Rockwell Automation Allen-Bradley Guardmaster MatGuard... User manual

User Manual Original Instructions
MatGuard Mat Manager with
MatGuard Pressure Sensitive
Sensor Mats
Catalog Numbers 440F-C28011, 440F-C28012, 440F-C28013,
440F-C28023, 440F-C28024, 440F-C28025, 440F-C28026

2Rockwell Automation Publication 440F-UM001B-EN-P - January 2024
MatGuard Mat Manager with MatGuard Pressure Sensitive Sensor Mats 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.
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).

Rockwell Automation Publication 440F-UM001B-EN-P - January 2024 3
Table of Contents
Preface
Who Would Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Standards Applied to Pressure Sensitive Safety Mats . . . . . . . . . . 7
EMC Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Functional Safety Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Markings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Handling and Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Mat Environmental and Operating Conditions . . . . . . . . . . . . . . . 9
Possible Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 1
Product Overview Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MatGuard Mat Manager. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure Sensitive Safety Mats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Active Uniting Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Perimeter Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safety Mat Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MatGuard Mat Manager Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Select the Mat Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Wiring the Mat Manager Safety Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chapter 2
System Design Nature of Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Nature of Safeguarding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Proper Positioning of Safety Mats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Combined Trip and Presence Sensing System . . . . . . . . . . . . . . . . . . 20
Presence Sensing System within a Guarded Perimeter . . . . . . . . . . 22
Fixed Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Design Practice and Measures Against Bypass . . . . . . . . . . . . . . . . . . . . . 23
Safety Mat Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Floor requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Mat Manager Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Select the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Interconnection to the Machine Safety Control Circuit . . . . . . . . . . 26
Reset Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Auxiliary Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Arc Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Final Safety Mat Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4Rockwell Automation Publication 440F-UM001B-EN-P - January 2024
Final Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 3
Install and Commission Safety Mat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Safety Mat Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Active Uniting Trim Fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Perimeter Trim Fixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mat Manager Installation and Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Mat Manager Enclosure Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Individual Safety Mat Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Safety Mat Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Safety Mat M12 QD Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Flying Lead Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power and I/O Connector Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
440F-C28011 and 440F-C28012 Mat Managers . . . . . . . . . . . . . . . . . . 43
440F-C28023 Mat Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
440F-C28024 and 440F-C28025 Mat Managers. . . . . . . . . . . . . . . . . . 48
440F-C28026 Mat Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
440F-C28013 Mat Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Reset Mode Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Check Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Electrical Functions Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Manual Reset Mode Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Auto Reset Model Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Functional Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Chapter 4
Maintenance Safety Mat Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Routine Inspection and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Thorough Inspection and Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Dismantle and Dispose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Chapter 5
Status Indicators and
Troubleshooting
Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Internal Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
No Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
No Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Unexpected Stoppage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Appendix A
Specifications MatGuard Mat Manager Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Safety Mat Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Mat Manager Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Spare Part List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Rockwell Automation Publication 440F-UM001B-EN-P - January 2024 5
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

6Rockwell Automation Publication 440F-UM001B-EN-P - January 2024
Notes:

Rockwell Automation Publication 440F-UM001B-EN-P - January 2024 7
Preface
\
This manual is a reference guide for proper installation of the
440F-C28xMatGuard™ Mat Manager Controller in combination with the
440F-MxMatGuard Pressure Sensitive Safety Mats. This manual describes the
procedures to install, wire, and troubleshoot both components within the
MatGuard Mat Manager safety system.
Who Would Use This Manual Use this manual if you design, install, program, or troubleshoot systems that
use the 440F-C28xMatGuard Mat Manager.
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 Applied to
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: Safety of machinery - Safety-related parts of control
systems - Part 1: General principles for design.
• ISO 13855: 2010 - 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.
• IEC 62061: 2021 - Safety of machinery - Functional safety of
safety-related electrical, electronic, and programmable electronic
control systems.
• ANSI B11.TR3 - 2000 (2015): Risk Assessment and Risk Reduction-A
guide to estimate, evaluate, and reduce risks that are associated with
machine tools.
IMPORTANT Read this manual before installation. After installation, this manual
must be retained in a safe and accessible place.

8Rockwell Automation Publication 440F-UM001B-EN-P - January 2024
EMC Directives The safety mat system complies with the requirements of Directives
WEEE 2012/19/EU, EMC 2014/30/EU, and MD 2006/42/EC. Normal operation
under interference conditions likely in industrial environments is confirmed
and has been tested and certified.
Functional Safety Data Compliance for the mat manager 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 for the safety mat sensors is
achieved with the requirements of a category 1 per EN ISO 13856-1, and PLd to
ISO 13849-1 in combination with the 440F-C28xMatGuard Mat Manager
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 - Mat Manager Markings (440F-C2801xx)

Rockwell Automation Publication 440F-UM001B-EN-P - January 2024 9
Figure 2 - MatGuard Pressure Sensitive Safety Mat Markings (440F-Mx)
Storage The Guardmaster® mat manager and safety mat sensors must be stored within
the temperature range -40…+70 °C (-40…+158 °F). The safety mats must be
stored vertically.
Handling and Transport The Guardmaster mat manager and safety mat sensors must be transported at
a temperature of -40…+70 °C (-40…+158 °F). The original packaging or similar
must be used together with stiffeners, if necessary, to protect from damage
and flex. Always unpack carefully and avoid damage by sharp objects.
When safety mats are moved into position, never pull or lift the sensors by
their connecting wires.
For the larger safety mats, two people are required for safe lifting and to help
prevent a risk of damage to the safety mats from excessive flex.
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. Tests are
recommended in such cases. Small pieces of the vinyl material are available if
tests are required.

