter 2
Safety Concept Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 3
Installation General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Correct Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Switch Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Actuator Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pair Proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mount the Switch and Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Auxiliary Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Padlock Accessory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OSSD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
GuardLink Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chapter 4
Wiring and System Integration Pin Assignment and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OSSD Mode Safety Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
GuardLink Mode Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
GuardLink System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Add Device to a Studio 5000 Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Upload Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Manual Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Lock Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OSSD Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GuardLink Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 3

Table of Contents

Chapter 5
Commission the Safety Switch Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
First-time Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Learn Additional Replacement Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Lock the Actuator Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Error Codes during the Commissioning Process . . . . . . . . . . . . . . . . . . . 26

Chapter 6
Device Status and Status Indicators during Power-up Routine . . . . . . . . . . . . . . . . . . . . . . . 27
Troubleshooting Status Indicators During Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Diagnostic/Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Mounting Holes of the Switch Body Cracked or Broken . . . . . . . . . 30

Chapter 7
Application Examples Wire to GLP Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Circuit Status as Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Safely-limited Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wire to GLT Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Wire to DI and EMD Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Circuit Status as Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Stopping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Wire to DG Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Wire to CR30 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Wire to POINT Guard I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wire to ArmorBlock Guard I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Wire to MSR55P Back EMF Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Appendix A
Specifications Safety Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Outputs (Guard Door Closed and Locked) . . . . . . . . . . . . . . . . . . . . . . . . . 52
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Compliance to European Union Directives . . . . . . . . . . . . . . . . . . . . . . . . 53
Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Preface

Who Should Use This Use this manual to design, install, program, or troubleshoot systems that use
the Guardmaster® 440G-MZ Guard Locking Safety Switches.
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.
It describes the procedures that you use to install, wire, and troubleshoot your
switch. This manual accomplishes the following:
• Explains how to install and wire your 440G-MZ safety switch
• Provides an overview of the Guardmaster 440G-MZ safety switch

Summary of Changes This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.

Topic Page
Added FCC and IC certification information 53

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 5

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.

Table 1 - Terms and Abbreviations

Term Definition
This signal is either static or dynamic. When static, this signal is LO when the system is
CLU (Command, Lock, operational and HI when a demand is placed on the safety system. The signal is
and Unlock) dynamic when an unlock or lock command is issued to a GuardLink-enabled guard
locking device, such as a 440G-MZ safety switch.
HI Logic state of being ON or a voltage level to be above the turn-on threshold.
LO Logic state of being OFF or a voltage level to be below the turn-off threshold.
NC No connection
The switch is in operational state when there is no demand on its safety function (that
Operational state is, the switch is closed and locked).
Typically a pair of solid-state signals pulled up to the DC source supply. The signals are
OSSD (Output Signal tested for short circuits to the DC power supply, short circuits to the DC common, and
Switching Device) short circuits between the two signals.
PLC A programmable logic controller or a programmable automation controller.
Reaction time Describes the time between the true state of the input to the ON state of the output.
Describes the time between the trigger of the input to the OFF state of the output.
Response time Throughout this manual, the safety outputs may be described as turning off
immediately, which means that the safety outputs turn off within the response time.
RFID Radio frequency identification
The switch is in safe state when there is a demand on its safety function (that is, the
Safe state switch is unlocked).
Standard coding Same as Low coding as defined in ISO 14119
A connection in a GuardLink® circuit that associates a safety device to the GuardLink
Tap circuit.
Unique coding Same as High coding as defined in ISO 14119

Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.

Resource Description
440G-MZ Guard Locking Switch Installation Instructions, Provides general guidelines for installing a Rockwell Automation® guard locking switch.
publication 440G-IN018
Provides a detailed description of module functionality, configuration, installation
Guardmaster EtherNet/IP Network Interface User Manual, procedure, and information on how to use the Guardmaster EtherNet/IP Network Interface
publication 440R-UM009 (440R-ENETR).
Guardmaster DG Safety Relay and GuardLink System User Manual, Provides general guidelines for configuring a Rockwell Automation Guardlink safety system.
publication 440R-UM015
Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
EtherNet/IP Network Devices User Manual, publication ENET-UM006 network.
Ethernet Reference Manual, publication ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
Provides guidance on how to conduct security assessments, implement Rockwell
System Security Design Guidelines Reference Manual, Automation products in a secure system, harden the control system, manage user access,
publication SECURE-RM001 and dispose of equipment.
Industrial Components Preventive Maintenance, Enclosures, and Contact Provides a quick reference tool for Allen-Bradley industrial automation controls and
Ratings Specifications, publication IC-TD002 assemblies.
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
Safety Guidelines for the Application, Installation, and Maintenance of general guidelines for the application, installation, and maintenance of solid-state control in
Solid-State Control, publication SGI-1.1 the form of individual devices or packaged assemblies incorporating solid-state
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.

You can view or download publications at rok.auto/literature.

6 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 1

Product Overview

Guardmaster 440G-MZ 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
Safety Switch Overview covered by the guard are in a safe condition. The safety control system allows
the hazardous machine functions to operate only when the guard is closed and
locked.

The locking bolt drive mechanism and logic confirm that the locking bolt is
allowed to extend only when the corresponding actuator is detected within
range.

RFID technology enables high precision operation while meeting the

requirements to prohibit actuator substitution as described in ISO 14119. The
440G-MZ safety switches are classified as Type 4 interlocking devices with
guard locking and the unique coded actuators are classified as having a high
level of coding according to ISO 14119.

The 440G-MZ safety switch features two OSSD outputs or a single-wire safety
output when connected in a GuardLink® system. These safety outputs are
enabled only when the locking bolt is sensed in its extended position. This
action only happens when the guard is both closed and locked.

The locking bolt drive mechanism uses a bi-stable solenoid. As a result, the
switch consumes little electrical power, with peak currents occurring (only
briefly) on startup and after each movement of the locking bolt.

Because of its bi-stable drive, not only does the device consume minimal
power, but it also does not produce heat while it is locked or unlocked.

Although the locking bolt drive uses a bi-stable solenoid, the device logic and
functionality are configured to replicate the functionality of a Power to Release
or Power to Lock solenoid-operated switch (depending on type).

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 7

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 Description
OSSD The lock signal (pin 5) is connected to 0V DC
GuardLink® A lock command is issued to the switch on the CLU signal from a GuardLink safety master.

IMPORTANT If power is removed from a Power to Release switch in the locked position, the
locking bolt remains in its extended position (switch locked). Use the auxiliary
release to unlock the switch.

ATTENTION: Under normal operating conditions, the locking bolt does not extend in
the absence of the actuator. The only exception is when power is removed from a
switch in the first 4 seconds of the start-up sequence. In this case, the bolt does
extend. If the guard door is closed when the start-up sequence is interrupted, the
guard door is locked. Use the auxiliary release to unlock the switch.

Guard Locking on Power to Lock Versions

With a Power to Lock switch, the locking bolt extends when the guard is closed
with the actuator inserted in the switch and a lock command is issued to the
switch:

Table 3 - Lock Command

Mode Description
OSSD The lock signal (pin 5) is connected to 24V DC
GuardLink A lock command is issued to the switch on the CLU signal from a GuardLink safety master.

IMPORTANT If power is removed from a Power to Lock switch or a fault occurs while in the
locked position, the bolt retracts and the switch unlocks.

ATTENTION: Under normal operating conditions, the locking bolt does not extend in
the absence of the actuator. The only exception is when power is removed from a
switch in the first 4 seconds of the start-up sequence. In this case, the bolt does
extend. If the guard door is closed when the start-up sequence is interrupted, the
guard door is locked. Use the auxiliary release to unlock the switch.

