Rockwell Automation Allen-Bradley Guardmaster 440G-LZS21SP Series User Manual Download Page 15 | Manualshive

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Rockwell Automation Publication 440G-UM001C-EN-P - June 2019

15

Installation

Chapter 3

Verify that two fasteners are used with at least one fastener that is fitted close to

the actuator bracket bend.

The following drawings show mounting possibilities when attaching to

extruded aluminum profile and flat surface guard doors.

IMPORTANT

The performance of the switch can only be guaranteed if the provided

actuator mounting bracket is used. Mounting the actuator without the
supplied bracket can result in the reduction of performance.

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Summary of Contents for Allen-Bradley Guardmaster 440G-LZS21SP Series

Page 1: ...Guardmaster Guard Locking Switch Catalog Numbers 440G LZS21SPx 440G LZS21SPRx 440G LZS21STLx 440G LZS21STRx 440G LZS21UPLx 440G LZS21UPRx 440G LZS21UTLx 440G LZS21UTRx User Manual OriginalInstructions ...

Page 2: ...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 Labels may also be on or inside the equipment to provide specific precautions WARNING Identifies informati...

Page 3: ...afety Concept Safety Standards 11 Safety Certification 11 Chapter3 Installation General Considerations 13 Correct Use 13 Orientation of Switches 14 Actuator Mounting 14 Allowable Approach Directions 16 Mounting the Switch Body 16 Actuator Alignment 17 Pair Proximity 18 Environmental Considerations 18 Removal of the Actuator Plug 19 Auxiliary Manual Release 20 Functional Testing 20 Chapter4 Wiring ...

Page 4: ...LED Indicators 31 Diagnosis of Physical Switch Anomalies 34 Troubleshoot Series Circuit 35 Chapter7 Application Examples Wiring to GLP Relay 37 Wiring to GLT Relay 38 Wiring to DI and EMD Relay 40 Wiring to DG Relay 41 Wiring to CR30 Relay 42 Wiring to 1734 Guard Point I O 44 Wiring to 1732 ArmorBlock Guard I O 48 AppendixA Specifications and Safety Ratings Introduction 53 Certifications 55 Compli...

Page 5: ...ntions are used throughout this manual Bulleted lists such as this one provide information not procedural steps Numbered lists provide sequential steps or hierarchical information Additional Resources The following document offers additional information about related Rockwell Automation products Topic Page Added information about 440G LZ being aType 4 interlocking device with low and high coding a...

Page 6: ...4V to the lock command to lock the switch This command applies to the 440G LZ switch PTL Power to Release Apply 24V to the lock command to unlock the switch This command applies to the 440G LZ switch Reaction Time Describes the time between the true state of the input to the ON state of the output Response Time Describes the time between the trigger of the input to the OFF state of the output Thro...

Page 7: ...ith guard locking The unique coded actuators are classified as having a high level of coding The Guardmaster 440G LZ guard lock safety switch features OSSD outputs These outputs are enabled only when the locking bolt is sensed in its extended position in the actuator This action only happens when the guard is both closed and locked The locking bolt drive mechanism uses a bi stable solenoid As a re...

Page 8: ...8 Rockwell Automation Publication440G UM001C EN P June 2019 Chapter 1 General Description Assembly Overview Locking bolt Actuator Switch body Actuator mounting bracket QR Code Alignment guide ...

Page 9: ...21UPRH Lock Status Power to Lock Standard Low level to EN ISO 14119 2013 440G LZS21SPLA 440G LZS21SPLB 440G LZS21SPLH Lock Status Unique High level to EN ISO 14119 2013 440G LZS21UPLA 440G LZS21UPLB 440G LZS21UPLH Lock Status Power to Release Standard Low level EN ISO 14119 2013 440G LZS21STRA 440G LZS21STRB 440G LZS21STRH Door Proximity Unique High level EN ISO 14119 2013 440G LZS21UTRA 440G LZS2...

Page 10: ...n Packaging Contents The box includes the following components Figure 1 Switch Body Including Connection Lead 3 m or 10 m Flying Lead or Pigtail Equipped with M12 QD Connector Figure 2 Actuator Mounting Bracket Figure 3 Actuator Figure 4 Mounting Screws 2 xT10 Torx Figure 5 Alignment Guide ...

Page 11: ...ding SIL 3 according to IEC 61508 and IEC 62061 with a proof interval of 20 years and Performance Level 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 Guardmaster 440G LZ safety switch for use in safety related applications where Performance Level e is required for the doo...

