Allen-Bradley 440G-EZS21STL05J Electromagnetic Safety Switch User Manual

440G-EZS21STL05J Electromagnetic Safety Switch

Product Information

The Electromagnetic Safety Switch is a safety device that is
designed to ensure the safe operation of machinery and equipment.
It is available in two catalog numbers: 440G-EZS21STL05J and
440G-EZS21STL05H. The switch provides important safety features and
status indicators to help prevent accidents and injuries.

Product Features

• Locking Principle: The safety switch utilizes a locking
  mechanism to secure the equipment and prevent unauthorized
  access.

• Protective Functions: The switch offers various protective
  functions, such as preventing unexpected starts, detecting door
  openings, and monitoring safety circuits.

• Status Indicators: The switch is equipped with status
  indicators, which provide visual feedback on the operational state
  of the device.

Product Usage Instructions

Before using the Electromagnetic Safety Switch, please read and
understand the user manual provided. Follow the instructions below
for proper installation, operation, and maintenance of the
switch:

Installation

1. Ensure that qualified personnel handle the installation
   process.

2. Refer to the project planning section of the user manual for
   mechanical mounting, electrical installation, and commissioning
   guidelines.

3. Follow all safety precautions and regulatory requirements
   during the installation process.

Operation

1. After installation, ensure that the switch is properly
   connected to the machinery or equipment.

2. Make sure that all safety circuits are correctly wired and
   functional.

3. Verify that the status indicators on the switch are displaying
   the appropriate operational state.

4. Regularly inspect the switch for any signs of damage or wear
   and replace if necessary.

Maintenance

1. Follow the recommended maintenance schedule provided in the
   user manual.

2. Perform routine inspections to check for loose connections,
   dirt, or debris that may affect the performance of the switch.

3. Clean the switch using a soft, dry cloth. Avoid using abrasive
   materials or solvents.

4. If any issues or malfunctions are detected, refer to the
   troubleshooting section of the user manual or contact the
   manufacturer for assistance.

Electromagnetic Safety Switch
Catalog Numbers 440G-EZS21STL05J, 440G-EZS21STL05H

User Manual

Original Instructions

Electromagnetic Safety 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.
These 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).
The following icon may appear in the text of this document.
Identifies information that is useful and can help to make a process easier to do or easier to understand.

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Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

Safety Information Product Overview Project Planning
Installation

Table of Contents
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Who Should Use This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Requirements for Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Project Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mechanical Mounting, Electrical Installation, and Commissioning 8 Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 2
Structure and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Product Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Locking Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Protective Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 3
Manufacturer of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Operating Entity of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Mounting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrical Control Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 OSSDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Course of the OSSD Test Over Time . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Locking Solenoid Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Application Diagnostic Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Thorough-check Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Regular Thorough Check Minimum Requirements . . . . . . . . . . . . . 17
Chapter 4
Mount Multiple Safety Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mount the Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Mount the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Table of Contents

Wiring

Chapter 5
Notes on cULus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Device Connection (M12, 5-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Device Connection (M12, 8-pin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Connect Safety Switches with T-connectors . . . . . . . . . . . . . . . . . . . . . . . 24

Commissioning

Chapter 6
Switch On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Thorough-check Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Maintenance and Troubleshooting

Chapter 7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Clean the Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Regular Thorough Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Specifications

Appendix A
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Order Information

Appendix B
Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Order Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Replacement Parts/ Accessories

Appendix C
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Appendix D
Declaration of Conformity (DoC) EU DoC (excerpt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Complete EU DoC for Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Preface

About This Publication
Who Should Use This Publication
Terminology

This user manual contains the information that is needed during the lifecycle of the 440G-EZ electromagnetic safety switch.
This user manual must be available to all people who work with the safety switch. The structure of this user manual is based on the lifecycle phases of the safety switch: project planning, mounting, electrical installation, commissioning, operation, and maintenance.

Use these operating instructions only if you are one of the following personnel: · Project developer (planner, developer, designer) · Installer · Electrician · Safety expert (such as a CE authorized representative, compliance officer, and a person who tests and approves the application) · Operator · Maintenance personnel

This manual uses the following terms and abbreviations throughout. For definitions of terms not listed here, refer to the publication AG-7.1.

Term Dangerous state

Definition A status of the machine or facility, where people can be injured. Protective devices help prevent this risk if the machine is operated within its intended use. The figures in this document always show the dangerous state of the machine as the movement of a machine part. In practice, there are different dangerous states, such as: · Machine movements · Electrical parts · Visible and invisible beam · A combination of multiple hazards

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 Updated template, no content changes

Page Throughout

Additional Resources

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

Resource 440G-EZ Interlocking Safety Switch Installation Instructions, publication 440G-IN019 Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Product Certifications website, rok.auto/certifications.

