Guardmaster 440G-LZ Guard Locking Switch

User Manual

Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment.
Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication
SGI-IN001_-EN-P available from your local Rockwell Automation sales office or online at
http://www.rockwellautomation.com/literature/) describes some important differences between solid-state
equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide
variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy
themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages
resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many
variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot
assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits,
equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell
Automation, Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
IMPORTANT

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

It is recommended that you save this user manual for future use.

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Preface
Read this preface to become familiar with the rest of the manual.
It provides information concerning:
who should use this manual
the purpose of this manual
related documentation
conventions used in this manual

Who Should Use This Manual

Use this manual if you are responsible for designing, installing,

programming, or troubleshooting systems that use the Guardmaster
440G-LZ guard locking switch.
You should have a basic understanding of electrical circuitry and
familiarity with safety-related systems. If you do not, obtain the proper
training before using this product.

Purpose of This Manual

This manual is a reference guide for the Guardmaster 440G-LZ guard

locking switch. It describes the procedures you use to install, wire, and
troubleshoot your switch. This manual:
Explains how to install and wire your 440G-LZ
Provides an overview of the Guardmaster 440G-LZ guard locking
switch

Conventions Used in This

Manual

The following conventions are used 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:
Resource

Description

Allen-Bradley Industrial Automation Glossary,

publication AG-7.1

Glossary of industrial automation terms and

abbreviations

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Preface
You can view and download publications at http://
www.rockwellautomation.com/literature/ . To order paper copies of
technical documents, contact your local Rockwell Automation distributor
or sales representative.

Terminology

OSSD

Output Signal Switching Device. Typically designates a pair of solid state

signals pulled up to the DC source supply. The signals are usually tested for
short circuits to the DC power supply, short circuits to the DC common, and
short circuits between the two signals.

Standard coding

Same as Low coding as defined in EN/ISO 14119:2013

Unique coding

Same as High coding as defined in EN/ISO 14119:2013

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Preface
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conventions Used in This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
3
3
3
4

Chapter 1
General Description

Guardmaster 440G-LZ Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Assembly Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Packaging Contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 2
Safety Concept

Safety Standards Applied to Guardmaster 440G-LZ. . . . . . . . . . . . . 11

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 3
Installation and Wiring

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pair Proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Orientation of Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the Actuator Direction of Approach . . . . . . . . . . . . . . . . . . . .
Mounting the Assembled Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the Switch Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Actuator to Switch Alignment . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator RFID Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED Error Codes During the Learning Process . . . . . . . . . . . . . . . . . .
Proving Basic Lock Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13
13
14
15
16
17
17
18
19
20
21
21

Chapter 4
Description of Operation

Description of LEDs During Operation . . . . . . . . . . . . . . . . . . . . . . . . .

Status/Diagnostic LED During Troubleshooting . . . . . . . . . . . . . . . .
Auxiliary Out Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guardmaster 440G-LZ Wiring with GSR Relay . . . . . . . . . . . . . . . . . .
Guardmaster 440G-LZ Wiring with Point I/O . . . . . . . . . . . . . . . . . . .
Guardmaster 440G-LZ Wiring with GLP Relay . . . . . . . . . . . . . . . . . .
Guardmaster 440G-LZ Troubleshooting Series Circuit . . . . . . . . . .
Unit Response Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OSSD Output Test Pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary/Manual Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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24
24
25
26
26
27
27
28
28

Table of Contents

Appendix A
Specifications

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental and General Protection . . . . . . . . . . . . . . . . . . . . . . . . .
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compliance to European Union Directives . . . . . . . . . . . . . . . . . . . . .
Overall Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Catalog Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29
29
29
30
31
31
32
32
34

Appendix B
Typical Installations

Switch Mounted Parallel to Hinge Axis . . . . . . . . . . . . . . . . . . . . . . . . . 35

Switch Mounted Perpendicular to Hinge Axis . . . . . . . . . . . . . . . . . . 36
Switch Mounted to a Sliding Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Chapter

General Description

Guardmaster 440G-LZ
Overview

This Guardmaster 440G-LZ guard locking switch functions by extending a

locking bolt from the switch through a hole in the actuator, thus
preventing the opening of a guard.
The locking bolt drive mechanism and logic ensure that the locking bolt
is allowed to extend only when the corresponding actuator is detected
within range.
The appropriate actuator is detected by RFID coding.
This version of the Guardmaster 440G-LC guard locking switch features
OSSD outputs that are enabled only when the locking bolt is sensed in its
extended position in the actuator, which happens only when the guard is
both closed and locked.
The locking bolt drive mechanism uses a bi-stable solenoid; as a result,
the switch consumes very little electrical power, with peak currents
occurring only briefly, upon start-up and after each movement of the
locking bolt.
Because of its bi-stable drive, not only does the device consume minimal
power, but it does not produce heat whether in its locked or unlocked
condition.
Despite the bi-stable design of the locking bolt drive, the device logic and
functionality are configured to replicate the functionality of a power-torelease or power-to-lock solenoid-operated switch (depending on type).