Page 12: ...4120 Application specific C level standards ATTENTION A risk assessment is required to prove that the selected switch can be used in the desired application A functional test of the system is necessary to validate that it works as expected see FunctionalTesting on page 20 Guard locking switches that are activated by the Power to Lock principle 440G LZS 21 L safety switch must only be used after a ...

Page 13: ...e magnetic or mechanical is recommended to maintain proper alignment of the actuator The locking bolt must be free to enter and withdraw from the hole in the actuator without binding This switch can be used on guards that do not require escape emergency or remote releases Use appropriate screws bolts or nuts that are fitted by tools to mount the switch and actuators to avoid tampering Do not over ...

Page 14: ...Orientation of Switches Can be used in all mounting orientations Actuator Mounting The actuator must be fitted to the actuator mounting bracket in such a manner that the white alignment triangles that are marked on both the actuator and switch body are in the installed position Verify that the locking bolt enters the actuator mounting bracket first ATTENTION For the switch actuator and actuator mo...

Page 15: ...lose to the actuator bracket bend The following drawings show mounting possibilities when attaching to extruded aluminum profile and flat surface guard doors IMPORTANT The performance of the switch can only be guaranteed if the provided actuator mounting bracket is used Mounting the actuator without the supplied bracket can result in the reduction of performance ...

Page 16: ...eners not provided are required for proper mounting to a rigid guard door frame IMPORTANT Washers are not required and if used can cause the mounting holes on the switch body to crack If it is decided to use a standard thread locking compound on the mounting screws of the switch body check the manufacturer s specification Many standardthread locking compoundscanattacktheplastic feetoftheswitch bod...

Page 17: ...ap 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 Use the alignment guide provided ATTENTION Afterinstallation verifythat thereisnopossibilityofliftingtheactuator overthe extendedlockingbolt ATTENTION Afterinstallation confirm that there is nopossibilityofcollision when the actuatorapproaches the switch body G H ...

Page 18: ...ikely cause jamming of the locking bolt which over time causes switch failure Ferromagnetic metal particles are especially harmful as they are attracted to the permanent magnet at the tip of the locking bolt Mounting for Protection from Ingress of Liquids The 440G LZ safety switch is rated for IP69 in accordance with IEC 60529 192 A2 2013 This rating involves a short term test that is made with hi...

Page 19: ...ing lip seal guards the locking bolt which extends and retracts during locking unlocking Removal of the Actuator Plug This plug can be broken out from the actuator if a through hole is required to avoid a food trap when mounted on the hazard side of a guard door Twist the plug with a screwdriver until it comes apart Figure 7 Removal of Actuator Plug IMPORTANT To be sure of maximum longevity when e...

Page 20: ...ain to confirm that the machine cannot start 6 Close the guard door and then confirm that the guard is mechanically locked and the diagnostic indicator is solid green 7 Test to confirm that the machine can start 8 Change the lock control at pin 3 to 24V for PTR and 0V for PTL types 9 Confirm the machine stops the guard door is mechanically unlocked and the machine cannot restart The manual release...

Page 21: ...he OSSD inputs are Safety A and Safety B These inputs are 24V DC signals which can contain test pulses The OSSD inputs allow the 440G LZ safety switches to be connected in series while maintaining a high level of safety performance OSSD Outputs The OSSD outputs are Safety A and Safety B These outputs are 24V signals that contain test pulses The test pulses are used to detect short circuits to 24V ...

Page 22: ...SSD input channels of the safety system with an On to Off delay of at least 6 ms 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 Connection Cat No 1 1 Safety wired Splitter T Port 898D 438Y D8 2 Safety wired Shorting Plug 898D 418U DM Safety A Safety B Lock 0V 24V 5 4 4 4 1 1 1 3 3 3 2 2 1 7 6 3 8 4 5 2 1 4 5 3 PWR OSSD 1 ...

Page 23: ...F8ABDM 1 2 meters 8 pin 889D F8ABDM 2 5 meters 8 pin 889D F8ABDM 5 10 meters 8 pin 889D F8ABDM 10 4 5 pin Patchcords 1 meter 5 pin 889D F5ACDM 1 2 meters 5 pin 889D F5ACDM 2 5 meters 5 pin 889D F5ACDM 5 10 meters 5 pin 889D F5ACDM 10 5 5 pin Cordsets 2 meters 5 pin 889D F5AC 2 5 meters 5 pin 889D F5AC 5 10 meters 5 pin 889D F5AC 10 Catalog Number Function Value 440G LZS21 P Lock Status 24V when sw...