Description Provides installation information for 440G-EZ switches.
Provides general guidelines for installing a Rockwell Automation industrial system. Provides declarations of conformity, certificates, and other certification details.

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

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Preface
Notes:

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Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

Introduction Intended Use

Safety Information

1 Chapter

This chapter contains general safety information about the safety switch.
Further information about specific product use situations can be found in the relevant chapters.
ATTENTION: Hazard due to lack of effectiveness of the protective device. If non-compliant, it is possible that the dangerous state of the machine cannot be stopped or stopped in a timely manner. · Read this publication carefully and confirm that you understand the content
fully before working with the device. · Follow all safety notes in this publication.

The 440G electromagnetic safety switch is a transponder safety switch with a locking function, which actuators control without contact, and is suitable for the following applications:
· Monitoring of movable physical guards · Locking device for process protection
Only use the safety switch within the limits of the prescribed and specified technical data and operating conditions.
Incorrect use, improper modification of, or tampering with the safety switch invalidates any warranty from Rockwell Automation; in addition, any responsibility and liability of Rockwell Automation for damage and secondary damage that this action causes is excluded.
The safety switch is not suitable for the ambient conditions such as, but not limited, to the following:
· Applications in which the dangerous state cannot be ended immediately (stopping time)
· Radioactivity (exception: natural radioactivity) · Vacuum or high pressure · High UV load · In the vicinity of low-frequency RFID devices · In the vicinity of magnetic fields
ATTENTION: Improper use of the safety switch If a voltage drop occurs, the locking device unlocks, regardless of whether the dangerous state of the machine has ended. This safety switch has a simple electromagnetic locking device. There is no locking device monitoring. · Do not use the safety switch as a safety locking device according to EN 14119. · Do not use the safety switch in applications in which the dangerous state
cannot be ended immediately (stopping/run-down time).

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Chapter 1 Safety Information

IMPORTANT Passing metal chips can impair the function of the safety switch.

Requirements for Qualified Only qualified safety personnel can configure, mount, connect, commission,

Personnel

and service the safety switch.

Project Planning

For project planning, a person is considered competent when they have expertise and experience in the selection and use of protective devices on machines and is familiar with the relevant technical rules and national work safety regulations.

Mechanical Mounting, Electrical Installation, and Commissioning

A person is considered qualified for the task when they have the expertise and experience in the relevant field and is sufficiently familiar with the application of the protective device on the machine to be able to assess whether it is in an operationally safe state.

Operation and Maintenance

For operation and maintenance, a person is considered competent when they have the expertise and experience in the relevant field and is sufficiently familiar with the application of the protective device on the machine and the machine operator has instructed them in its operation.

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2 Chapter

Product Overview

Structure and Function Product Features

The safety switch is an interlocking device with a locking device, which consists of a non-contact sensor with locking solenoid, and a coded actuator. The actuator has a low coding level.
If the protective device closes, the actuator leads to the sensor. When the actuation field is reached, the actuator code reads out and is evaluated by RFID. If the code is valid, the safe output signal switching device (OSSD) switches.
If the locking solenoid has power supply, the locking device is active.

Figure 1 – Sensor Overview
1

2

3

4
65
Item Description 1 Locking solenoid 2 Sensor surface 3 Cover plate 4 Plug connector IN 5 LOCK status indicator 6 OSSD status indicator

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Chapter 2 Product Overview

Figure 2 – Actuator Overview
1

2

3

Item Description 1 Anchor plate 2 Protective cap 3 Actuator surface
Product Models
The safety switch is available in different models. The following is an overview of the unique features of the models:
· One cable with M12 plug connector (5-pin) · One cable with M12 plug connector (8-pin)
Locking Principle
ATTENTION: Hazard due to lack of effectiveness of the protective device. If a voltage drop occurs, the locking device unlocks regardless of whether the dangerous state of the machine is ended. · Do not use the safety switch in applications where the dangerous state cannot
be ended immediately (stopping/run-down time).
Power to Lock Principle
· Lock locking device: voltage at locking device input · Unlock locking function: no voltage at locking device input
If voltage is interrupted, the locking device unlocks and the protective device can open immediately.
The locking device is not monitored, which means that the safety switch does not check whether the anchor plate is applied to the solenoid.
Protective Functions
The safety switch has the following internal protective functions: · Short- circuit protection at all outputs · Cross-circuit monitoring at OSSDs · Overload protection on OSSDs · Supply voltage reverse polarity protection

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Chapter 2 Product Overview
Status Indicators
The safety switch displays important status information with the status indicators.
Figure 3 – Status Indicators

12

Item Name

Color Description

1

OSSD

Green/Red

Green when the OSSD pair is in the ON state. Red when the OSSD pair is in the OFF state. (1)

2

LOCK

Yellow Turns ON when the magnet is supplied with voltage.

