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Multi-functional Access Box User Manual

1. 3 Switch on the power supply for at least five seconds e The change is confirmed by the illumination of the Power LED All other LEDs are off 4 Switch off power supply and set DIP switch five to OFF 5 Set DIP switch five to OFE Rockwell Automation Publication 442G UM001A EN P May 2015 23 Chapter4 Description of Operation e The next time the device is started the new setting will be activated Activating Deactivating Release Monitoring IMPORTANT Release monitoring can be activated only if guard lock monitoring is also active IMPORTANT When release monitoring is active the system enters into a latching fault when the escape release or manual release is actuated See System status table signal sequence incorrect status DIA red Lock flashes one time 1 Switch off power supply 2 Set DIP switches five and six as shown De activative release monitoring Activate release monitoring 3 Switch on the power supply for at least five seconds e The change is confirmed by the illumination of the Power LED All other LEDs are off 4 Switch off the power supply 5 Set DIP switch five to OFF e The next time the device is started the new setting will be activated 24 Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter4 Description of Operation Change Actuation Direction of Handle Assembly Fault Reset IMPORTANT Itis
2. Long ON short OFF ON Inserted Normal Operation OFF Closed Inserted With active guard lock monitoring Normal operation door closed bolt inserted Safety inputs FI1A FI1B are ON Safety outputs FO1A and FO1B are OFF With inactive guard lock monitoring Normal operation door closed bolt inserted Safety inputs FI1A FI1B are ON Safety outputs FO1A and F018 are ON Series Operation Normal operation door closed and locked Safety outputs on the previous device OFF Operation as separate device Normal operation door closed and locked Series Operation Normal operation door closed and locked Safety outputs on the previous device ON Not inserted Handle Config Standby Door open unit is ready for configuration of another handle assembly only 3 minutes after power up Handle configuration tip to prevent interruption during configuration close door and switch on guard locking up Handle Configuration Set Position acknowledgement after completion of handle configuration Cycle power or apply 24V to RST for at least 3 seconds to resume normal operation X X X X OFF OFF OFF OFF ON erron w x fo fre o fo on X X X X OFF X X X OFF Error during configuration or invalid DIP switch setting Input error e g missing test pulses illogical switch state from previous switch Handle assembly read error e g error in co
3. 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 and application notes sample code and links to software service packs You can also visit our Support Center at https rockwellautomation custhelp com for software updates support chats and forums technical information FAQs and to sign up for product notification updates In addition we offer multiple support programs for installation configuration and troubleshooting For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com services online phone 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 Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to b
4. 2005 e EN ISO 13849 1 2008 AC 2009 Performance Level e PLe Category 4 e EN ISO 14119 2013 e UL508 17 Edition dated 3 19 2013 The Guardmaster 442G MAB is certified for use in safety applications up to and including Performance Level PL e and Category 4 in compliance with ISO 13849 1 IMPORTANT Inthe estimation of the PL for the overall system a maximum value of 100 years can be assumed for the MITF according to the limit value in EN ISO 13849 1 2008 Chapter 4 This corresponds to a minimum value for the PFH of 2 47x10 h e When up to 10 devices are connected in series these limit values can be assumed for the entire switch chain as a subsystem As a subsystem this switch chain achieves PL e The 442G MAB must be installed in accordance with the applicable regulation and standards While the 442G MAB can be used for 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 The installed system including the safety control system and the means by which the machine stops must achieve the needed safety performance The 442G MAB is one element in the safety system Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter 2 Safety Concept Before safety components are used a risk assessment must be performed on the machine i n accordance with e EN
5. State 3 x flash DIA Lock The device indicates that it is ready to learn a new handle assembly This state will continue for three minutes after power up with the door open DIA LED Not Illuminated and State LED Flashes Approximately Every Three Seconds SS Power PP State flashes approximately every 3 seconds DIA Lock The device displays normal operation with the door open If this display also occurs with the door close the handle module has already been taught in and is being blocked on this 442G MAB Remedy Repeat handle configuration with a new handle assembly see Handle Configuration on page 9 Tip Close the door and activate guard locking to avoid interruptions during configuration Rockwell Automation Publication 442G UM001A EN P May 2015 Troubleshooting and Assistance Appendix A Individual Flickering Input LED on the Evaluation Unit Even when the 442G MAB is switched off it emits a pulse sequence at output FO1A to ensure the functional capability of the output circuit always So a faintly flickering LED can be seen on an input of an evaluation unit even though the evaluation unit does not switch on or signal any fault This usually does not result in any problems during operation Rockwell Automation Publication 442G UM001A EN P May 2015 4B AppendixA Troubleshooting and Assistance Notes 44 Rockwell Automation Publication 442G UM001A EN P May 2015
6. Figure 27 442G MABR URM PTR 442G MABR UT Left hand Guard Door Figure 28 Replace with Code Cover Controls and Indicators 442G MABR ULM C00 Blank Cover No controls or indicators C01 One illuminated push button 2 02 Two illuminated push buttons 52 53 C03 E stop 1 and two illuminated push buttons 52 53 IMPORTANT Refer to Figure 27 right hand guard door assembly and Figure 28 left hand guard door assembly for the positions of the controls Covers with push buttons are supplied with a colored lens kit including one blue green red and yellow and two white Rockwell Automation Publication 442G UM001A EN P May 2015 35 Chapter 6 36 Specifications Escape Release optional Cat No 442G MABE1 The standard shaft 115 mm 4 53 in is optimized for use on 40 mm and 45 mm profiles An extended shaft 250 mm 9 85 in is available see Chapter 3 Installation and Wiring on page 8 for instructions about mounting on smaller or larger profiles Accessories Description Mounting Plate Handle Assembly Cat No 442G MABAMPH Mounting Plate Lock Module 442G MABAMPL2 Mounting Plate Escape Release 442G MABAMPE Extended Shaft 250 mm 9 58 in for Escape Release 1 Use only if the lock module is also mounted to a plate 2 Use only if the handle module is also mounted to a plate Mating Cordset Description 19 pin M23 cordset
