Technical Data · Publication SWITCH-TD001 · Rockwell Automation
Allen-Bradley Guardmaster Safety Switches — Specifications (Bulletins 440G, 440H, 440K, 440N, 440P, 440T, 442G)
Complete specifications for the Allen-Bradley Guardmaster safety switch family covering guard locking, hinge, non-contact interlock, tongue interlock, trapped key, and multifunctional access box products. Includes solid-state OSSD and voltage-free electromechanical designs rated up to SIL 3 / PLe / Cat 4, with GuardLink, CIP Safety over EtherNet/IP, and standard safety-relay compatibility. Mirrored from Rockwell Automation Publication SWITCH-TD001H-EN-P, August 2025.
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Specifications
Safety Performance
| Top safety rating | SIL 3 / PLe / Category 4 (440G-MZ, TLS-Z GD2, SensaGuard, 442G) |
|---|---|
| Interlock classification | ISO 14119 Type 2 (tongue) and Type 4 (RFID/non-contact) |
| Coding levels | Low-coded (standard) and high-coded (unique) RFID per ISO 14119 |
| Functional safety standards | ISO 13849-1, IEC 62061, IEC 61508, IEC 60947-5-3 |
| Typical B10d (electromechanical) | > 2 x 10^6 operations at minimum load |
| Typical PFH_D (hinge) | < 3 x 10^-7 (MTTFd > 385 years) |
| 442G with CIP Safety MTTFd | 475 – 787 years depending on safety function |
| Mission time / Proof test interval | 20 years (PTI = 20 yr for trapped key) |
Electrical
| Operating voltage (solid-state) | 24V DC +10% / -15% Class 2 PELV / SELV |
|---|---|
| Operating voltage (electromechanical) | Up to 600V AC (A600/AC-15) or 690V (trapped key rotary) |
| Safety output (OSSD models) | 2 x PNP, 0.2 A max, ON = +24V DC |
| Auxiliary output (OSSD) | 1 x PNP, 0.2 A max, OFF = 0V DC |
| DC-13 utilization category | 24V DC, 200 mA (typical); 2 A (440G-MT) |
| AC-15 rating (electromechanical) | 6 A @ 120V, 3 A @ 240V, 1.4 A @ 500V, 1.2 A @ 600V |
| Trapped key current ratings | 20 A / 32 A / 63 A / 100 A (AC-23A) |
| Rated insulation voltage Ui | 75V (OSSD) / 500V (electromechanical) / 690V (trapped key) |
| Impulse withstand voltage Uimp | 1 kV (OSSD); 6 kV (trapped key rotary) |
Mechanical (Actuator, Holding Force, Life)
| Holding force Fmax — 440G-MZ | 3250 N (per ISO 14119) |
|---|---|
| Holding force Fzh — 440G-MZ | 2500 N (per ISO 14119) |
| Holding force Fzh — 440G-LZ | 1300 N (Fmax 1690 N) |
| Holding force Fzh — TLS-Z / TLS-GD2 | 2000 N / 450 lbf (steel bolts); 1500 N plastic pins |
| Holding force Fzh — 440G-MT | 1500 N / 337 lbf |
| Holding force — 442G MAB | Fzh = 2000 N; Locking force Fmax = 2600 N |
| Actuator alignment tolerance | ±5 mm (440G-MZ); ±2.5 mm (440G-LZ) |
| Mechanical life — solid-state | 500,000 – 1,000,000 cycles |
| Mechanical life — trapped key | 200,000 operations |
| Shear force to key (trapped key) | 15.1 kN (3394.62 lbf) |
| Actuation speed, max | 160 mm/s (6.29 in/s) typical |
Environmental
| Operating temperature (OSSD) | 0…55 °C (440G-MZ); -10…+60 °C (TLS-Z); -20…+60 (TLS-GD2) |
|---|---|
| Operating temperature (hinge) | -20…+80 °C (-4…+176 °F) |