10 Rockwell Automation Publication 440F-UM001B-EN-P - January 2024
Possible Misuse The Guardmaster system is designed for the protection of personnel by
sensing their presence on floor areas around machinery and other similar
hazards.
The Guardmaster system must be used only within the specification limits
given and must be installed strictly in accordance with the information that is
provided in this manual.
The Guardmaster 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 Guardmaster 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.
The machine control circuit must be configured in a way that the closing of the
Guardmaster system output contacts enables the starting circuit of the
machine, but does not directly cause the machine to start up. 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. (for example, near to welding
or induction heat equipment or near radio transmitters/
transceivers).

Rockwell Automation Publication 440F-UM001B-EN-P - January 2024 11
Summary of Changes This publication contains multiple changes throughout all chapters.
Familiarize yourself with this manual and the related installation instructions
before using your Guardmaster system or individual components.
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.

12 Rockwell Automation Publication 440F-UM001B-EN-P - January 2024
Notes:

Rockwell Automation Publication 440F-UM001B-EN-P - January 2024 13
Chapter 1
Product Overview
Introduction When designed by professional personnel for use as a safety product in an
industrial environment, the Guardmaster® MatGuard™ Mat Manager system
provides protection against risks that the isolation of electrical power can
eliminate when an operator is in the vicinity of the hazard. This manual covers
the installation and use of all components of the Allen-Bradley® Guardmaster
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 Guardmaster MatGuard Mat Manager system is composed of a mat
manager, one or more interconnected pressure sensitive safety mats, active
uniting trim, and perimeter trim, as shown in Figure 3.
Figure 3 - Basic System
MatGuard Mat Manager
The mat manager provides connections for eight individual safety mats. The
mat manager monitors the safety mats and deactivates outputs when a person
is detected.
Power and I/O Wiring
MatGuard
Mat Manager
Individual Safety Mat
Connections
Perimeter Trim
Safety Mats
Uniting Trim

14 Rockwell Automation Publication 440F-UM001B-EN-P - January 2024
Chapter 1 Product Overview
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 is installed 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.
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 4 and Figure 5 on page 15.
Figure 4 - 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.
Molded
Vinyl
Steel
Plates

Rockwell Automation Publication 440F-UM001B-EN-P - January 2024 15
Chapter 1 Product Overview
Figure 5 - 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,
see Safety Mat Installation on page 31. Also see
Safety Mat Specifications on page 66 for connected capacitance per channel
when safety mats are connected in a series.
The Guardmaster 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 Guardmaster system
forms a floor-level sensing system for hazardous areas around machinery.
MatGuard Mat Manager
Functionality
MatGuard Mat Manager is designed to accept up to eight individual safety
mats. The Guardmaster Mat Manager monitors the 24V DC series circuit
through each of the connected safety mats. The mat manager monitors each
channel and provides a status indication of each connected safety mat.
When the protective area is clear, the mat manager 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 mat manager 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 mat manager is detected and the mat manager outputs
goes to a safe (off) state.
Select the Mat Manager
The available control voltage, the required safety mat connections, the number
of required safety outputs, and preference for machine safety circuit
interconnection determine the correct mat manager for your application. See
Table 2 on page 16 for connection types.
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.
IMPORTANT Safety mats must match the connection type of the controller unit.

