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.

6Rockwell Automation Publication 442G-UM001B-EN-P - May 2016
Preface
Terminology
OSSD Output Signal Switching Device. Typically designates a pair of solid-state signals pulled
up to the DC source supply. The signals are tested for short circuits to the DC power
supply, short circuits to the DC common, and short circuits between the two signals.
Standard coding Same as Low coding as defined in EN/ISO 14119:2013
Unique coding Same as High coding as defined in EN/ISO 14119:2013

Rockwell Automation Publication 440G-UM001B-EN-P - May 2016 7
General Description Chapter 1
Chapter 1
General Description
442G MAB Overview The Guardmaster® Multifunctional Access Box is an electromagnetic
interlocking device with guard locking. The system consists of one locking
module and one handle assembly. An escape release is available as an option.
The Access Box functions by extending the locking bolt from the handle
assembly into the lock module. When the locking bolt is fully extended into
the lock module, the locking arm locks the bolt in this position, preventing the
opening of the guard. The version will determine whether it’s spring force or
solenoid force.
For Power to Release versions, the locking arm is kept in the locked position by
spring force and unlocked by solenoid force when the solenoid is switched ON.
For Power to Lock versions, the locking arm is kept in the locked position by
solenoid force and unlocked by spring force when the solenoid is switched
OFF.
Guard lock monitoring can be deactivated with DIP switches (see Change
Device Configuration (using DIP switches) on page 34).
With ACTIVE Guard Lock Monitoring:
In combination with a movable safety guard and the control system, this safety
device can prevent opening of the safety guard while a dangerous machine
movement is performed. The position of the guard locking is monitored
during this process.
Safety outputs (FO1A, FO1B) are enabled only when the locking bolt is sensed
in its extended position in the lock module AND the locking arm is in position
(for example, the guard is closed and the bolt is both extended and locked).
ATTENTION: For use as a guard locking device in accordance with EN ISO
14119, the guard lock monitoring must be ACTIVE.

8Rockwell Automation Publication 440G-UM001B-EN-P - May 2016
Chapter 1 General Description
With INACTIVE Guard Lock Monitoring:
In combination with a movable separating safety guard and the control system,
this safety device prevents dangerous machine movements from occurring
while the safety guard is open. A stop command is triggered if the safety guard
is opened during the dangerous machine function. The position of the guard
locking is not considered during this process.
Safety outputs (FO1A, FO1B) are enabled only when the locking bolt is sensed
in its extended position in the lock module (i.e, the guard door is closed and
the bolt is extended). In this mode, the status of the guard locking is not
considered.
Assembly Overview
Figure 1 - Locking Module with Control Cover
* Apply to hardware revision B and higher.
IMPORTANT The safety outputs (FO1A, FO1B) are not enabled until a handle assembly
has been configured (see Handle Configuration on page 15). After
configuration is completed, the lock module will only recognize the unique
code of the configured handle.
Manual Release
Cover
Terminals X2-X5
DIP Switches
Status/Diagnostic
Status Indicators
Locking Bar
Cable Entry M20 x 1.5 or
QD Connector (version-
dependent)
1 x Torx T8
6 x Torx T10
Marking for Maximum
Mounting Distance
Internal Reset*
Jumper*

Rockwell Automation Publication 440G-UM001B-EN-P - May 2016 9
General Description Chapter 1
Figure 2 - Handle Assembly
Figure 3 - Escape Release (optional)
IMPORTANT The length of the actuation shaft (115 mm (4.53 in.)) is optimized for
mounting on a 45 mm (1.77 in.) profile. An extended shaft is available 
(442G-MABASHFT). See Chapter 3, Installation and Wiring on page 15 for
instructions regarding mounting on smaller or larger profiles.
3 mm
(0.12 in.)
Locking Pin for Handle
Adjustment
Bolt Tongue
Guard Door Handle
Roll-out Bolt Locking
Mechanism Automatically
Extended Bolt Lock
Mechanism
2 x Torx T10
Protective
Sleeve
Setscrew
Handle Cover
Actuation Shaft
8 x 8 mm
(0.31 x 0.31 in.)

10 Rockwell Automation Publication 440G-UM001B-EN-P - May 2016
Chapter 1 General Description
Figure 4 - Lock Module Mounting Plate [mm (in.)]
Figure 5 - Handle Assembly Mounting Plate [mm (in.)]
Figure 6 - Escape Release Mounting Plate [mm (in.)]
IMPORTANT The use of mounting plates is optional.
35 (1.38)
10 (0.39)
35 (1.38)
15 (0.59)
6.5 (0.25)
20.54 (0.81) 17.5 (0.69)
M6 (4x)
17.5 (0.69)
170
(6.69)
86.05
(3.39)
135
(5.31)
155 (6.10)
46
(1.81)
110
(4.33)
4 (0.16)
30 (1.18)
16
(0.63)
10
(0.39)
32 (1.26)
15
(0.59)
6.5 (0.25)
12 (0.47)
17.5 (0.69)
17.5
89.4
(3.54)
135
(5.31)
130.5 (5.14)
12.5
(0.49)
4 (0.16)
170
(6.69)
25
(0.98)
30 (1.18)
110
(4.33)
17.5
M6 (4x)
10
(0.39)
32 (1.26)3
(0.12)
6.5
(0.25)
12 (0.47)
17.5
(0.69)
17.5
135
(5.31)
113.5 (4.47)
4 (0.16)
170
(6.69)
20
(0.79)
89.4
(3.54)
M6 (4x)
20
(0.79)
68
(2.68)
43.5
(1.71)
83
(3.27)
7.5
(0.29)
86.5 (3.40)
19.5
(0.77)