Assembly Overview Actuator

LINK and DEVICE

status indicators

8 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 1 Product Overview

Product Selection Table 4 - Catalog Number Explanation

440G-MZS 20 S N R J
a b c d e

a b c d e
Outputs (Safety/ Actuator Code Auxiliary Type Lock Type Connection Type
Auxiliary)
Code Description Code Description Code Description Code Description Code Description
20 Two safety/no aux S Standard code N No auxiliary R Power to Release J M12 5-pin
U Unique code L Power to Lock

Table 5 - Complete Switches, including Switch Body and Actuator

Type Actuator Coding Escape Release Cat No.
Standard (Low level to ISO 14119) 440G-MZS20SNRJ
Power to Release
Unique (High level to ISO 14119) 440G-MZS20UNRJ
No
Standard (Low level to ISO 14119) 440G-MZS20SNLJ
Power to Lock
Unique (High level to ISO 14119) 440G-MZS20UNLJ

Table 6 - Spare Actuators

Description Cat. No.
Standard code actuator (Low level to ISO 14119) 440G-MZAS
Unique code actuator (High level to ISO 14119) 440G-MZAU

Table 7 - Accessories
Description Cat. No.

L-shaped 440G-MZAM1

Actuator mounting bracket

Z-shaped 440G-MZAM2

Switch mounting bracket 440G-MZAM3

Padlock accessory 440G-MZAL

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 9

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:
• IEC 60947-5-3
• IEC 61508
• IEC 62061
• EN ISO 13849-1
• ISO 14119
• UL 508

Safety Certification The 440G-MZ safety switch is certified for use in safety applications up to and
including SIL 3 according to IEC 61508 and IEC 62061 with a proof test interval
of 20 years, and Performance Level e (PLe) Category 4 in compliance with ISO
13849-1.

Safety requirements are based on the standards applicable at the time of

certification.

The TÜV Rheinland group has approved the 440G-MZ safety switch for use in
safety-related applications where PLe is required for the door position
monitoring and guard locking functions.

The 440G-MZ safety switch must be installed in accordance with the applicable
regulation and standards.

While the 440G-MZ safety switch can be used for SIL 3, PLe, and Category 4
applications, the installation must comply with guard requirements (for
example, ISO 13854 and ISO 13857), and in some cases minimum (safe)
distance requirements (for example, ISO 13855).

The installed system, including the safety control system and the means by
which the machine stops, must achieve the needed safety performance. The
440G-MZ safety switch is one element in the safety system.

Additional guidance on guards, guard locking and guard interlock can be

found in:

• EN ISO 12100 • EN ISO 14119

• EN ISO 13854 • EN ISO TR 24119
• EN ISO 13855 • EN ISO 14120
• EN ISO 13857 • Application-specific C-level standards
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 11
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.
A functional test of the system is necessary to validate that it works as expected
(see Functional Testing on page 17).
Guard locking switches that use the Power to Lock principle (Cat. No.
440G-MZS20*NLJ*) must only be used after a risk assessment has shown that the
use of a Power to Release principle (Cat. No. 440G-MZS20*NRJ*) is inappropriate.
This assessment is necessary since the guard can be immediately opened after a
loss of power supply or upon deactivation of the unlocking signal.

Correct Use Review the following requirements and guidelines for proper use of the safety
switch to achieve optimal performance.
• The 440G-MZ safety switch is designed for use on medium- and full-
sized guards including guards where whole-body access to the
safeguarded area is possible.
• The switch is not to be used as a mechanical stop. Check that a separate
door stop is used.
• A separately mounted latch (for example, magnetic or mechanical) is
recommended to maintain proper alignment of the actuator. The
locking bolt must be free to enter and withdraw from the actuator
without binding.
• Use appropriate screws, bolts, or nuts that are fitted by tools to mount
the switch and actuator to avoid tampering.
• Do not over torque the mounting hardware.
• A minimum distance of 100 mm (3.94 in.) must separate adjacent
switches, see Pair Proximity on page 14.
• The 440G-MZ safety switch is designed for use in a NEC Class 2 circuit.
Connect the 440G-MZ safety switch to a dedicated Class 2 power supply
or use electronic circuit protection (for example, 1692-ZRCLSS) to
achieve NEC Class 2 compliance.

ATTENTION: For the switch, actuator, and actuator mounting bracket:

• Only use the designated mounting holes.
• Never drill or use to support other structures such as a conduit, cable ways, or other
hardware.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 13

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

The flexible actuator can move in multiple axes to accommodate guard door
misalignment (Figure 2). For optimal performance, verify that the locking bolt
can enter and withdraw from the tongue actuator without binding. A
separately mounted door latch is recommended to avoid door misalignment.

Figure 2 - Actuator Function

Pair Proximity If a pair of 440G-MZ safety switches are mounted too close to one another, the
two electromagnetic fields interact causing crosstalk, which can result in
nuisance faults and false operation.

A minimum of 100 mm (3.94 in.) must separate a pair of switches to help

achieve correct operation (Figure 3 on page 14).

Figure 3 - Minimum Distance between Switches [mm (in.)]

100 (3.94)

IMPORTANT If the minimum separation distance is not observed, the electromagnetic fields
interact causing crosstalk. Crosstalk can result in nuisance faults and false
operation.

14 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 3 Installation

Environmental 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
Considerations with high-pressure water jets at 80 °C (176 °F). The test is passed if no water
enters the enclosure of the switch that contains the electrical components and
the switch function is not impaired.

This rating does not promise protection from any liquids other than water and
does not promise the mechanical longevity from continuous or frequent
exposure.

Mount the Switch and

ATTENTION: Do not defeat, tamper, remove, or bypass this unit. Severe injury to
Actuator personnel could result.
The presence of spare actuators can compromise the integrity of the safety
systems. Personal injury or death, property damage, or economic loss can result.
Appropriate management controls, working procedures, and alternative protective
measures should be introduced to control their use and availability.

Three M5 fasteners (not provided) are required for proper mounting of the
switch to a rigid guard door frame (Figure 4). Two M5 fasteners (not provided)
are required to mount the actuator.

Figure 4 - Required Mounting Hardware for Switch and Actuator

2 x M5

3 x M5

IMPORTANT Do not use a washer with the screw at the base of the switch body. Using a
washer causes the plastic to crack.
Loctite 242 thread-locking adhesive is known to cause stress cracks in the
plastic housing of the 440G-MZ safety switch and should not be used. Lab tests
have determined that Loctite 425, a cyanoacrylate adhesive, does not cause
cracking and can be considered if the faster cure time is acceptable in the
application.

Check the manufacturer specifications of any thread-locking compound used

to secure the screws. It is recommended to use a cyanoacrylate-type
compound. Other compounds can cause stress cracks in the plastic feet of the
switch.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 15

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.
• Mount the switch on the inside of a hinged door

Actuator

Switch Switch
mounting mounting
bracket bracket

• Mount the switch on outside of a hinged door

Z-shaped Actuator
Mounting Bracket
Actuator

Z-shaped Actuator
Mounting Bracket

• Mount the switch on a sliding door

L-shaped Actuator L-shaped Actuator

Actuator Mounting Bracket Mounting Bracket

16 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 3 Installation

Auxiliary Release Operation of the auxiliary release causes a fault condition.

To reset the switch, cycle the power or issue a RESET command over the link in
a GuardLink® safety system.

Figure 5 - Auxiliary Release Operation [mm (in.)]

5 (0.2)

Top View

Padlock Accessory The padlock accessory (Figure 6) can be inserted through the actuator opening
of the 440G-MZ safety switch to help prevent the locking of the guard door and
restarting of the machine while an operator is inside the safeguarded area. The
padlock accessory can accommodate up to three nominal 6.35 mm (0.25 in.)
locks.