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Chapter 1

General Description

Guardmaster 440G-LZ
Assembly Overview
Actuator

Locking bolt

QR Code
Actuator
mounting bracket

Switch body

Packaging Contents

Alignment guide

The box includes the following components:

Switch body including connection lead: 3 m or 10 m flying lead or
pigtail equipped with M12 QD connector

Actuator mounting bracket

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

General Description

Chapter 1

Actuator

Actuator-to-actuator mounting bracket mounting screws: 2 x T10

Torx

Alignment guide

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Chapter 1

General Description

Notes:

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Chapter

Safety Concept

Safety Standards Applied to

the Guardmaster 440G-LZ
Guard Locking Switch

The Guardmaster 440G-LZ satisfies applicable requirements in the

following standards related to functional and machinery assembly:
IEC 60947-5-1: 2003+A1: 2009
IEC 60947-5-3: 1999/A: 2005
IEC 61508:2010 SIL 3
IEC 62061:2005 SIL 3
EN/ISO 13849-1:2008/AC: 2009 Performance Level e (PLe), Category
4
EN/ISO 14119:2013
UL 508 17th Edition dated 3/19/2013

Introduction

This section describes the safety performance level concept and explains
how the Guardmaster 440G-LZ meets the requirements for SIL 3, Cat. 4 or
Performance Level e (PLe) applications.

Safety Certification

The Guardmaster 440G-LZ is certified for use in safety applications up to

and including SIL 3 according to IEC 61508 and IEC 62061 with a proof test
interval of 20 years, Performance Level PLe and Category 4 in compliance
with ISO 13849-1.
Safety requirements are based on the standards applicable at the time of
certification.
The TV Rheinland group has approved the Guardmaster 440G-LZ for use
in safety-related applications where Performance Level e is required for
the door position and lock monitoring functions.
The 440G-LZ must be installed in accordance with the applicable
regulation and standards.
While the 440G-LZ can be used for SIL 3, PLe and Category 4 applications,
the installer must comply with guard requirements (e.g. EN/ISO13854
and EN/ISO 13857) and in some cases also minimum (safe) distance
requirements (e.g. EN/ISO 13855).

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

11

Chapter 2
The installed system, including the safety control system and the means
by which the machine stops, must achieve the needed safety
performance. The 440G-LZ is one element in the safety system.
Additional guidance on guards, guard locking and guard interlocking
may be found in:
EN/ISO 12100
EN/ISO 13854
EN/ISO 13855
EN/ISO 13857
EN/ISO 14119
EN/ISO TR 24119
EN/ISO 14120
Application specific C-Level standards

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Chapter

Installation and Wiring

General Considerations

The 440G-LZ guard locking switch is designed for use on guards that are
engineered to be rigid without sag. A separately mounted latch (e.g.
magnetic or mechanical) and mechanical stop are required.
It can be used on Full Body Access guards that do not require escape
release, emergency release or remote release guards, and in any situation
where the alignment tolerance falls within the stated specification.
Installation must be in accordance with the present manual and must be
carried out by qualified personnel exclusively. The 440G-LZ guard locking
switch is intended to be part of the safety-related control system of a
machine. Before installation, a thorough risk assessment must be
performed to determine whether the specifications of this device are
suitable for all foreseeable operational and environmental characteristics
of the application.
Refer to the Specifications section of this manual. Use appropriate screws,
bolts, or nuts fitted by tools to mount the switch and actuators to avoid
tampering.
Do not over-torque the mounting hardware.

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

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

Pair Proximity

During installation, make sure you observe the following restriction: you
must maintain a minimum distance between each pair of switches you
mount. Make sure to maintain a minimum distance of 120 mm (4.72 in.)
between any two switches and actuators, as indicated in the following
illustrations.

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Chapter 3

Installation and Wiring

120 mm

120 mm

If the recommended minimum proximity dimension is not observed, the

units will fault.

Orientation of Switches

14

Can be used in all mounting orientations.

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Installation and Wiring

Setting the Actuator

Direction of Approach

Chapter 3

The actuator can approach the switch from all four directions.





Ensure the white arrow on the actuator aligns with the white arrow on
the switch body.
The actuator must be fitted to the actuator mounting bracket in such a
manner that the white alignment triangles marked on both the actuator
and switch body are in the installed position.

Align the white triangles.

0.4 Nm

2 x T10 Torx screws

Ensure the locking bolt enters the actuator mounting bracket first.

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Chapter 3

Installation and Wiring

Ensure two fasteners are used with at least one fastener fitted close to the
actuator bracket bend.

Mounting the Assembled

Actuator

The following drawings show mounting possibilities when attaching to

extruded aluminum profile and flat surface guard doors.

Removal of the Actuator Plug

This plug may be broken out from the actuator if a through hole is
required to prevent a food trap when mounted on the hazard side of a
guard door.
The plug can be broken out by using a screwdriver and twisting until it
comes apart.

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Installation and Wiring

Mounting the Switch Body

Chapter 3

Three M5 fasteners (not provided) are required for proper mounting to a

rigid guard door frame.

3 x M5

Setting Actuator to Switch

Alignment

There are three ways to achieve proper alignment.

1. By setting gap G
2.5 mm (0.09 in.) [05 mm (00.19 in.)]

2. By mounting hole alignment H

6.5 mm (0.25 in.) [49 mm (0.150.35 in.)]

