Rockwell Automation Allen-Bradley Guard master 442G-MABH-Series User manual

Multifunctional Access Box with 
CIP Safety over EtherNet/IP
Catalog Numbers 442G-MABH-x, 442G-MABxB-Ux-x, 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-UM002A-EN-P - December 2016 3
Table of Contents
Preface
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Studio 5000™ Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Chapter 1
General Description Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Power to Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Power to Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Assembly Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
About the Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary/Manual Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bolt Locking Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical Ethernet Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chapter 2
Safety Concept Standards Applied to the Guardmaster 442G Multifunctional Access
Box with CIP Safety™ over EtherNet/IP® . . . . . . . . . . . . . . . . . . . . . . . 19
Safety Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Safety Requirements for Integrated Safety Applications. . . . . . . . . . . 21
Chapter 3
Use the Multifunctional Access
Box in an Integrated Safety
Controller-based System
Set the Network IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Set the IP Address with BOOTP/DHCP Server . . . . . . . . . . . . . . . . . 24
Restoring the Module to DHCP Mode . . . . . . . . . . . . . . . . . . . . . . . . . 26
Duplicate IP Address Detection and Resolution . . . . . . . . . . . . . . . . . 28
Add and Configure the Multifunctional Access Box in the 
Logix Designer Appication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Add Module to the I/O Configuration Tree. . . . . . . . . . . . . . . . . . . . . 29
Configure the Module Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Configure the Safety Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Save and Download the Module Configuration . . . . . . . . . . . . . . . . . . 35
Chapter 4
Status and Troubleshooting Network Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Lock Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Status/Diagnostic Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Fault Codes and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Clearing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4Rockwell Automation Publication 442G-UM002A-EN-P - December 2016
Table of Contents
Appendix A
Specifications Safety Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Appendix B
EtherNet/IP I/O Assemblies Input Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Output Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Tag Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Right-hand System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Left-hand System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Appendix C
Change Actuation Directions of
Handle Assembly
Change Actuation Direction of Handle Assembly. . . . . . . . . . . . . . . . 55

Rockwell Automation Publication 442G-UM002A-EN-P - December 2016 5
Preface
Use this manual if you are responsible for designing, installing, programming,
or troubleshooting systems that use the 442G Multifunctional Access Box with
CIP Safety over EtherNet/IP® protocol.
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.
This manual is a reference guide for the 442G Multifunctional Access Box with
CIP Safety over EtherNet/IP protocol. It describes the procedures to use to
install, wire, and troubleshoot the module. This manual:
• Explains how to install and wire your 442G Multifunctional Access Box
with CIP Safety over EtherNet/IP protocol
• Provides an overview of the 442G Multifunctional Access Box with CIP
Safety over EtherNet/IP protocol
Read and understand this manual before using the described products. Consult
your Rockwell Automation® representative if you have any questions or
comments.
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.
GuardLogix 5570 and Compact GuardLogix 5370 Controller
Systems Safety Reference Manual, publication 
1756-RM099
Provides the safety requirements needed to reach SIL3
in a safety system.
GuardLogix 5570 Controllers User Manual, publication 
1756-UM022
Provides information on how to install, configure,
program, and use GuardLogix™ 5570 controllers in
Studio 5000 Logix Designer™ projects.
Compact GuardLogix 5370 Controllers User Manual,
publication 1769-UM022
Provides information on how to install, configure,
program, and use Compact GuardLogix 5370
controllers.
Multifunctional Access Box with CIP Safety over 
EtherNet/IP® installation instructions, publication 
442G-IN004
Provides information on how to install the module.
This includes mounting information, wiring, and
specifications.

6Rockwell Automation Publication 442G-UM002A-EN-P - December 2016
Preface
Notes:

Rockwell Automation Publication 442G-UM002A-EN-P - December 2016 7
Chapter 1
General Description
Product Overview The access box with CIP-Safety over EtherNet/IP™ is a combined interlocking
module with guard locking and integrated control elements. The intended use
of the access box is at entry points for full-body access into automation cells or
areas that require restricted or controlled access.
The access box can be used in an integrated safety system with a GuardLogix™
safety controller. Safety data is exchanged by using CIP Safety via an 
EtherNet/IP network.
In combination with a movable safety guard and the control system, this safety
module can prevent opening of the safety guard while a dangerous machine
function is performed. The position of the guard locking is monitored during
this process.
• Starting commands that cause a dangerous machine function must
become active only when the safety guard is closed and locked.
• The guard locking module must not be unlocked until the dangerous
machine function has ended.
• Closing and locking a safety guard must not cause automatic starting of a
dangerous machine function. A separate start command must be issued.
The locking module detects the position of the safety guard and the position of
the bolt actuator. The position of the locking arm is also monitored. The bolt
actuator is moved into and out of the locking module by actuating the door
handle. When the bolt is fully inserted into the locking module, the locking
arm can lock the bolt actuator in this position.
The GuardLocked input signal is turned on 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).

8Rockwell Automation Publication 442G-UM002A-EN-P - December 2016
Chapter 1 General Description
Power-to-Release For Power-to-Release versions, the locking arm is kept in the locked position by
spring force and unlocked by solenoid force when power is applied to the
solenoid.
Guard locking is activated when the guard is in the closed position and power is
removed from the solenoid.
Guard locking is deactivated when voltage is applied to the solenoid.
Power-to-Lock For Power-to-Lock versions, the locking arm is kept in the locked position by
solenoid force when power is applied to the solenoid and unlocked by spring
force when power is removed from the solenoid.
Guard locking is activated when the guard is in the closed position and power is
applied to the solenoid.
Guard locking is deactivated when voltage is removed from the solenoid.
IMPORTANT Safety output signal Unlock is turned off.
IMPORTANT Safety output signal Unlock is turned on.
ATTENTION: If the safety guard is open when power is removed from the
solenoid and the guard is then closed, guard locking is activated. This can
lead to persons being locked in unintentionally.
IMPORTANT Safety output signal Unlock is turned off.
IMPORTANT Safety output signal Unlock is turned on.
ATTENTION: In the event of an unintended loss of power, guard locking will
be deactivated. Power-to-Lock versions should only be used for personal
protection if minimum safe distance is provided in accordance with
ENISO13855.

Rockwell Automation Publication 442G-UM002A-EN-P - December 2016 9
General Description Chapter 1
Assembly Overview Figure 1 - Components at a Glance
Figure 2 - Bus Module
Figure 3 - Locking Module with Control Cover
Bus Module
Escape Release
(optional)
Lock Module
Mounting Plates
Handle Assembly
Power Connectors
Status Indicators
Ethernet Connectors
Connector for Attaching
an Enabling Switch
(select models)
Status/Diagnostic
Status Indicators
1 x Torx T8
Marking for Maximum
Mounting Distance
Locking Arm
Manual Release Cover

10 Rockwell Automation Publication 442G-UM002A-EN-P - December 2016
Chapter 1 General Description
Figure 4 - Handle Assembly
Figure 5 - 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 installation instructions 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.)

Rockwell Automation Publication 442G-UM002A-EN-P - December 2016 11
General Description Chapter 1
About the Catalog Numbers Do not use this table as a configurator.
Refer to Figure 21 on page 52 and Figure 22 on page 53.
442G-MAB R B-U R E0 J P4679
abcde
aLock Type
R = Power-to-Release
L = Power-to-Lock
bR = Guard door hinged on the right
L = Guard door hinged on the left
cEO = Illuminated EStop in position S0 1
blank = no EStop
dJ = Enabling switch connector
blank = No connector for enabling switch
eP49 = Push buttons in positions 4 and 9 1
P4679 = Push buttons in positions 4, 6, 7, 9 1

12 Rockwell Automation Publication 442G-UM002A-EN-P - December 2016
Chapter 1 General Description
Auxiliary/Manual Release The manual release lets you unlock the guard door in the event of unforeseen
or uncommon circumstances.
The system enters into a latching fault (fault code 2744) when the manual
release is actuated.
To clear the fault, open the guard and cycle the LockSequenceFaultUnlatch
input signal (see Clearing Faults on page 45).
To unlock the guard door using the manual release:
1. Undo locking screw.
2. Use a screwdriver to lift the locking arm actuate the guard door handle.
Figure 6 - Auxiliary/Manual Release
IMPORTANT The manual release is not a safety function. The machine manufacturer must
select and use a suitable release according to the risk assessment. The
correct function must be checked at regular intervals.
IMPORTANTIMPORTANT The system might not enter into a latching fault if the manual release is
actuated slowly.
ATTENTION: The locking screw must be screwed back in and sealed after
assembly and after use of the manual release. Tightening torque is 0.5 N•m
(4.42 lb•in).
Torx (T8)