Figure 6 - Padlock Accessory (Cat. No. 440G-MZAL)

Up to three nominal
6.35 mm (0.25 in.) locks

Functional Testing A manual functional test must be made:

• After installation
• After any maintenance or change of component
• If the guard is used infrequently
- Less than once a month for SIL 3, cat. 3 or cat. 4, PLe
- Less than once a year for SIL 2, cat. 3, PLd

ATTENTION: During the functional test, verify that there are no persons in the
danger area and that the machine startup does not cause a hazard.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 17

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. Test again to confirm that the machine cannot start.
6. Close the guard door and then confirm that the guard is mechanically
locked and the device status indicator is steady green.
7. Test to confirm that the machine can start.
8. Change the lock signal at pin 5 to UNLOCK (24V for PTR and 0V for PTL
types).
9. Confirm the machine stops, the guard door is mechanically unlocked,
and the machine cannot restart.

GuardLink Mode
1. To begin a functional test of the 440G-MZ safety switch when
connected in a GuardLink system, all other devices on the link must be
in the operational state.
2. Confirm that the guard door is open.
3. Test to confirm that the machine cannot start.
4. Send a lock command to the 440G-MZ safety switch over the link.
5. Test again to confirm that the machine cannot start.
6. Close the guard door.
7. Send a lock command to the switch over the link.
8. Confirm that the switch is mechanically locked and the Device status
indicator is steady green.
A flashing green status indicator on the device indicates that another device on the link
is tripped. To proceed, verify that all other devices on the link are in operational state.
9. Test to confirm that the machine can start.
10. Send an unlock command to this 440G-MZ safety switch only over the
link.
11. Confirm that the machine stops, the guard door is mechanically
unlocked, and the machine cannot restart.

18 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 4

Wiring and System Integration

Pin Assignment and The 440G-MZ safety switch is available with a 5-pin DC Micro M12 quick-
disconnect connector. Table 8 shows the pin assignments and their functions
Function and typical mating cordsets. Other cordsets are available at DC Micro Cordsets
and Patchcords.

Table 8 - 5-pin Micro (M12) (1)

2
5

1
3
4
Function
Pin Color
OSSD Mode GuardLink® Mode
1 Brown +24V +24V
2 White Safety A Safety In
3 Blue 0V 0V
4 Black Safety B Safety Out
5 Gray Lock Command CLU
(1) The recommended cordset is catalog number 889D-F5AC-2 (2 m [6.5 ft]). For additional lengths, replace the 2 with 5 [5 m
(16.4 ft)] or 10 [10 m (32.8 ft)] for standard cable lengths.
The recommended patchcord for use with GuardLink® and ArmorBlock® Guard Safety I/O is the 2 m (6.5 ft) catalog number
889D-F5ACDM-2. Replace the 2 with 0M3 [0M3 (0.98 ft)], 1 [1 m (3.28 ft)], 5 [5 m (16.4 ft)], or 10 [10 m (32.8 ft)] for standard
cable lengths.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 19

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). This
description of the test pulses is provided for informational purposes; you
cannot modify them.

IMPORTANT To prohibit nuisance tripping, mask the OSSD input channels of the safety
system with an On to Off delay of at least 1 ms.

Figure 7 - Output Test Pulses

OSSD test pulses into a 10K resistive load.

Safety OSSD A
Safety OSSD B

5V/Div

580 μs

26 ms

2ms/Div

Safety OSSD A
Safety OSSD B

5V/Div
189 ms

20ms/Div

GuardLink Mode Safety When the 440G-MZ safety switch is connected in a GuardLink system, the
safety signals are Safety In and Safety Out. These signals are dynamic signals
Signals in operational state and two-way communication signals in the safe state.

GuardLink System ATTENTION: For information on a known anomaly, see Knowledgebase Article
Integration Unlocked 440G-MZ switch on GuardLink doesn't respond to lock command on power up.

Figure 8 on page 21 shows the basic components of a GuardLink system with a

DG safety relay master. The 440G-MZ safety switch, with embedded
GuardLink technology, connects to the link with a passive tap (as shown in
Figure 8 on page 21) or a passive power tap (catalog number 440S-PF5D4).

20 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 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 INPUT INPUT INPUT

A1 A2
4 5 6 5 4 5 6
S12 S22 S32 S42
IP: 192. 168. 1. ABC

LNK1
A1 A2 S11 S21
MS
PWR/Fault
LNK1
OUT
LNK2
IN 1
NS
IN 2
OUT X
9 0 1 IN X
A
2 3
8

Reset
7

4
5 6

FB
9 0 1
B Config/Set
2 3
8

DG Reset
7

4
5 6

Sel./Save
9 0 1 Time
C . 0.2.
2 3
8

12.14
4.6.8
7

4 .10.
5 6

7 LNK2
X1 X2 X3 X4
13 14 23 24
8

Item Description Cat. No.

1 5-pin device patchcord (1) 889D-F5NCDM-x (2) (3)
2 Cordset 889D-F4NE-y (4)
3 Terminator 898D-418U-DM2
4 GuardLink passive tap 440S-PF5D (5) (6)
5 4-pin link patchcords 889D-F4NEDM-x (3) (7)
6 GuardLink enabled tap 440S-SF5D (6)
7 EtherNet/IP™ Network Interface 440R-ENETR
8 DG Safety Relay 440R-DG2R2T
(1) Optional: Device can be connected directly to the passive tap.
(2) 10 m (32.8 ft) length, max.
(3) Replace x with 0M3 (300 mm [0.98 ft]), 0M6 (600 mm [1.97 ft]), 1 (1 m [3.3 ft]), 2 (2 m [6.6 ft]), 5 (5 m [16.4 ft]), or 10 (10 m
[32.8 ft]) for standard cable lengths.
(4) Replace y in order number with 2 (2 m [6.6 ft]), 5 (5 m [16.4 ft]), 10 (10 m [32.8 ft]), 15 (15 m [49.2 ft]), 20 (20 m [65.6 ft]), or
30 (30 m [98.4 ft]) for standard cable lengths.
(5) A passive power tap (Cat. No. 440S-PF5D4) can also be used.
(6) Mounting brackets sold separately. Cat. No. 440S-GLTAPBRK1 (pack of 1) or Cat. No. 440S-GLTAPBRK5 (pack of 5).
(7) 30 m (98.4 ft) length, max

Add Device to a Studio 5000 Information about how to add a 440G-MZ safety switch to a GuardLink system
in a Studio 5000® project can be found in the user manual for the GuardLink
Project safety master. See publication 440R-UM009 for information about using the
upload method or manual method to add a 440G-MZ safety switch in a
GuardLink circuit controlled by a Guardmaster® DG safety relay.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 21

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. Right-click the GuardLink and select Add Device.

2. Select the correct catalog number from the device list

22 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 4 Wiring and System Integration

Lock Command 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 Value
24V = Unlock
440G-MZS20*MR* Power to Release 0V = Lock
24V = Lock
440G-MZS20*ML* Power to Lock 0V = Unlock

Catalog codes for both types are explained in Table 4 on page 9.

GuardLink Mode

In a GuardLink system, the GuardLink safety master (for example a DG safety

relay) issues lock and unlock commands to the 440G-MZ safety switch via the
GuardLink Control, Lock, and Unlock (CLU) signal. This signal is either static
or dynamic. When static, this signal is LO when the system is operational and
HI when a demand is placed on the safety system. The signal is dynamic when
an unlock or lock command is issued to the 440G-MZ safety switch.

When multiple guard locking devices are installed in a GuardLink system, the
GuardLink safety master inserts a short delay between commands to each
successive device to minimize the momentary inrush current to the solenoids.
The device closest to the master receives the command first. The device
furthest away from the master receives the command last.