Page 24: ...tput Open Off or On High or Low Unlocked High 24V Low 0V Closed Off 0V Low 0V Unlocked High 24V Low 0V Closed On 24V Low 0V Locked Low 0V Low 0V Closed Off 0V High 24V Unlocked High 24V Low 0V Closed On 24V High 24V Locked Low 0V High 24V Inputs Outputs Door Lock Control OSSD Input LockStatus AUX OSSD Output Open Off or On High or Low Unlocked High 24V Low 0V Closed Off 0V Low 0V Locked Low 0V Low...

Page 25: ...witch 2 Switch 3 RTN 24V DC Power Supply 24 Green Pink Grey Brown Red Yel White A2 440R N23132 Initial Conditions All switches are locked Switch 1 receives Unlock command guard can then be opened Lock unlock command Switch 2 drops the 24V red and yellow from switch 1 OSSD outputs Green indicator flashes Switch 3 drops the 24V red and yellow from switch 3 OSSD outputs Green indicator flashes Pink G...

Page 26: ...26 Rockwell Automation Publication440G UM001C EN P June 2019 Chapter 4 Wiring Notes ...

Page 27: ... 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 Set up During commissioning connect the switch as shown in Figure 10 Connect brown wire PWR to 24V DC Connect blue wire GND to 0V DC Connect red wire Safety A and yellow wire Safety B to 24V DC Connect green wire Lock Command to 24V DC Safety A gray a...

Page 28: ... a new learn process when a unique coded replacement actuator is placed in the sensing field or guard closed position of the switch Red Safety A Pink Safety B Green Lock White Aux Blue Gnd Grey Safety A Yellow Safety B Brown 24 24V DC Com 24V DC 889D F8NB x or 889D F8AB x Lock NC NC NC Diag Status 440G LZ State Approximate Duration LED Indicators Step 1 Actuator Present 15 seconds Flashing green s...

Page 29: ... aligned Connect Pin 3 green wire to 24V DC to unlock the switch and withdraw the locking bolt If power is removed from a Power to Release switch in the locked position the locking bolt remains in its extended position switch locked Use the manual auxiliary release to unlock the switch IMPORTANT After a unique coded actuator is locked using this method no additional replacement actuators can be le...

Page 30: ... switch connect pin 3 green wire to 24V DC to lock the switch for example extend the locking bolt When you disconnect pin 3 it unlocks the switch If power is removed from a Power to Lock switch in the locked position the switch unlocks In either type of lock the locking bolt never extends in the absence of the actuator ...

Page 31: ...o either the 24V power supply or ground Check the power supply and the wiring to the switch Check that the input voltage is within specification measures between 20 4V and 26 4V DC LED Indicators Solid Green When the LED indicators are solid green the switch is in the operational state The guard door is closed and locked and the OSSD outputs are ON This is normal operation and no action is require...

Page 32: ...ash Green at 4 Hz When the LED indicators are flashing green at a 4 Hz rate it indicates the Lock command is ON but the guard door is in the open position RFID signal is not detected If the guard door is confirmed closed and this condition continues use a spare actuator to confirm the actuator is working properly LED Indicators Repeat Flash Pattern Green 3x Red 1x This LED flash pattern occurs whe...

Page 33: ... Damage to one or to both of the reeds inside the actuator can cause intermittent behavior of the switch Use a good actuator known with the switch to determine if the installed actuator is working properly Magnet misalignment Donotextendthelockingboltmechanically Useofatooltopulltheboltout oftheswitchcandamageorcausemisalignmentofthemagnetattheendof the bolt This can cause unreliable operation of ...

Page 34: ...cking Bolt Discolored and or Corroded Discoloration of the end of the locking bolt might be a sign of corrosion caused by incompatibility with a liquid used in the application Bulletin 440G LZ is resistant to most alkaline clean in place CIP cleaners It is recommended that the switch be thoroughly rinsed with water after exposure to CIP This step prevents adverse effects that may occur with long t...