Rockwell Automation Publication 442G-UM002A-EN-P - December 2016 13
General Description Chapter 1
Bolt Locking Mechanism The access box has two mechanisms for locking the bolt actuator to prevent
locking the guard and restarting the machine while an operator is inside the
safeguarded area.
One of the bolt locking mechanisms automatically extends when the handle is
in the OPEN position. The other mechanism is manually extended (see Figure
18). To pivot out, press the grooved part (only possible with the handle in the
OPEN position and the bolt retracted).
Note: The minimum padlock
diameter is 2 mm (0.08 in.) and the
maximum diameter is 10 mm
(0.39in.) You can fit a maximum of
three locks in an 8mm (0.31 in.)
diameter.
Figure 7 - Bolt Locking Mechanisms
Mounting Plates
Figure 8 - Handle Assembly Mounting Plate [mm (in.)]
IMPORTANT With the manual bolt locking mechanism rolled out, the bolt cannot be
extended.
IMPORTANT The use of the handle assembly mounting plate is required with the Ethernet
version of the access box. The use of the escape release mounting plate is
optional.
Automatically
Extending mechanism
Roll-out
Mechanism
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)

14 Rockwell Automation Publication 442G-UM002A-EN-P - December 2016
Chapter 1 General Description
Figure 9 - Escape Release Mounting Plate [mm (in.)]
Mounting Hardware Reference
Handle Assembly Mounting Plate is supplied with the following hardware:
4X DIN 7984-M6X12 ZN (screw)
4X DIN 433-6 NI (washer)
4X DIN 6797-JZ-D6,4 (lock washer)
Escape Release Mounting Plate is supplied with the following hardware:
4X DIN 7984-M6X8 (screw)
4X DIN 433-6 NI (washer)
4X DIN 6797-JZ-D6,4 (lock washer)
Typical Ethernet
Configurations
The Multifunctional Access Box with CIP Safety can be connected in any of
the following three network topologies: star, linear, or module level ring
(DLR).
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)
ATTENTION: The Multifunctional Access Box does not currently support time
sensitive applications based on CIP Sync™, including CIP Motion™
applications. Do not use the access box in DLR topologies where other nodes
are using CIP Sync or CIP Motion. To be used in linear topologies, where other
nodes are using CIP Sync or CIP Motion, the access box must be connected at
the end of the line.

Rockwell Automation Publication 442G-UM002A-EN-P - December 2016 15
General Description Chapter 1
Star Topology
The star structure consists of a number of modules connected to a central
switch. Modules can be added or removed without affecting the rest of the
network.
Figure 10 - Example of Star Topology
Linear Topology
The linear topology uses the embedded switching capability to form a daisy-
chain style network that has a beginning and an end. Linear topology simplifies
installation and reduces wiring and installation costs, but a break in the
network disconnects all modules downstream from the break. When this
topology is used, both Ethernet connections on the access box may be used. For
the network connection, use Link 1, Link 2, or both.
LNK1LNK2 NET OK
EtherNet/IP
1
2
IMPORTANT Modules without dual ports must include the 1783-ETAP module or be
connected at the end of the line.

16 Rockwell Automation Publication 442G-UM002A-EN-P - December 2016
Chapter 1 General Description
Figure 11 - Example of Linear Topology
Module-level Ring (DLR) Topology
A DLR network is a single-fault-tolerant ring network that is intended for the
interconnection of automation modules without the need for more switches.
The ring topology offers these advantages:
•Media redundancy
• Fast-network fault detection and reconfiguration
• Resiliency of a single-fault-tolerant network
• Easy implementation without more hardware requirements
One DLR network can support as many as 50 nodes. A DLR network supports
copper connections (maximum of 100 m [328 ft]), fiber-optic connections
(maximum of 2 km), or a mix of copper and fiber.
ATTENTION: The Multifunctional Access Box does not currently support time
sensitive applications based on CIP Sync, including CIP Motion applications.
Do not use the access box in DLR topologies where other nodes are using CIP
Sync or CIP Motion. To be used in linear topologies, where other nodes are
using CIP Sync or CIP Motion, the access box must be connected at the end of
the line.
LNK1LNK2 NET OK
EtherNet/IP
1
2
IMPORTANT This section summarizes a DLR network. To plan, configure, and monitor DLR
networks, see EtherNet/IP Embedded Switch Technology Application Guide,
publication ENET-AP005.

Rockwell Automation Publication 442G-UM002A-EN-P - December 2016 17
General Description Chapter 1
Figure 12 - Example Module-level Ring Topology
ATTENTION: The Multifunctional Access Box does not currently support time
sensitive applications based on CIP Sync, including CIP Motion applications.
Do not use the access box in DLR topologies where other nodes are using CIP
Sync or CIP Motion. To be used in linear topologies, where other nodes are
using CIP Sync or CIP Motion, the access box must be connected at the end of
the line.
LNK1LNK2 NET OK
EtherNet/IP
1
2

18 Rockwell Automation Publication 442G-UM002A-EN-P - December 2016
Chapter 1 General Description
Notes:

Rockwell Automation Publication 442G-UM002A-EN-P - December 2016 19
Chapter 2
Safety Concept
Standards Applied to the
Guardmaster 442G
Multifunctional Access Box
with CIP Safety over
EtherNet/IP
The Guardmaster® access box satisfies applicable requirements in the following
standards that are related to functional and machinery assembly:
• IEC 60947-5-3: 1999/A: 2005
• EN/ISO 13849-1:2008/AC: 2009 (Performance Level e [PLe],
Category 4)
• IEC 61508: 2010 (SIL 3)
• IEC 62061: 2005 (SIL cl3)
• EN/ISO 14119:2013
• UL 508 17th Edition dated 3/19/2013
Safety Certification The Guardmaster access box is a Type 4 interlocking module with guard
locking and high-coded RFID actuators according to EN ISO 14119.
The module is certified for use in safety applications up to and including
Performance Level PLe and Category 4 in compliance with EN ISO 13849-1
and SIL 3 according to IEC 61508 and IEC 62061, for guard position
monitoring, guard lock monitoring, and guard locking control.
Control of Guard Locking
The safety level of guard locking control is determined by the module PFHd
and by the external control (for example, PFHd of the standstill monitor).
Guard locking is controlled with the Unlock output signal.
Figure 13 - Control of Guard Locking
The following applies to modules with emergency stop.
Access Box
PFHd
(internal electronics)
PFHd
(for example,
standstill monitor)
Safety Output Signal
(Unlock)

20 Rockwell Automation Publication 442G-UM002A-EN-P - December 2016
Chapter 2 Safety Concept
Figure 14 - Emergency Stop Function
The following applies to modules with a connection for an enabling switch.
Figure 15 - Enabling Switch Function
The access box must be installed in accordance with the applicable regulation
and standards.
While the access box can be used for PLe and Category 4 applications, the
installer must comply with guard requirements (for example, EN/ISO13854
and EN/ISO 13857) and in some cases also minimum (safe) distance
requirements (for example, EN/ISO 13855).
The installed system, including the safety control system and the means by
which the machine stops, must achieve the needed safety performance. The 
access box is one element in the safety system.
Before safety components are used, a risk assessment must be performed on the
machine in accordance with:
• EN ISO 12100, Safety of machinery – Basic concepts - General
principles for design - Risk assessment and risk reduction.
• EN ISO 13849-1, Safety of machinery. Safety related parts of control
systems. General principles for design, Annex B
• IEC 62061, Safety of Machinery – Functional safety of safety-related
electrical, electronic, and programmable electronic control systems.
Correct use includes compliance with the relevant requirements for
installation and operation, in particular:
• EN ISO 13849-1, Safety of machinery. Safety related parts of control
systems. General principles for design
• EN ISO 14119, Safety of machinery. Interlocking modules that are
associated with guards. Principles for design and selection
Access Box
B10d
(Emergency stop)
PFHd
(internal evaluation
of the emergency
stop)
PFHd
(Safety controller)
Input Signal
(EStop)
Guard Locking Module
B10d
(Enabling switch)
PFHd
(internal evaluation
of the emergency
stop)
PFHd
(Safety controller)
Input signal
(EnablingSwitch)