See publication 440R-UM015 for more information.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 23

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. After the first-
time learn, this process can be repeated up to seven more times with
unique coded replacement actuators.

IMPORTANT When the switch learns a new actuator, it no longer recognizes previously
learned actuators.

Setup The 440G-MZ safety switch can be set up in OSSD mode or GuardLink® mode.

IMPORTANT If the 440G-MZ safety switch is connected in a GuardLink system, verify that the
GuardLink is powered ON and the switch is unlocked to insert the actuator and
initiate the teach process.

During commissioning, connect the switch as shown in Figure 11.

Figure 11 - Wiring

Brown
+24V DC
White NC
DEVICE Black
LINK NC
Gray
NC
Blue Gnd 0V

889D-F5NC-x
or
889D-F5BC-x

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 25

Chapter 5 Commission the Safety Switch

First-time Learn 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).

Table 10 - Commissioning Process for Unique Coded Switches

Step State Approximate Duration Status Indicators

1 Actuator Present 15 s Flashing 8x green, repeating (1)

Steady red (learning a replacement actuator)
2 Verifying Actuator 15 s Flashing red/green, slow
3 Programming Switch 15 s Flashing red/green, fast
Flashing green (number of times a new
4 Program Finalization 15 s actuator can be learned)
5 Run Mode (2) — Steady red
(1) Out of box condition only.
(2) When teaching an actuator, the switch must be unlocked to insert the actuator. At the end of the finalization step, the switch
remains unlocked and in the safe state.

IMPORTANT After teaching a new actuator, a power cycle is required to complete the
process.

Perform a functional test of the switch to validate that it works as expected (see
Functional Testing on page 17).

Learn Additional The switch automatically starts a new teach process when a unique coded
replacement actuator is inserted in the switch (in the guard closed position).
Replacement Actuators
IMPORTANT When the switch learns a new actuator, it no longer recognizes previously
learned actuators.

Lock the Actuator Code If the actuator is removed from the switch and then reinserted into the switch
during the 15-second Program Finalization stage (see Step 4 in Table 10), this
action triggers the switch to LOCK the actuator code. This action can be
performed during any of the eight unique coded actuator learn cycles.

IMPORTANT After a unique coded actuator is locked using this method, the switch cannot
learn additional replacement actuators for the remaining life of the switch. If
the actuator is lost or damaged, the switch must be replaced.

Error Codes during the The following indicator patterns repeat until a Power Off/On cycle is
completed.
Commissioning Process
Status/Diagnostic Indicator Error Code
Flashing 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-green Unit locked: cannot learn another actuator

26 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 6

Device Status and Troubleshooting

Status Indicators during 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
Power-up Routine 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. See Table 11.

Status Indicators During Table 11 shows the status of the 440G-MZ safety switch during run mode.
Run Mode Table 11 - Switch Status Indication During Run Mode
Indicator State Description
The switch is in the operational state with no demand on the safety
Steady green function (that is, closed and locked).
The switch is in the operational state with no demand on the safety
Flashing green @ 1 Hz (1) function, but the link is in the safe state due to a demand on
another device in the link.
Device The switch is ready to be locked, or attempting to lock. The lock
Flashing amber @ 1 Hz command is set to LOCK but the door is in the open position or
slightly ajar. Check that the door is closed.
The switch is in the safe state due to a demand on the safety
Steady red function (that is, unlocked).
Flashing red @ 1 Hz The switch is in the fault state.
Indicates no communication to the DG safety relay over the link.
Off The switch is wired directly to I/O and is not part of a GuardLink®
system.
The link is in the operational state. This switch and all other devices
Link (2) Steady green on the link are in the operational state.
The link is in the safe state due to a demand or fault on this switch
Steady red or another device in the link.
Flashing red @ 1 Hz The link is faulted.
(1) This state occurs when connected to a GuardLink system only
(2) The Link status indicator is only used when the 440G-MZ safety switch is connected in a GuardLink system. It is OFF when the
440G-MZ safety switch is connected directly to an I/O device or safety relay (OSSD mode).

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 27

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.

Diagnostic codes (Table 12) warn that a condition exists which prevents the
switch from transitioning to the operational state (for example, the switch is a
unique coded switch that must be commissioned), or causes the switch to fault
(for example, the input voltage is approaching the minimum value) if not
addressed.

Fault codes (Table 13 on page 29) provide information about why the switch is
in the faulted state (as indicated by the DEVICE status indicator flashing red.)
When a fault is present, perform the recommended action, if stated. Issue a
RESET command to the 440G-MZ safety switch over the link to clear the fault.

IMPORTANT When a Power to Lock switch faults in the locked position, the bolt retracts
and the switch unlocks.

Diagnostic Codes
Table 12 - Diagnostic Codes
Decimal Description Recommended Action
(Hex)
00 (00) No diagnostic No action required.
Input voltage is approaching Evaluate input voltage. Input voltage must be 20.4…26.4V under all
04 (04) minimum (20.4V DC) electrical load conditions.
A lock command has been sent to the device but the guard door is open
31 (1F) Ready to lock or ajar. Check the actuator alignment or close the guard door.
Device is attempting to lock Check actuator alignment. Check the wiring for the lock feedback
32 (20) input.
Device is attempting to Check for load on actuator or bolt. Check the wiring for the lock
33 (21) unlock feedback input.
Unique coded switch has not been paired with an actuator yet. Insert a
38 (26) Actuator not paired unique coded actuator (Cat. No. 440G-MZAU) to start the
commissioning process.
The actuator is not detected (RFID is not present). Close the guard door
40 (28) Guard door open to lock.

28 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 6 Device Status and Troubleshooting

Fault Codes
Table 13 - Fault Codes
Decimal Description Recommended Action
(Hex)
00 (00) No fault. No action required.
Evaluate input voltage. Input voltage must be 20.4…26.4V under all
05 (05) Power error electrical load conditions.
Failure to detect device type Check wiring and cycle power to the switch. If error persists, replace
07 (07) (OSSD or GuardLink) the switch.
08 (08) Internal memory (ROM) fault Internal memory fault. Reset the device. If error persists, replace it.
09 (09) Runtime memory (RAM) fault Internal memory fault. Reset the device. If error persists, replace it.
10 (0A) Internal memory (CPU) fault Internal memory fault. Reset the device. If error persists, replace it.
15 (0F) No response on GuardLink Check GuardLink wiring and connections.
31 (1F) GuardLink application fault GuardLink system fault. Reset the device. If error persists, replace it.
32 (20) Product application fault Product Application fault. Reset the device. If error persists, replace it.
Unique code actuator is A new actuator cannot be learned because the current actuator is
40 (28) locked locked.
41 (29) Invalid actuator detected Cannot teach a standard actuator to a unique coded switch.
Teaching is not possible. The switch has learned 8 actuators and
42 (2A) No learns left cannot learn any more actuators.
43 (2B) Actuator relearn Switch cannot learn a previously learned actuator. Use a new actuator.
Actuator moved out of range during teach process or the switch has
44 (2C) Actuator teach fault detected an invalid RFID tag.
Keep actuator within sensing range during learn process.
During operational state, the device failed to detect the bolt. On escape
release models, this fault can be caused by engaging the escape
56 (38) Bolt detection fault release. It can also occur if the auxiliary release was actuated.
Inspect the bolt. Disengage the escape release mechanism (if
applicable). Reset the device if the fault is not cleared.
Device attempted to lock for specified lock attempt length, but lock
57 (39) Failure to lock status input did not indicate that the device locked.
Check guard door and actuator alignment.
Device attempted to unlock for specified unlock attempt length, but
lock status input did not indicate that the device unlocked.
58 (3A) Failure to unlock Check the device. Verify that door is not applying a side load on the
locking bolt.
During operational state, the device failed to detect the RFID tag in the
59 (3B) Actuator detection fault actuator. Inspect the actuator and RFID tag for signs of damage. Fault
reset the device. If the error persists, replace the actuator.
An internal device fault has occurred. Reset the device. If error
255 (FF) Internal fault persists, replace it.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 29

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.
Loctite 242 thread-locking adhesive is known to cause stress cracks in the
plastic housing of the 440G-MZ safety switch and should not be used. Lab tests
have determined that Loctite 425, a cyanoacrylate adhesive, does not cause
cracking and can be considered if the faster cure time is acceptable in the
application.