(1) When a load that is too high applies to the application diagnostic output, the red OSSD status indicator remains continuously ON. The actual switching behavior of the safety switch is not affected.

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Chapter 2 Product Overview
Notes:

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3 Chapter

Project Planning

Manufacturer of the Machine
Operating Entity of the Machine
Assembly

ATTENTION: Failure to comply with obligations of manufacturer. Hazard due to lack of effectiveness of the protective device. · Conduct a risk assessment before using the safety switch. · Do not tamper with, open, or modify the components of the safety switch. · Do not repair defective devices ­ they must be replaced instead. · Confirm that switch-on commands, which bring about a dangerous state of
the machine, are not enabled until the protective device is closed. · Make sure that a stop command is triggered when the protective device is
opened during the dangerous machine state. The safety switches must not be defeated (such as jumpered contacts), rotated away, removed, or rendered ineffective in any other way. If necessary, put measures in place to reduce possibilities for defeat.
ATTENTION: Failure to comply with obligations of the operating entity. Hazard due to lack of effectiveness of the protective device. · Modifications to the machine and modifications to the mechanical mounting
of the safety switch necessitate a new risk assessment. The results of this risk assessment can require the operating entity of the machine to fulfill the obligations of the manufacturer. · Apart from during the procedures described in this document, the components of the safety switch must not be opened or modified. · Do not perform repair work on the components. Improper repair of the safety switch can lead to a loss of the protective function. · Verify that there is no bypassing by replacement actuators. Restrict access to actuators.
ATTENTION: Bypassing the protective device. Hazard due to lack of effectiveness of the protective device. Avoid incentives to manipulate the safety switch by taking at least one of the following measures: · Cover the sensor and the actuator with additional equipment or protect them
against access. · If possible, use permanent mounting methods for actuators (for example, glue,
safety screws, or rivets).

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Chapter 3 Project Planning
Electrical Control Integration
14

Mounting Location
· Select the mounting location so that the sensor and actuator are accessible for maintenance work and are protected against damage.
· Select a mounting location for the sensor that is as far away from the door hinge as possible.
· If necessary, fit an additional stop for the moving protective device.
Distance
When several safety switches are mounted to the machine, they must be mounted at a minimum distance to one another, see Mount Multiple Safety Switches on page 19.
Alignment
The safety switch can be mounted in any alignment. When mounted horizontally, the anchor plate with rotating bearings increases the manipulation protection. When mounted horizontally, if the movable physical guard triggers the actuator, the magnet holds the actuator. As the anchor plate has rotating bearings, the gravitational force rotates the actuator surface away from the sensor surface and the OSSDs go into the off state.
Mounting Methods
The sensor can be mounted in the following ways: · Surface mount: The sensor is mounted on the fixed part of the protective device (for example, the door frame). · Flush mount (1): The sensor is mounted in the fixed part of the protective device (for example, the door frame). There must be a suitable recess in the mounting surface. The thickness of the mounting surface must be 1.5…3 mm (0.06…0.12 in.).
Switch-on commands that put the machine in a dangerous state can only be activated when the protective device is closed. When the machine goes into a dangerous state, a stop command must be triggered if the protective device is opened. Depending on the safety concept, a safety relay or a safety controller analyzes the signal.
The control that is connected and all devices responsible for safety must comply with the required Performance Level and the required category (for example, according to ISO 13849-1).
OSSDs
Safety switches with local inputs and outputs can be directly integrated into the machine controller.
ATTENTION: Hazard due to lack of effectiveness of the protective device. If non-compliant, it is possible that the dangerous state of the machine cannot be stopped or not stopped in a timely manner. · Verify that the following control and electrical requirements are met so the
protective function can be fulfilled.
(1) For the recess dimensions for flush mounting, see Figure 12 on page 34
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Chapter 3 Project Planning
· The output signals from an OSSD pair must not be connected to each other.
· In the machine controller, both signals from an OSSD pair must be processed separately.
Figure 4 – Dual-channel and isolated connection of OSSD 1 and OSSD 2

· The machine must switch to the safe state at any time if at least one OSSD in an OSSD pair switches to the off state.
· Help prevent the formation of a potential difference between the load and the protective device. If you connect loads to the OSSDs (safety outputs) that then also switch if controlled with negative voltage (for example, electromechanical contactor without reverse polarity protection diode), you must connect the 0V connections of these loads and the connections of the corresponding protective device individually and directly to the same 0V terminal strip. If there is a fault, this way verifies that there can be no potential difference between the 0V connections of the loads and the connections of the corresponding protective device.
Figure 5 – No Potential Difference Between Load and Protective Device

ATTENTION: Hazard due to lack of effectiveness of the protective device. If non-compliant, it is possible that the dangerous state of the machine cannot be stopped or not stopped in a timely manner. Downstream contactors must be positively guided and monitored depending on applicable national regulations or required reliability of the safety function. · Make sure that downstream contactors are monitored (external device
monitoring, EDM).

