TLS-GD2 Guard Locking Safety Switches Installation Instructions
Introduction and Safety Information
This document provides installation instructions and updates for the Rockwell Automation 440G TLS-GD2 Guard Locking Safety Switches. It is essential to follow these instructions carefully for safe and correct installation and operation.
⚠️ ATTENTION:
- Installation must be performed by suitably competent personnel in accordance with the steps and specifications provided.
- The unit is not to be used as a mechanical stop. Guard stops and guides must be fitted.
- Adherence to recommended maintenance instructions is part of the warranty.
- The presence of spare actuators can compromise the integrity of safety systems, potentially leading to personal injury or death, property damage, or economic loss. Appropriate management controls, working procedures, and alternative protective measures must be implemented to control their use and availability.
⚠️ WARNING:
- Do not defeat, tamper with, remove, or bypass this unit. Severe injury to personnel could result.
Note: The safety contacts of these products are normally closed (N.C.), meaning they are closed when the guard is closed, the actuator is in place, and the machine is ready to start.
Product Overview and Dimensions
The 440G TLS-GD2 series safety switches are designed for interlocking applications. The following diagrams illustrate the physical dimensions and mounting details.
Diagram showing overall dimensions: 126 mm (4.96 in) length, 105 mm (4.13 in) width, 43 mm (1.69 in) height. Various mounting hole details are also shown with dimensions in mm (inches), including M3 and M5 screw sizes.
Diagram showing mounting hole patterns and dimensions for different catalog numbers: 440G-A27011, 440K-A11112, 440G-A27143.
Installation and Wiring
Follow these steps for installation:
- Ensure the unit is installed by qualified personnel according to the instructions.
- Fit guard stops and guides.
- Connect wiring according to the diagrams and specifications.
Visual sequence of installation steps, showing how components are assembled and connected.
Override Covers
Instructions for fitting override covers are provided.
Diagram showing the process of fitting override covers.
Wiring and Monitoring
The switches support monitoring of safety contacts and solenoid feedback. The following configurations are detailed:
- Monitoring in Series: Available when jumpers are in place. Specific pins (4-6 on M23 for TLS1/2, 4-6 & 7-8 for TLS3) or wire colors (Pink-Yellow for TLS1/2, Pink-Yellow & White-Red/Blue for TLS3) on the 12-pin cord set are used.
- Independent Monitoring: Requires the 12-wire cord set 889M-F12AH-*. Jumpers must be removed: between 12-41 for TLS1/2, and between 12-41 & 22-51 for TLS3.
Diagrams illustrating the wiring configurations and jumper settings for monitoring.
Wiring Diagrams
Detailed pinout diagrams are provided for different models:
- TLS-1 GD2 and TLS-2 GD2: Shows connections for 8-pin M12 and 12-pin M23 connectors, including safety contacts, solenoid power, and auxiliary contacts.
- TLS-3 GD2: Shows connections for 8-pin M12 and 12-pin M23 connectors, including safety contacts, solenoid power, and auxiliary contacts.
Diagrams illustrating the pin assignments for TLS-1, TLS-2, and TLS-3 models using 8-pin M12 and 12-pin M23 connectors. Specific terminals are labeled (e.g., A1, A2, 1-12, 21-22, 33-34, 41-42, 51-52, 53-54).
Jumper Configurations:
- Jumper on 12-41 (for TLS1/2)
- Jumper on 12-41 and 22-51 (for TLS3)
Technical Specifications
The following tables detail the technical specifications for the 440G series safety switches.
