Rockwell Automation Allen-Bradley Guard master 440F-C4000D User manual

User Manual Original Instructions
MatGuard Control Unit with
MatGuard Pressure Sensitive
Safety Mat System
Catalog Numbers 440F-C4000D, 440F-C4000P

2Rockwell Automation Publication 440F-UM003A-EN-P - January 2024
MatGuard Control Unit with MatGuard Pressure Sensitive Safety Mat System 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.
These labels may also be on or inside the equipment to provide specific precautions.
The following icon may appear in the text of this document.
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.
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).
Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation Publication 440F-UM003A-EN-P - January 2024 3
Table of Contents
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Who Would Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Sensitive Safety Mats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EMC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Functional Safety Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Markings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Handling and Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Mat Environmental and Operating Conditions . . . . . . . . . . . . . . . 7
Possible Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Product Overview Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MatGuard Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Sensitive Safety Mats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Active Uniting Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Perimeter Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Mat Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MatGuard Control Unit Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MatGuard Control Unit Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Approximate Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chapter 2
System Design Nature of Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Nature of Safeguarding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety Mat Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Combined Trip and Presence Sensing Device. . . . . . . . . . . . . . . . . . . 18
Safety Distance Calculations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Presence Sensing System Within Perimeter Guarding Area. . . . . . 20
Fixed Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bypass Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety Mat Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Floor requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MatGuard Control Manager Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Select the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Reset Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Auxiliary Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Arc Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Contactor Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Final Safety Mat Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4Rockwell Automation Publication 440F-UM003A-EN-P - January 2024
Table of Contents
Final Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chapter 3
Installation Safety Mat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Unite Trim Fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Perimeter Trim Fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Control Unit Installation and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Check the Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Check the Electrical Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Manual Mode Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Auto Reset Mode Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Under Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Check Safety Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Single-channel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Dual-channel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
All System Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Functional Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chapter 4
System Operation Pre-operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Chapter 5
Maintenance Safety Mat Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Routine Inspection and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Thorough Examination and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Dismantle and Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Symptom: No Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Symptom: No Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Symptom: Unexpected Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Appendix A
Specifications MatGuard Control Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Sensor Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Rockwell Automation Publication 440F-UM003A-EN-P - January 2024 5
Preface
About This Publication This manual is a reference guide for the proper installation of the
440F-C4000D/P MatGuard™ Control Unit in combination with 440F-Mx
MatGuard Pressure Sensitive Safety Mats.
Who Would Use This Manual Use this manual if you design, install, program, or troubleshoot systems that
use the 440F-C4000D/P MatGuard control unit.
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.
Qualified personnel must conduct all inspections and perform the following
tasks:
• Undergo the appropriate technical training.
• Instruct personnel in the operation of the machine and the current safety
guidelines.
• Read and have access to the user manual.
Safety Standards Pressure Sensitive Safety Mats
The following standards are referred to in this manual:
• ISO 12100: 2010 - Safety of machinery - General principles for design -
Risk assessment and risk reduction.
• BS EN ISO 13857: 2019 - Safety of machinery - Safety distances to help
prevent upper and lower limbs from reaching hazardous zones.
• ISO 14120: 2015 - Safety of machinery - Guards - General requirements
for the design and construction of fixed and movable guards.
• ISO 13849-1: 2015 (EN 954-1): Safety of machinery - Safety-related parts of
control systems - Part 1: General principles for design.
• ISO 13855 - Safety of machinery - Positioning of safeguards regarding the
approach speeds of parts of the human body.
• ISO 13856-1: 2013 - Safety of machinery - Pressure-sensitive protective
devices - Part 1: General principles for the design and testing of
pressure-sensitive safety mats and pressure-sensitive floors.
• IEC 60204-1: 2016 - Safety of machinery - Electrical equipment of
machines - Part 1: General requirements.
• ANSI B11.TR3 - 2000 (2015): Risk Assessment and Risk Reduction-A guide
to estimate, evaluate, and reduce risks that are associated with machine
tools.
• IEC 62061:2015: Safety Of Machinery - Functional Safety Of Safety-
Related Electrical, Electronic And Programmable Electronic Control
Systems
EMC Directives The safety mat system complies with the requirements of the European EMC
Directive. Normal operation under interference conditions likely in industrial
environments is confirmed and has been tested and certified.

