SensaGuardTM

Rectangular Flat Pack

Installation Instructions

Certifications

IMPORTANT:
SAVE THESE INSTRUCTIONS FOR FUTURE USE

440N-Z21SS2H-AS

Note: Refer to Technical Specifications for Certification information and ratings.

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2 SensaGuardTM Installation Instructions

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Select publication language and type "SensaGuard" in the search field.
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Bitte Ihre Sprache anwhlen und "SensaGuard" im Suchfeld eintippen.
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Slectionner la langue puis taper SensaGuard dans le champ de recherche.
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Selezionare la lingua desiderata e digitare "SensaGuard" nel campo di ricerca.
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Seleccione el idioma de publicacin y escriba "SensaGuard" en el campo de bsqueda.
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Seleccione a lngua de publicao e entre com "SensaGuard" no espao de busca.
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Wybierz jezyk publikacji i wpisz w polu poszukiwania "SensaGuard".

Table of Contents
Installation Instructions 3
Warnings 3
Technical Specification 3
Operating Characteristics 3
Outputs (internally fused) 3
Environmental 3
Protection 4
Dimensions 4
Mode of Operation 4
Status Indicators 4
Mounting Information 4
Nut Torque Specification 4
Minimum Distance Between Sensors 5
Misalignment Curve 5
Wiring Diagram 5
Recommended Mating Cable 5
Diagnostics 5
Troubleshooting 6
Application Wiring Examples 8
List of Recommended Relays 12
Maintenance 12
Repair 12
Declaration of Conformity 12

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 SensaGuardTM Installation Instructions 3

Installation Instructions
Installation must be in accordance with the following steps and stated specifications and should be
carried out by suitable competent personnel. The unit is not to be used as a mechanical stop. Guard
stops and guides must be fitted. Adherence to the recommended maintenance instructions forms part
of the warranty.

This device is intended to be part of the safety related control system of a machine. Before installation,
a risk assessment should be performed to determine whether the specifications of this device are suit-
able for all foreseeable operational and environmental characteristics of the machine to which it is to
be fitted. Refer to Technical Specifications for Certification information and ratings.

ATTENTION: The presence of spare actuators compromise the integrity of the safety sys-
tems. Personal injury or death, property damage or economic loss can result.
Appropriate management controls, working procedures and alternative protec-
tive measures should be introduced to control their use and availability.

Technical Specification
Safety Ratings
Standards IEC60947-5-3, IEC61508, ISO 13849-1
Safety Classification Cat. 4 Per ISO 13849-1, SIL CL3
PFHD: 1.12 x 10-9
Dual channel interlock may be suitable for
Functional Safety Data use in application up to PLe (according to
ISO 13849-1) and for use up to SIL3
systems (according to IEC 62061) depending
application characteristics.
Certifications CE marked for all applicable directives, cULus
(UL 508), and TV.

Operating Characteristics
Sensing Distance, Assured Make (mm) 15
Sensing Distance, Assured OFF (mm) 27
Typical misalignment See misalignment curve
Maximum output current (all
outputs, mA) 200
Input Current 50 mA (no load supply current)
Operational Current, Min. 1 mA DC
Off-state Current < 0.5 mA DC
Maximum # of switches, connected in series Unlimited. See unit response time section
Operating Voltage 24V DC +10% / -15%
Frequency of operating cycle 1 Hz
Response Time (Off) 54 ms first switch, 18 ms additional for each switch
Case Material Valox DR 48
Actuator Material Valox DR 48
Outputs (Guard door closed, Actuator in place)
Outputs Description Status
Safety 2 x PNP, 0.2 A max. ON (+24vdc)
Auxiliary 1 x PNP, 0.2 A max. OFF (0vdc)