| Operating temperature (442G CIP Safety) | -20…+55 °C (-4…+131 °F) |
| Storage temperature | -25…+75 °C (-13…+167 °F) |
| Enclosure rating | IP65, IP66, IP67, IP69, IP69K (440G-MZ, TLS-Z, SensaGuard) |
| Enclosure rating (hinge) | IP66 (Rotacam) / IP67 (Sprite, Ensign 3) |
| Shock and vibration | IEC 60068-2-27 (30 g, 11 ms); IEC 60068-2-6 (10…55 Hz, 1 mm) |
| Washdown / hygienic | ISO 14159:2004 + EN 1672-2005 food-splash area (440G-LZ) |
| Relative humidity | 5…95% noncondensing |
Safety Outputs & Contact Configuration
| Solid-state OSSD (440G-MZ, LZ, TLS-Z) | 2 x PNP safety + 1 x PNP auxiliary, short-circuit protected |
|---|---|
| Contact configuration — TLS-1 GD2 | 2 N.C. safety + 1 N.O. aux + 1 N.C./1 N.O. for lock monitoring |
| Contact configuration — TLS-3 GD2 | 2 N.C. safety + 1 N.O. aux + 2 N.C. for lock monitoring |
| Direct opening action | All electromechanical safety contacts (positive break) |
| Thermal current Ith | 10 A (electromechanical); 100 A isolation (trapped key rotary) |
| Response time (off) | 275 ms (440G-MZ); 100 ms first + 50 ms per switch (440G-LZ) |
| 442G CIP Safety risk times | E-stop 100 ms / guard 250 ms / guard lock 250 ms |
| Diagnostic indicators | Two bright 270° DEVICE + LINK status indicators (440G-MZ/LZ) |
Catalog Number Format
How to read an Allen-Bradley 440G, 440H, 440K, 440N, 440P, 440T, 442G catalog number. Each position encodes a specific configuration attribute.
Position
Meaning
Example
440G-MZ / 440G-LZ (solid-state guard locking)
440G-MZS20<coding><aux><lock><conn><feat> — e.g., 440G-MZS20SNRJE
20=two safety/no aux; S=standard coded; U=unique coded; N=no aux; R=Power to Release; L=Power to Lock; J=M12 5-pin; E=escape release
TLS-GD2 family (electromechanical guard locking)
440G-T<model><coding>-<seq> — TLS-1/2/3 designates contact config and lock type
TLS-1 = 2 N.C. safety + 1 N.O. aux + 1 N.C./1 N.O. lock; TLS-2 = Power to Lock; TLS-3 = extra N.C. lock monitor
440G-MT (heavy-duty guard locking solenoid)
440G-MT<nnnnn> catalog digits encode solenoid voltage, contacts, and actuator type
440G-MT47037 = 24V AC/DC, 3 N.C./1 N.O., GD2 standard actuator, M20 conduit
440H hinge interlocks (Sprite, Ensign 3)
440H-S / 440H-E prefix + shaft length (80/60/50/30 mm) + connector type
440H-S34019 = Sprite 80x10mm solid shaft, M16 conduit; 440H-E22037 = Ensign 3 pre-bored 2 N.C./1 N.O. BBM, 6-pin M12
440T trapped key (rotary, solenoid, bolt, timed)
440T-<family><contacts><rating> — MRKSE=rotary enclosure, RPSE=panel rotary, MSRUE=solenoid release, MSBLE=bolt, MSTUE=timed-delay
440T-MRKSE10x = 4 N.O. 20 A rotary enclosed; 440T-MSRUE12x = solenoid release 24V DC 32 A; 440T-MKEXE22 = 9-way key exchange
442G (multifunctional access box)
442G-MAB<lock><hand>-<controls> — R=Power to Release, L=Power to Lock; UR=right-hand, UL=left-hand; P49/EOP49/EOJP4679 = control suite
442G-MABRB-UR-EOP49 = Power to Release, right-hand, E-stop + two push buttons; CIP Safety variants add P49 suffix
Communication Protocols
Supported industrial networks and field buses for the products covered by this publication.
