Rockwell Automation Allen-Bradley Guard master 442G-MAB Series User Manual
Multifunctional access box
Hide thumbs
Also See for Allen-Bradley Guard master 442G-MAB Series:
- Installation instructions manual (8 pages) ,
- User manual (52 pages)
Related Manuals for Rockwell Automation Allen-Bradley Guard master 442G-MAB Series
Summary of Contents for Rockwell Automation Allen-Bradley Guard master 442G-MAB Series
- Page 1 User Manual Original Instructions Multifunctional Access Box Catalog Numbers 442G-MABH-x, 442G-MABx-Uxx-Cxx, 442G-MABE1...
- Page 2 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.
-
Page 3: Table Of Contents
Emergency Release ..........40 Rockwell Automation Publication 442G-UM001B-EN-P - May 2016... - Page 4 Catalog Numbers ..........55 Appendix A Troubleshooting and Assistance Status/Diagnostic LED Indicators During Troubleshooting ..59 Rockwell Automation Publication 442G-UM001B-EN-P - May 2016...
-
Page 5: Preface
Provides declarations of conformity, certificates, and www.rockwellautomation.com/global/certification/ other certification details. overview.page 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. Rockwell Automation Publication 442G-UM001B-EN-P - May 2016... -
Page 6: Terminology
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 442G-UM001B-EN-P - May 2016... -
Page 7: Mab Overview
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). Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 8: Assembly Overview
Cable Entry M20 x 1.5 or Marking for Maximum QD Connector (version- Mounting Distance dependent) Internal Reset* Figure 1 - Locking Module with Control Cover * Apply to hardware revision B and higher. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... - Page 9 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 instructions regarding mounting on smaller or larger profiles. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
- Page 10 M6 (4x) (6.69) 89.4 (3.54) (5.31) (2.68) (3.27) (0.79) (0.25) 43.5 (0.79) (1.71) 17.5 (0.39) 12 (0.47) 32 (1.26) (0.12) 113.5 (4.47) 4 (0.16) Figure 6 - Escape Release Mounting Plate [mm (in.)] Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
- Page 11 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) Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
- Page 12 Chapter 1 General Description Notes: Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
-
Page 13: Standards Applied To The Guardmaster 442G Multi- Functional Access Box
(for example, PFH d of the standstill monitor). int. Figure 1 - Guard Locking Device PFH d PFH d ext. int. (for example, (access box) standstill monitor) (guard locking) Rockwell Automation Publication 442G-UM001B-EN-P - May 2016... - Page 14 • EN/ISO TR 24119 Technical report that is associated with EN ISO 14119 addressing the logical serial connection of interlocking devices • EN/ISO 14120 General requirements for the design and construction of guards Rockwell Automation Publication 442G-UM001B-EN-P - May 2016...
-
Page 15: General Considerations
IMPORTANT The locking module disables the code for the previous handle assembly if configuration is conducted for a new handle assembly. A disabled handle assembly can be configured again only after a third handle assembly has been configured. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 16: Mounting
(approximately 40 N). ATTENTION: The escape release must ONLY be accessible from inside the safeguarded area. The installation must not allow access to the escape release from outside the safeguarded area. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 17: Terminal Assignment And Wiring
6 5 4 3 2 1 Hardware Rev B Firmware Rev B optional cover function* 19-pin M23 QD 6 5 4 3 2 1 6 5 4 3 2 1 Terminal assignment Hardware Rev A Firmware Rev A Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... - Page 18 For models with E-stop and three push buttons (lock module catalog numbers ending in –C04): Pink White/Green X2.5 Push button switching element (S4) Grey/Brown Yellow/Black X2.8 Push button LED (H4) Table 1 - Terminal Assignment Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
-
Page 19: Connection Of Cover Controls And Indicators
Indicators Figure 3 - As Mounted on a Right-hinged Guard Figure 4 - As Mounted on a Left-hinged Guard A U (24V) 5 4 3 Figure 5 - Connection of Controls and Indicators Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 20: Indicator Lens Set Installation