Updated Specifications (Page 6)
| Switch | Fmax | Fzh | Switching Current/Voltage | Contact Rating | Maximum Input |
|---|---|---|---|---|---|
| 440G-TLS* Plastic Pins 1 | 1950 N (488 lb) | 1500 N (337 lb) | A300 / AC-15 240V/3A, 120V/6A N150/DC-13 125V/2.2A | 2500V | 240V |
| 440G-TLS* Steel Bolts 2 | 2600 N (585 lb) | 2000 N (450 lb) | |||
| 440G-MT | 1950 N (488 lb) | 1500 N (337 lb) | 3 mA/18V, minimum 4 | M12 QD: D150/R150 30V DC/2 A M23 QD: B150/P150 63V DC/6 A | 30V 63V |
| 440G-L Atlas | 5000 N (1124 lb) | 3850 N (865 lb) | |||
| 440G-S Spartan | 1000 N (225 lb) | 770 N (173 lb) | |||
| 440G-TLSZ* Plastic Pins | 1950 N (488 lb) | 1500 N (337 lb) | 0.2 A/24V DC, maximum 5 | 2 x PNP, ON +24V DC, OFF 0V DC | 24V DC |
| 440G-TLSZ* Steel Bolts | 2600 N (585 lb) | 2000 N (450 lb) | |||
| 440G-LZ | 1690 N (380 lb) | 1300 N (292 lb) |
1 Plastic Pins, 2 Steel Bolts, 3 Switching Current/Voltage, 4 Minimum, 5 Maximum, 6 Contact Rating, 7 Maximum Input
General Specifications (Page 4)
| Parameter | English | Deutsch | Español | Français | Italiano |
|---|---|---|---|---|---|
| Safety Contacts | 2 N.C. + 1 N.C. direct opening action (TLS-1, TLS-2) 2 N.C. + 2 N.C. direct opening action (TLS-3) | 2 N.C. + 1 N.C. direkte Öffnung (TLS-1, TLS-2) 2 N.C. + 2 N.C. direkte Öffnung (TLS-3) | 2 N.C. + 1 N.C. acción de apertura directa (TLS-1, TLS-2) 2 N.C. + 2 N.C. acción de apertura directa (TLS-3) | 2 N.C. + 1 N.C. ouverture directe (TLS-1, TLS-2) 2 N.C. + 2 N.C. ouverture directe (TLS-3) | 2 N.C. + 1 N.C. ad azione diretta di apertura (TLS-1, TLS-2) 2 N.C. + 2 N.C. ad azione diretta di apertura (TLS-3) |
| Rated impulse withstand voltage UIMP | 2500V | 2500V | 2500V | 2500V | 2500V |
| Thermal Current | 10 A | 10 A | 10 A | 10 A | 10 A |
| Current, Min. | 5V 5 mA dc | 5V 5 mA dc | 5V 5 mA c.c. | 5V 5 mA cc | 5V 5 mA c.c. |
| Auxiliary Contacts | 1 N.O. + 1 N.O. (TLS-1, TLS-2) 1 N.O. (TLS-3) | 1 N.O. + 1 N.O. (TLS-1, TLS-2) 1 N.O. (TLS-3) | 1 N.O. + 1 N.O. (TLS-1, TLS-2) 1 N.O. (TLS-3) | 1 N.O. + 1 N.O. (TLS-1, TLS-2) 1 N.O. (TLS-3) | 1 N.O. + 1 N.O. (TLS-1, TLS-2) 1 N.O. (TLS-3) |
| Break Contact Force, Min | 30N (7lb) | 30N (7lb) | 30N (7lb) | 30N (7lb) | 30N (7lb) |
| Force F2 to IEC 60947-5-1, K.8.3.7 | 50N (11lb) | 50N (11lb) | 50N (11lb) | 50N (11lb) | 50N (11lb) |
| Actuator Holding Force, Max. | 2000 N (450 lb) | 2000 N (450 lb) | 2000 N (450 lb) | 2000 N | 2000 N |
| Actuation Speed, Max. | 160 mm (6.29 in) per second | 160 mm (6.29 Zoll) pro Sekunde | 160 mm (6.29 in) por segundo | 160 mm/s | 160 mm per secondo |
| Actuation Speed, Min. | 100 mm (3.94 in) per minute | 100 mm (3.94 Zoll) pro Minute | 100 mm (3.94 in) por minuto | 100 mm/mn | 100 mm per minuto |
| Ingress Protection Rating | IP67, IP69K * | IP67, IP69K * | IP67, IP69K * | IP67, IP69K * | IP67, IP69K * |
| Operating Temperature | (-20 °C...+60 °C), (-4 °F...+140 °F) | (-20 °C...+60 °C), (-4 °F...+140 °F) | (-20 °C...+60 °C), (-4 °F...+140 °F) | (-20 °C...+60 °C) | (-20 °C...+60 °C) |
| Mechanical Life | 1,000,000 operations | 1.000.000 Betätigungen | 1,000,000 operaciones | 1,000,000 operations | 1.000.000 di funzionamenti |
| Electrical Life | 1,000,000 operations | 1.000.000 Betätigungen | 1,000,000 operaciones | 1,000,000 operations | 1.000.000 di funzionamenti |