GuardLink Embedded on 440G-MZ; passive tap 440S-PF5D connects to 440R-ENETR + 440R-DG2R2T
CIP Safety over EtherNet/IP 442G Multi-functional Access Box with CIP Safety (PLe/Cat 4); Studio 5000 Add-on Profile
Device Level Ring (DLR) Supported on 442G CIP Safety for network resiliency (no CIP Sync / Motion)
Standard safety relay / Safety I/O OSSD and voltage-free contacts work with MSR126, MSR127, SmartGuard, ArmorBlock Guard I/O
ArmorBlock Guard I/O (5-pin M12) 440H-S2NNPPS / 440H-S2NNHPS direct-connect variants for hinge switches
M12 connectivity options 4-pin (2 N.C.), 5-pin (OSSD + GuardLink), 6-pin (3 N.C.), 8-pin (safety + aux + solenoid)
M23 12-pin / 19-pin TLS-GD2 12-pin wiring; 442G 19-pin cordset 889M-F19RM-2
Certifications & Compliance
SIL 3 / PLe / Cat 4 per ISO 13849-1 and IEC 62061 (top-of-line)
ISO 14119 Type 2 and Type 4 interlocking devices (low + high coding)
IEC 60947-5-1 (voltage-free contacts) and IEC 60947-5-3 (OSSD)
IEC 61508 functional safety
CE marked for all applicable EU directives
UKCA marked for all applicable UK regulations
cULus Listed (UL 508); some models cULus Listed to NFPA 79 applications
TÜV Certified (functional safety approval)
NRTL/C (hinge switches), SUVA (Rotacam)
ISO 14159:2004 + EN 1672-2005 hygienic design (440G-LZ food-splash)
RCM (Australian / New Zealand EMC)
RoHS compliant
Document Contents
Full PDF covers the following topics in detail:
- Introduction and summary of changes (Publication SWITCH-TD001H, August 2025)
- Guard Locking Switches — Solid-state OSSD: 440G-MZ (2500 N, GuardLink, IP69K), 440G-LZ (1300 N, hygienic), TLS-Z GD2 (2000 N, RFID)
- Guard Locking Switches — Electromechanical: TLS-GD2 (voltage-free, IP69K), 440G-MT (heavy-duty zinc), Atlas 5, 440G-S Spartan
- Hinge Switches: Sprite miniature (75x25 mm), Ensign 3 (90.5x31 mm), Rotacam heavy-duty die-cast
- Electromagnetic Safety Switches: 440G-EZ with Power to Lock for process protection (500 N holding, 25 N retaining)
- Non-contact Interlock Switches: SensaGuard RFID (SIL 3 / Cat 4 unique coded), Ferrogard magnetic 1/2/3/4/5/6/9/10/13/14/20/21, Sipha, MT-GD2
- Compact Safety Limit Switches: 1/2 N.C. 22 mm metal + plastic body, 30 mm DIN 50041 IEC style, 4-pin + 5-pin M12 variants
- Interlocking Switches — Electromechanical: Elf tongue, Cadet 3 tongue, Trojan T15, Trojan 5 and 6 universal tongue, MT-GD2 tongue
- Trapped Key Interlock Switches: Rotary (RKSE panel / RPSE enclosed, up to 100 A), Solenoid Release Units, Electronic Timed-delay (0.1 s – 30 min), Key Exchange (2…25 way), Bolt Interlocks, Prosafe Slamlock, Switchgear Adapters
- Multifunctional Access Box: 442G-MAB standard + 442G-MAB with CIP Safety over EtherNet/IP (DLR, Add-on Profile)
- Typical wiring diagrams, pin assignments (4/5/6/8-pin M12, 12-pin M23, 19-pin M23), and approximate dimensions for every family
- Product selection tables, accessories (actuators, brackets, override keys, dust covers), and connection system cordsets
Frequently Asked Questions
What's the difference between a 440G and a 440K safety switch?