IMPORTANT The escape release is not a safety function. The machine manufacturer must select and use a suitable release according to the risk assessment. The correct operation must be checked at regular intervals. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... - Page 21 2 Shaft length that is required when two mounting plates are used for the escape release and the handle assembly. The extended shaft (442G-MABASHFT) must be ordered separately. Handle module (0.39) (0.16) (0.14) Mounting plates (0.16) 58.5 (2.30) Escape release assembly Figure 8 - Example with Mounting Plates [mm (in.)] Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
- Page 22 2. Insert actuation shaft. The locking ring A must be in contact with the escape release B. 3. Tighten setscrew to 2 Nm 4. Slide protective sleeve over actuation shaft Figure 10 - Preparing the Escape Release Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
-
Page 23: Electrical Connection
IMPORTANT • To help ensure the stated degree of protection is achieved, the cover screws must be tightened to a tightening torque of 1 Nm. • Tighten screw for the cover for the mechanical release to 0.5 Nm. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... - Page 24 ATTENTION: Incorrect connections can result in equipment damage or malfunction. Observe the following requirements regarding the connection cables: Parameter Value Unit Wire cross-section minimum 0.13 (26 AWG) R maximum Ω/km C maximum nF/km L maximum 0.65 mH/km Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
- Page 25 Lay all Access Box connection cables in a common cable harness. UB 0V UA 0V FI1A/ FO1A/ FI1B FO1B + 24 V DC cabinet IMPORTANT Lay cables in a common harness Figure 11 - Mandatory Cable Laying Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
- Page 26 Chapter 3 Installation and Wiring Notes: Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
-
Page 27: Key To Symbols
Normal operation, door is open every three seconds See the user manual (pub. no. 442G-UM001A-EN-P) for more information on Troubleshooting. Latching faults. All other faults are non-latching. Reset according to the “Clearing Faults” section. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 28: Status/Diagnostic Status Indicators Table A
** Non-latching fault; open safety guard and close it again to reset. Status indicator flashes Any state ***See Troubleshooting and Assistance in Appendix A on page Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... - Page 29 ** Non-latching fault; open safety guard and close it again to reset. Status indicator flashes Any state ***See Troubleshooting and Assistance in Appendix A on page Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
-
Page 30: Status/Diagnostic Status Indicators Table B (Series Operation)
** Non-latching fault; open safety guard and close it again to reset. Status Any state ***See Troubleshooting and Assistance in Appendix A on page indicato r flashes Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 31: Operation With Control Systems
The control system must tolerate these pulses, which may Systems have a duration of up to 1 ms when the device is configured for series operation or 300 µs when the device is configured for standalone operation. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 32: Connection Of Guard Locking Control
The factory-default setting for Rev B models is for single-channel control (a jumper installed in the base of the lock module connects IMP1 and IMP2). IMPORTANT The jumper between IMP1 and IMP2 must be removed for dual-channel control. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 33: Proving Basic Lock Function
• It must not be possible to start the machine as long as the guard locking is deactivated. • It must be possible to open the safety guard. Repeat steps two through four for each safety guard. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 34: Change Device Configuration (Using Dip Switches)
(using DIP switches) • Changing system operation (standalone or series operation) • Deactivating guard lock monitoring • Deactivating release monitoring Dip switches Sticker with factory settings Figure 1 - Location of the Switches Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... - Page 35 All other status indicators are off. 4. Switch off power supply. 5. Set DIP switch five to OFF. • The next time the device is started, the new setting will be activated. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