Requirements for the Electrical Control of the Machine
· Use the control without test pulses. The safety switch is self-testing.
· The safety switch tests the OSSDs at regular intervals. To conduct this test, it switches each OSSD briefly (for max 1 ms) to the off state and checks whether this channel is voltage-free during this time.
· Make sure that the control of the machine does not react to these test pulses and the machine does not switch off.
· The inputs of a connected evaluation unit must be positive-switching (PNP), as the two outputs of the safety switch send a level of the supply voltage in the switched on state.

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Chapter 3 Project Planning 16

The OSSDs are short-circuit protected to 24V DC and 0V. When the actuator is in the response range of the sensor, the OSSDs signal the on state with the high signal level (non-isolated). If the actuator is removed from the response range of the sensor or there is a device fault, the OSSDs signal the off state with the low signal level.
The safety switch complies with the regulations for electromagnetic compatibility (EMC) for the industrial sector (Radio Safety Class A). Radio interference cannot be ruled out when used in residential areas.
ATTENTION: Hazard due to lack of effectiveness of the protective device. If non-compliant, it is possible that the dangerous state of the machine cannot be stopped or not stopped in a timely manner. · Verify that the following control and electrical requirements are met so the
safety switch can fulfill its protective function.

· The external voltage supply of the safety switch must be able to withstand brief power failures of 20 ms as specified in IEC 60204-1.
· The power supply unit must provide safe isolation according to IEC 61140 (SELV/PELV). Suitable power supplies are available as accessories, contact your local Allen-Bradley product distributor or Rockwell Automation sales office.

Course of the OSSD Test Over Time

Figure 6 – Course of the OSSD test over time

(1) V

OSSD 1 300 s t
V

OSSD 2

300 s t

(1) Usually every 40 ms. The interval is dynamic and can be smaller than 40 ms.
Locking Solenoid Control
The locking solenoid is activated through the upstream control. There is no internal activation or deactivation of the locking solenoid through the safety switch. The locking device and locking force are not monitored. When the machine starts, the following sequence must be followed:
1. Check whether safety switch OSSDs are in the on state. 2. Supply the locking solenoid with power. 3. Start the machine.
Application Diagnostic Output
The application diagnostic output signal changes as soon as the actuator is moved into or out of the response range of the safety switch. That is, when the movable protective device is opened or closed. This output is not a safety output.

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Chapter 3 Project Planning

Table 1 – Switching Behavior of the Application Diagnostic Output

Actuator Actuator not in the response area, or safety switch in an error state Actuator in the response area

Application Diagnostic Output Off On

For more information, see Specifications on page 31.

Thorough-check Concept

Appropriately qualified safety personnel must test the safety switch during commissioning, after modifications, and at regular intervals; see Thorough- check Requirements on page 27.
Regular thorough checks serve to investigate the effectiveness of the safety switch and discover anomalies that result from modifications or external influences (such as damage or manipulation).
The manufacturer and operating entity must define the type and frequency of the thorough checks on the machine based on the application conditions and the risk assessment. The process of defining the thorough checks must be documented in a traceable manner.
Regular Thorough Check Minimum Requirements
The following thorough checks must be conducted at least once a year: · Protective function of the safety switch · Switch housing for damage · Switch cables for damage · Safety switch for signs of misuse or manipulation · Locking solenoid for correct function

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Chapter 3 Project Planning
Notes:

18

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

4 Chapter

Installation

Mount Multiple Safety Switches

IMPORTANT When several safety switches are mounted, the minimum distance between the individual systems must be followed to avoid mutual interference.
Figure 7 – Spacing Requirement

Mounting

260 (10.24)
260 (10.24)
The sensor can be mounted in the following ways: · Surface mount — The sensor is mounted on the fixed part of the protective device (for example, the door frame). · Flush mount — The sensor is mounted in the fixed part of the protective device (for example, the door frame). There must be a suitable recess in the mounting surface. The thickness of the mounting surface must be between 1.5…3 mm (0.06…0.12 in.)
For recess dimensions for flush mounting, see Figure 12 on page 34. IMPORTANT Install the safety switch horizontally to help increase protection against manipulation.

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

19

Chapter 4 Installation

Mount the Sensor
1. Unscrew the mounting screw (hexagon socket, 2 mm [0.08 in.]) and remove the cover plate.

2. Mount the sensor on the fixed part of the protective device with 4 x M4 screws and secure it with four nuts.
· For surface mount: Mount the sensor on the fixed part of the protective device. The screws can be set in the front or the back.