Environmental
Operating Temperature -10+55C (+14+131F)
Operating Humidity 5% -95% relative
Washdown rating NEMA 3, 4X, 12,13, IP 69K
Shock & Vibration IEC68-2-27 30 g, 11 ms/IEC 68-2-6
1055Hz
Radio Frequency IEC 61000-4-3
IEC 61000-4-6

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4 SensaGuardTM Installation Instructions

Protection
Short-Circuit Protection Incorporated
Current limitation Incorporated
Overload Protection Incorporated
False Pulse Protection Incorporated
Transient Noise Protection Incorporated
Reverse Polarity Protection Incorporated
Overvoltage protection Incorporated
Thermal shutdown/restart Incorporated

Dimensions - mm (inches)
18.54
(0.73)
10.67
(0.42)
24.99 20.65 18.54 24.99 20.65 4.57
(0.984) (0.813) (0.73) (0.984) (0.813) (0.18)

88.14 68.31 77.98 88.14 57.96 82.55

(3.47) (2.689) (3.07) (3.47) (2.282) (3.25)
72.9 62.53
(2.87) (2.462)
77.98
(3.07)

10.66 4.57 4.57

(0.42) 5.08 (0.18) 5.08 (0.18)
( 0.2)) ( 0.2)
7.11
(0.28)
6.78
(0.267) 4.57
(0.18)
4.57
(0.18)

13.41
(0.528)

9.96 QD
(0.392) CONNECTOR
VERSION

M12 x 1

9.7
( 0.38)

Mode of Operation
Status indicators:
Status/Diag LED illuminates Green - Door/Guard closed, safety outputs active.
Status/Diag LED illuminates Red: - Door/Guard open, safety outputs off.
Status/Diag LED flashes Red or Green: - Unit failure. See Diagnostic section below.
Status/Diag LED flashes Amber when Sensor is approaching max. sensing distance.

Mounting Information
Use non-removable screws, bolts, or nuts to mount the switch and actuator. Do not over torque the
mounting hardware.
Position the switch and actuator so they are aligned with each other.
Mount the switch and actuator to removable guard, door or gate. Keep the switch and actuator within
the sensing range shown in the sensing/misalignment curve.

Nut Torque Specification

Switch/Actuator: 2.26 NM (20 inlbs)

Minimum Distance Between Sensors

200.00mm

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 SensaGuardTM Installation Instructions 5

Sensing/Misalignment Curve

SIDE
LOBES

ASSURED
SENSING
DISTANCE

SIDE
LOBES
0

10

15

20

25

30

35

Assured Make: 15mm

Assured OFF : 27mm
Sensing Distance (mm)

Note: There must be a minimum spacing of 9mm (0.35) if the actuator and sensor face approaches
laterally.This will prevent false triggering due to the side lobes areas.

Typical Wiring Diagram

Description Plastic
3-N/A 2-24V DC+
8-Safety A+
1-Aux A
8-Pin Micro (M12) 4-Safety B+
7-0V
5-Safety A
6-Safety B

Grey Safety A
Red Safety A+
Pink Safety B
8-Pin Cordset Yellow Safety B+
889D-F8AB-* White Aux A
or cable version Brown 24V DC+
Blue Gnd / 0V
Green N/A
* Replace symbol with 2 (2m), 5 (5m) or 10 (10m) for standard cable lengths.
Diagnostic
Unit Indicators (per IEC 60073)
State Status Troubleshooting
Off Not Powered NA
Status/Diag Red Not Safe, OSSD not active NA
LED Green Safe, OSSD active NA
Green flash Power up test or OSSD Check 24V DC or OSSD inputs
inputs not valid (yellow and red wire)
Red Flash 1 Hz Flash Recoverable Fault Recoverable fault check OSSD
4 Hz Flash Non-recoverable Fault outputs are not shorted to GND,
24V DC or each other. Cycle power.
Amber 1 Hz Flash margin indicator Sensor is reaching max. sensing
Flash safe, OSSD active distance; re-align sensor
with actuator

Note: Refer to Technical Specifications for Certification information and ratings.

