Rockwell Automation Allen-Bradley Guardmaster 440G-MZ User manual

Application Technique
Original Instructions
Safely-limited Speed and Guard Door Unlocking with Armor
PowerFlex Safety Function
Products: Guardmaster 440G-MZ Interlocking Switch, GuardLogix 5580 or Compact GuardLogix 5380 Controller, Armor PowerFlex
35S Integrated Safety, 700S-C Relay
Safety Rating: Cat. 3, PLd to ISO 13849-1: 2023
Topic Page
Important User Information 2
General Safety Information 3
Introduction 3
Use Sample Project Files 4
Safety Function Realization: Risk Assessment 4
Safety Function 5
Safety Function Requirements 5
Bill of Materials 8
Setup and Wiring 9
Configuration 11
Programming 16
Calculation of the Performance Level 26
Verification and Validation Plan 29
Additional Resources 29

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Safely-limited Speed and Guard Door Unlocking with Armor PowerFlex Safety Function Application Technique
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.
Labels may also be on or inside the equipment to provide specific precautions.
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).

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Safely-limited Speed and Guard Door Unlocking with Armor PowerFlex Safety Function Application Technique
General Safety Information
Contact Rockwell Automation to learn more about our safety risk assessment services.
Safety Distance Calculations
Non-separating safeguards provide no physical barrier to help prevent access to a hazard. Publications that offer guidance for calculating
compliant safety distances for safety systems that use non-separating safeguards, such as light curtains, scanners, two-hand controls, or
safety mats, include the following:
EN ISO 13855:2010 (Safety of Machinery – Positioning of safeguards with respect to the approach speeds of parts of the human body)
EN ISO 13857:2019 (Safety of Machinery – Safety distances to help prevent hazardous zones being reached by upper and lower limbs)
ANSI B11:19 2019 (Machines – Performance Criteria for Safeguarding)
Separating safeguards monitor a movable, physical barrier that guards access to a hazard. Publications that offer guidance for calculating
compliant access times for safety systems that use separating safeguards, such as gates with limit switches or interlocks (including
SensaGuard™ switches), include the following:
EN ISO 14119:2013 (Safety of Machinery – Interlocking devices associated with guards - Principles for design and selection)
EN ISO 13855:2010 (Safety of Machinery – Positioning of safeguards with respect to the approach speeds of parts of the human body)
EN ISO 13857:2019 (Safety of Machinery – Safety distances to help prevent hazardous zones being reached by upper and lower limbs)
ANSI B11:19 2019 (Machines – Performance Criteria for Safeguarding)
In addition, consult relevant national or local safety standards to verify compliance.
Introduction
This safety function application technique explains how to wire, configure, and program a GuardLogix® controller to interface with an
Armor™ PowerFlex® integrated safety AC drive to perform Safely-limited Speed (SLS) functions. The integrated safety Armor PowerFlex
encoder feedback is used to bring velocity data into the GuardLogix safety task. The GuardLogix safety controller contains logic to monitor
SLS. When the hazard is at a safe speed and an SLS request is made, safety logic unlocks the locking guard door. The Armor PowerFlex safety
digital safety inputs are used to monitor the guard locking switch and safe speed selector switch. The safety outputs are used to control the
lock function of the locking guard door switch.
The motion control actuator for the safety functions is the motor the Armor PowerFlex AC drive controls. Any malfunction the safety system
detect results in a Safe Stop 1 (SS1) which is a safely monitored decel, followed by Safe Torque Off (STO).
This example uses a 1756-L84ES GuardLogix primary only controller, but you can substitute a Compact GuardLogix controller that supports
the safety rating that is demonstrated in this safety function application technique. The Safety Integrity Software Tool for the Evaluation of
Machine Applications (SISTEMA) calculations that are shown later in this document must be recalculated if different products are used.
IMPORTANT This application example is for advanced users and assumes that you are trained and experienced in safety system
requirements.
ATTENTION: Perform a risk assessment to make sure that all task and hazard combinations have been identified and addressed. The
risk assessment can require additional circuitry to help reduce the risk to a tolerable level. Safety circuits must consider safety
distance calculations, which are not part of the scope of this document.
ATTENTION: While safety distance or access time calculations are beyond the scope of this document, compliant safety circuits must
often consider a safety distance or access time calculation.

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Safely-limited Speed and Guard Door Unlocking with Armor PowerFlex Safety Function Application Technique
Use Sample Project Files
Sample project files (AutoCAD, EPLAN, ACD, SISTEMA, and Verification and Validation checklist) are attached to this document to help you
implement this safety function.
To access these files, follow these steps.
1. If you are viewing the PDF file in a browser and do not see the Attachments link , download the PDF file and open it in the Adobe
Acrobat Reader application.
2. Click the Attachments link .
3. Right-click and save the desired file.
4. Open the file in the appropriate application.
Safety Function Realization: Risk Assessment
The Performance Level required (PLr) is the result of a risk assessment and refers to the amount of the risk reduction to be conducted by the
safety-related parts of the control system. Part of the risk reduction process is to determine the safety functions of the machine. In this
application, the Performance Level required by the risk assessment is category 3, Performance Level d (cat. 3, PLd), for each safety function.
A safety system that achieves cat. 3, PLd, or higher, can be considered control reliable. Each safety product has its own rating and can be
combined to create a safety function that meets or exceeds the PLr.
From: Risk Assessment (ISO 12100)
1. Identification of safety functions
2. Specification of characteristics of each function
3. Determination of required PL (PLr) for each safety function
To: Realization and PL Evaluation

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Safely-limited Speed and Guard Door Unlocking with Armor PowerFlex Safety Function Application Technique
Safety Function
This application technique includes three Safety Functions:
1. Guard Door Unlock at Safely-limited Speed (SLS)
2. Guard Door Unlock at standstill speed: Safe Stop 1 (SS1)
3. Prevention of an Unexpected Startup with guard door monitoring
Safety Function Requirements
Guard door unlocking is a safety function when used to protect people. The guard door unlock is a safety output function that is based on
safety inputs detection of safe-to-enter conditions. All safe entry conditions must be detected with safety integrity that meets the level of
the unlock safety function.
When SLS is requested, the motor speed must go below the programmed speed limit before the SLS check time delay expires. After the delay
expires, the speed must remain below the limit. After the delay expires, if motor speed is below the SLS, the gate is unlocked, and this action
allows access to the hazardous area. You must perform a risk assessment to determine the SLS for the motor.
If the programmed speed limit is exceeded after the delay expires, a Safe Stop 1 (SS1) is generated to stop the motor, after which STO is
activated, and this action causes the motor torque to be disabled.
A two-position maintained key selector switch is used to request SLS. When the key is in the SLS mode position, the key can be removed to
preserve SLS mode while the task that requires SLS is performed.
If the door is unlocked or open, and the safety system is not in SLS or SS1 mode, then STO is activated.
The safety functions in this application technique each meet or exceed the requirements for category 3, Performance Level d (cat. 3, PLd),
per ISO 13849-1 and control reliable operation per ANSI B11.19.
Guard Door Unlock at Safely-limited Speed
For tasks that require motion, a safety function to limit and monitor the speed of the motor can be used so that harm can be avoided, or at
least reduced, if motion occurs.
Normal operation with Automatic Restart is shown in the following diagram. After Check Delay expires, the speed must stay below the Active
Limit, or the SLS Limit will be set to ON(1). The SLS Limit, once set, remains at ON(1) until the SLS function is reset. For automatic restart
operation, the SLS function is reset when the request is removed OFF(0), provided no SLS faults have occurred.
Speed
Active Limit
Request
SLS Active
SLS Limit
Check
Delay
Start SLS Begin Speed
Monitoring Initiate STO, SS1, SS2, or SOS
Condition
for Reset

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Safely-limited Speed and Guard Door Unlocking with Armor PowerFlex Safety Function Application Technique
Both the door and lock are monitored to help prevent an unexpected startup. Startup cannot occur until the door is closed and locked. After
the door is closed, hazardous motion cannot resume until the door is locked via a lock request, and the STO condition is removed by using a
manual action (Safety Circuit Reset) so the motor can be enabled.
The safety function meets the requirements for category 3, Performance Level d (cat. 3, PLd), per ISO 13849-1, and SIL 2 per IEC 62061, and
control reliable operation per ANSI B11.19.
SLS Operation
To operate the SLS function, follow these steps.
1. While the motor is at speed, request SLS if there are no faults within the Safe Motion instructions (SFX/SS1/SLS).
The SLS request must remain high (1) throughout the SLS procedure. After SLS is requested, the motion application is signaled to
reduce the motor speed below the SLS Active Limit. SLS monitoring begins after a programmable time delay (7.3 seconds in this
example) to verify that the motor speed is below the programmed SLS Active Limit. Once the monitoring begins, if the motor speed
is below the limit, the gate is unlocked to allow access to the hazardous area.
2. When the task that requires access has been completed, close the monitored door.
3. To lock the door, remove the SLS request to initiate a lock request.
4. The SLS request is removed. The motor speed can now be increased above the SLS.
Recover from SS1 Due to Time Delay Expiration
If the speed does not go below the programmed speed limit before the delay expires, a Safe Stop 1 (SS1) is requested. When the SS1 completes
(standstill speed is reached), an STO request is made, which causes the motor torque to be disabled. With the motor disabled and speed
below standstill, the gate is unlocked. To recover, follow these steps.
1. If the monitored door is open, close it.
2. Remove the SLS request.
3. Press the Safety Reset to lock the guard door, and on the falling edge of the reset the STO is removed, which allows the motor to be
enabled.
Recover from SS1 When SLS is Exceeded
The gate is assumed to be unlocked and open when the speed limit is exceeded.
If SLS is exceeded after the programmable delay expires, an SS1 request is generated. When the SS1 completes (standstill speed is reached),
an STO request is made, which causes the motor torque to be disabled. To recover, follow these steps.
1. Close the monitored door.
2. Remove the SLS request.
3. Press the Safety Reset to lock the guard door, and on the falling edge of the reset the STO is removed, which allows the motor to be
enabled.
IMPORTANT Risk assessment is used to determine the SLS limits for the application.