3. Using the alignment guide

provided

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Chapter 3

Installation and Wiring

ATTENTION: After installation, ensure

that there is no possibility of lifting the
actuator over the extended locking bolt.

ATTENTION: After installation, ensure

there is no possibility of collision when

the actuator approaches the switch body.

Actuator RFID Setting

Switches with standard coded actuators

These switches are ready for use and need no special RFID setting.
Switches with unique coded actuators
Before use, the switches must first learn a new RFID guard actuator. This
task is not performed at the factory, as there are two possible methods:
Multi-time learning: the switch can learn up to eight actuators
consecutively.
One-time learning: The switch learns one actuator only, for life,
irreversibly.
The one-time learning method may be invoked at any time, not just
during RFID setting. For example, the switch could multi-time learn four
different actuators consecutively, then complete a one-time learning
process that would prevent it from learning any additional actuators.
Learning the First Multi-Time Actuator
Connect the switch to 24V DC (see the wiring diagrams on page 21), and
ensure that the lock command is off.
The Status/Diagnostic LED will blink a number of times corresponding to
the number of times a new actuator may be acquired (a total of eight
times when the switch is new), then repeat, indicating that the switch has
yet to learn a new actuator.
The switch automatically starts the learning process as soon as an
actuator is placed in the guard-closed position of the switch.

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Installation and Wiring

Chapter 3

Learning Sequence as Indicated by the Status/Diagnostic LEDs

Actuator present

Blinking green, 1 Hz rate

Verifying actuator

Blinking green/red, 1 Hz rate (15 sec)

Programming switch (15 sec)

Blinking green/red, 4 Hz rate (15 sec)

Program finalization

Blinking green (remaining number of times

a new actuator may be acquired, 15 sec)

Ready state (learning process is complete)

Solid green (Power-to-release)

Solid red (Power-to-lock)

Learning Additional Multi-Time Actuators

Mount the new actuator on the guard and repeat the above process.,
introducing the actuator to the switch as previously described. During
program finalization, the LED will blink green a number of times
corresponding to the number of remaining learnable actuators.
Note: Once a new actuator is learned by a unique coded switch, any
previous actuator is no longer usable by that switch.
One-time Learning Process
Proceed just as in the multi-time teaching process described above,
with the following exception: at the programming finalizing (last) stage,
withdraw the actuator from the switch, until the LED turns solid red, then
immediately reposition the actuator near the switch. This process must
be executed within 15 seconds.
The LED blinks, then turns solid to indicate that the learning process is
complete.

Power-to-release

Solid green

Power-to-lock

Solid red

Note: For power-to-release switches, you will need to execute a manual

release in order to withdraw the actuator away from the switch as
described above.

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Chapter 3

Installation and Wiring

Status/Diagnostic LED Error

Codes During the Learning
Process

Proving Basic Lock Function

The following code sequences persist until a Power On/Off cycle is

completed.

Status/Diagnostic LED Flashes (4 Hz)

Error Code

Green

OSSD inputs not valid

Red-red-red-green

Cannot learn a standard actuator

Red-red-red-green-green

Actuator already learned

Red-red-red-green-green-green

Bad RFID; actuator moved out of range

Red-red-red-green-green-green-green

Exceeded learning eight actuators

Red-red-red-green-green-green-greengreen

Unit locked: cannot learn another actuator

To prove basic lock function and to verify correct actuator alignment, it

may be necessary to extend the locking bolt. The locking bolt cannot be
extended by mechanical means; you must proceed electrically. The
following basic connections are required:
Pin 2 (brown wire) must be connected to 24V DC
Pin 7 (blue wire) must be connected to 0V (GND)
In the case of a power-to-release switch, the locking bolt will extend
when the guard is shut and the actuator is aligned. Connect Pin 3 (green
wire) to 24V DC to unlock the switch and withdraw the locking bolt.
If power is removed from a power-to-release switch in the locked
position, the locking bolt will remain in its extended position (switch
locked). Use the manual auxiliary release to unlock the switch.
In the case of a power-to-lock switch, connect Pin 3 (green wire) to 24V
DC to lock the switch (i.e. extend the locking bolt). Disconnecting Pin 3
will unlock the switch.
If power is removed from a power-to-lock switch in the locked position,
the switch unlocks.
In either type of lock, the locking bolt never extends in the absence of the
actuator.

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Installation and Wiring

Chapter 3

Wiring
3 Lock Command
8 Safety A+

2 24V DC+
Keyway
1 Aux
7 0V

4 Safety B+
5 Safety A

8-Pin Micro (M12)

Color
White
Brown
8-Pin Cordset
Green
889D-F8AB-* or
Yellow
cable version
Grey
Pink
Blue
Red

Connections Systems

6 Safety B

Function
Aux
24V DC+
Lock
Safety B+
Safety A
Safety B
Gnd/0V
Safety A+

Pin
1
2
3
4
5
6
7
8

The following connection system components facilitate connection:




Safety-wired Splitter/T-Port

Cat. No 898D-438Y-D8
3
8
4
5

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

2
1
7
6

21

Chapter 3

Installation and Wiring

Safety-wired Shorting Plug

Cat. No 898D-418U-DM

4
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5

PWR
OSSD 1+
NA
OSSD 2+
NA

8-pin Device Patchcords

Cat. No.