Tightening torque: 1 N·m (8.85 lb·in)

20

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

Chapter 4 Installation
· For flush mount: Mount the sensor in the fixed part of the protective device.
Tightening torque: 1 N·m (8.85 lb·in)
3. Set the cover plate on the sensor. 4. Tighten the mounting screws to 1 N·m (8.85 lb·in).
Mount the Actuator
1. Align the actuator to the mounted sensor. 2. Mount the actuator on the moving part of the protective device (for
example, the door) with 4 x M4 screws. Tightening torque: 1 N·m (8.85 lb·in). Use disposable screws, if possible. · Maximum angle between the sensor and the actuator is 3° when the
protective device is closed.
3°
3. Cover the drill holes of the actuator with protective caps.

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

21

Chapter 4 Installation
Notes:

22

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

5 Chapter

Wiring

Notes on cULus Device Connection (M12, 5-pin)
Device Connection (M12, 8-pin)

For use according to the requirements of UL 508, the following conditions must also be met:
· Voltage supply Uv sensor secured with 2 A fuse
· Voltage supply Uv magnet secured with 2 A fuse

Figure 8 – Device Connection Pin Assignment (Convex Connector, M12, 5-pin, A-coded)

2

1

5

3

4

Pin Wire Color (1)

1

Brown

2

White

3

Blue

4

Black

5

Gray

Designation
+24V DC OSSD 1
0V OSSD 2 Magnet

Description
Safety switch voltage supply OSSD 1 output 0V DC voltage supply OSSD 2 output Magnet activation 24V DC

(1) Applies to the extension cables recommended as accessories.

IMPORTANT Pay attention to the tightness of the plug connector.

Figure 9 – Device Connection Pin Assignment (Convex Connector, M12, 8-pin, A-coded)

3

2

8

4

1

5

7

6

Pin Wire Color (1) Designation Description

1

White

Aux Application diagnostic output (not safe)

2

Brown

+24V DC Safety switch voltage supply

3

Green

Magnet Magnet activation 24V DC

4

Yellow

In 2

OSSD 2 input (2)

5

Gray

OSSD 1 OSSD 1 output

6

Pink

OSSD 2 OSSD 2 output

7

Blue

0V

0V DC voltage supply

8

Red

In 1

OSSD 1 input (2)

(1) Applies to the extension cables recommended as accessories. (2) When used as an individual safety switch or as the first safety switch in a cascade apply 24V DC.

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

23

Chapter 5 Wiring

IMPORTANT Pay attention to tightness of the plug connector.

Connect Safety Switches with T-connectors

The following connection system components facilitate connection.

24V 0V Safety A Safety B

5

4

1

4

1

4

1

2

Lock

3

3

3

Item

Connection

Safety-wired Splitter/T-Port

Convex M12

Concave M12

3

2

1

8

4

1

7

5

6

Concave M12

Safety-wired Shorting Plug

Cat. No. 898D-438Y-D8
898D-418U-DM

2

5

3

2

Pin 1 PWR

Pin 2 OSSD 1+

1

Pin 3 NA

Pin 4 OSSD 2+

4

Pin 5 NA

8-pin Device Patchcords

1 m (3.3 ft)

3

2 m (6.6 ft)

5 m (16.4 ft)

10 m (32.8 ft)

5-pin Patchcords

1 m (3.3 ft)

4

2 m (6.6 ft)

5 m (16.4 ft)

10 m (32.8 ft)

5-pin Cordsets

2 m (6.6 ft)

5

5 m (16.4 ft)

10 m (32.8 ft)

Cat. No. (1) 889D-F8ABDM-1 889D-F8ABDM-2 889D-F8ABDM-5 889D-F8ABDM-10
Cat. No. (1) 889D-F5ACDM-1 889D-F5ACDM-2 889D-F5ACDM-5 889D-F5ACDM-10
Cat. No. (1) 889D-F5AC-2 889D-F5AC-5
889D-F5AC-10

(1) Add the letter S to the catalog numbers for stainless steel connectors (example: 889DS-F5AC-1).

24

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

Switch On
Thorough-check Requirements

Commissioning

6 Chapter

ATTENTION: Hazard due to lack of effectiveness of the protective device. If non-compliant, it is possible that the dangerous state of the machine cannot be stopped or not stopped in a timely manner. · Before commissioning the machine, have qualified safety personnel check
and release it. · Verify that the time for the safety requirement (closing the protective device
again) is longer than the response time.

The device initializes after it is switched on. OSSDs are switched off in the meantime. The OSSD light-emitting diode lights up after initialization.

The protective device and its application must be thoroughly checked in the following situations:
· Before commissioning.
· After changes to the configuration or the safety function.
· After changes to the mounting, the alignment, or the electrical connection.
· After exceptional events, such as after a manipulation has been detected, after modification of the machine, or after replacing components.