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 6

Series Circuit

RTN
24VDC
Power
Troubleshooting

Supply+24
Actuator 1 Actuator 2 Actuator 3 Actuator 4 Actuator 5
1606
-XL120D

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Switch 1 Switch 2 Switch 3 Switch 4 Switch 5

Blu te Blu te Blu te Blu te Blu

e hi e hi e hi e hi e
W W W W

Yel
Yel
Yel
Yel

Yel
Red
Red
Red
Red

+24 V +24 V +0 V +0 V

White
Red
Pink
+0 V

Pink
Pink
Pink
Pink

Gray
Gray
Gray
Gray
Gray

Brown
Brown
Brown
Brown
Brown

+24 V +24 V +0 V +0 V +0 V
SensaGuardTM Installation Instructions

Actuator 1 is in sensing range. Actuator 2 is in sensing range. Actuator 4 is in sensing range. Actuator 5 is in sensing range. OSSDs are OFF
Actuator 3 is in sensing range.
Recoverable fault Switch Switch Switch Switch
Switch 4 is functioning properly
. 5 is functioning properl y .
1 is functioning properly 2 is functioning properly 3 has fault.
OSSDs are energize to 24 V OSSDs are energize to 24 V Series inputs are 0 V . Series inputs are 0 V .
See TableAboveRed LED is flashing OSSDs are de-energized to 0V . OSSDs are de-energized to 0V.
Green LED is ON. Green LED is ON.
Green LED is Flashing to indicate Green LED is Flashing to indicate

Note: Refer to Technical Specifications for Certification information and ratings.

Series inputs are not 24V. Series inputs are not 24V.
 RT
24V DC
Power +24
Supply
A1 S11 S52 S12 13 23 33 41
1606

e
e
Pink Red Pink

Blu

Blu
Blu
Gray Yel Gray
White White White 440R-N23127
Red Pink Red
Yel Gray

Sensor 1
Sensor 2
Sensor 3
Yel

Actuator 1
Actuator 2
Actuator 3
n n
Brown ow ow
Br Br S21 S22 S34 A2 14 24 34 42

Initial Conditions: Actuator 1 is moved out of Sensor 2 drops the 24 volts Sensor 3 drops the 24 volts
OFF All actuators are in sensing sensing range. (red and yellow) from Sensor 1 (red and yellow) from Sensor 2
distance. OSSD outputs. OSSD outputs.
Green LED flashes. Green LED flashes.

0 ms 54 ms 72 ms 90 ms
Unit Response Time (does not include safety relay response time)

Note: Refer to Technical Specifications for Certification information and ratings.

Actuator 1 is out of sensing Actuator 1 is moved into sensing Sensor 2 OSSD inputs (red and yellow) Sensor 3 OSSD inputs (red and
ON range. range. transition to 24V DC from Sensor 1 yellow) transition to 24V DC from
Actuator 2 and 3 are in Sensor 1 OSSD outputs are OSSD outputs. Sensor 2 OSSD outputs.
sensing range. energized. Sensor 2 OSSD outputs are energized Sensor 3 OSSD outputs are
energized.

0 ms 360 ms 378 ms 396 ms

SensaGuardTM Installation Instructions

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7
 8
+24V DC
+24V DC

SensaGuard SensaGuard SensaGuard SensaGuard

Unit 1 Unit 1 Unit 2 Unit 3

Red

Pink

Blue
Gray
Red
Red
Red

Yellow
Brown
Pink
Pink
Pink

Blue
Blue
Blue

Gray
Gray
Gray

Yellow
Yellow
Yellow

Brown
Brown
Brown
A1 S11 S52 S12 13 23 33 41
Reset A1 S11 S52 S12 13 23 33 41
Reset
MSR127RP MSR127RP
S21 S22 S34 A2 14 24 34 42 S21 S22 S34 A2 14 24 34 42