1 meter, 8-pin

889D-F8ABDM-1

2 meters, 8-pin

889D-F8ABDM-2

5 meters, 8-pin

889D-F8ABDM-5

10 meters, 8-pin

889D-F8ABDM-10

Note: Add the letter S to above cat. nos. for stainless steel connectors;
e.g. 889DS-F8ABDM-1

5-pin Patchcords

Cat. No.

1 meter, 5-pin

889D-F5ACDM-1

2 meters, 5-pin

889D-F5ACDM-2

5 meters, 5-pin

889D-F5ACDM-5

10 meters, 5-pin

889D-F5ACDM-10

Note: Add the letter S to above cat. nos. for stainless steel connectors;
e.g. 889DS-F5ACDM-1

5-pin Cordsets

Cat. No.

2 meters, 5-pin

889D-F5AC-2

5 meters, 5-pin

889D-F5AC-5

10 meters, 5-pin

889D-F5AC-10

Note: Add the letter S to above cat. nos. for stainless steel connectors;
e.g. 889DS-F5AC-1
More detailed information may be found online at ab.com/product
catalogues/ (search for Connection Systems).
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Chapter

Description of Operation

Status/Diagnostic LEDs
During Operation

During operation, the LEDs indicate the status of the Guardmaster

440G-LZ guard locking switch as follows:
Power-to-Lock
Versions

Guard
Status

Lock
CMD

OSSD
Input

Lock
Status

Power on and lock Open or

CMD off
closed

Off

Off or
on

Unlocked Blinks 6x green

then solid red

Off

Lock CMD on, door Open

open

On

Off or
on

Unlocked Fast flash green

Off

Lock CMD on, door Closed

closed

On

Off

Locked

Slow flash green Off

Lock CMD on, door Closed

closed

On

On

Locked

Solid green

On

Power-toGuard
Release Versions Status

Lock
CMD

OSSD
Input

Lock
Status

LED
Status

OSSD
Status

Power on with
door open

Open

Off

Off or
on

Unlocked Blinks 6x green, Off

then blinks 1x
red, followed by
fast flash green

Power on with
door closed

Closed

Off

Off

Locked

Blinks 6x green, Off

then blinks 1x
red, followed by
slow flash green

Power on with
door open, and
OSSD input active

Closed

Off

On

Locked

Blinks 6x green, On
then blinks 1x
red, followed by
solid green

On

Off or
on

Unlocked Solid red

Unlock CMD on,

Open or
and door closed or closed
open

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

LED
Status

OSSD
Status

Off

23

Chapter 4

Description of Operation

Status/Diagnostic LEDs
During Troubleshooting

This section explains the meaning of the various LEDs during

troubleshooting.
LED Status

Switch Status

Off

Not powered

Solid green

Door shut, locked, and OSSDs are ON.

Fast flash, green (4 Hz)

Waiting to lock, actuator is not within range

Slow flash, green (1 Hz)

Door shut, locked. OSSDs are OFF because theres no safety

input signal.

Solid red (PTL versions)

Door open or shut, not locked. No lock signal.

Solid red (PTR versions)

Door open or shut, not locked. Unlock signal is ON.

Flashing 3x green, then red - repeats Attempting to lock/unlock, actuator not aligned.
Flashing 3x green, then red Failure to lock/unlock. Align actuator, then cycle power.
repeating, then finally fast flash red

Auxiliary Out Function

24

Slow flash, red (1 Hz)

OSSD fault, check outputs are not shorted to GND, 24V DC,
or each other. Cycle power to reset.

Fast flash, red (4 Hz)

General fault. Cycle power to reset.

The Auxiliary Out only changes state when the door is shut and locked,
regardless of OSSD status.
Power-to-Lock Versions

Lock CMD

Lock Status

Auxiliary Out

Door open

On or off

Unlocked

On

Lock CMD on, door closed

On

Locked

Off

Power-to-Release Versions

Lock CMD

Lock Status

Auxiliary Out

Door open

On or off

Unlocked

On

Lock CMD off, door closed

On

Locked

Off

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Description of Operation

Chapter 4

Guardmaster 440G-LZ Wiring

with GSR Relay

440G-LZS

889D-F8AX-X

Brn
Yel
Red

24V DC Supply

Reset

Wht Pnk Gry Blu

N/C

Pigtail

Grn

E-Stop

Power
In1
In2
Out
Logic

A2
A1
+
24VDC
DI

S11

L11

S12

S22

S32

S42
IN2

IN1

0
LOGIC
8

L12

S21

Test Out

Y32

6 5

1
2
3
4

S34

A1
A2
+
24VDC

B1

B2

37

38

47

48

37 38 47 48

EMD
17 18 27 28

13

14

23

24

L12

L11

X32

17

18

27

K1

28

K2

K1

K2

24V DC COM

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

25

Chapter 4

Description of Operation

Point to Point I/O with Unlock request.