- Page 36 See System status table, signal sequence incorrect status (DIA red, lock flashes one time). 1. Switch off power supply. 2. Set DIP switches five and six as shown. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
-
Page 37: Change Actuation Direction Of Handle Assembly
(a) to position (b). 4 mm 5 - Turn the door handle to 7 - Close cover. the right. 8 - Screw in the mounting screws and tighten to 2 Nm. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 38: Fault Reset
IMPORTANT The guard door must be in the open position to clear a latching fault. IMPORTANT IMPORTANT The system might not enter into a latching fault if the mechanical release is actuated slowly. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... - Page 39 (for example, with sealing lacquer). Tightening torque is 0.5 Nm. 1. Undo locking screw. 2. Lift locking arm using a screwdriver and actuate the guard door handle. Torx (T8) Figure 3 - Auxiliary/Manual Release Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
-
Page 40: Emergency Release
Use the safety outputs to generate a stop command. Hole for Sealing the Emergency Release 14.6 (0.57) (0.63) Rotary Knob Snap-in Bolt 37.5 (1.48) Flange (0.08) Flange Driver 16.9 (0.66) 25.9 (1.02) 21 (0.83) Figure 4 - Emergency Release Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 41: Bolt Locking Mechanism
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. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 42: Series Operation
ATTENTION: If there is a malfunction or damage to the product, attempts at repair shall not be made. The unit should be replaced or alternative safeguarding shall be implemented before machine operation is allowed. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 43: Cat 1 Stop With Kinetix® 300 And Glt Time Delay Safety Relay
(IN_x_COM) must be used in this signal activation/de-activation transition. Note that the terminal designations for X3.6 and X3.7 are different on Hardware Rev. A and Hardware Rev. B MAB. Rev. A Rev. B Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 44: Cat 0 Stop With Glt Time Delay Safety Relay
GLT. The gray/brown wire must remain unconnected. Note that the terminal designations of X3.6 and X3.7 are different on Hardware Rev. A and Hardware Rev. B MAB. Rev. A Rev. B Rev. A Rev. B Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 45: Cat 1 Stop With Powerflex® 525 And Glt Time Delay Safety Relay
Note 1: When using a Hardware Rev. A MAB, connect the violet wire to terminal 51 of the GLT. The gray/brown wire must be remain unconnected. Note that the terminal designations for X3.6 and X3.7 are different on Hardware Rev. A and Hardware Rev. B MAB. Rev. A Rev. B Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 46: Cat 1 Stop With Smc™-50 And Glt Time Delay Safety Relay
Note that the terminal designations of X3.6 and X3.7 are different on Hardware Note that the terminal designations of X3.6 and X3.7 are different on Hardware Rev. A and Hardware Rev. B MAB. Rev. A and Hardware Rev. B MAB. Rev. A Rev. B Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 47: Gsr-Di And Glp Safety Relay
External transient suppression may be required when non- Rev. A Rev. B ”EJ” contactors are used. Rev. A Rev. B K3 and K4 = 700-HPSXZ24 DPDT Safety relays with 700-ADL12 suppression - red status indicator modules. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 48: Gsr-Si And Glp Safety Relay
External transient suppression may be required when non- ”EJ” contactors are used. Rev. A Rev. B K3 and K4 = 700-HPSXZ24 DPDT Safety relays with 700-ADL12 Rev. A Rev. B suppression - red status indicator modules. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 49: Cat 1 Stop With Speed Monitored Guard Lock Function With Powerflex 525, Gsr-Si, And Glp Safety Relay
Note 2: When using a Hardware Rev. A MAB, connect the violet wire to terminal 51 of the GLT. The gray/brown wire must remain unconnected. Note that the terminal designations of X3.6 and X3.7 are different on Hardware Rev. A and Hardware Rev. B MAB. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 50: And Glp Safety Relay
Note 3: When using a Hardware Rev. A MAB, connect the violet wire to terminal 51 of the GLT. The gray/brown wire must remain unconnected. Note that the terminal designations of X3.6 and X3.7 are different on Hardware Rev. A and Hardware Rev. B MAB. Rev. A Rev. B Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 51: Kinetix 300 And Glp Safety Relay