The thorough check verifies the following:
· All relevant regulations are complied with and the protective device is active for all operating modes of the machine.
· The documentation corresponds to the state of the machine, including the protective device.

Qualified safety personnel or specially qualified and authorized personnel must conduct the thorough checks and must be document results in a traceable manner.

IMPORTANT

· Check whether the protective device of the machine is effective in all operating modes in which the machine can be set.
· Verify that operating personnel have been instructed in the function of the protective device before starting work on the machine. The machine operator has overall responsibility for the instruction, which qualified personnel must conduct.

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

25

Chapter 6 Commissioning
Notes:

26

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

7 Chapter

Maintenance and Troubleshooting

Maintenance Troubleshooting

Clean the Switch

IMPORTANT

· Do not use aggressive cleaning agents (such as isopropanol or spirit). · Do not use any substances that hinder the wetting properties of
lacquers. · We recommend anti-static cleaning agents.

Regular Thorough Check
The safety switch must be checked regularly. The manufacturer and the operating entity of the machine defines the type and frequency of thorough checks, see Thorough-check Concept on page 18.
The regular thorough checks serve to investigate the effectiveness of the safety switch and detect any ineffectiveness due to modifications or external influences (for example, damage or manipulation).
IMPORTANT Conduct the thorough checks according to the instructions from the manufacturer and the machine user.

ATTENTION: Hazard due to lack of effectiveness of the protective device. If non-compliant, it is possible that the dangerous state of the machine cannot be stopped or not stopped in a timely manner. · Immediately shut down the machine if the behavior of the machine cannot be
clearly identified. · Immediately shut down the machine if a machine fault cannot be determined
or safely rectified. · Secure the machine so that it cannot switch on unintentionally.

ATTENTION: Hazard due to unexpected starting of the machine. When any work is taking place, use the protective device to secure the machine or to verify that the machine is not switched on unintentionally.

ATTENTION: Hazard due to lack of effectiveness of the protective device. If non-compliant, it is possible that the dangerous state of the machine cannot be stopped or not stopped in a timely manner. · Do not repair device components. · Do not modify or manipulate device components. · Apart from during the procedures described in this document, the device
components must not be opened.

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

27

Chapter 7 Maintenance and Troubleshooting
IMPORTANT If you cannot remedy the fault with the help of the information that is provided in this chapter, contact your local Allen-Bradley product distributor or Rockwell Automation sales office.
Perform one of the following steps when an error occurs: · Check voltage supply. · Check cables. · Check alignment of safety switch and actuator. · Check ambient conditions (for example, interfering RFID frequencies or magnetic fields, distances to other safety switches).
IMPORTANT If a safety switch has a fault in a cascade with an end connector, the OSSDs of all safety switches between the safe evaluation unit and the safety switch concerned switch into the off state.

28

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

Technical Data

Specifications

A Appendix

Table 2 – Features

Attribute Safe switch on distance Sao Typical switch on distance So Safe switch off distance Sar Max actuation frequency Locking force Magnetic retaining force when not supplied with power Alignment tolerance for locking device
Vertical
Horizontal
Aperture angle

Value 4 mm (0.16 in.) 15 mm (0.59 in.) 45 mm (1.77 in.) 0.5 Hz 500 N (112.4 lbf) 25 N (5.6 lbf)
5 mm (0.2 in.) 5 mm (0.2 in.) 3°

Table 3 – Safety

Attribute

Value

Standards

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

Safety classification (guard door sensing)

PLe category 4 per ISO 13949-1, SIL 3 per IEC 61508 and IEC 62061

Certifications

CE Marked for all applicable EU directives, cULus (UL 508), TÜV, C-Tick

Performance level

PLe (ISO 13849-1) (1)

Category

4 (ISO 13849)

Safety integrity level

SIL 3 (EN 61508)

SIL claim limit

SIL CL 3 (EN 62061)

PFH (average frequency of a dangerous failure per hour)

1.5 x 10-8 at 40 °C (104 °F) and 1000 m (3280.8 ft) above sea level

TM (mission time)

20 years (ISO 13849-1)

Type

Type 4 (ISO 14119)

Coding level

Low coding level (ISO 14119)

Safe state when a fault occurs

At least one OSSD is in the OFF state

(1) In a cascade, the performance level for the cascade as a whole depends on the number and type of devices in the cascade. PLe is only possible in cascades with a maximum of six devices.

Table 4 – System Connection of Variant with 1 x M12 Plug Connector, 5-pin

Attribute Voltage supply Local inputs and outputs Length of connecting cable

Value Convex, M12, 5-pin, A-coded (common plug connector for voltage supply and outputs) 150 mm (5.91 in.)