7. Guardmaster 442G Multi functional Access Box is an electromagnetic interlocking device with guard locking The system consists of one locking module and one handle assembly An escape release is available as an option The 442G MAB functions by extending the locking bolt from the handle assembly into the lock module When the locking bolt is fully extended into the lock module the locking arm locks the bolt in this position preventing the opening of the guard Depending on the version this is by spring force or solenoid force For power to release versions the locking arm is kept in the locked position by spring force and unlocked by solenoid force when the solenoid is switched ON For power to lock versions the locking arm is kept in the locked position by solenoid force and unlocked by spring force when the solenoid is switched OFF Guard lock monitoring can be deactivated with DIP switches see Change Device Configuration using DIP switches on page 22 ATTENTION For use as a guard locking device in accordance with EN ISO 14119 the guard lock monitoring must be ACTIVE With ACTIVE Guard Lock Monitoring In combination with a movable safety guard and the control system this safety device can prevent opening of the safety guard while a dangerous machine movement is performed The position of the guard locking is monitored during this process Safety outputs FO1A FO1B are enabled only when the locking bolt is sensed in
8. ISO 13849 1 Safety of machinery Safety related parts of control systems General principles for design Annex B e EN ISO 12100 Safety of machinery Basic concepts General principles for design Risk assessment and risk reduction Correct u se includes compliance with the relevant requirements for installation and operation in particular e EN ISO 13849 1 Safety of machinery Safety related parts of control systems General principles for design e ENISO 14119 Safety of machinery Interlocking devices that are associated with guards Principles for design and selection e EN 60204 1 Safety of machinery Electrical equipment of machines General requirements Additional guidance on guards guard locking and guard interlocking may be found in e EN ISO 12100 Safety of machinery General principles for design Ris k assessment and risk reduction e EN ISO 13855 Safety of machinery Positioning of safeguards with respect to the approach speeds of parts of the human body e EN ISO 13857 Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs e EN ISO TR 24119 Technical report associated with EN ISO 14119 addressing the logical serial connection of interlocking devices e EN ISO 14120 General requirements for the design and construction of guards Rockwell Automation Publication 442G UM001A EN P May 2015 7 Chapter3 Installation and Wiring General Con
9. Inspection and Service s4 44 csceuedee oe pda ex teas deen heteneeystees dea eegea 28 5 Wiring Examples ssssssssossossssessossossooeeoee 29 6 SPECIFICATIONS essssoesssooosessooessesosessooe 33 Dimensions isa aia a a a E E AE AEEA 34 Environmental Protection ccseceeseceeeeeeeeeeeeeeeeeeesenes 34 Catalog NUMDerS osoin ea eaa danse ne e AER 35 Appendix A Troubleshooting and Assistance 37 Rockwell Automation Publication 442G UM001A EN P May 2015 iii Table of Contents iv Rockwell Automation Publication 442G UM001A EN P May 2015 Who Should Use This Manual Purpose of This Manual Conventions Used in This Manual Additional Resources Rockwell Automation Publication 442G UM001A EN P May 2015 Preface Read this preface to become familiar with the rest of the manual It provides information concerning e Who would use this manual e The purpose of this manual e Related documentation e Conventions that are used in this manual Use this manual if you are responsible for designing installing programming or troubleshooting systems that use the 442G Multi functional Access Box You must 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 This manual is a reference guide for the 442G Multi functional Access Box It describes the procedures to use to install
10. its extended position in the lock module AND the locking arm is in position i e the guard is closed and the bolt is both extended and locked With INACTIVE Guard Lock Monitoring In combination with a movable separating safety guard and the control system this safety device prevents dangerous machine movements from occurring while Chapter 1 General Description the safety guard is open A stop command is triggered if the safety guard is opened during the dangerous machine function The position of the guard locking is not taken into account during this process Safety outputs FO1A FO1B are enabled only when the locking bolt is sensed in its extended position in the lock module i e the guard door is closed and the bolt is extended In this mode the status of the guard locking is not taken into account IMPORTANT The safety outputs FO1A FO1B will not be enabled until a handle assembly has been configured see Handle Configuration on page 9 After configuration is completed the lock module will only recognize the unique code of the configured handle Assembly Overview Cover for manual release Status Diagnostic LED indicators 1x Torx T8 DIP switches ae X j eS Terminals X2 X5 Locking bar Depending on version cable entry M20 x 1 5 or QD connector Marking for maximum mounting distance Figure 1 Locking Module with Control Cover 2 Rockwell Automation Publication 442G UM001A EN P May 2
11. mating cordset Cat No 889M F19RM 2 The lock modules are factory preset for standalone operation See the User Manual for setting up the device for series operation cable entry models only 3 On QD models terminal X5 6 is connected internally to terminal X3 4 Table 1 Terminal Assignment 10 Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter3 Installation and Wiring Connection of Cover Controls and Indicators n Il n Il Figure 9 As Mounted on a Right hinged Guard Figure 11 Connection of Controls and Indicators Rockwell Automation Publication 442G UM001A EN P May 2015 I Qo o gt JL e e Ce eR uae 11 Chapter3 Installation and Wiring Indicator Lens Set Installation O J Click Og 99 9 i On Figure 12 Installing Lens Cover fet a Color Lens Escape Release Figure 13 Removing Lens Cover The escape release is used to open a locked safety guard from inside the safe guarded area without tools With release monitoring active default factory setting the system enters into a latching fault when the escape release is actuated To reset the device turn the
12. only possible to perform this change when the bolt is not extended and an escape release is not yet mounted If for some reason a right hand assembly needs to be mounted on a left hinged guard door or a left hand assembly needs to be mounted on a right hinged guard door the actuating direction of the door handle must be changed The example that is shown is for changing from right to left hand operation see Figure 19 1 Press door handle up 3 Push cover aside 2 Unscrew mounting screws on handle assembly 6 Only if using an escape release using the hexagon head 4 Lift the locking pin on the door handle using a screw turn the joint counterclockwise from position a to screwdriver and hold it in this position position b 4mm 5 Turn the door handle to 7 Close cover R the right D x 3 8 Screw in the mounting screws and tighten to 2 Nm Final state after repositioning Figure 19 Change Actuation Direction Switch off the operating voltage at the locking module for a minimum of three seconds or apply 24V to the input RST for a minimum of three seconds The State LED flashes quickly approximately 5 Hz A self test is performed during this time up to eight seconds The LED then cyclically flashes three times Rockwell Automation Publication 442G UM001A EN P May 2015 25 Chapter4 Description of Operation Auxiliary Manual Release 26 Close safety guar