Page 35: ...d Guard 1 functions properly OSSDs are energized to 24V Green LED is ON Actuator 2 is in sensing range and guard is locked Guard 2 functions properly OSSDs are energized to 24V Green LED is ON Actuator 3 is in sensing range and guard is locked Guard 3 has a fault See Diagnostic table Red LED is flashing Actuator 4 is in sensing range and guard is locked Guard 4 functions properly Series inputs are...

Page 36: ...36 Rockwell Automation Publication440G UM001C EN P June 2019 Chapter 6 Diagnostics andTroubleshooting Notes ...

Page 37: ...4V 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 0 1 2 3 4 5 6 7 8 LOGIC Brn Brn Blk Blk Blu Blu 23 24 Safety Status to PLC L11 A2 Brn Red Yel Grn Wht Blu Gry Pnk Reset 440G LZS21SPR A SLS Request to PLC 24V DC COM Status SafetyInput1 SafetyCommon SafetyInput2 K 300 Safe Torque off STO Connector With Wiring Heade...

Page 38: ...roximity 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 ...

Page 39: ...he safety gate is initiated by pressing the Gate Unlock Request The Y32 output of the GLT turns OFF which commands the PowerFlex drive to bring the motor to a stop After the configured time delay eight seconds expires the GLT safety outputs turn off and the gate becomes unlocked After you leave the cell 24V DC Red OSSD A Pink OSSD B Green Lock White Aux Blue Gnd Grey OSSD A Yellow OSSD B Brown 24 ...

Page 40: ... 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 13 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 assessm...

Page 41: ...ked While the gate is unlocked the DI 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 Wiring to DG Relay The 440G LZ safety switch can be used in G...

Page 42: ... for guard locking applications Figure 15 on page 43 shows an example schematic The CR30 monitors the motor running signal from the PowerFlex 525 When the motor is not running the safety gate can be unlocked and the PowerFlex 525 goes to a Safe Torque Off state L1 L2 L3 M K1 K2 K1 K2 Status Control Control 24V DC Machine Control System 24V Com A1 S32 X3 X2 X4 14 S42 13 23 24 S11 S12 S21 S22 X1 A2 ...

Page 43: ...o the safety switch The unlock Stop Time delay is set to five seconds and the ULR Latch Unlock Request is set to ON When an unlock request is made the command is issued five seconds after the motor stops running and the unlock request is latched ON 05 CR30 02 01 00 03 04 A1 15 20 21 16 06 18 A2 07 19 08 10 11 12 13 14 09 17 24VDC 24V DC Com Reset NC 440C CR30 22BBB Unlock Motor Not Running Lock Ga...

Page 44: ... Status auxiliary signal The PLC logic checks to see if the door is closed before issuing a lock command The schematic for this example is shown in Figure 22 on page 47 Figure 17 1734 and 440G LZ Safety Switch Schematic 1734 IB8S 1734 AENT 1734 OB8S 24V DC Com I0 I1 I2 T0 I3 T1M COM COM I4 I5 I6 T2 I7 T3M COM COM 0 1 2 6 3 7 4 5 O0 O1 O2 O3 COM COM O4 O5 O6 O7 COM COM COM COM COM COM 24V DC K1 K2 ...

Page 45: ... example Points 0 and 1 monitor the OSSD outputs of the 440G LZ safety switch The Type is set to Single and the Mode must be set to Safety Set the On Off delay time to 6 ms to filter out the test pulses from the 440G LZ safety switch Points 2 and 3 monitor the status of the output contactors K1 and K2 The Type should be set to Single The discrepancy time will be dependent on the contactor device A...

Page 46: ...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 as well as supplies power to the OSSD inputs By setting it to Standard you can programmatically turn these points OFF and ON Figure 20 1734 IB8S Module Properties Test Output Figure 21 shows the General Tab of the 173...

Page 47: ...h 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 22 1734 OB8S Module Properties Output Configuration Figure 23 on page 48 shows an example logic program A Dual Channel Input Stop DCS function block monitors the safety switch and a Configurable Redundant Output CROUT function block control co...

Page 48: ...00 Example Logic Program Wiring to 1732 ArmorBlock Guard I O The 440G LZ can be connected to a 1732ES or 1732DS ArmorBlock by using an 871A TS5 DM1 field attachable connector The cordset 889D F8NB has 24 AWG wires which allows three wires connected to one pin An example schematic is shown in Figure 24 on page 49 ...