6Rockwell Automation Publication 440F-UM003A-EN-P - January 2024
Preface
Functional Safety Data Compliance for the MatGuard control unit is achieved with the requirements
of a category 3 per EN ISO 13856-1, PLd per ISO 13849-1, and SIL 2 per IEC 62061
regarding reliability and electrical faults and can be met for the associated part
of the machine control system. Compliance with the requirements of
EN ISO 13856-1 category 1 is achieved for the safety mat sensors.
Safety Certification The type of safeguarding system must be suitable for the application for which
it is intended. A documented process of risk assessment of the machinery or
process reveals the identity and nature of the hazards together with other
relevant information. The machinery manufacturer must conduct a risk
assessment to determine the PL or SIL requirements. The characteristics of the
safeguarding system must then be compared with the results of the risk
assessment to determine whether the risk can be reduced to an acceptable
level. On some applications, to achieve an acceptable level of risk, it can be
necessary to combine multiple types of safeguarding systems.
Markings Figure 1 - Control Unit Marking 440F-C4000P
MATGUARD PRESSURE SENSITIVE SAFETY MAT SYSTEM
CONTROL UNIT
Supply Voltage 230/110VAC (see selector) 50-60Hz or 24VAC/DC
IP65 Hoseproof, Dust tight
Safety Contacts 250V 2A N/O Aux Contacts 250V 2A N/C
MatGuard Mat Voltage 24VDC
EN 954-1 Category 3, System Response Time 35ms
See user manual for further information
MANUAL
RESET MODE
MACHINE
ENABLED
POWER
AUTO
RESET MODE
PRESS
TO RESET
ISOLATE ALL POWER
SUPPLIES BEFORE OPENING
MADE IN THE UK
83HA TYPE 1 A300
IND CONT EQ
MatGuard
Type No: 440F-C4000P
R

Rockwell Automation Publication 440F-UM003A-EN-P - January 2024 7
Preface
Figure 2 - Control Unit Marking 440F-C4000D
Figure 3 - Safety Mat Marking
Storage Store MatGuard control units and safety mats within the temperature range
-40…+70 °C (-40…+158 °F). Store safety mats vertically.
Handling and Transport Transport MatGuard control units and safety mats at a temperature of
-40…+70 °C (-40…+158 °F). To protect from damage and flex, use the original
packaging or similar together with stiffeners, if necessary. Always unpack
carefully and avoid damage by sharp objects.
When you move safety mats into position, never pull or lift safety mats by their
connecting wires.
Safety Mat Environmental
and Operating Conditions
In general, the covering has excellent resistance to acids, alkalis, and salt. Hot
acids, alkalis, and concentrated and organic acids have a deleterious effect on
prolonged exposure. The covering has fair resistance to aliphatic solvents, fair
to poor resistance to aromatic and chlorinated solvents, and poor resistance to
ketones and most esters. Combinations of chemicals can have unpredictable
effects. We recommend tests in such cases. Small pieces of the vinyl material
are available if tests are required.
A1
•
1 2 MC Y1 Y3 Y5 + RESET IND
•
13 23 31
•
A2
 RESET IND 3 4 MC Y2 Y4 Y6
•
14 24 32
•
110/230VAC selectable
24V AC/DC
440F-C4000D
EN 1760-1, EN 954-1 Cat 3
Response time: 35mS
MADE IN ENGLAND
POWER
AUTO RESET MODE
MANUAL RESET MODE
MACHINE ENABLED
R
83HA A300
IND CONT EQ
MatGuard
Isolate
before
opening
MADE IN U.S.A.
REFER TO USER MANUAL
Model No.
EN 1760-1
R
4 M 20 IND CONT EQ
MatGuard SENSOR MAT
IMPORTANT Never pull or lift sensor mats by their connecting wires when moving
the mats into position.
For larger sensor mats, two people are required for safe lifting to help
prevent the risk of damage to the mat sensor from excessive flexing.

