Rockwell Automation Allen-Bradley Guardmaster 442G-MAB B-U... User manual

Multifunctional Access Box
Catalog Numbers 442G-MABH-x, 442G-MABx-Uxx-Cxx, 442G-MABE1
User Manual
Original Instructions

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 442G-UM001B-EN-P - May 2016 3
Table of Contents
Preface
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Chapter 1
General Description 442G MAB Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Assembly Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Chapter 2
Safety Concept Standards Applied to the Guardmaster 
442G Multifunctional Access Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 3
Installation and Wiring General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Handle Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Terminal Assignment and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connection of Cover Controls and Indicators . . . . . . . . . . . . . . . . . . . 19
Indicator Lens Set Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Escape Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 4
Description of Operation Key to Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Status/Diagnostic Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Status/Diagnostic Status Indicators Table A
(Standalone Operation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Status/Diagnostic Status Indicators Table B (Series Operation) . . . 30
Operation with Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Connection of Guard Locking Control . . . . . . . . . . . . . . . . . . . . . . . . . 32
Dual-Channel Solenoid Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Proving Basic Lock Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Change Device Configuration (using DIP switches). . . . . . . . . . . . . . 34
Change Actuation Direction of Handle Assembly. . . . . . . . . . . . . . . . 37
Fault Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Auxiliary/Manual Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Emergency Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4Rockwell Automation Publication 442G-UM001B-EN-P - May 2016
Table of Contents
Chapter 4 (continued)
Bolt Locking Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Series Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chapter 5
Application Wiring Examples Cat 1 Stop with Kinetix® 300 and GLT Time Delay Safety Relay . . 43
Cat 0 Stop with GLT Time Delay Safety Relay . . . . . . . . . . . . . . . . . . 44
Cat 1 Stop with PowerFlex® 525 and GLT Time Delay Safety Relay45
Cat 1 Stop with SMC™-50 and GLT Time Delay Safety Relay. . . . . 46
Cat 0 Stop with Speed Monitored Guard Lock Function with 
GSR-DI and GLP Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Cat 0 Stop with Speed Monitored Guard Lock Function with 
GSR-SI and GLP Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cat 1 Stop with Speed Monitored Guard Lock Function with
PowerFlex 525, GSR-SI, and GLP Safety Relay . . . . . . . . . . . . . . . . . 49
Cat 1 Stop with Speed Monitored Guard Lock Function with 
SMC-50 and GLP Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Cat 1 Stop with Speed Monitored Guard Lock Function with 
Kinetix 300 and GLP Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Cat 1 Stop with Speed Monitored Guard Lock Function with
PowerFlex 70 and GLP Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 6
Specifications Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Appendix A
Troubleshooting and Assistance Status/Diagnostic LED Indicators During Troubleshooting . . . . . . 59

Rockwell Automation Publication 442G-UM001B-EN-P - May 2016 5
Preface
Read this preface to become familiar with the rest of the manual. It provides
information concerning:
•Who would use this manual
•The purpose of this manual
• Related documentation
• Conventions that are used in this manual
Who Should Use This Manual Use this manual if you are responsible for designing, installing, programming,
or troubleshooting systems that use the 442G Multi-functional Access Box.
You must have a basic understanding of electrical circuitry and familiarity with
safety-related systems. If you do not, obtain the proper training before using
this product.
Purpose of This Manual This manual is a reference guide for the 442G Multi-functional Access Box. It
describes the procedures to use to install, wire, and troubleshoot the device.
This manual:
• Explains how to install and wire your 442G Multi-functional Access Box
• Provides an overview of the 442G Multi-functional Access Box
Conventions Used in This
Manual
The following conventions are used throughout this manual:
• Bulleted lists such as this one provide information, not procedural steps.
• Numbered lists provide steps or hierarchical information.
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.
Resource Description
Allen-Bradley Industrial Automation Glossary, 
publication AG-7.1
Glossary of industrial automation terms and
abbreviations
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1 Provides general guidelines for installing a Rockwell
Automation industrial system.
Product Certifications website, http://
www.rockwellautomation.com/global/certification/
overview.page
Provides declarations of conformity, certificates, and
other certification details.