Guardmaster 440G-LZ Wiring

with Point I/O

24V DC Supply

Fault
Reset

Pigtail

Grn

Wht
Blu

889D-F8AX-X

Pnk
Gr
y

Brn
Yel
Red

Safety
Reset

N/C

I0

I1

I4

I5

I2

I3

I6

I7

COM

COM

T0

T1

Unlock
Request

COM COM

T2

K1
K2

T3M

1734-IB8S

24V DC COM
Unlock
Signal

O0

O1

O4

O5

O2

O3

O6

O7

COM

COM

COM COM

COM

COM

COM

K1
K2

COM

1734-OB8S

E-Stops with Speed Monitoring, Guard Locking and Servo Drive

Guardmaster 440G-LZ Wiring

with GLP Relay
24V DC, Class 2 Supply

Brn Red Yel

440GLZS21SPRA

Grn
Wht Blu Gry Pnk

Gate
Unlock
Request

Reset &
Gate Lock
Request

Drive Status
to PLC
Reset

SLS
Request
to PLC

X14 X24 51 A1 S44 S54 Y32 L12

0
0
0
LOGIC
1 SL1
1
1 SL2
2
2
2
9
9
9
3
3
8
3
8
8
7 6 54
7 6 54
76 54

Reset

E-Stop
800FM-MT44
800F-MX02S

S11 S12 S21 S22 A1 13

23 S34

1
2
3
4

GLP

DI

440R-GL2S2P

440R-D22R2

S12 S22 L61 A2 AP P12 P22 L11

S32 S42 L12 L11 A2 14

Stop/Start/SLS
from PLC

LOGIC
8

Safety
Status
to PLC

6 5

K 300
24 Y32

Safe Torque-off (STO)

Connector With
Wiring Header
+24V DC

Gate Open
- Unlocked

Blk Blk

COM
Status

Brn
Brn

Blu
Blu

Safety Input 1

E-Stop
800FM-MT44
800F-MX02S

872C-D8NP18-E5 (2)

24V DC COM

26

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Safety Common
Safety Input 2

Description of Operation

Chapter 4

Troubleshooting Series
Circuit
+24
24V DC
Power RTN
Supply

Switch 1

Switch 2

Switch 3

Switch 4

Switch 5

1606XL120D

Gre

Bro
wn

en

Gre

Actuator 2 is in sensing range

and guard is locked.
Guard 2 functions properly.
OSSDs are energized to 24V.
Green LED is ON.

Gre
0V
0V

Lock/Unlock

Actuator 3 is in sensing
range and guard is locked.
Guard 3 has a fault.
See Diagnostic table.
Red LED is flashing.

Bro
wn

en

Pink
Grey
Blue

0V
0V

Lock/Unlock

Bro
wn

en

Pink
Grey
Blue

Actuator 1 is in sensing range

and guard is locked.
Guard 1 functions properly.
OSSDs are energized to 24V.
Green LED is ON.

Gre

Red
Yellow
White

Lock/Unlock

Pink
Grey
Blue

+24V
+24V

Bro
wn

en

Red
Yellow
White

Gre

Red
Yellow
White

Pink
Grey
Blue

Recoverable
Fault

Red
Yellow
White

Pink
Grey
Blue

Red
Yellow
White

+24V
+24V

Lock/Unlock

Bro
wn

en

0V
0V

Lock/Unlock

Actuator 4 is in sensing range

and guard is locked. Guard
4 functions properly. Series
inputs are 0V. OSSDs are
de-energized to 0V. Green
LED is flashing to indicate
series inputs are not 24V.

Actuator 5 is in sensing range

and guard is locked. Guard 5
functions properly.
Series inputs are 0V. OSSDs
are de-energized to 0V. Green
LED is flashing to indicate
series inputs are not 24V.

OSSDs
are OFF

Unit Response Times When

Connected in Series
RTN
24V DC
Power +24
Supply

Switch 1 receives
Unlock command
(guard can then
be opened).
0 ms

Switch 1 guard is
closed

Switch 1 OSSD
outputs are
energized.

0 ms

Switch 2 drops the 24 volts

(red and yellow) from
switch 1 OSSD outputs.
Green LED flashes.
100 ms

Switch 2 OSSD inputs (red

and yellow) transition to
24V DC from switch 1 OSSD
outputs. Switch 2 OSSD
outputs are energized.
600 ms

Green

Blu
e

Switch 3
Switch 3

Red
Yel
White
Pink
Grey
Br
ow
n

Actuator 3

e
Blu

Switch 2

Actuator 2

Switch 2

Green

Green

Initial Conditions:
All switches are
locked

Pink
Grey
White
Red
Yel
Brown

Lock/unlock
command

Switch 1

Actuator 1

Switch 1

Blu
e

A2 S11 S52 S12

1606XL120D

Pink
Grey
White
Red
Yel
Br
ow
n

13

23

33

41

14

24

34

42

440R-N23132

S21 S22 S34 A1

Switch 3 drops the 24 volts

(red and yellow ) from
switch 3 OSSD outputs.
Green LED flashes.
150 ms

200 ms

Switch 3 OSSD inputs (red

and yellow) transition to
24V DC from switch 2
OSSD outputs. Switch 3
OSSD outputs are energized.
625 ms

650 ms

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

27

Chapter 4

Description of Operation

OSSD Output Test Pulses

The Guardmaster 440G-LZ guard locking switch uses test pulses to check
for OSSD output faults. This process is illustrated graphically as follows:
Occurs every 25 ms

Occurs every 11 sec

Safety A

600 s

300 s

Occurs every 25 ms

Safety B

Occurs every 11 sec

600 s

300 s

Auxiliary/Manual Release
The manual release is provided to allow you to
unlock the guard door in the event of
unforeseen and uncommon circumstances.
< 2.5 (0.098) dia.