16 Rockwell Automation Publication 440F-UM001B-EN-P - January 2024
Chapter 1 Product Overview
Mat managers are available with two different safety mat connector types:
Wiring the Mat Manager
Safety Outputs
The MatGuard Mat Manager connects into the machine safety circuit through
the power and I/O connector on the top side of the enclosure. For units
without a power and I/O connector, termination occurs directly to the main
control board terminal connection. See Install and Commission on page 31.
Safety output contacts are wired into the machine safety circuit, which defines
the overall performance of the safety system. Figure 6 on page 17 is a typical
illustration of the specific wiring required. See Mat Manager Installation and
Wiring on page 35 for details on your specific unit.
Table 2 - MatGuard Mat Managers
Cat. No. Power Required (1) Safety Mat
Connector Safety Outputs Auxiliary Outputs Output Current [A] Power/IO Connector Type Manual Reset
Button (2)
440F-C28011 24V DC (8) M12 Micro QD 4-pin 2 N.O. 1 N.C. 4 A Brad Harrison 12-pin No
440F-C28012 115/230V AC (8) M12 Micro QD 4-pin 2 N.O. 1 N.C. 4 A Brad Harrison 12-pin No
440F-C28013 24V DC, 115/230V AC (8) M12 Micro QD 4-pin 2 N.O. 1 N.C. 4 A Terminal strip Yes
440F-C28023 115/230V AC (8) M12 Micro QD 4-pin 6 N.O. 1 N.O. 4 A Harting 24-pin No
440F-C28024 24V DC (8) Cord grips (3) 2 N.O. 1 N.C. 2 A M12 QD 8-pin Yes
440F-C28025 24V DC (8) Cord grips (3) 2 N.O. 1 N.C. 2 A M12 QD 8-pin No
440F-C28026 24V DC (8) M12 Micro QD 4-pin 2 N.O. 1 N.C. - M23 QD 12-pin No
(1) Supplied through the Power/IO Connector.
(2) Mounted on enclosure (front).
(3) Accepts flying leads from the safety mat.
•Enclosure-mounted Cord Grips:
Use this connection type to connect
safety mats (up to eight) with
standard cables, without connectors
(flying leads). Safety mat cables end
directly to the main control board.
•Enclosure-mounted M12 Micro QD
connectors:
This connection type is ideal for easy
installation and quick replacement if
individual (up to eight) safety mats
are ever damaged. Use when safety
mats are supplied with M12
connectors.

Rockwell Automation Publication 440F-UM001B-EN-P - January 2024 17
Chapter 1 Product Overview
Figure 6 - Safety Mat System, Automatic Reset, Dual-channel Output, and Output Monitoring
The machine safety circuit includes various I/O control components:
• Bulletin 800F and 800T operators: Panel operators for starting, stopping,
fault resetting.
• Bulletin 100S safety contactors: For isolation and control of motor rated
contactors.
When the system is wired as described previously, the expected operation is:
• When the protective area is clear, the mat manager provides a signal to
the machine control circuit to allow the machine to start.
• When the protective area is not clear (a person steps on a safety mat), the
conductive plates touch and the resistance drops in the circuit. The mat
manager 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 mat manager is detected and the mat manager outputs
goes to a safe (off) state.
Stop
M
A
Start
Fuse
+24V DC
Reset
L1 L2 L31
Motor
K1
K2
1234
K1
Aux
K2
Aux
5678
K2
K1
DC Ground
PE Ground
Auxiliary
Output
12 1 2 4 3
91167108
Up to 8
Safety Mat
440F-C28011
Mat Manager

18 Rockwell Automation Publication 440F-UM001B-EN-P - January 2024
Chapter 1 Product Overview
Notes:

Rockwell Automation Publication 440F-UM001B-EN-P - January 2024 19
Chapter 2
System Design
We recommend that only personnel with experience in safety-related control
system design, and who are suitably competent in electrical and mechanical
engineering, design the system.
Nature of Hazard The Guardmaster® system provides protection against such risks that can be
minimized by the isolation of electrical power when an operator is in the
vicinity of the hazard. Additional measures can be required to deal with other
hazards that are identified at 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:
1. The machine must stop if a person is in a position of being able to reach
into the hazardous zone.
2. The machine must come to a stop before an approaching person can be
in the position of being able to reach into the hazardous zone.
3. The system must not be easily bypassed.
The recommended use of the Guardmaster system gives presence sensing over
the whole area where access is possible to the hazard (see the examples in
Figure 7). Other uses of the Guardmaster system, for example, solely as a
perimeter access guard, or as a machine enabling device, are not
recommended.
Figure 7 - Layout Examples
IMPORTANT The risk assessment is included in ISO 12100-2010 and detailed in ANSI
B11.TR3 2000 (2015).
Safety Mats
Hazard
Hazard

20 Rockwell Automation Publication 440F-UM001B-EN-P - January 2024
Chapter 2 System Design
Proper Positioning of Safety
Mats
The position of the safety mats depends on the use case. Safety mats can be
used as:
• Combined trip and presence sensing devices.
• Presence sensing systems within a perimeter guarded area.
Combined Trip and Presence Sensing System
The positioning of the safety mat edges is calculated as a horizontal distance
from the hazardous zone. Define the hazardous zone as a volume, with
consideration of all possible modes of the machine and 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.
If other safeguard measures are used with the Guardmaster system, they can
affect the requirements for the size and position of the safety mats, as shown
in Figure 8.
Figure 8 - Safety Mat Access (arrows show access)
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 9 on page 21.
• 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 Guardmaster system.
Determine the proper safety mat position:
1. Determine the routes where unobstructed access to the hazardous zone
is required across the Guardmaster safety mats. 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 9 on page 21). Applications that
use the Guardmaster system as a combined trip and presence sensing
Hazard Hazard Hazard
Safety Mats Safety Mats Safety Mats
Fixed Gear
Extended
Fixed Gear