Note 3: The digital input, configured for abort index in MotionView software, must be active-high when the safety function is requested. Digital input common (IN_x_COM) must be used in this signal activation/de-activation transition. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 52: Powerflex 70 And Glp Safety Relay
GLP. The gray/brown wire must remain unconnected. Note that the terminal designations of X3.6 and X3.7 are different on Hardware Rev. A and Hardware Rev. B MAB. Rev. A Rev. B Rev. A Rev. B Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 53: Specifications
Lock module with cover 750 g (26.45 oz), handle assembly 1000 g (35.27 oz), Escape release 500 g (17.64 oz)) Materials Glass fiber reinforced plastic, nickel-plated die-cast zinc, anodized aluminum handle, stainless steel hardware Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 54: Dimensions
(filings, shavings, and so on), which can become lodged in the locking and handle modules. For this purpose, a suitable installation position should be selected. The device should be covered during paint work. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... -
Page 55: Catalog Numbers
Right-hand Guard Door (Figure 442G-MABR-URM-* 442G-MABR-UT-* Left-hand Guard Door (Figure 442G-MABR-ULM-* Replace * with Code: Cover Controls and Indicators Blank Cover (No controls or indicators) One illuminated push button (S2) Two illuminated push buttons (S2,S3) Rockwell Automation Publication 440G-UM001B-EN-P - May 2016... - Page 56 Use only if the lock module is also mounted to a plate. Use only if the handle module is also mounted to a plate. Mating Cordset Description Cat. No. 19-pin M23 cordset 889M-F19RM- Add 2, 5, or 10 for cable length in meters. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
- Page 57 Lock Module Replacement Cover, E-stop, two push buttons 442G-MAB-C03 Lock Module Replacement Cover, E-stop, three push buttons 442G-MAB-C04 Lock Module Replacement Cover, E-stop 442GL-MAB-C05 Includes one blue, green, red and yellow, and two white. Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
- Page 58 Chapter 6 Specifications Notes: Rockwell Automation Publication 440G-UM001B-EN-P - May 2016...
-
Page 59: Status/Diagnostic Led Indicators During Troubleshooting
The 442G-MAB is now ready for operation again. DIA LED Illuminated and State LED Flashes One Time Power State 1 x flash Lock Fault: Fault during handle configuration or invalid DIP switch position. Possible causes: • Invalid DIP switch position Rockwell Automation Publication 442G-UM001B-EN-P - May 2016... - Page 60 3. Close the door(s). 4. Switch the voltage on again or release the reset button. 5. Wait until the State LED flashes at regular intervals. The Access Box is now ready for operation again. Rockwell Automation Publication 442G-UM001B-EN-P - May 2016...
- Page 61 Lock Fault: Handle assembly read error (e.g. error in code/code not readable). Possible causes: • EMC interference, e.g. caused by clocked cables near the Access Box. • Hardware fault in the handle assembly Rockwell Automation Publication 442G-UM001B-EN-P - May 2016...
- Page 62 • 24V DC or 0V is present at one of the two safety outputs during the switch-on process. • A safe control system with clocking outputs is connected. Remedy: 1. Check the wiring and correct it. Rockwell Automation Publication 442G-UM001B-EN-P - May 2016...
- Page 63 3. Switch the voltage on again or release the reset button. 4. Wait until the State indicator flashes at regular intervals. 5. Close the safety doors. If there is no internal fault, the Access Boxes are now ready for operation again. Rockwell Automation Publication 442G-UM001B-EN-P - May 2016...
- Page 64 Access Box. Remedy: Repeat handle configuration with a new handle assembly (see Handle Configuration on page 15). Rockwell Automation Publication 442G-UM001B-EN-P - May 2016...
- Page 65 FO1A to verify the functional capability of the output circuit at all times. So, a faintly flickering LED can be seen on an input of an evaluation unit even though the evaluation unit does not switch on or signal any fault. Rockwell Automation Publication 442G-UM001B-EN-P - May 2016...
- Page 66 Appendix A Troubleshooting and Assistance Notes: Rockwell Automation Publication 442G-UM001B-EN-P - May 2016...
- Page 68 How Are We Doing? form at http://literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf. Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, Guardmaster, Kinetix, Powerflex, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.