If power is supplied to the switch and the latter

is in its locked state, invoking the auxiliary
release will cause the switch to enter a fault
condition (blinking red LED).
To reset the switch, simply cycle the power.

28

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Appendix

Specifications

Introduction

This appendix provides the specifications for the Guardmaster 440G-LZ

guard locking switch.
Note: The holding force Fzh is in accordance to EN/ISO 14119:2013,
clause 5.7.4. Additional validation was performed in accordance with IEC
60947-5-1:2009, clause C.1.2.2.

Safety Ratings

Standards

IEC 60947-5-3, IEC 60947-5-1, IEC 61508, EN/

ISO 13849-1, IEC 62061, EN/ISO14119, UL 508

Safety Classification: Guard door sensing and

lock monitoring

PLe Category 4 per ISO 13849-1, SIL 3 per IEC

61508 and IEC 62061

Functional Safety Data: Guard door sensing and PFHD: 9.1 x 10-10
lock monitoring
Dual channel interlock may be suitable for use
in applications up to PLe (in accordance with
ISO 13849-1) and for use up to SIL 3 systems (in
accordance with IEC 62061), depending on
application characteristics.
Mission time/PTI: 20 years

Operating Characteristics

440G-LZS21*PR*

Power-to-release

440G-LZS21*PL*

Power-to-lock

Switch function

OSSDs enable when guard closed and locked

Torque for M5 mounting of switch and actuator 2 Nm max.

mounting bracket
Locking bolt insertion for assured locking and
holding force

Minimum of 5 mm (0.19 in.), maximum of 10

mm (0.39 in.)

Approach speed

Minimum of 2 mm/s

Locking bolt alignment tolerance X, Y, Z

Maximum of +/- 2.5 mm

Holding force Fmax (EN/ISO 14119)

1,690 N

Holding force Fzh (EN/ISO 14119)

1,300 N

Maximum output current (each output)

200 mA

Quiescent power consumption, Locked or

Unlocked

2.5 W

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

29

Appendix A

Specifications

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

Maximum number of switches connectable in

series

Unlimited, See Chapter 4, Unit Response Times

Operating voltage Ue

24V DC + 10% / -15% Class 2 SELV

Maximum frequency of operating cycles

0.2 Hz

Dwell time between subsequent locking/

unlocking

2.5 s

Response time (Off)

100 ms first switch, +50 ms for each additional

switch

Risk time (according to IEC 60947-5-3)

100 ms

Start-up time (availability)

5s

Usage category (IEC 60947-5-2)

DC-13 24V 200 mA

Insulation voltage Ui (IEC 60947-5-1)

75 V

Impulse withstand voltage Uimp (IEC 60947-5- 1 kV

1)
Pollution degree (IEC 60947-5-1)

Manual (auxiliary) release

Built-in

Emergency release

No

Escape release

No

Protection class (IEC 61140)

Class II

* See nomenclature section below, and cat. nos. section on page 34.

Nomenclature for Complete Switches

440G-LZS21

S
U

Outputs (Guard Closed

and Locked)

30

a
a
Standard Coding
Unique Coding

P
b
R
L

c
b
Power-to-Release
Power-to-Lock

A
B
H

c
3 m Cable
10 Cable
M12 8-pin

Outputs

Description/Status

Safety

2 x PNP, 0.2 A max. / ON (+24V DC)

Auxiliary

2 x PNP, 0.2 A max. / OFF (+0V DC)

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Specifications

Environmental

General

Protection

Certifications

Appendix A

Operating temperature [C (F)]

055 (+14131)

Storage temperature [(C (F)]

-2575 (+13167)

Operating humidity

595%, relative

Enclosure ingress rating

NEMA 3, 4x, 12, 13, IP66, IP67, IP69K

Shock and vibration

IEC 68-2-27 30 g, 11 ms/IEC 68-2-6 1055 Hz

Hygienic

ISO 14159:2004 and EN 1672-2005 (for part of

the machine defined as food splash area)

Washdown

Suitable for sodium hydroxide-based

washdown fluids

Radio frequency / EMC

IEC-60947-5-3, FCC-1 (Parts 18 & 15), R&TTE

Materials

ABS, locking bolt and mounting bracket 304

stainless steel

Weight switch/actuator

Switch 400 g, actuator 22 g,

actuator mounting bracket 60 g

Connection

Flying lead or pigtail with M12 8-pin QD

connector (stainless steel)

Short-circuit protection

Incorporated

Current limitation

Incorporated

Overload protection

Incorporated

Reverse polarity protection

Incorporated

Overvoltage protection

Incorporated (up to 60V max.)

Thermal shutdown/restart

Incorporated

See the Product Certification link at http://

www.rockwellautomation.com/rockwellautomation/certification/ 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
C-Tick Marked
TV Certified for Functional Safety up to SIL 3 Category 4 for use in
safety applications up to and including SIL 3, in accordance with IEC
61508 and EN 62061, Performance Level e and Category 4 in
accordance with ISO 13849-1, both for guard positioning and for
lock monitoring according to EN/ISO 14119:2013.

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

31

Appendix A

Specifications

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 Directive
and EMC Directive), see EU Declaration of Conformity on page 37 of this
manual.

Overall Dimensions

Switch Body
9.525
(0.37) dia.

9.5
(0.37)

33
(1.29)

22.5
(0.88)

2 x 5.5
(0.22) dia.
10
(0.39)

50
(1.97)
25
(0.98)

134.5 (5.29)

45 (1.77)

22.5
(0.89)

10
(0.39)

22.9
(0.90)

8
(0.31)

140 (5.51)

Actuator and Actuator Mounting Bracket

51.5 (2.03)
40 (1.57)
40
(1.57)

65
(2.56)
25.4
(1.0)

6 x 6.35
(0.25) dia.

12.5
7
(0.28) 25 (0.98)(0.5)

32

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

47
(1.85)
3
(0.12)

Specifications

Appendix A

Switch Mounting Bracket 440G-LZAM2

+1
R6 -3
40 (1.57)

54
(2.12)

2x 15
(2x 0.59)

100 (3.93)

2x 6.35
(2x 0.25)

145.5
(5.72)

2x 33
(2x 1.3)

6.35
(0.25)

4x R6
1 mm

3x 5.5
(3x 0.22)

22.75 (0.89)
18.5
(0.73)
2x 15.5 (2x 0.61)

3 x 5.5
(3x 0.22)

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

2x 31.5
(2x 1.24)

6x M5
x 0.8-6H

33

Appendix A

Cat. Nos.

Specifications

Complete switches, including switch body, actuator and actuator

mounting bracket
Cat. No.
Connection

Type

Power-toRelease

Power-to-Lock

Actuator Coding

3 m lead

10 m lead

6 in. pigtail with

M12 8-pin Quick
Disconnect

Standard
(Low level to EN/
ISO 14119:2013)

440G-LZS21SPRA

440G-LZS21SPRB

440G-LZS21SPRH

Unique
(High level to EN/
ISO 14119:2013)

440G-LZS21UPRA 440G-LZS21UPRB

440G-LZS21UPRH

Standard
(Low level to EN/
ISO 14119-2013)

440G-LZS21SPLA

440G-LZS21SPLB

440G-LZS21SPLH

Unique
(High level to EN/
ISO 14119:2013)

440G-LZS21UPLA 440G-LZS21UPLB

440G-LZS21UPLH

Spare actuators and actuator mounting bracket

Type

Power-to-Release

Power-to-Lock

Coding

Cat. No.

Standard
(Low level EN/ISO 14119:2013)

440G-LZASPR

Unique
(High level EN/ISO 14119:2013)

440G-LZAUPR

Standard
(Low level EN/ISO 14119:2013)

440G-LZASPL

Unique
(High level EN/ISO 14119:2013)

440G-LZAUPL

Actuator mounting bracket

440G-LZAM1

Accessories
Description
Switch body mounting bracket

34

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Cat. No.
440G-LZAM2

Appendix

Typical Installations

Switch Mounted Parallel to

Hinge Axis

The X and Y positions can be

adjusted using the slotted holes of
the mounting bracket and
appropriate selection of the three
Y
pairs of actuator bracket holes,
once the bracket is centered.
Mounting
The tolerance to misalignment is
bracket
2.5 mm.

Z
X

440G-LZAM2

The Z (height) position is adjusted

by sliding the actuator bracket up/
down on the profile. If the setting
gap is centered between the
minimum of 0 mm and the
maximum of 5 mm, a tolerance to
misalignment of 2.5 mm is
achieved.

Y
Actuator
Hole
14mm

Locking bolt
9mm
X

The Z position should be carefully selected to offset the anticipated door

sag or door drop. At the same time, ensure that the alignment is such that
it is not possible to lift the door up and off the locking bolt. Also make
sure that there is no possibility that the actuator would collide with the
switch when the guard door is being closed. It is essential to check the
alignment periodically throughout the use of the guard locking switch.

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

35

Appendix B

Typical Installations

Switch Mounted
Perpendicularly to
Hinge Axis

The Z (height) position is adjusted

by sliding the actuator bracket up/
down on the profile. If the setting
gap is centered between the
minimum of 0 mm and the
maximum of 5 mm, a tolerance to
misalignment of 2.5 mm is
achieved.

The X and Y positions can be

adjusted using spacers
underneath the switch and
appropriate selection of the three
pairs of actuator bracket holes,
once the bracket is centered.
The tolerance to misalignment is
2.5 mm.
The Z position should be carefully
selected to offset the anticipated
door sag or door drop. At the same
time, ensure that the alignment is
such that it prevents lifting the
door up and off the locking bolt.
Also check to ensure there is no
possibility that the actuator would
collide with the switch when
closing the guard door. It is
essential to check the alignment
periodically throughout the use of
the guard locking switch.

36

Minimum radius when

guard hinge axis is
perpendicular to the
switch body axis

0m

The X and Y positions can be

adjusted using the slotted holes of
the mounting bracket and
appropriate selection of the three
pairs of actuator bracket holes,
once the bracket is centered.
The tolerance to misalignment is
+/- 2.5 mm.