| Torque Settings, Max. | 1.4 Nm (12.39 lb-in) fixing bolts 1.2 Nm (10.62 lb-in) lid screws 1.0 Nm (8.8 lb-in) terminal screws 0.8 Nm (7.08 lb-in) terminal block screws | 1.4 N•m (12.39 lb-in) Befestigungsschrauben 1.2 N•m (10.62 lb-in) Deckelschrauben 1.0 N•m (8.8 lb-in) Klemmenschrauben 0.8 N•m (7.08 lb-in) Kopfbolzen | 1.4 Nm (12.39 lb-in) tornillos de sujeción 1.2 Nm (10.62 lb-in) tornillos de la tapa 1.0 Nm (8.8 lb-in) tornillos terminales 0.8 Nm (7.08 lb-in) pernos de cabezales | 1.4 N•m 1.2 N•m 1.0 N•m 0.8 N•m | 1.4 Nom per i bulloni di fissaggio 1.2 Nom per le viti del coperchio 1.0 N•m per le viti dei morsetti 0.8 N•m per i bulloni della testa |
| Lock Type | Power to Release (TLS-1, TLS-3) Power to Lock (TLS-2) | Strom für Freigabe (TLS-1, TLS-3) Strom für Verriegelung (TLS-2) | De liberación eléctrica (TLS-1, TLS-3) De bloqueo eléctrico (TLS-2) | Ouverture à l'alimentation (TLS-1, TLS-3) Verrouillage à l'alimentation (TLS-2) | Potenza di rilascio (TLS-1, TLS-3) Potenza di bloccaggio (TLS-2) |
| Power supply | 24V ac/dc or 110V ac or 230V ac | 24V AC/DC oder 110V AC oder 230V AC | 24V ca/cc o 110V ca o 230V ca | 24 V ca/cc ou 110 V ca ou 230 V cc | 24V c.a./c.c. o 110V c.a. o 230V c.a. |
| Pollution degree | 3 | 3 | 3 | 3 | 3 |
Maintenance and Repair
Maintenance Schedule
- Weekly: Check correct operation of the switching circuit. Inspect for signs of abuse or tampering. Inspect switch casing for damage, especially at lid or conduit entry seals.
- At least every 6 months: Isolate all power. Remove lid. Inspect terminals for tightness. Clean out dirt accumulation. Check for wear or damage (e.g., cam assembly, contact oxidation) and replace if apparent. Replace covers, tighten screws to specified settings. Restore power and check operation. Re-apply tamper-evident varnish to fixings.
Repair
If there is any malfunction or damage, no attempts at repair should be made. The unit must be replaced before machine operation is allowed. DO NOT DISMANTLE THE UNIT.
Compliance and Usage Information
ISO 14119 Compliance Update
This supplement provides information needed for ISO 14119 compliance, replacing EN 1088 as the harmonized standard for interlocking devices. It also updates specifications, warnings, and application information.
Intended Use
| Product | Guard Locks Position Detection | Actuator Inserted into Switch |
|---|---|---|
| 440G-L, -MT, -S, -T | Yes | Yes |
| 440G-TLSZ | Yes | Yes |
| 440G-LZ Coded RFID actuator | Yes | Yes |
ISO 14119 Coding Types
ISO 14119 defines types of interlocking devices and coding. The following table outlines the coding levels:
| Product Type | Low | High |
|---|---|---|
| 440G-L, -MT, -S, -T | 2 | 4 |
| 440G-TLSZ | 2 | 4 |
| 440G-LZ | 4 | 5 |
UL508 Information
When used in elevated ambients, the temperature rating of field wiring shall not be less than ambient. Use copper conductors only. Use polymeric conduit only. Use one conduit entrance for field connections.
ATTENTION:
Discard the plastic transit plugs (shipped with select conduit models only) at installation and replace with UL Listed outlet box plugs or the equivalent.
Additional Safety Information
Improper selection or installation of these devices affects the integrity of safety systems and can result in personnel injury or death, property damage, or economic loss.
Comply with the following standards:
- ISO 14119 (selection, accessibility, arrangement, fastening, substitute actuation, escape release, motivation to defeat, actuation mode)
- ISO 13857 and ISO 13855 (guard openings and minimum safe distances)
- IEC 62061 or ISO 13849-1 and ISO 13849-2 (functional safety)
Management controls, working procedures, training, and additional protective measures should be used to minimize the motivation to defeat and to manage the use and availability of spare actuators.
