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, Pushbuttons, and Key Selector: Provides highly convenient and controlled local access and operation. The key selector adds a layer of restricted access or mode selection, ideal for supervisor-level control, maintenance modes, or specific operational sequences.
- 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. This model uses discrete wiring connections (M20 conduit).
- 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-C04 is typically used in industrial environments where robust machine safeguarding is critical, especially for applications requiring full-body access, high holding force, and a need for controlled, authorized access or mode selection at the point of operation.
Common applications include:
- Robotic Cells: Securing access to robotic workcells, with the key switch providing restricted access for programming or maintenance modes.
- Automated Production Lines: Safeguarding large access doors to automated machinery, where different levels of access or operational modes are required.
- High-Hazard Machinery: Applications like large presses, cutting machinery, or heavy material handling systems where the high holding force and secure access are paramount.
- Packaging and Printing Presses: Securing access to high-speed or large machinery, with the key switch enabling specific setup or override functions.
- Systems Requiring Authorized Intervention: Any machine or process where access to the interior for maintenance or troubleshooting should only be granted by authorized personnel via a key.
Related Products
The 442G-MABR-UT-C04 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 mechanical operation and safety interlock.
- 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 safety outputs of the 442G (e.g., door closed, bolt locked, E-Stop status) and control the machine’s safe state.
- Safety Light Curtains / Safety Scanners: Often used in conjunction with access boxes to provide additional presence detection within the safeguarded area.
- Additional Emergency Stop Devices: While the 442G has an integrated E-Stop, more 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.
- Keys for the Key Selector Switch: Specific keys for the integrated key selector switch will be needed to enable its functionality.
Installation and Maintenance
Installation and maintenance of the Allen-Bradley 442G-MABR-UT-C04 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 machine frame, 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 and key switch) 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, E-Stop active) 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 all guard locking, access control, E-Stop, pushbutton, and key switch functions operate correctly and safely.
Maintenance (General Guidelines):
- Regular Inspections: Periodically inspect the unit for any physical damage, wear, or misalignment. Check the integrity of the cable entries and connections.
- Actuator Check: Ensure the unique coded RFID bolt actuator (part of the handle assembly) is clean and free from obstruction. Verify its proper engagement and disengagement with the lock module.
- Operational Checks: Regularly test the locking mechanism, E-Stop, pushbuttons, and key selector switch for smooth and reliable operation. Verify the status LEDs are functioning correctly.
- Cleaning: Keep the unit clean, especially the actuator and sensing areas, to prevent debris from affecting performance.
- Lubrication: Follow manufacturer guidelines for any required lubrication of mechanical parts.
- Firmware Updates (if applicable): For versions that support it (though this is a discrete wired version), ensure firmware is up to date.
- Documentation: Maintain comprehensive records of installation, testing, and maintenance.
Product Guarantee
Allen-Bradley, a brand of Rockwell Automation, provides a standard manufacturer’s warranty for its new products. This warranty typically covers defects in materials and workmanship for a specific period (e.g., 1 year) from the date of purchase.
For the 442G-MABR-UT-C04:
- New Purchase: If purchased new from an authorized Rockwell Automation distributor, it will come with the full manufacturer’s warranty.
- Aftermarket/Used: If acquired from a surplus dealer, reconditioner, or as “new old stock,” the original manufacturer’s warranty may no longer be valid. In these cases, the seller might offer their own limited warranty (e.g., 30-day, 1-year), or the item might be sold “as-is.”
It is highly recommended to purchase Allen-Bradley safety products from authorized distributors to ensure authenticity, full warranty support, access to proper documentation, and reliable technical support, all of which are crucial for safety-rated devices.