R 30

The Z (height) position is adjusted

by sliding the actuator bracket up/
down on the profile. If the setting
gap is centered between the
minimum of 0 mm and the
maximum of 5 mm, a tolerance to
misalignment of 2.5 mm is
achieved.

Min

Switch Mounted to a Sliding

Guard Door

2 mm
(at min. radius)

Z
Y
Mounting
bracket
440G-LZAM2

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

Typical Installations

Appendix B

EU Declaration of Conformity
Identification of the product:

Guard Locking Safety Switch

Name and address of the manufacturer:

Rockwell Automation, Inc.
2 Executive Drive
Chelmsford, MA 01824
USA

Name and address of the authorised representative:

Rockwell Automation B.V.
Rivium Promenade 160
2909 LM Capelle aan den Ijssel
The Netherlands

This declaration of conformity is issued under the sole responsibility of the manufacturer.
Object of the declaration:

Allen Bradley / Guardmaster 440G-LZ21 Series

(reference the attached list of catalogue numbers)

The object of the declaration described above is in conformity with the relevant EU harmonisation legislation:
2004/108/EC
EMC Directive
(EMC)
2006/42/EC
Machinery Directive
(MD)
References to the relevant harmonised standards used or references to the specifications in relation to which
conformity is declared:
EN 60947-1:2007
Low-voltage switchgear and controlgear Part 1: General rules
EN 60947-5-3:1999 + A1:2005
Low- voltage switchgear and controlgear Part 5-3: Control circuit devices
and switching elements Requirements for proximity devices with defined
behaviour under fault conditions (PDF)
EN 60204-1:2006 + A1:2009
Safety of Machinery Electrical equipment of machines General
requirements
IEC 61508: Part 1-7:2010
Functional Safety of electrical /programmable electronic safety related
systems
EN ISO 13849-1:2008
Safety related parts of control systems Part 1: General principles of design
EN 62061:2005
Safety of Machinery Functional safety of safety related electrical, electronic
and programmable electronic control systems
EN ISO 14119:2013
Safety of Machinery Interlocking devices associated with guards
Principles for design and selection
Notified Body:
TUV Rheinland IndustrieService GmbH
51105 Koln Germany
performed:
EU Type Examination
and issued the certificate:
968/EZ 616.00/13
Additional information:
Person authorised to compile the
Authorised representative (see details above).
technical file (MD):
Product Safety Function (MD):
Interlocking devices suitable for use in safety related applications up to PLe
(EN ISO 13849-1) and SIL/SIL CL (EN 61508/EN 62061)
Signed for and on behalf of the above named manufacturer:
Place and date of issue:
Milwaukee, WI USA
11-Nov-2013
Name, function:
Daniel L. Nachtigall, Technical Leader Product Certification Engineering
Signature:

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

37

Appendix B

Typical Installations

Series 1

Catalogue number

Description

440G-LZ21****
Guard locking RFID non-contact safety switches
Accessories
889D-F8AB-*
Cordset for use with sensors with Micro (M12) connector
Patchcord for use with sensors with Micro (M12) connector
889D-F8ABDM-*
1) If no series number is given, then all series are covered
2) Yes = Product is certified to this directive.
N/R = This directive is not required for this product

Directive 2
EMC
MD
Yes
Yes
N/R
N/R

NOMENCLATURE:
440G-LZS21
1
1
2

3
4

38

U
2

P
3

R
4

H
5

Designates Product Type

440G-LZS21 Guard locking RFID non-contact safety switch w/2 safety outputs and 1 auxiliary output
Designates Actuator Coding Type
U Unique
S Standard code
Designates Sensor Type
P Plastic Switch
Designates Lock Mode
R Power to release
L Power to lock
Designates Connection Type
H 8 pin micro (M12) connector pigtail
A 3 meter cable
B 10 meter cable

Rockwell Automation Publication 440G-UM001A-EN-P November 2013

N/R
N/R

Rockwell Automation Support

Rockwell Automation provides technical information on the web to assist you in using its products.
At http://www.rockwellautomation.com/support, you can find technical manuals, technical and application
notes, sample code and links to software service packs, and a MySupport feature that you can customize to
make the best use of these tools. You can also visit our Knowledgebase at
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forums, software updates, and to sign up for product notification updates.
For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer
TechConnectSM support programs. For more information, contact your local Allen-Bradley distributor or
Rockwell Automation representative, or visit http://www.rockwellautomation.com/support/.

Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in
this manual. You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434

Outside United States or Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/
Canada
phone_en.html, or contact your local Rockwell Automation representative.

New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure they are fully operational when shipped from the
manufacturing facility. However, if your product is not functioning and needs to be returned, follow these
procedures.

United States
Outside United States

Contact your distributor. You must provide a Customer Support case number (call the phone number above to
obtain one) to your distributor to complete the return process.
Please contact your local Rockwell Automation representative for the return procedure.

Rockwell Automation, Allen-Bradley, and POINT I/O are trademarks of Rockwell Automation, Inc. Guardmaster is a registered trademark of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are the property of their respective companies.

www.rockwel lautomation.com
Power, Control and Information Solutions Headquarters
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe/Middle East/Africa: Rockwell Automation NV, Pegasus Park, De Kleetlaan 12a, 1831 Diegem, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846

Publication 440G-UM001A-EN-P November 2013

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