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Safely-limited Speed and Guard Door Unlocking with Armor PowerFlex Safety Function Application Technique
Guard Door Unlock at Zero Speed (Safe Stop 1 and Standstill Monitoring)
A guard door unlock condition for a properly executed SS1 with standstill monitoring allows entry when the actuator is in a standstill
condition with STO activated. The safety function for SS1 standstill unlocking uses the same block diagram as SLS and is not analyzed
separately in this example.
This example uses an operator interface to trigger the SS1 monitoring that is used to unlock the guard door when the actuator is within
standstill speed limits. The triggering event is not considered part of the safety function for this application.
Prevention of Unexpected Startup with Guard Door Monitoring
The guard door closed/locked status is the input of the subsystem. If the guard door is unlocked or opens when not commanded, or a safety
fault is detected the actuator motor control executes an SS1. The SS1 monitors the encoder speed feedback to verify that the properly
configured decel ramp is activated, followed by Safe Torque Off (STO) at standstill speed. The motor is prevented from resetting until a safe
running condition is confirmed.
Considerations for Safety Distance and Stopping Performance
Based on the selection of a sensor subsystem, the risk assessment determines if a safety distance calculation is required. Typically, a safety
distance calculation is required if a non-separating sensor subsystem (such as a light curtain) is selected for the safety function. If a safety
distance calculation is required for this safety function, the following documents can be referenced:
• GuardLogix 5580 and Compact GuardLogix 5380 Controller Systems Safety Reference Manual, publication 1756-RM012
• Machinery Safebook 5 – Safety-related control systems for machinery, publication SAFEBK-RM002
• Safety Function: Light Curtain Products: Light Curtain GuardLogix Controller, publication SAFETY-AT191
IMPORTANT Risk assessment is used to determine the conditions necessary for guard door unlock.
IMPORTANT A risk assessment may require additional safeguarding methods such as hold-to-run devices and proximity to
complementary safety functions such as E-stops and lifelines.
Axis Speed
Standstill Speed
Stop
Monitor
Delay
Decel
Speed
Tol.
Decel
Reference
Speed, y
Stop Time, Max
Decel Reference
Rate, y/x
Decel Ramp
Speed
Limit
Stop Delay, x

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Safely-limited Speed and Guard Door Unlocking with Armor PowerFlex Safety Function Application Technique
Bill of Materials
This application technique uses these products.
Choose one of the following safety-controller hardware groups.
Quantity Cat. No. Description
1440G-MZS20SNRJ Guard locking switch — 440G-MZ: OSSD, Power to Release, M12 5-pin QD connector
1889D-F5AC-xx DC Micro (M12), female, straight, 5-pin, PVC cable, yellow, unshielded, IEC color coded, no connector, specify length
1800FM-KM22MX02 Two-position key selector switch, metal, maintained, right key removal, two N.C. contacts
1DSM9H/DSM9X Incremental encoder. BEI Electronic Version 5G2, SIL 3 type. 2048PPR.
1700S-CF620EJBC Safety control relay, 8 pole, 3 N.O./1 N.C. base, 3 N.O./1 N.C. auxiliary, bifurcated contact, 24V DC (with electric coil)
11606-XLP72E Compact power supply, 24…28V DC, 72 W, 120/240V AC 1
Quantity Controller Cat. No. Description
1
GuardLogix 5580(1)
(1) If your PLr is SIL 3/PLe, use a GuardLogix 5580 controller with a safety partner, cat. no. 1756-L8SP.
1756-L81ES GuardLogix processor, 3 MB standard memory, 1.5 MB safety memory
1756-L82ES GuardLogix processor, 5 MB standard memory, 2.5 MB safety memory
1756-L83ES GuardLogix processor, 10 MB standard memory, 5 MB safety memory
1756-L84ES GuardLogix processor, 20 MB standard memory, 6 MB safety memory
11756-PA72 Power supply, 120/240V AC input, 3.5 A @ 24V DC
11756-A7 Seven-slot ControlLogix® chassis
1Compact GuardLogix 5380–
SIL 2
5069-L306ERS2 Compact GuardLogix processor, 0.6 MB standard memory, 0.3 MB safety memory
5069-L306ERMS2
5069-L310ERMS Compact GuardLogix processor, 1.0 MB standard memory, 0.5 MB safety memory
5069-L310ERMS2
5069-L320ERS2 Compact GuardLogix processor, 2.0 MB standard memory, 1.0 MB safety memory
5069-L320ERMS2
5069-L330ERS2 Compact GuardLogix processor, 3.0 MB standard memory, 1.5 MB safety memory
5069-L330ERMS2
5069-L340ERS2 Compact GuardLogix processor, 4.0 MB standard memory, 2.0 MB safety memory
5069-L340ERMS2
5069-L350ERS2 Compact GuardLogix processor, 5.0 MB standard memory, 2.5 MB safety memory
5069-L350ERMS2
5069-L380ERS2 Compact GuardLogix processor, 8.0 MB standard memory, 4.0 MB safety memory
5069-L380ERMS2
5069-L3100ERS2 Compact GuardLogix processor, 10.0 MB standard memory, 5.0 MB safety memory
5069-L3100ERMS2
11606-XLP72E Compact power supply, 24…28V DC, 72 W, 120/240V AC input

