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:

Rockwell Automation Publication 440F-UM003A-EN-P - January 2024 11
Chapter 1
Product Overview
Introduction When designed by professional personnel for use as a safety product in an
industrial environment, the MatGuard™ safety mat system provides protection
against risks that can be eliminated by the isolation of electrical power when
an operator is in the vicinity of the hazard. This manual covers the installation
and use of all components of the Allen-Bradley® MatGuard Mats system.
Only suitably trained and qualified personnel can conduct all installation
procedures, which must be in accordance with statutory requirements for
safety.
System Components The MatGuard safety mat system is composed of a safety mat control unit, one
or more interconnected pressure sensitive safety mats, active uniting trim,
and perimeter trim, as shown in Figure 4.
When the system includes a suitable safety mat control unit, the control unit
detects a presence on the safety mat, a short circuit, or an open circuit. Under
each of these conditions, the safety control issues a stop command. Multiple
safety mats can combine into one safety mat system with the use of joining
trim.
Figure 4 - Basic System Anatomy
Active uniting trim maintains active
sensing area at mat junctions
Heavy-duty ribbed vinyl
Flexible sealing bead
Perimeter trim secures
Cable underneath trim
Mat at
rest
hen the mat is activated, the
non-conductive compressible
separators (shown in red)
compress into their recess
allowing the two plates to make
contact giving all over sensitivity.
W
Mat
Upper conductive plate
activated
Non-conductive
Lower conductive plate
compressible separator
STD 4.5 m
Different ribbed pattern on reverse side
Checker pattern Straight rib pattern
(side 1) (side 2)
Wire
location
Wire
location
Different ribbed pattern on reverse side
Checker pattern
(Side 1) Straight rib pattern (Side 2)
Wire location
STD 4.5 m
(14.76 ft)
Wire location
Active uniting trim maintains active
sensing area at safety mat
junctions
Non-conductive compressible
separator
Upper conductive plate
Lower conductive plate
Heavy-duty ribbed vinyl
Flexible sealing bead
Perimeter trim secures
safety mats to the floor
Cable underneath the trim
Mat at
rest
Mat
activated
W hen the safety mat is activated, the
non-conductive compressible separators
(shown in red) compress into their
recesses, allow the two plates to make
contact, and give all-over sensitivity.

12 Rockwell Automation Publication 440F-UM003A-EN-P - January 2024
Chapter 1 Product Overview
MatGuard Control Unit
The MatGuard control unit that is shown in Figure 5 monitors all safety mats
that are connected together to form a safeguarded zone. The safeguarded zone
can be up to a total of 100 m2(1076 ft2) and made from any number of safety
mats.
The control unit detects a presence on the safety mat, a short circuit, or an
open circuit. Under each of these conditions, the safety output relays turn off.
When interfaced properly, the machine or hazardous motion receives a stop
signal and an auxiliary output relay turns on.
Figure 5 - MatGuard Control Units
Pressure Sensitive Safety Mats
Pressure sensitive safety mats are designed to
detect persons on their surface. Individual safety
mat sections are available in rectangular standard
sizes and also in specially cut shapes, up to the
size of the largest standard safety mat.
Active Uniting Trim
Active uniting trim installs between adjacent
safety mats to detect individuals present on the
junction of the safety mats. There are no dead
areas within the detection zone when safety mats
are properly installed.
Perimeter Trim
Perimeter trim is used around the edges of the
safety mats to hold the safety mats in place and
to help prevent trip hazards. Various lengths and
corner pieces are available to fit the safety mat
area.
440F-C4000P 440F-C4000D

Rockwell Automation Publication 440F-UM003A-EN-P - January 2024 13
Chapter 1 Product Overview
Safety Mat Functionality All safety mats have the same construction and operation principle. Each
safety mat has two conductive plates that are held apart by non-conductive
compressible separators. The operating principle of the safety mat is shown in
Figure 6 and Figure 7.
Figure 6 - Safety Mat at Reset
Each safety mat has four attached wires that operate at 24V DC and connect in
series. Safety mats are available with Micro QD connections or flying lead
cables. Your catalog selection defines the exit points on the safety mat wiring.
When the safety mat is activated, the non-conductive compressible separators
(shown as black) compress into their recess, which allows the two plates to
make contact.
Figure 7 - Safety Mat Activated
Safety mat wiring is connected directly to the mat manager, which monitors
the individual safety mat connections.
You can arrange multiple safety mats around the machinery and, depending
on the configuration, safety mats can be wired in series to protect a large area.
The MatGuard safety mat system is intended for the detection of adult persons
with a weight of 35 kg (77.16 lb) or more and is suitable for the detection of
adults with walking aids (for example, walking sticks or frames). The
MatGuard safety mat system forms a floor-level sensing system for hazardous
areas around machinery.
MatGuard Control Unit
Functionality
The MatGuard control unit is designed to accept one series of safety mats. The
MatGuard control unit monitors the 24V DC series circuit of safety mats,
providing a status indication of the safety mat system.
When the protective area is clear, the MatGuard control unit provides a signal
to the machine control circuit to allow the machine to start. When the
protective area is not clear (personnel is present stepping on a safety mat), the
conductive plates touch in the safety mat and the resistance in the circuit
drops. The MatGuard control unit monitors this action and turns the output
off to initiate the machine shut-down sequence. Any single electrical fault in
the safety mat, wiring, or safety mat manager is detected, and the MatGuard
control unit outputs goes to a safe (off) state.
IMPORTANT The system is not suitable for the detection of children. The system
must not be used with any additional covering on the safety mat.
Molded
Vinyl
Steel
Plates

14 Rockwell Automation Publication 440F-UM003A-EN-P - January 2024
Chapter 1 Product Overview
MatGuard Control Unit Selection
The mounting option, the size of the control unit, and the Manual Reset button
determines the correct MatGuard control unit for your application. See
Table 2.
Approximate Dimensions Figure 8 - Dimensions [mm (in.)]
Table 2 - MatGuard Control Units
Cat. No. Power Required Safety Mat
Connector Safety Outputs Auxiliary Outputs Mounting Power/IO Connector Type
Manual Reset
Button
440F-C4000P 24V AC/DC
115/230V AC Direct wiring (1 input) 2 N.O. 1 N.C. Mounting holes for
polycarbonate
enclosure, IP65 Direct wiring Yes
(on enclosure)
440F-C4000D 24V AC/DC
115/230V AC Direct wiring (1 input) 2 N.O. 1 N.C. DIN rail, IP40 Direct wiring No
75 (3.0)130 (5.2)
4 x M4 (0.16)
113.5 (4.5)
180 (7.1)
10 (0.39)
11
(0.43)
163.5 (6.4)
152 (6.0)
DIN Rail [35 (1.38)]
120 (4.7)
73 (2.9)
440F-C4000P (Polycarbonate) 440F-C4000D

Rockwell Automation Publication 440F-UM003A-EN-P - January 2024 15
Chapter 1 Product Overview
Figure 9 - Basic System and Connections 440F-C4000P (Two Contactors)
341223 2413 1431 32MC
MCN/O PB R IND
–ve NL
+ve
AM
230 110
L1 L2 L3
K1
K2
110/230V AC
Supply Terminal
110/230V AC
Selector Switch
Primary Fuse
500 mA
Control Unit
Sensor
Mats
Primary Fuse
500 mA
Lid-Mounted Reset Button
Status Indicators
24V AC/DC
Machine-enabled
Green
Manual Reset Mode
Green
Power
Green
Auto Reset Mode
Green
Manual Reset/
Auto Reset
Remote Reset Push Button
(if necessary)
Contactor
Control Power
Volt Free
Aux.
Contactsfor
Indication
(if
necessary)
Remote Reset Terminals Remote Reset Indication Terminals Contactor Monitoring Terminals Auxiliary Terminals Safety Output Terminals Mat Connection Terminals

16 Rockwell Automation Publication 440F-UM003A-EN-P - January 2024
Chapter 1 Product Overview
Figure 10 - Basic System and Connections 440F-C4000D (Two Contactors)
A1 IND 1 2 MC Y1 Y3 Y5
A2
13 23 31
14 24 32IND 3 4 MC Y2 Y4 Y6
+
-
Y1 Y 2 Y3 Y4 Y5 Y6
+-
K1 AUX K1
K1 AUX K2
L1 L2 L3
LN
Illumination
(if necessary)
Contactor Monitoring
Auxiliary
Contactor Control
Power
Sensor Mats
24V AC/DC Supply Optional Remote
Indication Unit
110/230V AC Supply
Remote Reset
Push Button
(if necessary)
110/230V AC
Selectable
24V AC/DC
RESET
RESET

Rockwell Automation Publication 440F-UM003A-EN-P - January 2024 17
Chapter 2
System Design
We recommend that only persons who have experience in safety-related
control system design, and are suitably competent in electrical and mechanical
engineering, design the system.
Nature of Hazard The MatGuard™ safety mat system provides protection against such risks that
can be minimized by the isolation of electrical power when an operator is near
the hazard. Additional measures are required to address other hazards
identified in a risk assessment (for example, part ejection and hot surfaces).
These measures can include fixed guards, interlocked guards, and warning
notices.
Nature of Safeguarding The system design must satisfy three main requirements:
• The machine must stop if a person is in a position where they are able to
reach into the hazardous zone.
• The machine must come to a stop before an approaching person can be
in the position where they are able to reach into the hazardous zone.
• The system must not be easily bypassed.
The recommended use of the MatGuard safety mat system is to give presence
sensing over the entire area where access is possible to the hazard (see
Figure 11). Other uses of the MatGuard safety mat system such as a perimeter
access only guard or as a machine enabling device, are not recommended.
Figure 11 - Layout Examples
Safety Mat Positioning The position of the safety mats depends on the use case. You can use safety
mats as:
• Combined trip and presence sensing devices.
• Presence sensing systems within a perimeter guarded area.
IMPORTANT A risk assessment is included and detailed in ISO 12100-2010 and
detailed in ANSI B11.TR3 2000 (2015).
Hazard
Hazard
Safety Mats

18 Rockwell Automation Publication 440F-UM003A-EN-P - January 2024
Chapter 2 System Design
Combined Trip and Presence Sensing Device
The position of safety mat edges is calculated as a horizontal distance from the
hazardous zone. Define the hazardous zone as a volume, account for all
possible modes of the machine, and for all variations in the size of the
workplace. To check the adequacy of the safeguards, record the dimensions
and position of the hazardous zone and the use case assumptions.
Other safeguarding measures that are used with the MatGuard safety mat
system can affect the requirements for the size and position of the safety mats,
as shown in Figure 12.
Figure 12 - Safety Mat Positioning
Safety Mat Position Requirements
• Determine the safe distance to the hazard - There must be sufficient
space to allow the minimum distance from the hazard to the accessible
safety mat perimeter to be in accordance with ISO 13855 safety distance
calculations. See Figure 13 on page 19.
• Full coverage of safety mats around the hazard - Safety mats must cover
the entire floor area between the defined perimeter and the hazard so
that it is not possible to approach or stand in the vicinity of the hazard
without actuating the MatGuard safety mat system.
Determine Proper Safety Mat Position
1. Determine the routes where unobstructed access to the hazardous zone
is required across the MatGuard safety mat system. Consider:
- All routine needs for access, such as product inspection, machine
inspection and adjustment, tool changes, and clearing blockages.
- Visual observation of the process.
- Space requirements of people and ancillary equipment close to the
machine during interventions.
2. There must be sufficient space to allow the minimum distance from the
hazard to the accessible safety mat perimeter, in accordance with the
safety distance calculations (see Figure 13 on page 19). Applications that
use the MatGuard Mats system as a combined trip and presence sensing
system must be in accordance with ISO 13855.
Hazard Hazard Hazard
Extended Fixed Guard
Fixed Guard
Sensor Mats Sensor MatsSensor Mats
Arrows Show Access
IMPORTANT If the machine is designed in conformity with an existing harmonized
European C type standard for that machine (which gives specific
formulas or minimum distances), then these standards must be used in
preference to the standards given in ISO 13855.

Rockwell Automation Publication 440F-UM003A-EN-P - January 2024 19
Chapter 2 System Design
3. Safety mat sensors must cover the entire floor area between the defined
perimeter and the hazard so it is not possible to approach, or be in the
vicinity of, the hazard without actuating the MatGuard safety mat
system.
Safety Distance Calculations
Applications that use the safety mat system as a combined trip and presence
sensing system must be done in accordance with ISO 13855. See Figure 13.
Figure 13 - Methodology Flowchart
The calculated minimum distance is the minimum horizontal distance from
the outer edge of the MatGuard safety mat system detection zone to the
nearest part of the hazard.
The ISO 13855 formula for floor-mounted safety mats is:
S = (1600 x T) + 1200 mm
S is the minimum safety distance in millimeters.
The factor of 1600 is based on the standard assumption of 1600 mm/s
(63 in./s) as the approach speed.
T is the overall stopping time in seconds.
The added 1200 mm (47.24 in.) is parameter C given in ISO 13855 and
accounts for stride length and arm reach.
Are specific formulas or
minimum distances given in the
type C standard?
Determine the minimum
distance according to the C type
standard.
Use this minimum distance.
YES
NO
Calculate the minimum distance
by the formulas in ISO 13855.
Can this minimum distance be
achieved?
YES
Does the minimum distance
allow persons to be within the
danger zone without being
detected?
NO
Use this minimum distance.
YES
Use this minimum distance
together with supplemented
measures, depending on the
risk.
NO
Can the overall response time be
reduced, or can parameter C be
reduced?
NO
Use additional or alternative
protective equipment.
Reduce the overall response
time and/or reduce parameter
C.
YES

20 Rockwell Automation Publication 440F-UM003A-EN-P - January 2024
Chapter 2 System Design
The overall stopping time T is the sum of two parts:
T = t1 + t2
t1 is the maximum time between actuation of the sensing function and
the output signal switching devices being in the off state.
For the MatGuard safety mat system, t1 = 35 ms.
t2 is the response time of the machine, that is, the time that is required to
stop the machine or remove the risks after receiving the output from the
MatGuard safety mat system.
The response time of the machine that is used in the calculation must be the
worst case time. Some machines have inconsistent response times, which are
dependent upon the mode of operation, the nature of the workpiece, and the
point in the operating cycle at which stopping is initiated. Allow for conditions
that can affect the response time, such as wear on brakes. An allowance for
further delays in the machine control system can be required in some
circumstances.
Calculation Example
In the following example, the MatGuard safety mat system is used with a
machine with a worst case response time measured as 0.485 seconds.
Using the formula,
T = t1 + t2
= 35 ms + 485 ms
= 520 ms = 0.520 s
S = (1600 x 0.520) + 1200 mm
= 832 + 1200 mm = 2032 mm
Safety mats are required from 2032 mm (80 in.) up to the edge of the machine
baseplate.
Presence Sensing System Within Perimeter Guarding Area
If the area around the hazard is enclosed within a guarded perimeter (see
Figure 14), the requirements of ISO 13855 Safe Distance Requirements do not
necessarily apply. In these applications, the MatGuard safety mat system
detects the presence of an operator to help prevent reset of the perimeter-
guarding system and the restart of the machine while the operator is inside the
enclosure.
Figure 14 - Guarded Perimeter
Hazard
Safety Mats
Fixed Guarding
Interlocked Door
(with locking)