In the current Guardmaster line, 440G is the bulletin prefix for guard locking safety switches (both solid-state OSSD families such as 440G-MZ, 440G-LZ, and TLS-Z GD2, and electromechanical families such as TLS-GD2, 440G-MT, and 440G-S). 440K is reserved for non-locking interlock and limit-switch accessories (actuators, covers, dust caps) that share components with the 440G family. If you need to physically hold a guard shut until a machine is safe (high inertia, pneumatic release), you want a 440G. If you only need to monitor door position, a 440H hinge, 440N non-contact, or 440K limit switch is sufficient.
Which Guardmaster safety switches are CIP Safety compatible?
The 442G Multi-functional Access Box with CIP Safety is the only device in SWITCH-TD001H that natively speaks CIP Safety over EtherNet/IP. It's rated PLe / Cat 4, supports Device Level Ring (DLR) topology for network resiliency, and integrates into Studio 5000 Logix Designer via an Add-on Profile. Note it does not support CIP Sync / CIP Motion, and should not share a DLR with multi-cast I/O devices. All other Guardmaster switches connect either through GuardLink taps (440G-MZ), standard safety relays (MSR series), or ArmorBlock Guard I/O using hardwired OSSD or voltage-free contacts.
What is the holding force of the 440G-MZ, and how does it compare to the 440G-MT?
The 440G-MZ solid-state guard locking switch delivers Fzh = 2500 N (562 lbf) per ISO 14119, with Fmax = 3250 N. It's the highest holding force in the OSSD guard-locking line and is rated SIL 3 / PLe / Cat 4. The 440G-MT heavy-duty electromechanical solenoid switch is rated Fzh = 1500 N (337 lbf) with Fmax = 1600 N. Choose the 440G-MT when you need a die-cast zinc alloy housing for harsh environments with voltage-free contacts; choose the 440G-MZ when you need higher holding force plus GuardLink diagnostics.
When should I use a locking vs. non-locking safety switch?
Use a guard locking switch (440G, 442G, TLS) whenever the hazard does not stop immediately after a stop request — high-inertia rotating machines, fast rotating machines, and machines where high-pressure pneumatics must be released before the guard can safely open. The locking mechanism physically holds the guard closed until the machine is safe. Use a non-locking interlock (440H hinge, 440N SensaGuard / Ferrogard non-contact, Trojan / Cadet / Elf tongue) when the hazard disappears as soon as power is removed — no need to trap a person out during coast-down.
What's the difference between Power to Release and Power to Lock models?
Power to Release (R suffix in 440G-MZ / TLS-1 GD2 / 440G-MT) means the solenoid must be energized to unlock the guard — fail-safe: a power loss keeps the guard locked. Power to Lock (L suffix in 440G-MZS20*L*, TLS-2 GD2) requires power to engage the lock — fail-unlocked: a power loss releases the guard. Risk assessment drives the choice. Rockwell defaults to Power to Release for the vast majority of applications because it holds the guard shut through power anomalies.
Can the TLS-GD2 be used without a PLC or safety relay?
The TLS-GD2 is an electromechanical switch with voltage-free contacts (2 N.C. safety + 1 N.O. auxiliary + lock monitoring), so it must be wired to a safety-rated logic device — a Guardmaster MSR safety relay (MSR126/127), a SmartGuard controller, a GuardLogix safety task, or an equivalent safety PLC — to achieve its SIL 3 / PLe rating. Direct wiring to a contactor coil is allowed for single-channel non-safety applications, but that defeats the safety rating. The TLS-Z GD2 solid state variant outputs OSSD pulses that connect directly to safety I/O.
What IP rating do I need for washdown environments?
For food-and-beverage and pharma washdown, SWITCH-TD001H recommends IP69K-rated switches: the 440G-MZ (IP65/66/67/69/69K), 440G-LZ (IP69k with hygienic ISO 14159 / EN 1672 compliance and sodium-hydroxide washdown fluid compatibility), SensaGuard stainless-steel non-contact variants, and TLS-GD2 (IP66/67/69K). The 440G-LZ is the go-to for food-splash zones because it's explicitly qualified against the hygienic design standards, not just the IP rating.
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