Rockwell Automation Publication SAFETY-AT201A-EN-P - August 2023 9
Safely-limited Speed and Guard Door Unlocking with Armor PowerFlex Safety Function Application Technique
Choose an Armor PowerFlex 35S drive.
Setup and Wiring
For detailed information on how to install and wire the products in this application technique, refer to the publications that are listed in the
Additional Resources on page 29.
System Overview
The 440G-MZ guard locking switch is wired to the Safety Armor PowerFlex integrated safety IO. Guard door power is supplied from an
external power supply. The dual-channel closed and locked signals are connected to safety inputs 0 and 1. Safety output 0 controls the guard
door unlock via an interposing 700S-CF safety relay. The interposing relay is used to interface the bi-polar safety output to the guard door
unlock signal.
An external power supply is connected to the 440G-MZ switch to provide solenoid power.
Safety speed feedback is supplied by one incremental encoder monitoring the AC motor actuator. The encoder is wired to the encoder input
of the safety Armor PowerFlex 35S AC drive. The data for the encoder is passed internal to the drive to the internal safety speed-monitoring
channel.
This example was tested using available components. An induction AC motor with dual-channel incremental encoder feedback that is
compatible with the encoder input of the safety Armor PowerFlex AC drive was used for this example.
Quantity Cat. No. Description
135S-6xx-xxxx Safety Armor PowerFlex AC drive
3889D-E5NC-xx DC Micro (M12), female, straight, 5-pin, PVC cable, red, unshielded, IEC color coded, no connector, specify length
1889D-F8FB-xx DC Micro (M12), female, straight, 8-pin, PVC cable, black, braided shield, IEC color coded, no connector, specify length
1AC Motor Application dependent. Use the motor nameplate data to configure the Armor PowerFlex motor control.

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Safely-limited Speed and Guard Door Unlocking with Armor PowerFlex Safety Function Application Technique
Electrical Schematic
For an electrical schematic in AutoCAD or EPLAN format, see the attached files. For instructions on how to access the attachments, see Use
Sample Project Files on page 4.
Network Architecture
E
12V
COM
A
A-
B
B-
Z
Z-
Case
Armor_PF_S
1
2
3
4
5
6
7
8
0
B_Cos+
1
2
3
4
5
6
7
8
0
WH
BN
GN
YW
GY
PK
BL
RD
889D-F8FB-xx
Armor
PowerFlex
35S Encoder
ENCODER
1
2
3
4
5
6
7
8
0
A_Sin-
A_Sin+
B_Cos-
NC
NC
COM
Power
Shield
SLS Keyswitch
BN
WH
BL
BK
GY
889D-F5AC-xx
+24V
Safety A
0V
Safety B
Unlock Command
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
440G-MZ
440G-MZS20SNRJ
1
2
3
4
5
Unlock
Gate
K1
K1
+24V 0V
Armor_PF_S
SFTY IN 0,1
1
2
3
4
5
Test Out1
IN1
Com
IN0
Test Out0
1
2
3
4
5
SFTY OUT 0
N/C
Sink Out
24V Com
Source Out
24V Com
1
2
3
4
5
1
2
3
4
5
SFTY IN 2,3
1
2
3
4
5
Test Out1
IN3
Com
IN2
Test Out0
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
BN
WH
BL
BK
GY
BN
WH
BL
BK
GY
BN
WH
BL
BK
GY
Armor
PowerFlex
35S
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
TB
TB
A1 A2
+24V
889D-E5NC-xx
889D-E5NC-xx
889D-E5NC-xx
Power to
Release
GuardLogix 5580 Controller Compact GuardLogix 5380 Controller