8Rockwell Automation Publication 440F-UM003A-EN-P - January 2024
Preface
Possible Misuse The MatGuard safety mat system is designed for the protection of personnel by
sensing their presence on floor areas around machinery and other similar
hazards.
Only use the MatGuard safety mat system only within the given specification
limits, and install units strictly in accordance with the information that is
provided in this manual.
The MatGuard safety mat system alone does not provide protection against
hazards that arise from the ejection of materials, gases, and radiation. For
these applications, additional protective measures, such as physical guards,
are required.
The MatGuard safety mat system is not intended:
• For use as a perimeter only guard.
• For use as a machine initiation or reinitiation device.
• For use for use in explosive atmospheres.
Configure the machine control circuit so that the closing of the MatGuard
safety mat system output contacts enables the starting circuit of the machine,
but does not directly cause the machine to start. The start or restart of the
machine must only be possible by a separate and deliberate action at the
designated machine controls.
Table 1 - Chemical Resistance of Safety Mat Covering
Substance Safety Mat Resistance
Water (sea) Excellent
Ethyl alcohol Excellent
Sodium chloride Excellent
Bleach Excellent
Hydrochloric acid Fair to excellent
Sulphuric acid Fair to excellent
Nitric acid Fair to excellent
Acetic acid Fair
Petrol (gasoline) Fair
Trichloroethylene Fair to poor
Benzene Poor
Acetone Poor
Lubricating oil Fair to excellent
Cutting fluids Fair to excellent
Oil (auto) Fair to excellent
Brake fluids Poor to fair
IMPORTANT Special measures can be required in the presence of abnormally high
levels of E.M.I. (electromagnetic interference), for example, near to
welding or induction heating equipment, or near radio transmitters or
transceivers.

Rockwell Automation Publication 440F-UM003A-EN-P - January 2024 9
Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
Resource Description
Hazardous Location Switch Amplifiers with Safeguarding Devices Wiring
Diagram, publication 937TH-WD001 Provides examples for how to connect safeguarding devices to isolating switch amplifiers.
Safety Mat and E-stop Control Using SmartGuard 600 Packaged Safety
Controller Safety Application Example, publication SAFETY-AT008 Provides guidance on how to wire, configure, and program a SmartGuard™ 600 safety
controller for use with a dual-channel safety mat and E-stop.
Safety Mat Control Using CompactBlock Guard I/O and GuardLogix Integrated
Safety Controller Safety Application Example, publication SAFETY-AT011
Provides guidance on how to wire, configure, and program a GuardLogix® integrated safety
controller with a CompactBlock™ Guard I/O™ module for use with a dual-channel safety mat
and E-stop.
Safety Mat Stop Safety Function Application Technique, publication
SAFETY-AT118 Explains how to wire, configure, and program a compact GuardLogix controller and POINT
Guard I/O™ module to monitor a 440F safety mat.
Safety Function: Safety Mat Stop Application Technique, publication
SAFETY-AT122 Explains how to wire and configure a Guardmaster® dual-input safety relay (GSR DI) to
monitor a pair of 440F safety mats and an E-stop.
Safety Mat Stop via a GuardLogix Controller Safety Function Application
Technique, publication SAFETY-AT159 Explains how to wire, configure, and program a compact GuardLogix controller and POINT
Guard I/O module to monitor a 440F safety mat.
System Security Design Guidelines Reference Manual, publication
SECURE-RM001
Provides guidance on how to conduct security assessments, implement
Rockwell Automation® products in a secure system, harden the control system, manage user
access, and dispose of equipment.
UL Standards Listing for Industrial Control Products, publication
CMPNTS-SR002 Assists original equipment manufacturers (OEMs) with construction of panels to conform to
the requirements of Underwriters Laboratories.
American Standards, Configurations, and Ratings: Introduction to Motor
Circuit Design, publication IC-AT001 Provides an overview of American motor circuit design, which is based on methods that are
outlined in the NEC.
Industrial Components Preventive Maintenance, Enclosures, and Contact
Ratings Specifications, publication IC-TD002 Provides a quick reference tool for Allen-Bradley® industrial automation controls and assemblies.
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-state Control, publication SGI-1.1
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
general guidelines for the application, installation, and maintenance of solid-state control in
the form of individual devices or packaged assemblies that incorporate solid-state
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications Provides declarations of conformity, certificates, and other certification details.

10 Rockwell Automation Publication 440F-UM003A-EN-P - January 2024
Preface
Notes: