Rockwell Automation Allen-Bradley Guardmaster 440G-LZS21SP... User manual

Guardmaster Guard Locking Switch
Catalog Numbers 440G-LZS21SPx, 440G-LZS21SPRx, 440G-LZS21STLx, 440G-LZS21STRx, 440G-LZS21UPLx, 440G-
LZS21UPRx, 440G-LZS21UTLx, 440G-LZS21UTRx
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 440G-UM001C-EN-P - June 2019 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 Guardmaster 440G-LZ Safety Switch Overview. . . . . . . . . . . . . . . . . . . 7
Assembly Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Packaging Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2
Safety Concept Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 3
Installation General Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Correct Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Orientation of Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Actuator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Allowable Approach Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mounting the Switch Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Actuator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pair Proximity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal of the Actuator Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Auxiliary/Manual Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 4
Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OSSD Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
OSSD Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connections Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Auxiliary Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lock Command. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Response Time When Connected in Series Circuit. . . . . . . . . . . . . . . 25

4Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Table of Contents
Chapter 5
Commissioning Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
First Time Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Learning Additional Replacement Actuators . . . . . . . . . . . . . . . . . . . . 28
Locking the Actuator Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Error Codes during the Commissioning Process . . . . . . . . . . . . . . . . . 29
Prove Basic Lock Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 6
Diagnostics and Troubleshooting LED Indicators during Power-up Routine. . . . . . . . . . . . . . . . . . . . . . . 31
LED Indicators during Normal Operation . . . . . . . . . . . . . . . . . . . . . . 31
Diagnosis of Switch Condition Using LED Indicators. . . . . . . . . . . . 31
Diagnosis of Physical Switch Anomalies . . . . . . . . . . . . . . . . . . . . . . . . . 34
Troubleshoot Series Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Chapter 7
Application Examples Wiring to GLP Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Wiring to GLT Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Wiring to DI and EMD Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring to DG Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wiring to CR30 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wiring to 1734 Guard Point I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Wiring to 1732 ArmorBlock Guard I/O . . . . . . . . . . . . . . . . . . . . . . . . 48
Appendix A
Specifications and Safety Ratings Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Compliance to European Union Directives. . . . . . . . . . . . . . . . . . . . . . 55
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Appendix B
Typical Installations Switch Mounted Parallel to Hinge Axis . . . . . . . . . . . . . . . . . . . . . . . . . 57
Switch Mounted Perpendicularly to Hinge Axis . . . . . . . . . . . . . . . . . 58
Switch Mounted to a Sliding Guard Door . . . . . . . . . . . . . . . . . . . . . . . 59
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 5
Preface
Summary of Changes This manual contains new and updated information as indicated in the
following table.
Who Should Use This Manual Use this manual to design, install, program, or troubleshoot systems that use
the Guardmaster 440G-LZ guard lock safety switches.
You are required to have a basic understanding of electrical circuitry and
familiarity with safety-related control 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 Guardmaster 440G-LZ guard locking
switch. It describes the procedures you use to install, wire, and troubleshoot
your switch. This manual:
• Explains how to install and wire your 440G-LZ switch, and
• Provides an overview of the Guardmaster 440G-LZ guard locking
switch.
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 sequential steps or hierarchical information.
Additional Resources The following document offers additional information about related Rockwell
Automation products:
Topic Page
Added information about 440G-LZ being a Type 4 interlocking device with low and
high coding, according to EN ISO 14119
7 and 54
Separated Installation & Wiring chapters 13 and 21
Added a note warning against the use of washers when mounting the switch body 16
Added information about mounting for Protection from particle build-up under
Environmental Considerations
18
Revised the Commissioning section for easier understanding 27
Created Diagnostics and Troubleshooting Chapter 31
Created Application Examples Chapter in order to add application examples for DG
Relay, CR30 and GSR GLT Relay
37
Added Mechanical Lifetime under Specifications 53
Resource Description
Allen-Bradley Industrial Automation Glossary,
publication AG-7.1
Glossary of industrial automation terms and
abbreviations

6Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Preface
You can view and download publications at http://
www.rockwellautomation.com/literature/. To order paper copies of technical
documents, contact your local Rockwell Automation distributor or sales
representative.
Terminology The Industrial Automation Glossary contains terms and abbreviations used by
Rockwell Automation to describe industrial automation systems. Below is a list
of specific terms and abbreviations used in this manual.
NC No connection
N.C. (Normally
Closed)
An electrical contact whose normal state (for example,
no pressure or electrical potential applied) is in the
closed position.
N.O. (Normally
Open)
An electrical contact whose normal state (i.e., no
pressure or electrical potential applied) is in the open
position.
PLC A programmable logic controller or a programmable
automation controller.
PTL (Power to
Lock)
Apply 24V to the lock command to lock the switch. This
command applies to the 440G-LZ switch.
PTL (Power to
Release)
Apply 24V to the lock command to unlock the switch.
This command applies to the 440G-LZ switch.
Reaction Time Describes the time between the true state of the input to
the ON state of the output.
Response Time Describes the time between the trigger of the input to
the OFF state of the output. Throughout this manual,
the safety outputs may be described as turning off
immediately. This means that the safety outputs will
turn off within the response time.
RFID Radio frequency identification.
OSSD (Output
Signal
Switching
Device)
Typically a pair of solid-state signals pulled up to the DC
source supply. The signals are usually 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
440G-LZL 440G-LZ power-to-lock guard locking switch
440G-LZR 440G-LZ power-to-release guard locking switch
Unique coding Same as High coding as defined in ENISO14119:2013

Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 7
Chapter 1
General Description
Guardmaster 440G-LZ
Safety Switch Overview
This Guardmaster® 440G-LZ guard lock safety switch functions by extending a
locking bolt from the switch through a hole in the actuator, which prohibits
the opening of a guard.
The locking bolt drive mechanism and logic confirm that the locking bolt is
allowed to extend only when the corresponding actuator is detected within
range.
RFID technology enables high precision operation while meeting the
requirements to prohibit actuator substitution as described in EN ISO 14119.
The 440G-LZ safety switches are classified according to ISO 14119 as Type 4
interlocking devices with guard locking. The unique coded actuators are
classified as having a high level of coding.
The Guardmaster 440G-LZ guard lock safety switch features OSSD outputs.
These outputs are enabled only when the locking bolt is sensed in its extended
position in the actuator. This action only happens when the guard is both
closed and locked.
The locking bolt drive mechanism uses a bi-stable solenoid. As a result, the
switch consumes little electrical power, with peak currents occurring (only
briefly) on startup and after each movement of the locking bolt.
Because of its bi-stable drive, not only does the device consume minimal power,
but it also does not produce heat while it is locked or unlocked.
Despite the bi-stable design of the locking bolt drive, the device logic and
functionality are configured to replicate the functionality of a Power to Release
or Power to Lock solenoid-operated switch (depending on type).

8Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Chapter 1 General Description
Assembly Overview
Locking bolt Actuator
Switch body
Actuator
mounting bracket
QR Code
Alignment guide

Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 9
General Description Chapter 1
Catalog Numbers Table 1 - Catalog Number Explanation
Table 2 - Complete Switches, including Switch Body, Actuator, and Actuator Mounting Bracket
Table 3 - Spare Actuators and Actuator Mounting Bracket
Table 4 - Accessories
440G-LZS21
abcd
abbd
S Standard Coding P AUX- Lock Status R Power to Release A 3 m Cable
U Unique Coding T AUX- Door Proximity L Power to Lock B 10 Cable
H M12 8-pin
Type Actuator Coding Cat. No.
Connection
3 m lead 10 m lead 6 in. pigtail with M12
8-pin Quick Disconnect
Auxiliary Type
Power to Release Standard (Low level to ENISO14119:2013) 440G-LZS21SPRA 440G-LZS21SPRB 440G-LZS21SPRH Lock Status
Unique (High level to ENISO14119:2013) 440G-LZS21UPRA 440G-LZS21UPRB 440G-LZS21UPRH Lock Status
Power to Lock Standard (Low level to ENISO14119-2013) 440G-LZS21SPLA 440G-LZS21SPLB 440G-LZS21SPLH Lock Status
Unique (High level to ENISO14119:2013) 440G-LZS21UPLA 440G-LZS21UPLB 440G-LZS21UPLH Lock Status
Power to Release Standard (Low-level ENISO14119:2013) 440G-LZS21STRA 440G-LZS21STRB 440G-LZS21STRH Door Proximity
Unique (High-level ENISO14119:2013) 440G-LZS21UTRA 440G-LZS21UTRB 440G-LZS21UTRH Door Proximity
Power to Lock Standard (Low-level ENISO14119:2013) 440G-LZS21STLA 440G-LZS21STLB 440G-LZS21STLH Door Proximity
Unique (High-level ENISO14119:2013) 440G-LZS21UTLA 440G-LZS21UTLB 440G-LZS21UTLH Door Proximity
Type Coding Cat. No.
Power to Release Standard (Low-level ENISO14119:2013) 440G-LZASPR
Unique (High-level ENISO14119:2013) 440G-LZAUPR
Power to Lock Standard (Low-level ENISO14119:2013) 440G-LZASPL
Unique (High-level ENISO14119:2013) 440G-LZAUPL
Actuator mounting bracket 440G-LZAM1
Description Cat. No.
Switch body mounting bracket 440G-LZAM2

10 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Chapter 1 General Description
Packaging Contents The box includes the following components:
Figure 1 - Switch Body Including Connection Lead: 3 m or 10 m Flying Lead or Pigtail Equipped
with M12 QD Connector
Figure 2 - Actuator Mounting Bracket
Figure 3 - Actuator
Figure 4 - Mounting Screws: 2 x T10 Torx
Figure 5 - Alignment Guide

Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 11
Chapter 2
Safety Concept
Safety Standards The Guardmaster® 440G-LZ safety switch satisfies applicable requirements in
the following standards that are related to functional safety and machinery
assembly:
• IEC 60947-5-1: 2003+A1: 2009
• IEC 60947-5-3: 1999/A: 2005
• IEC 61508:2010 SIL 3
• IEC 62061:2005 SIL 3
• EN ISO 13849-1:2008/AC: 2009 Performance Level e (PLe),
Category4
• EN ISO 14119:2013
• UL 508 17th Edition dated 3/19/2013
Safety Certification The Guardmaster 440G-LZ safety switch is certified for use in safety
applications up to and including SIL 3 according to IEC 61508 and IEC
62061 with a proof interval of 20 years, and Performance Level PLe Category 4
in compliance with ISO 13849-1.
Safety requirements are based on the standards applicable at the time of
certification.
The TÜV Rheinland group has approved the Guardmaster 440G-LZ safety
switch for use in safety-related applications where Performance Level “e” is
required for the door position and lock monitor functions.
The 440G-LZ safety switch must be installed in accordance with the
applicable regulation and standards.
While the 440G-LZ safety switch can be used for SIL 3, PLe, and Category 4
applications, the installer must comply with guard requirements (for example,
ENISO13854 and EN ISO 13857), and in some cases minimum (safe)
distance requirements (for example, EN ISO 13855).

12 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Chapter 2 Safety Concept
The installed system, including the safety control system and the means by
which the machine stops, must achieve the needed safety performance. The
440G-LZ safety switch is one element in the safety system.
Additional guidance on guards, guard locking and guard interlock can be
found in:
• EN ISO 12100
• EN ISO 13854
• EN ISO 13855
• EN ISO 13857
• EN ISO 14119
• EN ISO TR 24119
• EN ISO 14120
• Application-specific C-level standards
ATTENTION: A risk assessment is required to prove that the selected switch
can be used in the desired application. A functional test of the system is
necessary to validate that it works as expected (see Functional Testing on
page 20).
Guard locking switches that are activated by the Power to Lock principle,
440G-LZS 21 **L* safety switch, must only be used after a risk assessment has
shown that the use of a Power to Release principle, 440G-LZS21**R* safety
switch is inappropriate. This assessment is necessary since the guard can be
immediately opened after a loss of power supply or upon de-activation of the
unlocking signal.

Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 13
Chapter 3
Installation
General Considerations Installation must be in accordance with the present manual and implemented
by qualified personnel exclusively. The 440G-LZ guard locking safety switch is
intended to be part of the safety-related control system of a machine.
Correct Use Review the following requirements and guidelines for proper use of the safety
switch in order to achieve optimal performance.
• The 440G-LZ guard locking safety switch is designed for use on small-
and medium-sized guards that are engineered to be rigid without sag and
allow partial body access to the safeguarded area.
• The switch is not to be used as a mechanical stop. Check that a separate
door stop is used.
• Use in applications where the alignment tolerance falls within the stated
specification (± 2.5 mm [0.10 in.] in X, Y, Z directions). A separately
mounted latch (for example, magnetic or mechanical) is recommended
to maintain proper alignment of the actuator. The locking bolt must be
free to enter and withdraw from the hole in the actuator without
binding.
• This switch can be used on guards that do not require escape,
emergency, or remote releases.
• Use appropriate screws, bolts, or nuts that are fitted by tools to mount
the switch and actuators to avoid tampering.
• Do not over torque the mounting hardware.
• The locking bolt must never be extended mechanically. Only extend the
bolt electrically. These basic connections are required:
– Pin 2 (brown wire) must be connected to 24V DC
– Pin 7 (blue wire) must be connected to 0V (GND)
– Pin 3 (green wire) is the lock command (0 or 24V DC). See Lock
Command on page 25 for description of lock command for PTR and
PTL type switches.
• Adjacent switches must be separated by a minimum distance of 200 m
(8in.), see Pair Proximity on page 18.
ATTENTION: Before installation, a thorough risk assessment must be
performed to determine whether the specifications of this device are
suitable for all foreseeable operational and environmental characteristics of
the application.

14 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Chapter 3 Installation
• Mount the switch away from any source of metal particles. See
Environmental Considerations on page 18.
• The 440G-LZ is designed to be used in a NEC Class 2 circuit. Connect
the 440G-LZ to a dedicated Class 2 power supply or use electronic
circuit protection (for example, 1692-ZRCLSS) to achieve NEC Class 2
compliance.
Orientation of Switches Can be used in all mounting orientations.
Actuator Mounting The actuator must be fitted to the actuator mounting bracket in such a manner
that the white alignment triangles that are marked on both the actuator and
switch body are in the installed position.
Verify that the locking bolt enters the actuator mounting bracket first.
ATTENTION: For the switch, actuator, and actuator mounting bracket:
• Only use the designated mounting holes.
• Never drill or use to support other structures such as a conduit, cable ways,
or other hardware.
Align the white triangles.
0.4 Nm 2 x T10 Torx screws

Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 15
Installation Chapter 3
Verify that two fasteners are used with at least one fastener that is fitted close to
the actuator bracket bend.
The following drawings show mounting possibilities when attaching to
extruded aluminum profile and flat surface guard doors.
IMPORTANT The performance of the switch can only be guaranteed if the provided
actuator mounting bracket is used. Mounting the actuator without the
supplied bracket can result in the reduction of performance.

16 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Chapter 3 Installation
Allowable Approach
Directions
The actuator can approach the switch from all four directions.
Verify that the white arrow on the actuator aligns with the white arrow on the
switch body.
Mounting the Switch Body Three M5 fasteners (not provided) are required for proper mounting to a rigid
guard door frame.
IMPORTANT Washers are not required and if used can cause the mounting holes on the
switch body to crack.
If it is decided to use a standard thread-locking compound on the mounting
screws of the switch body, check the manufacturer’s specification. Many
standard thread-locking compounds can attack the plastic feet of the switch
body, which can cause stress cracks. It is recommended to use
cyanoacrylate-type thread-locking compounds.
3 x M5

Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 17
Installation Chapter 3
Actuator Alignment There are three ways to achieve proper alignment.
1. By setting gap
“G” 2.5 mm (0.09 in.)
[
0…5 mm (0…0.19 in.) ]
2. By mounting hole alignment
“H” 6.5 mm
(0.25 in.) [4…9 mm (0.15…0.35 in.)]
3. Use the alignment
guide
provided
ATTENTION: After installation, verify that
there is no possibility of lifting the actuator
over the extended locking bolt.
ATTENTION: After installation, confirm that
there is no possibility of collision when the
actuator approaches the switch body.
G
H


18 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Chapter 3 Installation
Pair Proximity Maintain a minimum separation of approximately 200 mm (8 in.) between any
two switches and actuators, as indicated in the following illustration.
Figure 6 - Minimum Required Distance Between Two Switches
This restriction applies to both pairs of 440G-LZ safety switches and
combinations of 440G-LZ safety switches with the TLS-Z guard locking
switches and/or 440N-Z SensaGuard™ noncontact safety switches. All of these
devices use inductive field technology for sensing actuator proximity and
RFID technology for actuator code identification.
Environmental
Considerations
Mounting for Protection from Particle Build-up
Particle build-up in the vicinity of the locking bolt will likely cause jamming of
the locking bolt, which over time causes switch failure. Ferromagnetic metal
particles are especially harmful as they are attracted to the permanent magnet
at the tip of the locking bolt.
Mounting for Protection from Ingress of Liquids
The 440G-LZ safety switch is rated for IP69 in accordance with IEC
60529:192 + A2:2013. This rating involves a short-term test that is made with
high-pressure water jets at 80° C (176° F). The test is passed if no water enters
IMPORTANT If the minimum separation distance is not observed, the inductive fields
interact causing cross talk. Cross talk results in nuisance faults and false
operation.
200 mm (8 in.)
IMPORTANT The correct installation is to mount the switch away from any
source of metal particles. Perform preventative maintenance
periodically to keep the switch clean of metallic particles. Pay
particular attention during installation to be sure that any
drilling swarf is excluded from the vicinity of the switch.

Rockwell Automation Publication 440G-UM001C-EN-P - June 2019 19
Installation Chapter 3
the enclosure of the switch that contains the electrical components and the
switch function is not impaired.
This rating does not promise protection from any liquids other than water and
does not promise the mechanical longevity from continuous or frequent
exposure.
However, the 440G-LZ safety switch is used in CIP (clean-in-place)
applications by virtue of the following features:
• Stainless steel is used for all metal parts including the M12 quick-
disconnect.
• The product plastics are resistant to most alkaline cleaners used in CIP.
• An internal nitrile-rolling lip seal guards the locking bolt, which extends
and retracts during locking/unlocking.
Removal of the Actuator Plug This plug can be broken out from the actuator if a through-hole is required to
avoid a food trap when mounted on the hazard side of a guard door.
Twist the plug with a screwdriver until it comes apart.
Figure 7 - Removal of Actuator Plug
IMPORTANT To be sure of maximum longevity when exposed to CIP, it is recommended
that the switch be mounted in the inverted position with the actuator at the
bottom. This position allows liquids to drain away from the locking bolt.
Removing the plug in the middle of the actuator improves drainage (see
Removal of the Actuator Plug).
It is also recommended that the switch be thoroughly rinsed with water
after exposure to CIP. This step prevents adverse effects that may occur with
long-term exposure.

20 Rockwell Automation Publication 440G-UM001C-EN-P - June 2019
Chapter 3 Installation
Auxiliary/Manual Release
Functional Testing A manual functional electric test must be made:
•After installation
• After any maintenance or change of component
• If the guard is used infrequently
–Less than once a month for SIL 3/PLe
– Less than once a year for SIL 2/PLd
1. Confirm that the guard door is open.
2. Connect the 24V DC power to pin 2 and ground (0V) to pin 7. The
switch conducts a self-testing routine at the end of which the diagnostic
indicator is solid red.
3. Test to confirm that the machine cannot start.
4. Confirm the lock control at pin 3 is set to 0V for PTR and 24V for PTL
types.
5. Test again to confirm that the machine cannot start.
6. Close the guard door and then confirm that the guard is mechanically
locked and the diagnostic indicator is solid green.
7. Test to confirm that the machine can start.
8. Change the lock control at pin 3 to 24V for PTR and 0V for PTL types.
9. Confirm the machine stops, the guard door is mechanically unlocked, and
the machine cannot restart.
The manual release is provided to
allow you to unlock the guard door if
an unforeseen and uncommon
circumstance occurs.
If power is supplied to the switch and
the switch is in its locked state, if you
invoke the auxiliary release, it causes
the switch to enter a fault condition
(blinking red status indicator).
To reset the switch, simply cycle the
power.
< 2.5 (0.098) dia.
ATTENTION: During the functional test, confirm that there are no persons in
the danger area and that the machine startup does not cause a hazard.