13. 015 Chapter 1 General Description 3mm 0 12 Ve g Guard door handle Locking pin for handle adjustment Roll out bolt locking mechanism Automatically extending bolt locking mechanism Bolt tongue 2x Torx T10 Figure 2 Handle Assembly Actuation shaft 8x8 mm Protective Handle Setscrew Cover 0 31 x 0 31 in sleeve Figure 3 Escape Release optional IMPORTANT The length of the actuation shaft 115 mm 4 53 in is optimized for mounting on a 45 mm 1 77 in profile An extended shaft is available 442G MABASHFT See Chapter 3 Installation and Wiring on page 8 for instructions regarding mounting on smaller or larger profiles Rockwell Automation Publication 442G UM001A EN P May 2015 3 Chapter 1 General Description 35 1 38 20 54 0 81 17 5 0 69 a gt t f 135 6531 46 110 E a i 170 4 33 1 81 36 05 660 bi 3 39 s 6 5 0 25 30 1 18 15 iso 10 0 9 175 0 69 1 1 35 1 38 155 6 10 4 0 16 Figure 4 Lock Module Mounting Plate mm in 17 5 0 69 a 3 54 170 16 669 Me ao Ae a 135 175 4 i 110 6 5 0 25 04 433 RA 30 1 18 i 10 175 039 12 0 47 oii 15 32 1 26 Le 4 0 59 130 5 5 14 I 4 0 16 Figure 5 H
14. 15 Copyright 2015 Rockwell Automation Inc All rights reserved Printed in the U S A
15. 442G MABASHFT Cat No 889M FI9RM 3 3 Add 2 5 or 10 for cable length in meters Replacement Parts Description Replacement Handle for Handle Assembly Cat No 442G MABADH Replacement Indicator Lens Covers 442G MABALENS 4 Lock Module Replacement Cover no controls 442G MAB C00 Lock Module Replacement Cover one push button 442G MAB C01 Lock Module Replacement Cover two push buttons 442G MAB C02 Lock Module Replacement Cover E stop and two push buttons 442G MAB C03 4 Includes one blue green red and yellow and two white Rockwell Automation Publication 442G UM001A EN P May 2015 Status Diagnostic LED Indicators During Troubleshooting Appendix A Troubleshooting and Assistance DIA LED Illuminated and State LED Not Illuminated HES Power State E DIA Lock Fault Internal fault Possible causes e Data error e Locking arm is blocked e Internal component fault Remedy 1 Check whether the locking arm is blocked possibly by the bolt of the handle assembly 2 Switch off the voltage at all devices or press the reset button if present that controls ALL integrated reset inputs in the series connection 3 Close the door 4 Switch the voltage on again or release the reset button 5 Wait until the State LED flashes at regular intervals The 442G MAB is now ready for operation again DIA LED Illuminated and State LED Flashes One Time ME Power Sta
16. G UM001A EN P May 2015 Chapter3 Installation and Wiring Electrical Connection A WARNING e To ensure safety both safety outputs F01A F01B must always be evaluated e Diagnostic outputs OD OT OL and OI must not be used as safety outputs e Lay the connection cables with protection to prevent the risk of short circuits see Requirements for Connection Cables on page 16 ATTENTION Incorrect electrical connections can lead to damage or malfunction of the device All electrical connections must either be isolated from the mains supply by a safety transformer according to IEC 61558 2 6 with limited output voltage in the event of a fault or by other equivalent isolation measures A 24V DC Class 2 power supply is required Alternative solutions must comply with the following requirements a Electrically isolated power supply with a maximum open circuit voltage of 30V DC and a limited current of maximum 8 A b Electrically isolated power supply in combination with fuse as per UL248 This fuse should be designed for max 3 3 A and should be integrated into the 30V DC voltage section The mounting of conduits directly on the 442G MAB is not allowed Cables are only allowed to be connected using a suitable cable gland Cable glands can be used if they are UL listed QCRV and are suitable for the related cable diameter 22 17 AWG All electrical outputs must have an adequate protective circuit for inductive loads The o
17. Indicators Chapter 4 Description of Operation LED not illuminated LED illuminated y LED flashes X Any state LED Indicator Operating Mode Power Green Diagnostics Setup Normal Operation 18 State Green Diagnostic Red Lock Yellow Green flash 1 x State Error during handle configuration or invalid DIP switch setting Green flash 2 x Input fault only applies when switch is configured for series operation Green flash 3 x Green flash 4x Handle module read error Output fault off Yellow flash 1 x Signal sequence erroneous Off Off Internal fault Off Off Positive acknowledgement after completion of handle configuration Power cycle or device RESET are required to resume normal operation Flashes green approximately Off every three seconds Normal operation door open Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter 4 Description of Operation Status Diagnostic LEDs Table A Standalone Operation 2z gt a LL ya a celz 5 e 2 5 2 82 da 23 22 32 2 F a 5 d Ss 59 S 3 55 5 g amp 3s E aS o o ss se a 2 a s z s z S 22 22 EF 22 X 2 52 2s 2 38 25 3 E z Normal tion d Open Not OFF OFF OFF OFF OFF OFF Long OFF 4 ormal operation door open inse
18. LED flashes at regular intervals The 442G MAB is now ready for operation again DIA LED Illuminated and State LED Flashes Three Times HE Power PE State 3 x flash E DIA Lock Fault Handle assembly read error e g error in code code not readable Possible causes e EMC interference e g caused by clocked cables near the 442G MAB e Hardware fault in the handle assembly Rockwell Automation Publication 442G UM001A EN P May 2015 39 Appendix A 40 Troubleshooting and Assistance e Different potentials at the fence and door which causes compensating currents that could lead to this error message Remedy in case of EMC interference or potential differences 1 Check the area of use regarding increased EMC radiation or lack of grounding connections of the protective enclosure 2 Switch off the voltage at all devices or press the reset button if present that controls ALL integrated reset inputs in the series connection 3 Switch the voltage on again or release the reset button 4 Wait until the State LED flashes at regular intervals The 442G MABs are now ready for operation again Remedy in case of hardware fault in the handle assembly Replace the handle assembly and repeat the instructions for the handle configuration see Handle Configuration on page 9 Tip Close the guard door and activate guard locking to avoid interruptions during the handle configuration DIA LED Illuminated
19. Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt amp Allen Bradley Guardmaster Rockwell Software and Rockwell Automation are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Table of Contents PROTACC iiss iiciorasee tea eae aaa E heb O EES EEE eae eae E v Who Should Use This Manual ccc cece eeeeeeeeeeeeeeeeeeueeeeees v Purpose of This Manual ccsvedecas doe eeeeedecawiaraenedenme neds ackeeaganeeus v Conventions Used in This Manual ccceseceeeeeeeeeeeeeeeeeeeees v Additional Resources sccatenisansatrnraeatnhecs cee weneerarate nieces v Terminology n no cactesueaaetayen to cancoad ou eraes Oo oes commaeeas eeees vi 1 General Description ccc cece cece cece cece ee eceeee 1 442G MAB Overview ceasdesciesecieeliedcaloadatdeies dendulGadesentetedes 1 Assembly Overview secs etin esse old aly 5 hues iad rea ena Stara tee 2 2 Safety Concepts 6 c cscs sh dieewaaWie kins edewatiieweteescielia es 6 Standards Applied to the Guardmaster 442G Multi functional Access Box 6 Safety Certification e oa wie d es dew ena tecccnSees SEREN EEEE EDERA 6 3 Installation and Wiring cccccccccccccccccees 8 General Considerations tps sahe kde ea dae ecatedenemoedtsmerecnnseaaesas anes 8 MOUNEING so cc2 csctoS
20. User Manual AB Allen Br adley 442G Multi functional Access Box Catalog Numbers 442G MABH 442G MAB U C 442G MABE1 Allen Bradley Rockwell Software Automation 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 resp
21. Wiring IMPORTANT Care should be taken when mounting the lock module cover to avoid pinching the ribbon cable TIP For easier installation it is recommended that the handle assembly be mounted to the guard door before the silver handle is attached to the handle assembly Handle Configuration The unique coded handle assembly must be assigned to the locking module before the system is functional During configuration of the handle the safety outputs are switched off e Insert bolt tongue in the locking module e Apply operating voltage U and Up e The State LED flashes 5 Hz as the device performs a self test up to 8 seconds e Programming begins when the State LED flashes 1 Hz After approximately 60 seconds the State LED turns off e To complete the configuration switch off the operating voltage UB fora minimum of 3 seconds or apply 24V to the input RST for a minimum of three seconds IMPORTANT The locking module disables the code for the previous handle assembly if configuration is carried out for a new handle assembly A disabled handle assembly can be configured again only after a third handle assembly has been configured Terminal Assignment and Wiring LED Lock ye DIA rd State gn Power gn Figure 8 Connections and LEDs Rockwell Automation Publication 442G UM001A EN P May 2015 9 Chapter3 Installation and Wiring 12345678 123456 73 optional cover function lt ss Terminal
22. and State LED Flashes Four Times SS Power BE State 4x flash E DIA M Lock Fault Output fault Possible causes e The connected control system and the 442G MAB do not have a common reference potential common ground e A ground loop is produced by bridges having been installed both on the 442G MAB and in the control cabinet e The internal output circuit is damaged e 24V DC or OV is present at one of the two safety outputs during the switch on process e A safe control system with clocking outputs is connected Remedy 1 Check the wiring and correct it Rockwell Automation Publication 442G UM001A EN P May 2015 Troubleshooting and Assistance Appendix A 2 Switch off the voltage at all devices or press the reset button if present that controls ALL integrated reset inputs in the series connection 3 Switch the voltage on again or release the reset button 4 Wait until the State LED flashes at regular intervals 5 The 442G MABs are now ready for operation again if no fault occurred in the internal output connection DIA LED Illuminated and Lock LED Flashes One Time HE Power State 4 x flash ay DIA LE Lock Fault Signal sequence incorrect Possible causes e Bolt actuator broken e EMC interference e Hardware fault in the handle assembly e Different potentials between fence and door e With active release monitoring escape release or manual release was activated Rem
23. andle Assembly Mounting Plate mm in 17 5 19 5 86 5 3 40 7 5 0 69 0 77 0 29 M6 4x 170 6 69 p 89 4 l l 235 8 54 i 68 83 a 20 5 31 EE i 2 68 3 27 6 5 0 25 0 25 20 435 71 D y Xo 10 17 5 039 12 0 47 3 32 1 26 0 12 113 5 4 47 4 0 16 1 Figure 6 Escape Release Mounting Plate mm in Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter1 General Description Mounting Hardware Reference Handle Module Mounting Plate is supplied with the following hardware 4X DIN 7984 M6X12 ZN screw 4X DIN 433 6 NI washer 4X DIN 6797 JZ D6 4 lock washer Locking Module Mounting Plate is supplied with the following hardware 4X DIN 912 M6X25 8 8 ZN screw 4X DIN 433 6 NI washer 4X DIN 6797 JZ D6 4 lock washer Escape Release Mounting Plate is supplied with the following hardware 4X DIN 7984 M6X8 screw 4X DIN 433 6 NI washer 4X DIN 6797 JZ D6 4 lock washer Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter2 Safety Concept Standards Applied to the Guardmaster 442G Multi functional Access Box Safety Certification Chapter 2 Safety Concept The Guardmaster 442G MAB satisfies applicable requirements in the following standards related to functional and machinery assembly e IEC 60947 5 3 1999 A
24. assignment 19 Conductor Cordset Terminal Description Violet Lock command A Red E stop circuit A Grey E stop circuit B Safety input channel A connect FO1A from previous n a device when switch configured for series operation Safety input channel B connect F01B from previous n a device when switch configured for series operation Red Blue i reli output channel A ON when guard is closed and Green Black ay output channel B ON when guard is closed and Connected internally to X3 5 Reset device is reset if 24V DC is applied for at least 3 seconds Grey Pink Bolt monitoring output ON when guard is closed and bolt White Green is inserted in lock module White Yellow Fault diagnostic ON when the switch is in a fault state White Grey S1 A2 E stop circuit A Black 1 B2 E stop circuit B S1 E stop monitoring contact conduit models only na Auxiliary Green Yellow L Connector housing GND Yellow Brown S2 Push button switching element 52 Brown Green H2 Push button LED H2 White Push button switching element S3 Yellow Push button LED H3 n a Door monitoring output ON when the door is closed Lock monitoring output ON when guard is closed and locked Pink Grey Brown Reserved for future use Power Supply for solenoid and monitoring outputs Brown Power supply for safety outputs 3 1 19 pin
25. cable with protection Fuse Protection for Power Supply The power supply must be provided with fuse protection depending on the number of devices and current required for the outputs The following rules apply Maximum current consumption of an individual device Lmax Iug Iua IFO1A FO1B Iug Device operating current 80 mA Iua Load current of monitoring outputs OD OT OL and OI 4x max 50 mA solenoid switches Ifoia foig Load current of safety outputs FO1A FO1B 2 x max 200 mA Maximum current consumption of multiple devices connected in series Lmax Ipoia Fois nX lyg lya n Number of connected devices Requirements for Connection Cables ATTENTION Incorrect connections can result in equipment damage or malfunction Observe the following requirements with respect to the connection cables Parameter Unit Wire cross section minimum 0 13 26 AWG mm R maximum 60 Q km Cmaximum 120 nF km L maximum mH km 16 Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter 3 Installation and Wiring Lay all 442G MAB connection cables in a common cable harness 24VDC _________ lees lesaceeeseaceuce T AS E EEE L cabinet l Important lay cables in a common harness Figure 17 Mandatory Cable Laying Rockwell Automation Publication 442G UM001A EN P May 2015 17 Chapter 4 Description of Operation Key to Symbols Status Diagnostic LED
26. cast zinc anodized aluminum handle stainless steel hardware Rockwell Automation Publication 442G UM001A EN P May 2015 33 Chapter 6 Specifications Dimensions mm in 15 0 59 89 4 3 52 S naa 15 4 0 61 tH 1000 39 p9 5 26 S0 SLL L8 L 9 LL LAA SE S hhi 40 1 57 40 40 1 57 z 1 57 i LRA iJ 6 6 Co 114 NI 4 49 N i I I Ke J CLOSED 437 la e e o7 7 OPEN 4 0 16 m 155 3 6 11 Ae 130 5 12 Figure 26 Dimensions for MAB Mounted without Optional Mounting Plates Environmental Protection 0 39 __ 1235 104 4 47 4 09 T 33 19 2 0 75 M20x1 5 3 27 0 06 4x T SA aR 2 tah aT SA E j l 2 01 mi 62 5 2 46 a 289 3 11 39 Lasting and correct safety function requires that the sy