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

29

Appendix A Specifications

Table 5 – System Connection of Variant with 1 x M12 Plug Connector, 8-pin

Attribute Voltage supply Local inputs and outputs Length of connecting cable

Value Convex, M12, 8-pin, A-coded (common plug connector for voltage supply and inputs and outputs) 150 mm (5.91 in.)

Table 6 – Electrical

Attribute

Value

OSSD pairs

1

Rated impulse withstand voltage Uimp

1500V

Pollution degree

3 (external, according to EN 60947-1)

Power-up delay (after supply voltage applied) (1)

2.5 s

Supply voltage when an individual safety switch is connected

Supply voltage Vv sensor
Supply voltage Vv magnet Supply voltage when a cascade is connected

24V DC (19.2…28.8V) Class 2 supply 24V DC (19.2…28.8V) Class 2 supply

Supply voltage Vv sensor
Supply voltage Vv magnet Muting time when supply voltage is interrupted

24V DC (22.8…28.8V) Class 2 supply 24V DC (21.6…28.8V) Class 2 supply 4 ms

Rated insulation voltage Ui

32V DC

Cable capacitance

400 nF (for Out A and Out B)

Device fuse

0.6…1 A

Current consumption at 24V

Locking device deactivated

50 mA

Locking device active

350 mA

Protection class

III (EN 61140/IEC 61140)

Response time (2)

50 ms (3)

Release time (4)

100 ms (3)

Risk time (5)

100 ms (3)

(1) Once the supply voltage has been switched on, the OSSDs are in the OFF state during the time delay before availability. The time that is specified applies to one sensor; in a cascade, 0.1 s must be added per sensor.
(2) Response time for moving the OSSDs into the OFF state when the actuator is removed from the response area or when the OSSD input signals go into the OFF state.
(3) In a cascade, the value is multiplied by the number of safety switches in the cascade. (4) Response time for moving the OSSDs into the ON state when the sensor detects the actuator and the OSSD input signals are
in the ON state. (5) The risk time is the time that is required to detect internal and external faults. External errors affect the OSSDs (short-circuit
to an OSSD and cross-circuit between the two OSSDs). At least one of the two OSSDs is safely switched off during the risk time.

Table 7 – Mechanical Data
Attribute Dimensions (W x H x D)
Safety switch Actuator Material Sensor housing Actuator housing Anchor plate Weight Safety switch Actuator

Value
120 x 60 x 38.5 mm (4.72 x 2.36 x 1.52 in.) 120 x 60 x 20.5 mm (4.72 x 2.36 x 0.81 in.)
Anodized aluminum Fiber-glass-reinforced PVC Nickel-plated steel
510 g (18 oz) 210 g (7.41 oz)

30

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

Appendix A Specifications

Table 8 – Inputs
Attribute Rated voltage ON state OFF state ON state OFF state

Value 24V DC 5 mA 0 mA 19.2…28.8V DC 0…2V DC

Table 9 – Outputs

Attribute
2 OSSDs (Out 1 and Out 2)
1 Application diagnostic output (Aux) Switching voltage (all outputs)
ON state OFF state Switching current (OSSDs) ON state OFF state Test pulse duration (OSSDs)

Value 2 x PNP, max 100 mA, short-circuit protected and overload-proof 25 mA max (1), short-circuit protected (resistive load)
19.2…28.8V DC 0…2V DC
100 mA 500 µA 300 µs

(1) A higher load affects the behavior of the status indicators, see Status Indicators on page 11.

Table 10 – Environment
Attribute Enclosure rating Ambient operating temperature Storage temperature Relative humidity Vibration resistance Shock resistance
EMC
Minimum distance between two safety switches

Value IP 67 (IEC 60529) -20…+55 °C (-4…+131 °F) -25…+70 °C (-13…+158 °F) 50% at 70 °C (158 °F) (IEC 60947-5-2) 1 mm/10…55 Hz (IEC 60068-2-6) 30 g, 11 ms (IEC 60068-2-27) In accordance with IEC 61326-3-1, IEC 60947-5-2, IEC 60947-5-3, and EN 300330 V2.1.1 Depending on alignment, see Mount Multiple Safety Switches on page 19.

Approximate Dimensions

Figure 10 – 440G-EZ Sensor with 1 x M12 Convex [mm (in.)] 122 (4.8)

42 (1.65)
14.5 (0.57)
6.5 (0.26)

4.5 (0.18)
44 (1.73)

24 (0.94)

(05..252)(13.344)

10 (0.39)

12.5

(0.49)

5.7

(0.22)

(1)
L

(1) L = 150±2 mm (5.91±0.79 in.)

120 (4.73)

44 60 (1.73) (2.36)

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

31

Appendix A Specifications

Figure 11 – 440G-EZ Sensor Actuator [mm (in.)]

17.8

3.7

8 (0.31)

(0.70)

(0.15)

4.5 (0.18)

6

(0.24)

20.5

16.8 (0.81)

(0.66)

120 (4.72) 8
44 (1.73) (0.31)

44

60

(1.73) (2.36)

10 (0.39)

Figure 12 – Flush Mount [mm (in.)]

15.2 14.4 (0.57) (0.60)
28 (1.10)

44 (1.73) 22
(0.87) 22 (0.87) 14.4 (0.57)

Ø42

44

(1.65)

(1.73)

16.3 (0.64)

83.5 (3.29)

32 (1.26) Ø5 (0.20) x 4

32

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

Package Contents Order Information

Order Information
· Safety switch · Actuator · Four protective caps · Safety note · Mounting instructions
Table 11 – 440G-EZ Product Selection Sensor Connection Type Electromagnetic switch Cable with 5-pin M12 connector Electromagnetic Switch Cable with 8-pin M12 connector

B Appendix
Cat. No. 440G-EZS21STL05J 440G-EZS21STL05H

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

33

Appendix B Order Information
Notes:

34

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

Replacement Parts Accessories

C Appendix
Replacement Parts/Accessories

Description Actuator

Cat. No. 440G-EMAS

Table 12 – DC Micro (M12) Cables

Description

Cat. No.

8-pin cordset — concave, straight

889D-F8AB-x (1)

8-pin patchcord — concave, straight

889D-F8ABDM-x (2)

5-pin cordset — concave, straight

889D-F5AC-x (1)

5-pin patchcord — concave, straight

889D-F5ACDM-x (2)

(1) Replace the x with a 2 [2 m (6.6 ft)], 5 [5 m (16.4 ft)], or 10 [10 m (32.8 ft)] for standard cable lengths. (2) Replace the x with a 1 [1 m (3.3 ft)], 2 [2 m (6.6 ft)], 3 [3 m (9.8 ft)], 5 [5 m (16.4 ft)], or 10 [10 m (32.8 ft)] for standard cable
lengths

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

35

Appendix C Replacement Parts/Accessories
Notes:

36

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

EU DoC (excerpt)
Complete EU DoC for Download

D Appendix
Declaration of Conformity (DoC)
The undersigned, who represents the manufacturer in the following section, hereby declares that the product complies with the regulations of the following EU directives (including all relevant changes), and that it is based on the relevant standards and/or technical specifications.
You can find the EU declaration of conformity for the protective device at rok.auto/certifications.

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

37

Appendix D Declaration of Conformity (DoC)
Notes:

38

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

Index

A
accessories 35 actuator
mount 21 overview 10 alignment 14 application diagnostic output 16 approximate dimension 31 assembly 13
C
clean switch 27
commission 25 concept
thorough-check 17 conformity
declaration of 37 connect
safety switch T-connector 24
content package 33
control locking solenoid 16
cULus note 23
D
dangerous state 5 declaration of conformity 37 device connection
M12, 5-pin 23 M12, 8-pin 23 diagnostic output application 16 dimension approximate 31 distance 14 DoC 37
E
electrical installation 8
electrical control integration 14 requirement 15
F
features product 9
flush mount 19

function 9 protective 10
I
indicator status 11
information safety 7
installation 19 electrical commission 8
integration electrical control 14
intended use 7 introduction
safety information 7
L
location mounting 14
locking principle 10 locking solenoid
control 16
M
M12, 5-pin device connection 23
M12, 8-pin device connection 23
machine manufacturer 13 operating entity 13
maintenance 8, 27
manufacturer machine 13
mechanical mounting 8 method
mounting 14 minimum requirement
thorough-check 17 model 10 mount
actuator 21 flush 19 multiple safety switches 19 sensor 20 surface 19 mounting 19 location 14 mechanical 8 method 14 multiple safety switches mount 19

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

39

Index

O
operating entity machine 13
operation 8 ordering information 33 OSSD 14
test course over time 16
overview actuator 10 product 9 sensor 9
P
package content 33 personnel
qualified 8 planning
project 8, 13
Power to Lock principle 10
principle Power to Lock 10
product features 9 model 10 overview 9
project planning 8, 13
protective function 10

switch clean 27
switch on 25
T
terminology 5 thorough-check
minimum requirement 17 regular 27 requirement 25 thorough-check concept 17 troubleshooting 27
W
wiring 23

Q
qualified personnel requirement 8

R
regular thorough check 27 replacement part 35
requirement electrical control 15 minimum thorough-check 17 qualified personnel 8 thorough-check 25

S
safety information 7
safety switch connect T-connector 24
sensor mount 20 overview 9
specifications 29 status indicator 11 structure 9 surface mount 19

40

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

Electromagnetic Safety Switch User Manual

Rockwell Automation Publication 440G-UM003C-EN-P – March 2022

41

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