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K1 K2
K1 K2
GND GND
MSR127RP with 1 sensor, monitored manual reset, driving 100S or 700S safety controllers. MSR127RP with 3 sensors in series, monitored manual reset, driving 100S or 700S safety controllers
Application Wiring Examples

+24V DC
+24V DC
SensaGuard SensaGuard SensaGuard GuardShield
Unit 1 Unit 2 Unit 3 SensaGuard
Unit 1
SensaGuardTM Installation Instructions

Red
Red
Red

Pink
Pink
Pink
Pink

Blue
Blue
Blue
Blue

Gray
Gray
Gray
Gray
Red

Yellow
Yellow
Yellow

Brown
Brown
Brown
Brown
Pink

Blue
Gray
Yellow
Brown

Note: Refer to Technical Specifications for Certification information and ratings.

A1 S11 S52 S12 13 23 33 41 Reset A1 S11 S52 S12 13 23 33 41

MSR127RP
MSR127TP
S21 S22 S34 A2 14 24 34 42 S21 S22 S34 A2 14 24 34 42

K1 K2 K1 K2
GND GND
MSR127RP with 3 sensors and 1 440L light curtain in series, monitored manual reset, driving 100S or 700S safety relays. MSR127RP with 1 sensor, automatic reset, driving 100S or 700S safety controllers
Note: Light curtain must be last (farthest from MSR127).
 +24V DC
+24V DC

SensaGuard SensaGuard SensaGuard

SensaGuard SensaGuard SensaGuard GuardShield
Unit 1 Unit 2 Unit 3
Unit 1 Unit 2 Unit 3

Red
Red
Red

Pink
Pink
Pink
Pink

Blue
Blue
Blue
Blue

Gray
Gray
Gray
Gray

Yellow
Yellow
Yellow

Brown
Brown
Brown
Brown

Red
Red
Red

Pink
Pink
Pink

Blue
Blue
Blue

Gray
Gray
Gray

Yellow
Yellow
Yellow

Brown
Brown
Brown
Application Wiring Examples

A1 S11 S52 S12 13 23 33 41

A1 S11 S52 S12 13 23 33 41

MSR127TP
MSR127TP
S21 S22 S34 A2 14 24 34 42
S21 S22 S34 A2 14 24 34 42

K1 K2
K1 K2 GND
GND

Note: Refer to Technical Specifications for Certification information and ratings.

MSR127TP with 3 sensors and 1 440L light curtain in series, automatic reset, driving 100S or 700S safety contactors.
MSR127TP with 3 sensors in series, automatic reset, driving 100S or 700S relays. Note: Light curtain must be last (farthest from MSR127)
SensaGuardTM Installation Instructions

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9
 10
+24V DC

Red
Blue

Blue
Yellow

Brown
Brown
GuardShield SensaGuard
Pink Gray Pink Gray
S12 S20 S32 S12 S20 S32 S51 S11 S21 S31 S41 13 23 31 Y40 Y41 Y42 A1 S12 S20 S32 S32
440R-H23179 440R-H23177 440R-H23180

MSR221P MSR211P MSR230P

S42 S50 S62 S42 S50 S62 S34 Y1 Y2 Y3 14 24 32 Y32 Y33 Y30 A2 S42 S50 S62 S32
Pink Gray Pink Gray

SensaGuard SensaGuard K1 K2 K4

Red
Red

Blue
Blue

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Yellow
Yellow

Brown
Brown
K2 K1 K3
GND

MSR200 series with 3 sensors and 1 440L light curtain, automatic reset, driving 100S or 700S safety contactors.
Note: Light curtain can be attached to any input
Application Wiring Examples

+24V DC
SensaGuardTM Installation Instructions

Red
Blue

Blue
Yellow

Brown
Brown
GuardShield SensaGuard
Pink Gray Pink Gray

Note: Refer to Technical Specifications for Certification information and ratings.