27. d and switch guard locking on The system is in normal mode again The manual release is provided to allow for unlocking the guard door in the event of unforeseen or uncommon circumstances With release monitoring active default factory setting the system enters into a latching fault when the escape release is actuated To reset the device turn the power off for at least three seconds or apply 24V to the input RST for a minimum of three seconds IMPORTANT The guard door must be in the open position to clear a latching fault Note The system might not enter into a latching fault if the mechanical release is actuated slowly IMPORTANT The mechanical release is not a safety function The machine manufacturer must select and use a suitable release according to the risk assessment The correct function must be checked at regular intervals and after use of the manual release for example with sealing lacquer Tightening A ATTENTION The locking screw must be screwed back in and sealed after assembly torque is 0 5 Nm 1 Undo locking screw 2 Lift locking arm using a screwdriver and actuate the guard door handle Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter4 Description of Operation ys Tn oZ Figure 20 Auxiliary Manual Release Bolt Locking Mechanism The 442G MAB has two mechanisms for locking the bolt actuator to prevent locking the guard and restarting the machine while an ope
28. de X X X X OFF OFF OFF OFF ON 4x l gt Output error e g short circuits or loss of switching capability or short circuit at the outputs Diagnostics X X X X OFF OFF OFF OFF ON O O Internal fault e g component faulty data fault X X X X OFF OFF OFF OFF ON 1x Fa O A Signal sequence erroneous e g broken bolt With active release monitoring escape release or manual release was actuated Power is ON for a long time with short xix x Px tx xd xd xd x ora ong i interruption One million operating cycles exceeded LED not illuminated e LED flashes x Latching fault to reset use the RST input or briefly disconnect the device from the O power supply Non latching fault open safety guard and close it again to reset See Troubleshooting and Assistance in Appendix A on page 37 20 Rockwell Automation Publication 442G UM001A EN P May 2015 LED illuminated Any state Chapter4 Description of Operation Operation with Control Systems Proving Basic Lock Function Do not use a control system with pulsing or switch off the pulsing function in your control system The control system must tolerate these pulses which may have a duration of up to 1 ms when the device is configured for series operation or 300 us when the device is configured for standalone operation With Active Guard Lock Monitoring 1 Switch on operating v
29. e monitoring is activated factory setting off Release monitoring is deactivated 22 Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter 4 Description of Operation Changing System Operation configuring device for standalone or series operation IMPORTANT The terminal assignment also changes on changing the configuration see Table 1 Terminal assignment on page 10 1 Switch off power supply 2 Set DIP switches 1 2 and 5 as shown Switching from series to standalone operation Switching from standalone to series operation ON ON 1 2 5 T2 5 3 Switch on the power supply for at least five seconds e The change is confirmed by the illumination of the Power LED All other LEDs are off 4 Switch off power supply 5 Set DIP switch five to OFE e The next time the device is started the new setting will be activated Activating Deactivating Guard Lock Monitoring locking does not influence the safety outputs The safety guard can be opened immediately This setting is not allowed to be used in applications in which e g there is hazard due to overrunning machinery movement i WARNING If guard lock monitoring is inactive the position of the guard 1 Switch off power supply 2 Set DIP switches three four and five as shown Deactivating guard lock monitoring Activating guard lock monitoring ON ON 2 345 23 4 5 6
30. e returned follow these procedures 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 Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation 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 442G UM001A EN P May 20
31. ect 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 gt gt IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARC FLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal
32. edy 1 Open all safety doors on which the LED Lock is flashing regardless of the number of flashing pulses so that no passage is possible 2 Switch off the voltage at all devices or press the reset button if present that controls the integrated reset inputs 3 Switch the voltage on again or release the reset button 4 Wait until the State LED flashes at regular intervals 5 Close the safety doors If there is no internal fault the 442G MABs are now ready for operation again Rockwell Automation Publication 442G UM001A EN P May 2015 41 Appendix A 42 Troubleshooting and Assistance DIA LED Not Illuminated and State LED Not Illuminated or Does Not Flash HE Power State DIA Lock Possible causes e Handle configuration is complete e DIP switch five still set to ON system configuration series or standalone operation not fully completed Remedy e When the handle configuration is complete the operating voltage must then be switched off at the locking module for at least three seconds to activate the new code of the handle assembly in the locking module As an alternative 24V can be applied to the input RST for at least three seconds e Complete the device configuration see Change Device Configuration using DIP switches on page 22 process set DIP switch five to OFF Restart the 442G MAB DIA LED Not Illuminated and State LED Flashes Three Times ME Power BE
33. mponent faulty data 5 X X X OFF OFF OFF OFF ON O fault a Signal sequence erroneous e g broken bolt A A OFF OFF OFF OFF ON O et 1x With active release monitoring escape release or manual release was actuated X X X x x x x aa Power is ON for a long time with short One million operating cycles exceeded a interruption Latching fault to reset use the RST input or briefly disconnect the device from LED not illuminated e LED illuminated ee LED flashes x Any state Non latching fault open safety guard and close it again to reset See Troubleshooting and Assistance in Appendix A on page 37 Rockwell Automation Publication 442G UM001A EN P May 2015 19 Chapter 4 Description of Operation Status Diagnostic LEDs Table B Series Operation Operating Mode Position of the Bolt Safety Outputs FOIA and FO1B Door Mounting Monitoring Output Bolt Tongue 0T Guard Locking Mon itoring Output OL Diagnostics Moni toring Output 01 Output 0D Power green Safety Inputs Lock yellow FIA and DIA red 5 Hz gt lt Door Position gt lt Guard Locking Self test X State Self test after power up Not Long OFF inserted short ON iis State green Normal operation door open Not Long ON inserted short OFF Normal operation door closed Long ON OFF Inserted short OFF Normal operation door closed bolt inserted safety inputs FI1A FI1B OFF