Check the manufacturer specifications of any thread-locking compound used

to secure the screws. It is recommended to use a cyanoacrylate-type
compound. Other compounds can cause stress cracks in the plastic feet of the
switch.

30 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 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.

Wire to GLP Safety Relay 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. In the example shown in
Figure 12, the GLP safety relay allows the gate to be unlocked when the motor is
running at a Safely-limited Speed.

Figure 12 - GLP and 440G-MZ Safety Switch Schematic

+24V DC, Class 2, PELV

Reset SLS
& Lock Request
Request to PAC
K300 Stop/Start/SLS
440G-MZS20*NR* Status from PAC
Unlock Reset to PAC
Request 800FM-MT44
Safety
Status
to PAC
Gry
Kinetix® 300 Drive
X14 X24 51 A1 S44 S54 Y32 L12 S11 S12 S21 S22 A1 13 23 S34
LOGIC SL1 SL2 LOGIC

GLP 3 5 8 DI 4
Safe Torque-off
440R-GL2S2P 440R-D22R2 (STO)
S12 S22 L61 A2 AP P12 P22 L11 S32 S42 L11 L12 A2 14 24 Y32 Connector with
Wiring Header
White

Black

Brown 1
Blue +24V DC
2
889D-F5NC-X COM
3
Brown

Status
Black

4
Safety Input 1
800FM-MT44
5
Brown

Safety COM
Blue
6
Black Safety Input 2
Blue
872C-D8NP18-E5

24V DC COM

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 31

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.

IMPORTANT Start the GLP logic configuration from “0” to configure X14 and X24 for use as
safety outputs.

Starting

Close the gate and press Reset to lock the gate and turn on the GLP safety
outputs. Press Start to turn the motor ON.

Safely-limited Speed

A normal production stop is performed by pressing Stop. Access through the

safety gate is initiated by pressing Gate Unlock Request. The Y32 output of the
GLP safety relay turns ON, which makes an SLS request to the PAC. The PAC
commands the Kinetix® drive to bring the motor to a safe slow speed. When
the proximity sensors detect the speed has dropped below the Safely-limited
Speed (5 Hz), the gate becomes unlocked. The operator can enter the machine
cell, as the motor continues to run at the safe slow speed. After you leave the
cell and close the gate, press Reset to lock the gate and return the machine to
production speeds.

The circuit meets the safety requirements up to Category 3, Performance

Level d in accordance with ISO 13849-1 and SIL CL 2 in accordance with
IEC 62061.

32 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 7 Application Examples

Wire to GLT Safety Relay 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.

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. The risk assessment must
determine adequate time delay for the machine to achieve a safe state before
unlocking the gate.

Figure 13 - GLT and 440G-MZ Safety Switch Schematic

+24V DC, Class 2, PELV

440G-MZ

L1 L2 L3

Reset and PowerFlex R S T

Safety Gate Gate 525
Unlock Gate Lock
11 +24V DC
Request Request
1 Stop
2 Start
440G-MZS20*NR*
Power to Release
No aux
4 Gnd
S11 S12 51 S54 A1 S44 Y32 B2
LOGIC RANGE TIME

3 4 8 Gate control
GLT power supply
889D-F5NC-X 440R-GL2S2T
S12 S22 L61 A2 L11 L12 14 24 Gate control
circuit
Brown (+24)
Gray - Lock Cmd S1
S2
White - OSSD 1 U V W
Black - OSSD 2

Blue (Gnd) M

24V DC Com

Circuit status as shown: The gate is open and unlocked. The motor is off. The
GLT safety relay is ready for reset. The GLT safety relay has a Logic setting of
3: (Category 1 Stop), a Range setting of 4 (10 seconds) and a Time setting of 8
(80%). The Y32 output turns OFF immediately; 8 seconds later, the safety
outputs turn OFF.

The safety outputs (14 and 24) and the single wire safety output (L11) are OFF
and the auxiliary output (Y32) is ON.

IMPORTANT Start the GLT logic configuration from 0 to configure 14 and 24 for use with
pulse testing; the PowerFlex® 525 drive can operate with pulse tested inputs to
S1 and S2.

Starting

Close the gate. Press Reset and Gate Lock Request to lock the gate and turn on
the GLT safety outputs. Press Start to turn the motor ON.
Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 33
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. After you
leave the cell and close the gate, press Reset to lock the gate and return the
machine to a production state.

The circuit meets the safety requirements up to Category 3, Performance

Level d in accordance with ISO 13849-1 and SIL CL 2 in accordance with IEC
62061.

34 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 7 Application Examples

Wire to DI and EMD 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
Safety Relay EMD enables the gate to be unlocked after a configured delay time expires.

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.

Upon initial power-up, the safety switch must be cycled for the DI to recognize
the safety switch OSSD signals.

In the example shown in Figure 14, an E-stop initiates the machine shutdown.
After an eight-second delay, the safety switch is allowed to be unlocked and the
hazards that remain are turned OFF. A selector switch is required to maintain
the gate in an unlock state. The risk assessment must determine adequate time
delay for the machine to achieve a safe state before unlocking the gate.

Figure 14 - DI Safety Relay with EMD Safety Relay and 440G-MZ Safety Switch Schematic
+24V DC, Class 2, PELV
Brown

Reset

Brown = +24V DC
White = OSSD 1
Black = OSSD 2
L1 L2 L3
Blue = 24V DC COM
440G-MZS20*NR* Gray = Lock CMD
Gray

Unlock
K1
E-stop
Blue K2

White Black
A1 A2 S11 S21 S12 S22 S32 S42 A1 A2 B1 B2 37 38 47 48
Power
In 1
In 2
DI Test Out
LOGIC
IN1 IN 2
EMD RANGE TIME
37 38 47 48
M
Out 2 2 8
Logic 17 18 27 28
L12 L11 Y32 S34 13 14 23 24 L12 L11 X32 17 18 27 28

K1 K2

24V DC COM

Circuit Status as Shown

The E-stop is released. The gate is open and unlocked. K1 and K2 are OFF. The
DI safety relay is configured for two inputs with monitored manual reset. The
EMD safety relay is configured for 8-second off-delay; Range setting of 2 is 10
s, Time setting of 8 is 80% of the range. The X32 terminal is ON because the
EMD safety outputs are OFF.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 35

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 off-
delay timer. After 8 seconds, X32 goes to 24V. The unlock switch is enabled, and
the gate can be unlocked. While the gate is unlocked, the DI safety relay cannot
turn the safety outputs back ON. After you leave the cell and close the gate,
open the unlock switch to lock the gate, and release the E-stop.

The circuit can meet the safety requirements up to Category 4, Performance

Level e in accordance with ISO 13849-1 and SIL CL 3 in accordance with
IEC 62061.

36 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 7 Application Examples

Wire to DG Safety Relay 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. The DG safety relay can
accommodate up to 32 devices on each input. The devices can be a mix of many
different safety devices. When guard locking devices are included in the
GuardLink system, the lock/unlock command must come from the machine
control system through the 440R-ENETR module.

See publication 440R-UM015 for further details.

Figure 15 - DG Safety Relay with 440G-MZ Safety Switch Schematic

+24V DC, Class 2, PELV

440G-MZS20*NR* 440G-MZS20*NR*

889D-F5NCDM-X 889D-F5NCDM-X

440S-PFSD 440S-PFSD

Brown
889D-F4NE-X Blue

Control
Status
White

440G-MZS20*NR* 440G-MZS20*NR*
Black

L1 L2 L3

+ S12 S22 S11 S21 A1 13 23 X4

A K1
Machine Control TIME
Control Status
B
System
DG 0 K2
889D-F5NCDM-X 889D-F5NCDM-X C
440R-DG2R2T
S32 S42 X2 X1 A2 14 24 X3
440S-PFSD 440S-PFSD
M
White

Black

440R-ENETR

Brown
K1 K2
889D-F4NE-X Blue

24V DC Com

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 37

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. When the motor is not
running, the safety gate can be unlocked, and the PowerFlex 525 drive goes to a
Safe Torque Off state.

Figure 16 - CR30 Safety Relay with 440G-MZ Safety Switch Schematic

+24V DC, Class 2, PELV

L1 L2L3

Safety Gate PowerFlex R S T

525
Lock 11 +24V DC
Unlock
440G-MZS20*NR* 1 Stop
Power to Release
No aux Reset 2 Start

R5
Motor Not Running t081=2
R6

00 01 02 03 04 05 06 07 08 09 10 11 4 Gnd
Gate control
CR30 440C-CR30-22BBB power supply
889D-F5NC-X A1 A2 12 13 14 15 16 17 18 19 20 21
Gate control
circuit

Brown (+24) S1
S2 U VW
Black - OSSD 2
White - OSSD 1
Gray - Lock Cmd M
Blue (Gnd)

24V DC Com

Figure 17 on page 39 shows an example CR30 safety relay configuration that

works with the schematic in Figure 16.

38 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 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. When an unlock request is made, the command is issued 5
seconds after the motor stops running, and the unlock request is latched ON.

Figure 17 - CR30 Configuration in CCW

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 39

Chapter 7 Application Examples

Wire to POINT Guard I/O 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.
Module
Figure 18 - 1734 Module and 440G-MZ Safety Switch Schematic

440G-MZ

Safety Gate 1734-AENT 1734-IB8S 1734-OB8S

Ethernet I/P
to GuardLogix®
PLC and HMI
0 1 I0 I1 I4 I5 O0 O1 O4 O5
440G-MZS20*NR*
Power to Release
2 3 I2 I3 I6 I7 O2 O3 O6 O7
No aux
4 5 COM COM COM COM COM COM COM COM
24V DC Com

6 7 T0 T1M T2 T3M COM COM COM COM

+24V DC

K1 K2
889D-F5NC-X K1 K2

Black - OSSD 2
White - OSSD 1
Blue (Gnd)
Gray - Lock Cmd
Brown (+24)

Figure 19 shows the General tab of the 1734-AENTR module properties.

The Input Status can be set to Rack Optimization, Enhanced Rack

Optimization, or Combined Status - Power - Muting as these settings are used
by the Dual Channel Input Stop (DCS) logic block to verify that the 1734-IB8S
switch is operational. The Output Data must be set to Test, as the test outputs
are used to generate test pulses for the output contactors, K1 and K2.

Figure 19 - 1734-AENTR Module Properties - General

40 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 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.

Points 2 and 3 monitor the status of the output contactors, K1 and K2. The Type
should be set to Single. Set Mode to Safety Pulse Test. Safety pulse testing is
used to detect potential faults in the monitoring circuit.

Figure 21 - 1734-IB8S Module Properties - Input Configuration

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 41

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. By setting it to Standard, you can
programmatically turn these points OFF and ON, in case a nonrecoverable
fault occurs with the switch.

Figure 22 - 1734-IB8S Module Properties - Test Output

Figure 23 shows the General tab of the 1734-OB8S module properties. Set the
Module Definition with the following settings:
• Input Data: None
• Output: Safety
• Input Status: Pt. Status
Figure 23 - 1734-OB8S Module Properties - General

42 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 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. 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.

Rung Description
With the Test Data output setup set as Standard, an HMI input can cycle power ON and OFF to the
0 440G-MZ safety switch to recover from a fault, if necessary. Upon powerup, the N.C. contact
automatically applies power to the 440G-MZ safety switch.
The Dual Channel Input Stop monitors the outputs of the 440G-MZ safety switch. The DCS block is set
1 for automatic start on powerup (cold start) and automatic restart each time the switch is locked.
The output of the DCS in Rung 1 provides a tag that shows the input 440G-MZ input status is OK. This
2 tag is used in Rung 4 to enable the Configurable Output to be reset.
A momentary contact from an HMI input starts a short on delay timer. HMI input must be held long
3 enough for the timer to expire. This timer is intended to help prevent inadvertent reset. The preset
value can be adjusted to suit the application.
When the timer is done, the OSF_Storage_Bit is set. When the HMI_CROUT_Actuate button in Rung 4 is
4
released, the OSF_Storage_Bit goes LO and the OSF_Output_Bit goes HI.
5 When the OSF_Output_Bit goes HI, the CROUT_Actuate tag is set. The CROUT_Actuate tag is self-sealing
because the OSF_Output_Bit is HI only momentarily.
The GMZ_Crout block is set for negative feedback. The CROUT block output cannot go HI unless the
6 external contactor status at Feedback 1 and 2 is HI.
7 The two CROUT outputs turn ON the ArmorBlock® outputs, which energize the external contactors.
From an HMI input, you can lock or unlock the 440G-MZ safety switch. The HMI input must be a
8 maintained switch.
9 Notify the HMI if a fault is present on the DCS block.
10 An HMI input can reset the DCS if a fault is present.
11 Notify the HMI if a fault is present on the CROUT block.
12 An HMI input can reset the CROUT if a fault is present.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 43

Chapter 7 Application Examples

Figure 25 - 1734 Example Studio 5000® Program

44 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 7 Application Examples

Wire to ArmorBlock 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
Guard I/O Module patchcord. An example schematic is shown in Figure 26.

Figure 26 - ArmorBlock Schematic

1732ES-IB12XOB4

889D-F5NCDM-X

889D-E5NC-10 889D-E5NC-10

White (2) A1 A2 Blue (3)

K1
Brown (1) White (2)

K1 100S Contactors or
700S or 700-HPS Relays
K2
Black(4) A1 A2 Gray (5)
Black (4) Gray (5)
K2

Figure 27 shows the General tab of the ArmorBlock module properties. The
Input Status must be set to Combined Status - Muting and the Output Data
must be set to Combined.

Figure 27 - Module Properties - General

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 45

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.

Figure 28 - Module Properties - Input Configuration

Figure 29 shows the Test Output tab of the ArmorBlock Module Properties. In
this example, Points 0 and 1 are set to Standard, which allows the program to
control these points. Point 0 applies power to the 440G-MZ safety switch. By
setting it to standard, you can programmatically turn this point off and on if
the 440G-MZ safety switch has a fault condition. Point 1 is the lock/unlock
command. In this example, the 440G-MZ safety switch is a PTR type, so 24V
unlocks the switch. Points 4 and 5 are used to monitor the contactor outputs
and are set to Pulse Test.

Figure 29 - Module Properties - Test Output

Figure 30 shows the Output Configuration tab of the ArmorBlock module

properties. Points 0 and 1 drive the output contactors K1 and K2. The point
Types are set to Dual, and the Modes are set to Safety.

Figure 30 - Module Properties - Output Configuration

46 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 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.

Rung Description
With the Test Data output setup set as Standard, an HMI input can cycle power ON and OFF to the
0 440G-MZ safety switch to recover from a fault, if necessary. Upon powerup, the N.C. contact
automatically applies power to the 440G-MZ safety switch.
The Dual Channel Input Stop monitors the outputs of the 440G-MZ safety switch. The DCS block is set
1 for automatic start on powerup (cold start) and automatic restart each time the switch is locked.
The output of the DCS in Rung 1 provides a tag that shows the input 440G-MZ input status is OK. This
2 tag is used in Rung 4 to enable the Configurable Output to be reset.
A momentary contact from an HMI input starts a short on delay timer. HMI input must be held long
3 enough for the timer to expire. This timer is intended to help prevent inadvertent reset. The preset
value can be adjusted to suit the application.
When the timer is done, the OSF_Storage_Bit is set. When the HMI_CROUT_Actuate button in Rung 4 is
4 released, the OSF_Storage_Bit goes LO and the OSF_Output_Bit goes HI.
When the OSF_Output_Bit goes HI, the CROUT_Actuate tag is set. The CROUT_Actuate tag is self-sealing
5 because the OSF_Output_Bit is HI only momentarily.
The GMZ_Crout block is set for negative feedback. The CROUT block output cannot go HI unless the
6 external contactor status at Feedback 1 and 2 is HI.
7 The two CROUT outputs turn ON the ArmorBlock outputs, which energize the external contactors.
From an HMI input, you can lock or unlock the 440G-MZ safety switch. The HMI input must be a
8 maintained switch.
9 Notify the HMI if a fault is present on the DCS block.
10 An HMI input can reset the DCS if a fault is present.
11 Notify the HMI if a fault is present on the CROUT block.
12 An HMI input can reset the CROUT if a fault is present.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 47

Chapter 7 Application Examples

Figure 31 - Example Studio 5000 Program

48 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Chapter 7 Application Examples

Wire to MSR55P Back EMF 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
Safety Relay 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.

Figure 32 - MSR55P Back EMF Relay Schematic

+24V DC Class 2 PELV

L1L2 L3
R S T
Unlock Vm -Monitoring
Reset voltage PowerFlex
525
t s - time Setting
(delay)
Status 1 Stop
to PAC 2 Start

S11S21 S22 S12 A1 L12 Y32 S34 A1 11 23 33 43 53 A3 X1 X2 X3 4 Gnd

LOGIC MSR55P Vm
440R-S35014 7
2 ts
Safety Gate DIS 3 Gate Control
440R-D22S2 Power Supply
S32 S42 L11 A2 34 44 14 24 A2 12 24 34 44 54 ON ERR A4 L1 L2 L3
Gate control
circuit
440G-MZS20*NR*
Power to Release S1
889D-F5NC-X S2
No aux UVW
Fuses*

Brown (+24)
Black - OSSD 2
ON status
White - OSSD 1
ON status
Gray - Unlock Request M
Error status 3~
Blue (Gnd)

24V DC Com

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 49

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.

Safety Ratings Attribute Value

Standards IEC 60947-5-3, IEC 61508, ISO 13849-1, IEC 62061, ISO 14119, UL 508
Type 4 interlocking device with guard locking per ISO 14119 with low (standard) and high (unique)
Safety classification coding per ISO 14119
Suitable for use in applications up to and including PLe Cat 4 per ISO 13849-1, SIL CL 3 per IEC 62061,
and SIL 3 per IEC 61508
• OSSD mode (1)
Proof test interval = 20 years
PFHd = 3.17E-09
Functional safety PFD = 3.67E-04
• GuardLink® mode(2)
Proof test interval = 20 years
PFHd = 2.93E-09
PFD = 3.59E-04
Certifications CE Marked for all applicable EU directives, c-UL-us, TÜV
(1) This data is given for the 440G-MZ safety switch when used in OSSD mode (connected to a safety I/O or safety logic device).
(2) This data is given for the 440G-MZ safety switch when used in a GuardLink safety system.

Operating Characteristics Attribute Value

Torque for M5 mounting of switch and actuator
mounting bracket 2 N•m (17.7 lb•in) max
Locking bolt alignment tolerance X, Y, Z ±5 mm (0.2 in.) max
Holding force Fmax (ISO 14119) 3250 N
Holding force Fzh (ISO 14119) 2500 N
Output current, max (each output) 200 mA
Quiescent power consumption, locked or unlocked 1.5 W
Lock signal current 1 mA
Peak current and duration, at turn on or after lock/
150 mA for approximately 800 ms following lock/unlock operation.
unlock operation

Steady state current, max • OSSD mode: 40 mA

• GuardLink mode: 50 mA
Operating voltage Ue 24V DC +10% / -15% Class 2 PELV
Operating cycle frequency, max 0.2 Hz
Dwell time between subsequent locking/unlocking 2.5 s
Response time (Off) (IEC 60947-5-3) 275 ms
Start up time (availability) 8s
Utilization category (IEC 60947-5-2) DC-13 24V 200 mA
Insulation voltage Ui (IEC 60947-5-1) 75V
Impulse withstand voltage Uimp (IEC 60947-5-1) 1 kV
Pollution degree (IEC 60947-5-1) 3
Auxiliary release Built in
Protection class (IEC 61140) Class II
Mechanical life 500,000 cycles

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 51

Appendix A Specifications

Outputs (Guard Door Closed Attribute Value

and Locked) Safety outputs (OSSD mode) 2 x PNP, 0.2 A max / ON (+24V DC)

Environmental Attribute Value

Operating temperature 0…55 °C (32…131 °F)
Storage temperature -25…+75 °C (-13…+167 °F)
Operating humidity 5…95%, noncondensing
• IP65
• IP66
Enclosure ingress rating • IP67
• IP69
• IP69K

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.)
Radio frequency/EMC IEC 60947-5-3, FCC-1 (Parts 18 and 15), RED

General Attribute Value

Switch • Housing - ABS
• Front brace – SS304 (machined), SS316 (cast)
• Housing and housing cover – SS304
• Spring – SS302
Materials Actuator • Grommet – nitrile rubber
• Screws - stainless steel
• Tongue – SS410
Brackets High-strength low alloy steel
Padlock Accessory SS410
• Switch 0.75 (1.7)
• Actuator 0.27 (0.6)
Weight [kg (lb)] • Actuator L mounting bracket 0.27 (0.6)
• Actuator Z bracket 0.54 (1.2)
• Switch L bracket 1 (2.2)
• Short-circuit
• Current limitation
Protection Type • Overload
• Reverse polarity
• Overvoltage
• Thermal shutdown/restart

52 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Appendix A Specifications

Certifications Visit rok.auto/certifications for Declaration of Conformity, Certificates, and

other certification details.
• 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. Also in accordance with
IEC 61508 and EN 62061, Performance Level e and Category 4 in
accordance with ISO 13849-1, both for guard position monitoring and
for guard locking according to ISO 14119.
• FCC Notice (for U.S. Customers)
This device complies with Part 15 of the FCC Rules. Operation is subject
to the following conditions:
a. This device many not cause harmful interference, and
b. This device must accept any interference received, including
interference that may cause undesired operation.

Changes and Modifications not expressly approved by

Rockwell Automation can void your authority to operate this
equipment under Federal Communications Commissions rules.
• This device complies with Industry Canada license-exempt RSS
standard(s). Operation is subject to the following two conditions: (1)
this device may not cause interference, and (2) this device must accept
any interference, including interference that may cause undesired
operation of the device.
Le présent appareil est conforme aux CNR d'Industrie Canada
applicables aux appareils radio exempts de licence. L'exploitation est
autorisée aux deux conditions suivantes : (1) l'appareil ne doit pas
produire de brouillage, et (2) l'utilisateur de l'appareil doit accepter tout
brouillage radioélectrique subi, même si le brouillage est susceptible
d'en compromettre le fonctionnement.

Compliance to European This product bears the CE marking and is approved for installations within the
European Union and EEA regions. It has been designed and tested to meet the
Union Directives Machine Safety and EMC directives.

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 53

Appendix A Specifications

Approximate Dimensions Figure 33 - Switch Body [mm (in.)]

2 x Ø5.5 153 (6.02)
(0.22) 134.5 (5.3)
33
(1.3) 22.5
(0.89)

6 14.9 (0.59)
(0.24) 176.8 (6.96)
45.2 15
(1.78) 33 (1.3) (0.59) 15 (0.59) 5.9
(0.23)
50 39.5
Ø5.1 47.5
25.3 (1.97)(1.87)(1.56)
(0.2) (1)
22.6 0.3 134.5 (5.3)
(0.89) (0.01) 153 (6.02)
182.7 (7.19)

Figure 34 - Actuator [mm (in.)]

14
65 (2.56) (0.55) 32.5
15 Ø32.9 (1.3) (1.28) 23.8
10
(0.59) 7.3 (0.28) (0.39) 14 (0.94)
25.6 (1.01) (0.55)
30 40
(1.18) 20 (1.57)
12.8 (0.5) (0.79) 10
6 x Ø6.3 (0.25) 30 (0.39)
(1.18) 7.5
4 x Ø6.5 (0.3) Ø12.4 3 (0.12)
(0.26) (0.49) 23.7
50 (1.97) (0.93)
4
(0.16)
9.9
(0.39) 59.3
(2.33)

12.5
(0.49)

Figure 35 - Actuator on Z Bracket [mm (in.)]

2 x 30.1 (1.19) 74.2 (2.9) 7.2 (0.28) 72.1 (2.8) REF
2 x 32.5 (1.28) 2 x 25.6 (1) 7.5
(0.29) 30.3 (1.2) 40 (1.6)

3 x 50 (2) 65 (2.6) 59.3 46.8

REF (2.3) (1.8)
3 x 27.6 (1.1)
6 x Ø8.5 (0.33) 40.5 6 x Ø6.3 (0.2)
(1.6)
14.6 (0.6)
104.3 (4.1)

124.3 (4.9)
74.2 (2.9)

65 4 x Ø7.1 (0.3)
(2.6)
30.3 (0.33) 6 x Ø6.3 (0.2)

40 (1.6)
46.8 6 x Ø8.5 (0.33) 2 x Ø8.5 (0.33)
76.6 (3.01) 29.3 (1.2) (1.8)
REF

124.3 (4.9) REF

54 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Appendix A Specifications

Figure 36 - Actuator on L Bracket [mm (in.)]

83.5 (3.3)
55.4 (2.2) 7.2
32.5 (1.27) 2 x 12.8 (0.5)
33.8 (1.3) (0.28)
4 x Ø6.3 (0.24)
45.3 7.5 (0.3)
27.6 (1.8)
65 (2.6) 2 x 50 (1.96)
(1.1) REF
65 (2.6) 50 (1.96)
2 x Ø8.5 (0.33) 7.5
23.3 (0.3)
(0.9) 7.2 (0.28)
12.8 (0.5)

2 x Ø8.5 (0.33) 37.2

32.5 (1.27) (1.4) 59.3 (2.3)

40 65
(1.6) (2.6)
27.6 (1.1)
2 x Ø8.5 (0.33)
45.3 (1.8) 27 (1.06) 23.7 (0.9)
REF 60.5 (2.4)

60.5 (2.4) REF

Figure 37 - Switch on L Bracket [mm (in.)]

47.8 (1.9)
34.4 (1.4) 22.5 (0.9) 5.3 (0.2)

3 x Ø5.2 (0.2)
2 x 80 (3.1)

134.5
(5.3)
160 (6.3) 182 (7.2)
80 REF REF
(3.1)

30.4 (1.2) 2 x Ø8.5 (0.33) 33 (1.3) 6 42.2

(0.24) (1.7)

25.3 (1) 60.5 (2.4)

REF

68.8 (2.7)
REF

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 55

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
35 (0.79)
(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 (3.4)

56 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 Index

A D
abbreviation 6 device status 27
accessories 9 DG safety relay
actuator application 37
dimension 54 DI safety relay
spare 9 application 35
actuator code diagnostic code 28
lock 26 dimension
allowable approach direction 14 approximate 54
application direction
ArmorBlock Guard I/O 45 allowable approach 14
CR30 safety relay 38
DG safety relay 37
DI safety relay 35 E
EMD safety relay 35 EMD safety relay
GLP safety relay 31
GLT safety relay 33 application 35
MSR55P back EMF safety relay 49 environmental 52
POINT Guard I/O 40 error codes
approximate dimension 54 commissioning process 26
ArmorBlock Guard I/O European Union Directive
application 45 compliance 53
assembly overview 8 example
assignment application 31
pin 19
auxiliary release 17
F
fault code 29
C FCC notice 53
CE Marked 53 first-time learn 26
certification 53 functional testing 17
safety 11 GuardLink mode 18
characteristic OSSD mode 18
operating 51
CLU 6
code
G
diagnostic 28 general specification 52
fault 29 GLP safety relay
coding application 31
standard 6 GLT safety relay
unique 6 application 33
command guard locking
lock 23 Power to Lock 8
command, lock, and unlock 6 Power to Release 8
commission GuardLink
safety switch 25 safety signal 20
commissioning process system integration 20
error codes 26
complete switch 9
compliance
I
European Union Directive 53 Industry Canada
concept license-exempt RSS standard 53
safety 11 ingress protection 15
content installation 13
package 10 integration
correct use 13 GuardLink system 20
CR30 safety relay
application 38

Rockwell Automation Publication 440G-UM004C-EN-P - August 2020 57

Index

L R
L bracket rating
dimension 55 safety 51
learn RCM Marked 53
additional replacement actuator 26 reaction time 6
first-time 26 release
license-exempt RSS standard auxiliary 17
Industry Canada 53 replacement actuator
lock learn 26
actuator code 26 response time 6
lock command 23 RSS standard
Industry Canada license-exempt 53
run mode
M status indicator 27
mount
switch body 15
mounting holes S
cracked/broken 30 safe state 6
MSR55P back EMF safety relay safety
application 49 certification 11
concept 11
rating 51
N signal
notice GuardLink 20
FCC 53 OSSD 20
standard 11
selection
O product 9
operating characteristic 51 setup 25
operational state 6 spare actuator 9
orientation specification 51
switch 14 environmental 52
OSSD 6 general 52
operating characteristic 51
OSSD mode output 52
safety signal 20 standard
output safety 11
specification 52 standard coding 6
output signal switching device 6 state
overview operational 6
assembly 8 safe 6
status
device 27
P status indicator
package content 10 power-up routine 27
padlock accessory 17 run mode 27
dimension 56 switch
pair proximity 14 commission 25
pin assignment 19 complete 9
POINT Guard I/O orientation 14
setup 25
application 40 switch body
Power to Lock
dimension 54
guard locking 8 mount 15
Power to Release mounting holes
guard locking 8 cracked/broken 30
power-up routine system integration
status indicator 27 GuardLink 20
product selection 9
protection
ingress 15
proximity
pair 14

58 Rockwell Automation Publication 440G-UM004C-EN-P - August 2020

 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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Publication 440G-UM004C-EN-P - August 2020

Supersedes Publication 440G-UM004B-EN-P - July 2020 Copyright © 2020 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.