Main Features and Advantages
- Integrated Safeguarding Solution: Combines guard locking and access control, providing a comprehensive safety solution for machine access points.
- High Holding Force (2000N): Ensures that heavy or misaligned guard doors are held securely, suitable for high-inertia or high-risk applications.
- Power to Release (PTR): The lock unlocks when power is applied, which is a critical safety feature for personnel protection. In the event of a power failure, the guard remains locked, preventing accidental access to a potentially hazardous machine state.
- High Coded RFID Actuator: Offers the highest level of tamper resistance according to ISO 14119, preventing defeat of the safety function. Each actuator has a unique code recognized by its paired lock module.
- Integrated E-Stop and Pushbuttons: Provides convenient local control directly at the point of access, including an emergency stop and two user-configurable pushbuttons (e.g., for “request to enter” or “start cycle”).
- Diagnostic LEDs: Four clear LEDs provide immediate status feedback and diagnostic information, simplifying troubleshooting and minimizing downtime.
- Flexible Integration: Can be wired as a standalone device or in series with other safety devices while maintaining PLe Cat 4 rating. Available with discrete wiring connections (M20 conduit, as in this model) or increasingly with CIP Safety over EtherNet/IP for network integration.
- Tolerance to Misalignment: Designed to tolerate a certain degree of guard door misalignment, which simplifies installation and reduces nuisance trips.
- Optional Escape Release: Allows personnel inside the safeguarded area to exit quickly and easily in an emergency (shaft and handle assembly sold separately).
- Padlock Capability: Provides provisions for attaching padlocks for personal control, allowing maintenance personnel to secure the guard in an open position during intervention.
Application Field
The Allen-Bradley 442G-MABR-UT-C03 is typically used in industrial environments where robust machine safeguarding is critical, especially for applications requiring full-body access and a high holding force.
Common applications include:
- Robotic Cells: Securing access to robotic workcells to prevent human-robot collisions during operation.
- Automated Assembly Lines: Safeguarding large access doors to automated assembly machinery.
- Die Press / Stamping Machines: Protecting operators from the hazardous motion of presses.
- Metalworking Machinery: Ensuring safety during operation of various metal forming or cutting machines.
- Packaging and Printing Presses: Securing access to high-speed or large machinery in packaging and printing industries.
- Conveying Systems: Preventing access to dangerous moving parts on large conveyor systems.
- Any large guard doors: Where a standard interlock switch might not provide sufficient holding force or misalignment tolerance.
Related Products
The 442G-MABR-UT-C03 is a component of a complete safeguarding solution. Related products include:
- 442G-MABH-R (Handle Assembly): The “R” in the model number implies it is designed to mate with a right-hand handle assembly, which contains the unique coded RFID bolt actuator. This handle is crucial for the operation of the 442G system.
- Guardmaster Safety Relays or Safety PLCs: Devices like the Guardmaster 440R or a Compact GuardLogix/ControlLogix with a safety processor are used to monitor the outputs of the 442G and control the machine’s safe state.
- Safety Light Curtains / Safety Scanners: Often used in conjunction with access boxes to provide presence detection within the safeguarded area.
- Emergency Stop Devices: While the 442G has an integrated E-Stop, additional E-Stop buttons may be strategically placed around the machine.
- Auxiliary Pushbuttons/Indicators: Other control panel components might be used in conjunction with the integrated pushbuttons on the 442G.
- Cables and Connectors: Specific M20 cable glands and associated wiring are required for electrical connection.
- Mounting Accessories: Brackets or plates for secure attachment to machine guards or frames.
- Escape Release Accessories: If an escape release function is desired (for personnel trapped inside), an escape release shaft and related components (e.g., 442G-MABASHFT) would be required.
Installation and Maintenance
Installation and maintenance of the Allen-Bradley 442G-MABR-UT-C03 must strictly follow Rockwell Automation’s documentation, including the installation instructions and user manual, along with relevant local and international safety standards (e.g., ISO 13849-1, ISO 14119, IEC 62061).
Installation (General Guidelines):
- Mechanical Mounting: The lock module and its corresponding handle assembly must be precisely mounted on the guard door and fixed structure, ensuring proper alignment. The 442G is designed to tolerate some misalignment, but optimal performance requires correct installation.
- Wiring: Connect the power supply (typically 24V DC), safety inputs (from the lock module’s internal contacts), and control outputs (for the integrated pushbuttons) according to the wiring diagrams in the manual. Ensure all wiring is protected and properly terminated using the M20 cable entries.
- Integration with Safety Circuit: Integrate the safety outputs of the 442G (e.g., door closed, bolt locked) into the machine’s safety control system (e.g., safety relay, safety PLC). The system must be designed to achieve the required Performance Level (PLe) and Category (Cat 4).
- Functional Test: After installation, perform a thorough functional test as per the manual and relevant safety standards to verify that the guard locking and access control functions operate correctly and safely. This includes testing the E-Stop, pushbuttons, and the lock/unlock mechanism.