S12 S20 S32 S12 S20 S32 S51 S11 S21 S31 S41 13 23 31 Y40 Y41 Y42 A1 S12 S20 S32 S32
440R-H23179 440R-H23177 440R-H23180

MSR221P MSR211P MSR230P

S42 S50 S62 S42 S50 S62 S34 Y1 Y2 Y3 14 24 32 Y32 Y33 Y30 A2 S42 S50 S62 S32
Pink Gray Pink Gray

SensaGuard SensaGuard K1 K2 K4

Red
Red

Blue
Blue

Yellow
Yellow

Brown
Brown
K2 K1 K3
Reset
GND

MSR200 series with 3 sensors and 1 440L light curtain, manual reset, driving 100S or 700S safety contactors.
Note: Light curtain can be attached to any input.
 +24V DC

Red
Red

Blue
Blue

Yellow
Yellow

Brown
Brown
SensaGuard SensaGuard
Pink Gray Pink Gray
S12 S20 S32 S12 S20 S32 S51 S11 S21 S31 S41 13 23 31 Y40 Y41 Y42 A1 S12 S20 S32 S32
440R-H23179 440R-H23177 440R-H23180

MSR221P MSR211P MSR230P

S42 S50 S62 S42 S50 S62 S34 Y1 Y2 Y3 14 24 32 Y32 Y33 Y30 A2 S42 S50 S62 S32
Pink Gray Pink Gray

SensaGuard SensaGuard K1 K2 K4

Red
Red

Blue
Blue

Yellow
Yellow

Brown
Brown
K2 K1 K3
GND

MSR200 series with 4 sensors, automatic reset, driving 100S or 700S safety contactors.
Application Wiring Examples

+24V DC

Red
Red

Blue
Blue

Yellow
Yellow

Brown
Brown
SensaGuard SensaGuard
Pink Gray Pink Gray
S12 S20 S32 S12 S20 S32 S51 S11 S21 S31 S41 13 23 31 Y40 Y41 Y42 A1 S12 S20 S32 S32

Note: Refer to Technical Specifications for Certification information and ratings.

440R-H23179 440R-H23177 440R-H23180

MSR221P MSR211P MSR230P

S42 S50 S62 S42 S50 S62 S34 Y1 Y2 Y3 14 24 32 Y32 Y33 Y30 A2 S42 S50 S62 S32
Pink Gray Pink Gray

SensaGuard SensaGuard K1 K2 K4

Red
Red

Blue
Blue

Yellow
Yellow

Brown
Brown
K2 K1 K3
SensaGuardTM Installation Instructions

Reset
GND

MSR200 series with 4 sensors, manual reset, driving 100S or 700S safety contactors.

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12 SensaGuardTM Installation Instructions

List of recommended relays

MSR126, MSR127, MSR123, MSR124, MSR131, MSR138, MSR211, MSR121, MSR200 Family
(Except MSR210), MSR300 Family, SmartGuard, 1791 DS DeviceNet Safety I/O.
Relay must have light curtain inputs.

Check the machine is

isolated and stopped
whenever the interlocked
guard door is open.
IMPORTANT: After
installation and
commissioning, the
actuator, switch and switch
lid fixing screws should be
coated with tamper evident
varnish or similar compound.

Maintenance
Monthly
Check the correct operation of the switching circuit. Also check for signs of abuse or tampering.
Inspect the switch casing for damage

Repair
If there is any malfunction or damage, no attempts at repair should be made. The unit should be
replaced before machine operation is allowed.

Declaration of Conformity
This is to declare that the products shown on this document conforms with the
Essential Health and Safety Requirements (EHSRs) of the European Machinery
Directive. These products also conform to EN 60947-5-3, EN 60204-1 and have
Third Party Approval.

For a comprehensive certificate please visit: www.ab.com/safety.

Copyright 2012 Rockwell Automation, Inc. All Rights Reserved.

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