34. must not start automatically Rockwell Automation Publication 442G UM001A EN P May 2015 21 Chapter4 Description of Operation e The State LED is ON The Lock LED is ON for a long time with a short interruption guard door unlocked or is ON continuously guard door locked 3 Use the control system to start the machine 4 Open the guard door for power to release versions use the control system to unlock the guard door e The machine must switch off and it must not be possible to start it as long as the safety guard is open Repeat steps two through four for each safety guard Ch ange Device Configuration The 442G MAB can be configured using DIP switches The following settings using DIP switches are possible e Changing system operation standalone or series operation e Deactivating guard lock monitoring e Deactivating release monitoring Dip switches Sticker with factory settings Figure 18 Location of the Switches Function of the Switches ON et Factory settings are A B Ifc shown Detail Switch Function on Device is configured for standalone operation factory setting A 142 off Device is configured for series operation on Guard lock monitoring is deactivated B 344 off Guard lock monitoring is activated factory setting on DIP switch configuration enabled C 5 off DIP switch configuration inhibited factory setting D 6 on Releas
35. oltage The State LED flashes 5 Hz as the device performs a self test up to 8 seconds When the self test is complete the State LED flashes at regular intervals 2 Close all safety guards and insert the bolt tongue into the locking module For power to lock versions activate guard locking e The safety outputs FO1A FO1B are ON e The machine must not start automatically e It must not be possible to open the safety guard e The State LED and the Lock LED are illuminated continuously 3 Use the control system to start the machine e It must not be possible to open the guard door as long as the machine is running 4 Use the control system to stop the machine and unlock the door e The safety guard must remain locked until there is no longer any risk of injury e It must not be possible to start the machine as long as the guard locking is deactivated e It must be possible to open the safety guard Repeat steps two through four for each safety guard With Inactive Guard Lock Monitoring 1 Switch on operating voltage The State LED flashes 5 Hz as the device performs a self test up to 8 seconds When the self test is complete the State LED flashes at regular intervals 2 Close all safety guards and insert the bolt tongue into the locking module As soon as the bolt tongue is inserted in the locking module the safety outputs FO1A FO1B are ON independent of whether the guard door is locked or unlocked e The machine
36. perating Characteristics continued Standards IEC 60947 5 3 EN ISO 13849 1 ISO 14119 UL 508 Protection Type Short circuit and reverse polarity protected cross fault evaluated for risks of electrical shock and fire only detection suitable for NFPA 79 applications only Safety Classification Type 4 interlocking device with guard locking and high Current Consumption lyg no load on any 80 mA coded RFID actuators according to ISO 14119 outputs Functional Safety Data PFHd 2 47 x 10 PLe Cat 4 according to ISO 13849 1 Mission time 20 years B10d for E stop 1 0 x 10 cydes With energized guard locking solenoid and unloaded outputs 01 0L 0T and OD 350 mA Certifications cULus UL 508 and CE Marked for all applicable Push button no load per LED 5 mA EU directives External Fuse Refer to 442G MAB Multi functional Access Box User Outputs Manual Safety Outputs F01A F01B Semiconductor outputs PNP Response Time On 570 ms Output Current maximum each 200 mA Response Time Off 350 ms first switch 5 ms each additional switch Output voltage Uroyq Urgig 50 mA switching current ON Ug 2V Up OFF 0 1V DC Risk Time per IEC 60947 5 3 350 mS Monitoring Outputs Monitoring Outputs 0D OT OL 0I P switching and short circuit proof Discrepancy Time Start up Time availability 10 ms maximum 0 5 s configured for standalone operation 8 s configured for
37. power off for at least three seconds or apply 24V to the input RST for a minimum of three seconds IMPORTANT The guard door must be in the open position to clear a latching fault Note A latching fault may not occur if the escape release is actuated slowly IMPORTANT The escape release is not a safety function The machine manufacturer must select and use a suitable release according to the risk assessment The correct operation must be checked at regular intervals Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter3 Installation and Wiring IMPORTANT The length of the actuation shaft 115 mm 4 53 in is optimized for mounting on 40 mm 1 57 in and 45 mm 1 77 in profiles For mounting on profiles larger than 45 mm or if using mounting plates on a 45 mm profile an extended shaft is required order separately 442G MABASHFT Refer to the table below for instructions about sizing the extended shaft and mounting the escape release on smaller or larger profiles Use the following table to determine if the extended shaft is needed 442G MABASHFT ordered separately to prepare the escape release for smaller or larger profiles Length Required for Actuation Shaft Without With Mounting Profile Mounting Plates Width Plates 4mm each D 17 5 D D 13 5 D 21 52 Shaft Required Necessary Work Steps 30mm Standard shaft Shorten to required length 40mm Standard shaft or extended Without mo
38. rator is inside the safeguarded area One of the bolt locking mechanisms automatically extends when the handle is in the OPEN position The other mechanism is manually extended see Figure 18 To pivot out press the grooved part only possible with the handle in the OPEN position and the bolt retracted IMPORTANT With the manual bolt locking mechanism rolled out the bolt cannot be extended Note Minimum padlock diameter is 2 mm 0 08 in and the maximum diameter is 10 mm 0 39 in You can fit a maximum of three locks in an 8 mm 0 31 in diameter Lili Ss Figure 21 Bolt Locking Mechanisms Roll out mechanism Automatically extending mechanism Rockwell Automation Publication 442G UM001A EN P May 2015 27 Chapter4 Description of Operation Series Operation Inspection and Service 28 A maximum of ten devices can be connected in series Resetting in Switch Chains IMPORTANT Ifyou use the reset input RST for resetting devices that are connected in series all devices in the chain must be reset at the same time Resetting individual switches will result in faults Periodically check the correct operation of the switching function Also check for signs of abuse or tampering Inspect the switch casing for damage Check the safe function of the device particularly after any of the following e Set up work e The installation or replacement of a 442G MAB module e An extended period withou
39. rted short ON Normal tion door closed closed NOt ore ofr on ore oFF OFF long ON eTa E aaa inserted short OFF amp Long ON With active guard lock monitoring Normal g OFF h 5 OFE operation door closed bolt inserted Safety Ss shor Long ON outputs FO1A and FO1B are OFF Closed Inserted OFF ON ON OFF OFF 0 short OFF Ps short With inactive guard lock monitoring Normal ON operation door closed bolt inserted Safety inputs FO1A and FO1B are ON Closed Inserted ON ON ON ON ON OFF n e Normal operation door closed and locked Handle Door open unit is ready to configure another a handle assembly only 3 minutes after power config Open Not ore ore ofr or ore OFF 3x i peas P uration inserted P Standby Handle configuration tip to prevent the Closed Inserted ON ON ON ON ON OFF 2Hz f interruption of the hand close door and switch on guard locking Setup Positive acknowledgement after completion of the handle configuration Cycle power or X X X OFF OFF OFF OFF OFF OU apply 24V to RST for at least 3 seconds to resume normal operation P Error during configuration or invalid DIP X X X OFF OFF OFF OFF ON 1x O switch setting X X X OFF X X X OFF 2 a 3x 5 Se read error e g error in Output error e g short circuits or loss of X X X OFF OFF OFF OFF ON 4x o switching capability or short circuit at the P e outputs E f Internal fault e g co
40. series operation Output Voltage Ua 2V Uy Maximum Length of Switch Chain 10 MAB devices Maximum Load each 50 mA maximum Utilization Category IEC 60947 5 2 DC 13 24V 200 mA Push Button Controls and Indicators Insulation Voltage U IEC 60947 1 30V Operating Voltage 5 24V DC Impulse Withstand Voltage Uimp 15KV Operating Current 1 100 mA Pollution Degree IEC 60947 1 3 Breaking Capacity maximum 250 mW Manual Release Built in ISO 14119 Power Supply LED 24V DC Mechanical Life 1 000 000 operations Operating Characteristics Environmental Torque Settings maximum 1 Nm lock module cover screws 6x Ambient Temperature C F atUg DC 20 55 4 131 0 5 Nm manual release locking screw 24V 2 Nm handle set screw handle and escape release Locking Force Fmax 2600 N Storage Temperature C F 20 65 4 149 Holding Force Fzh ISO 14119 2000 N Enclosure Rating IP65 Maximum Impact Energy Withstand 300J Operating Humidity 5 80 relative Locking Bolt Alignment Tolerance Horizontal 4 mm Vertical 5 mm Vibration Shock IEC 60068 2 27 30 g 11 ms IEC 60068 2 6 10 55 Hz Operating Voltage Ug Class 2 PELV 24V DC 10 15 required Physical Characteristics Auxiliary Power Un Class 2 PELV 24V DC 10 15 required Weight Lock module with cover 750 g handle assembly 1000 g escape release 500 g Materials Glass fiber reinforced plastic nickel plated die
41. siderations Mounting Chapter 3 Installation and Wiring Installation must be in accordance with the present manual and must be performed by qualified personnel exclusively The 442G MAB guard locking switch system 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 see page 33 of this device are suitable for all foreseeable operational and environmental characteristics of the application Use appropriate screws bolts or nuts that are fitted by tools to mount the lock module and handle assembly to avoid tampering Do not over torque the mounting hardware ATTENTION With two wing hinged guard doors one of the two guard door wings must also be latched mechanically D O T LTI SEAR TSS sr a ee O m N va f JS PS iR ANR A PEU RWS AER fon L SI Gj Nis FZ Figure 7 Installation Example for Guard Door That Is Hinged on the Right Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter3 Installation and
42. sion when EJ contactors are used used no external transient suppression is required Non EJ contactors may require external transient suppression Figure 24 Connection Example for GSR DI and EMD Expansion Module Rockwell Automation Publication 442G UM001A EN P May 2015 Maintained Two position Set for 21 second unlock delay 31 Chapter5 Wiring Examples 24V DC 442G MAB PTR Safety Reset Safety Outout B Green Safety Output A Red Blue Fault Reset 0 nh 4 4 2 2 a 2 A 889M F19RM X Unlock Request COM COM COM COM D OD DO T0 T1 T2 13M Unlock Violet Brn An Bolt Mon White Green a 17 D a D D D2 OV COM Ua 1734 1B85 oTo M K1 and K2 100S C09EJ14BC EJ contactors have intergral transient suppression when EJ 00 01 04 05 contactors are used used no A D D external transient suppression K1 is required C Non EJ contactors may require Rst Grey PInk 2 2 bs u K external transient suppression a lo 2 COM COM COM COM A COM COM COM COM D D D 2 1734 0B8S Blu Figure 25 Connection Example with Point 1 0 32 Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter6 Specifications Chapter 6 e e e Specifications Safety Ratings O
43. stem must be protected against debris filings shavings etc which can become lodged in the locking and handle modules For this purpose a suitable installation position should be selected The device should be covered during paint work 34 Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter6 Specifications Catalog Numbers Handle Assembly one required per system f EAR e l 2 2 Figure 27 Right Handle for use on guard doors that are hinged on the right or slide from the right a ee an B C N D L gt C Q Figure 28 Left handle for use on guard doors that are hinged on the left or slide from the left Machine Layout Cat No Right hand Guard Door Figure 27 442G MABH R Left hand Guard Door Figure 28 442G MABH L Lock Module one required per system Cat No Lock Type Machine Layout Cable Entry M20 Connector 19 pin M23 Right hand Guard Door Figure 27 442G MABL URM pu Rightchand Guard Door Figue27 yr Left hand Guard Door Figure 28 442G MABL ULM Right hand Guard Door
44. t any use e A fault condition e Any change to the DIP switch setting If there is a malfunction or damage to the product attempts at repair shall not be made The unit should be replaced or alternative safeguarding shall be implemented before machine operation is allowed Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter 5 Wiring Examples Chapter 5 e e Wiring Examples 440R D22R2 Al L12 K1 A 442G MAB PTR A p m K A S11 Y32 821 34 LOGIC i 8 7 Xa 889M F19RM X NEL 5 4 Red Blue 512 ig Green Brn 522 14 KI Reset 32 z a Grey Pink Unlock Request oTo Violet wo Ly 2 K1 and K2 100S CO9EJ14BC EJ contactors have intergral Blue transient suppression when EJ contactors are used used no external transient suppression is required Non EJ contactors may require external transient suppression Figure 22 Connection Example for Standalone Operation The switch can be reset via the RST input To do this a voltage of 24V is applied to the RST input for at least three seconds Rockwell Automation Publication 442G UM001A EN P May 2015 29 Chapter 5 Wiring Examples 24V DC OV COM 12345678 12345678 aaa EIGE optional cover function gt 3 F
45. tch off the voltage or press the reset button if present that controls the integrated reset input Close the door s 4 Switch the voltage on again or release the reset button 5 Wait until the State LED flashes at regular intervals The 442G MAB is now ready for operation again Rockwell Automation Publication 442G UM001A EN P May 2015 Troubleshooting and Assistance Appendix A DIA LED Illuminated and State LED Flashes Two Times series connection only HE Power BE State 2 x flash E DIA Lock Fault Input error Possible causes e 24V DC missing at safety inputs Fl1A and or FI1B of the first 442G MAB e FI1A is connected with FO1B or FI1B is connected with FOIA e Conventional safety components switching contacts are connected to FI1A and or FI1B e A safe control system with clocking outputs is connected e All connections are correct but there is no common potential for the series connected devices several power supply units for one chain e An upstream unit is set as a standalone device Remedy 1 Check the wiring and correct it or switch off the clock pulses or check the upstream devices for incorrect DIP switch configuration 2 Switch off the voltage at all devices or press the reset button if present that controls ALL integrated reset inputs in the series connection 3 Close the door s 4 Switch the voltage on again or release the reset button 5 Wait until the State
46. te 1x flash E DIA Lock Fault Fault during handle configuration or invalid DIP switch position Possible causes e Invalid DIP switch position Rockwell Automation Publication 442G UM001A EN P May 2015 37 Appendix A 38 Troubleshooting and Assistance Remedy 1 Check the DIP switch setting Configuration must be repeated if the setting is incorrect Follow the instructions in Changing Device Configuration on page 22 Function of the switches ON Factory settings are All sp Ici shown Detail Switch Function on Device is configured for standalone operation factory setting A 142 off Device is configured for series operation on Guard lock monitoring is deactivated B 344 off Guard lock monitoring is activated factory setting on DIP switch configuration enabled C 5 off DIP switch configuration inhibited factory setting on Release monitoring is activated factory setting D 6 ae off Release monitoring is deactivated DIA LED Illuminated and State LED Flashes Two Times standalone operation only ME Power PE State 2 x flash EE DIA Lock Fault Input error Possible causes e 24V DC missing at safety inputs FILA and or FI1B e A safe control system with clocking outputs is connected to safety inputs FILA and or FI1B Remedy 1 Check the wiring and correct it if necessary or switch to standalone mode 2 Swi
47. tee uclcsWeaeds en tea itches atic HeslsaVeteus tee codteust 8 Handle Configuration 5 44 ca Sssannes vagacsedaweane besaaneacmedeataaenee eaeees 9 Terminal Assignment and Wiring ccc cece cece eeeeeeeeeeeeeeaenees 9 Connection of Cover Controls and Indicators ceeeeceeeeeeeeeeees 11 Indicator Lens Set Installation 0 ccseeeceeeeeeeeeeeeeeeeeeeees 12 Escape Release eiers ea e ume a enna ene Ree aN 12 Electrical Connection lt a5 069 u cn 2x3 Us es bey ea nau nein shod ood eo ee lott 15 4 Description of Operation cceccccccccccccccees 18 Key 10 SWiMDOls wsnssresine nnee aa iE R Ea 18 Status Diagnostic LED Indicators neneeese 18 Status Diagnostic LEDs Table A Standalone Operation 0 0eeeees 19 Status Diagnostic LEDs Table B Series Operation eeeeeeeeeeeees 20 Operation with Control Systems ceeeeeeeseeeeeeeeeeeeeeeeees 21 Proving Basic Lock PUNGHONG 03 1 xdy wsiecduaciwimae Mbakay bodied ey codes caine 21 Change Device Configuration using DIP switches ceeeeeeeeeeees 22 Change Actuation Direction of Handle Assembly 00eeeeeeeeeeeees 25 Fall RESET a tae vadp aca nacancade wiura Maddon E eoamee A ON 25 Auxiliary Manual Release 0cceceeeeecceceenseeeceesettoesetes 26 Bolt Locking Mechanisi s lt cvscuatortatasacevacakeessuvieasaencncn ence 27 Series Operation ssec cresien ee tas ec chanten tae N a i a 28
48. unction Term 24V 4 lock mdA 7 gt X4 Function Term Safety In A 1 Safety In B 2 Safety Out A 4 Safety Out B 5 Reset 6 a X5 Function Term ov 5 442G MAB PTR Function Term K 24V 4 7 N A o Lock Cmd A 7 _ JF 440R D22R2 im C x4 Al L12 Function Term Safety In A 1 A2 Di L11 o o Safety In B 2 Safety Out A 4 Safety Out B 5 an 32 lo ol Reset 6 To a a X5 Function Term LOGIC o uu oV 5 8 21 o o Te 442G MAB PTR 69 A K1 and K2 1005 CO9EJ14BC s2 S8 at EJ contactors have intergral 522 4 Kr transient suppression when EJ YY contactors are used used no 532 ZB external transient suppression K is required EN A Non EJ contactors may require 4 24 K2 external transient suppression Figure 23 Connection Example for Series Operation 30 Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter 5 Wiring Examples 24V DC ai 440R D22R2 Al L12 K 442G MAB PTR ae a T 11 Y32 Reset DI s21 534 a LOGIC p 8 889M FISRM X 7H 3h 6 3 Paes Red Blue a er Green KH 22 CON G Reset MAB lt S Grey Pink 532 B Unlock Request KI 42 L 74 2 Blue Violet Unlock Command 440R EM4R2D Al L12 EMD RHE L112 B3 A2 L11 Unlock ba B1 X32 o K1 and K2 100S C09EJ14BC ie t EJ contactors have intergral transient suppres
49. unting plates shorten standard shaft shaft to required length With two mounting plates shorten extended shaft and protective sleeve to required length 45mm Standard shaft or extended Without mounting plate none shaft With mounting plates shorten extended shaft and protective sleeve to required length 50mm Extended shaft Shorten extended shaft and protective sleeve to required length 1 Shaft length required when only one mounting plate is used 2 Shaft length required when two mounting plates are used for the escape release and the handle assembly 3 The extended shaft 442G MABASHFT must be ordered separately Handle module 0 Mounting plates Escape release assembly Figure 14 Example with Mounting Plates mm in Rockwell Automation Publication 442G UM001A EN P May 2015 13 Chapter 3 Installation and Wiring Actuation shaft Protective sleeve D 13 5 0 53 182 4 0 16 7 16 3 0 12 per plate 4 0 16 per plate 55 5 2 19 8 0 32 011 2 0 44 014 0 55 Figure 15 Shortening the Extended Actuation Shaft mm in Prepare the Escape Release 3 Attach door handle Insert actuation shaft The locking ring A must be in contact with the escape release B Tighten setscrew to 2 Nm Slide protective sleeve over actuation shaft Figure 16 Preparing the Escape Release Rockwell Automation Publication 442
50. utputs must be protected with a free wheeling diode for this purpose RC interference suppression units must not be used Power devices which are a powerful source of interference must be installed in a separate location away from the input and output circuits for signal processing The cable routing for safety circuits should be as far away as possible from the cables of the power circuits To prevent EMC problems it is imperative you follow the Requirements for Connection Cables on page 16 Follow EMC guidelines on devices in the immediate vicinity of the 442G MAB system and their cables In order to avoid EMC interference the physical environmental and operating conditions at the installation site of the device must comply with the requirements according to the standard DIN EN IEC 60204 1 2006 section 4 4 2 EMQ IMPORTANT Toensure the stated degree of protection is achieved the cover screws must be tightened to a tightening torque of 1 Nm Tighten screw for the cover for the mechanical release to 0 5 Nm Rockwell Automation Publication 442G UM001A EN P May 2015 15 Chapter3 Installation and Wiring Safety in Case of Faults e The operating voltage UB is reverse polarity protected e The safety inputs FI1A FI1B and safety outputs FO1A FO1B are short circuit protected e A short circuit between FI1A and FI1B or FOIA and FO 1B is detected by the device e A short circuit in the cable can be excluded by laying the
51. wire and troubleshoot the device This manual e Explains how to install and wire your 442G Multi functional Access Box e Provides an overview of the 442G Multi functional Access Box The following conventions are used throughout this manual e Bulleted lists such as this one provide information not procedural steps e Numbered lists provide steps or hierarchical information The following document offers more information about related Rockwell Automation products Resource Description Allen Bradley Industrial Automation Glossary Glossary of industrial automation terms and publication AG 7 1 abbreviations 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 Chapter Preface Terminology OSSD Output Signal Switching Device Typically designates a pair of solid state signals pulled up to the DC source supply The signals are 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 vi Rockwell Automation Publication 442G UM001A EN P May 2015 442G MAB Overview Rockwell Automation Publication 442G UM001A EN P May 2015 Chapter 1 General Description The

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