Page 49: ... F D H C G EtherNet 4 3 2 1 1 2 3 4 1T1 2 I1 3 C 4 I0 5T0 1T1 2 I1 3 C 4 I0 5T0 1T1 2 I1 3 C 4 I0 5T0 1T1 2 I1 3 C 4 I0 5T0 1T1 2 I1 3 C 4 I0 5T0 1T1 2 I1 3 C 4 I0 5T0 X100 X1 X10 2 O1 1 24 3 C 4 O0 5 C 2 O1 1 24 3 C 4 O0 5 C 3 5 4 2 1 3 5 4 2 1 24V DC 24V Com 871A TS5 DM1 5 pin Field Attachable Connector 1732ES IB12XOB4 Red OSSD A Pink OSSD B Green Lock White Aux Blue Gnd Grey OSSD A Yellow OSSD ...

Page 50: ...put Configuration Figure 27 shows the Test Output tab of the ArmorBlock Module Properties In this example Points 0 and 1 are set to Standard This allows these points to be controlled by the program Point 0 applies power to the 440G LZ By setting it to standard the user can programmatically turn this point off and on if the 440G LZ switch has a fault condition Point 1 is the lock unlock command In ...

Page 51: ... program A Dual Channel Input Stop function block monitors the 440G LZ and a Redundant Output function block controls two contactors This example can be used as a starting point for implementation users must incorporate additional logic based on the risk assessment for the machine Figure 29 Example Studio 5000 Program ...

Page 52: ...52 Rockwell Automation Publication440G UM001C EN P June 2019 Chapter 7 Application Examples Notes ...

Page 53: ...e C 1 2 2 1 300 N Maximum output current each output 200 mA Quiescent power consumption locked or unlocked 2 5W Lock signal current 3 5 mA signal on green lock unlock wire Peak current during turn on or after Lock Unlock operation 400 mA Duration of peak current at turn on or after Lock Unlock operation 100 ms Number of switches connectable in series Unlimited see ResponseTimeWhen Connected in Ser...

Page 54: ...ting NEMA 3 4x 12 13 IP66 IP67 IP69K Shock and vibration IEC 68 2 27 30 g 1 06 oz 11 ms IEC 68 2 6 10 55 Hz Hygienic ISO 14159 2004 and EN 1672 2005 for part of the machine that is defined as food splash area Washdown Suitable for sodium hydroxide based washdown fluids Radio frequency EMC IEC 60947 5 3 FCC 1 Parts 18 15 R TTE Attribute Value Materials ABS lock bolt and mount bracket 304 stainless ...

Page 55: ...cordance with ISO 13849 1 both for guard position and for lock monitor according to EN ISO 14119 2013 Compliance to European Union Directives This product bears the CE Mark and is approved for installations within the European Union and EEA regions It has been designed and tested to meet the following directives Machine Safety and EMC For a complete list of standards used including Machine Safety ...

Page 56: ...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 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 57: ...s 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 selectionofthethreepairs of actuator bracket holes once the bracket is centered The tolerance to misalignment is 2 5 mm 0 10 in The Z height position is adjusted by sliding the actuato...

Page 58: ...selection of the three pairs of actuator bracket holes once the bracket is centered The tolerance to misalignment is 2 5 mm 0 10 in The Z position can be carefully selected to offset the anticipated door sag or door drop Simultaneously be sure that the alignment is such that it prohibits lifting the door up and off the locking bolt Also check to be sure there is no possibility that the actuator wo...

Page 59: ... by sliding the actuator bracket up down on the profile If the setting gap is centered between the minimum of 0 mm and the maximum of 5 mm 0 20 in a tolerance to misalignment of 2 5 mm 0 10 in is achieved The X and Y positions can be adjusted using the slotted holes of the mounting bracket and appropriate selectionofthethreepairs of actuator bracket holes once the bracket is centered The tolerance...

Page 60: ...60 Rockwell Automation Publication440G UM001C EN P June 2019 Appendix B Typical Installations Notes ...

Page 61: ...Rockwell Automation Publication440G UM001C EN P June 2019 61 Typical Installations Appendix B Notes ...

Page 62: ...62 Rockwell Automation Publication440G UM001C EN P June 2019 Appendix B Typical Installations ...

Page 63: ......

Page 64: ...e for your product Use the code to route your call directly to a technical support engineer http www rockwellautomation com global support direct dial page Literature Library Installation Instructions Manuals Brochures and Technical Data http www rockwellautomation com global literature library overview page Product Compatibility and Download Center PCDC Get help determining how products interact ...

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