The Allen Bradley 440G-TZS21UPRH represents the pinnacle of industrial safety interlock technology, belonging to the renowned Guardmaster TLS-Z GD2 series. This power-to-release guard locking switch combines advanced RFID coding with robust mechanical design to deliver uncompromising personnel protection in demanding manufacturing environments. As industries worldwide tighten safety standards and pursue higher Performance Levels (PL), this switch emerges as a critical component for machinery guarding applications requiring Category 4 / PLe / SIL 3 safety architectures.
Technical Specifications Matrix
The 440G-TZS21UPRH specifications establish benchmarks for industrial safety interlock performance. Understanding these technical parameters enables engineers to specify and integrate this switch correctly within safety control systems.
| Parameter | Specification |
|---|---|
| Manufacturer | Allen Bradley (Rockwell Automation) |
| Series / Family | 440G TLS-Z GD2 Guard Locking Switch |
| Part Number | 440G-TZS21UPRH |
| Operation Type | Power to Release (断电释放) |
| Solenoid Voltage | 24V AC/DC |
| Safety Contacts | 2 × PNP N.C. (0.2A max) |
| Auxiliary Contacts | 1 × PNP N.O. (Lock Status, 0.2A max) |
| Actuator Type | Fully-Flex (440G-A27143) |
| Holding Force | 2000N (450 lbs) |
| Connection Type | 8-Pin Micro (M12) Quick Disconnect |
| Housing Material | Glass-filled PBT (UL approved plastic) |
| Enclosure Rating | IP66, IP67, IP69K |
| Dimensions (L×W×D) | 92mm × 39mm × 126mm |
| Operating Temperature | -10°C to +60°C (+14°F to +140°F) |
| Safety Classification | PLe, Category 4, SIL 3 |
| Certifications | CE, cULus, CCC, TÜV, C-TICK, KC |
Advanced Safety Features
The 440G-TZS21UPRH incorporates multiple layers of protection that distinguish it from conventional safety interlocks. The embedded RFID uniquely coded door target provides superior reliability compared to standard magnetic or mechanical actuators. This technology prevents defeat through external magnets or unauthorized actuator duplication, addressing the ISO 14119 requirement for tamper-resistant guard monitoring.
The switch utilizes two-channel solid-state OSSD (Output Signal Switching Device) outputs that connect directly to ISO 14119 compliant safety controllers. The OSSD outputs undergo continuous pulse testing approximately every 45 milliseconds, enabling the safety relay to detect wiring faults including shorts to ground, shorts to 24V, or cross-channel shorts. This diagnostic capability ensures that single faults cannot silently defeat the safety function.
The fully-flexible actuator design accommodates misalignment and vibration common in industrial environments, particularly with sliding or hinged guard doors that may sag over time. The stainless-steel actuator guide protects against damage from poor door alignment, significantly extending service life in harsh manufacturing conditions.
Compatibility and Integration Analysis
The 440G-TZS21UPRH integrates seamlessly with Rockwell Automation’s comprehensive safety ecosystem. The following table outlines compatible safety relays and controllers:
| Category | Compatible Products |
|---|---|
| Guardmaster Safety Relays | 440R-D22R2, 440R-D22S2, 440R-S12R2, 440R-S13R2, 440R-GL4S2P, 440R-GL4S2T |
| MSR Series Relays | MSR57, MSR126, MSR127, MSR131, MSR138, MSR211, MSR320 |
| Safety Controllers | SmartGuard 600, Safety PLC I/O (1756-L7xS, 1769-LxxERMS) |
| Safety I/O Modules | 1734-IB8S, 1734-OB8S |
| Kinetix Safety Drives | 2198-xxx-ERS2, 2918-xxxx-ERS3 |
M12 Connection Pinout
The 8-pin M12 quick-disconnect simplifies wiring and enables rapid switch replacement during maintenance. The following pin configuration applies:
| Pin | Wire Color | Function |
|---|---|---|
| 1 | White | Auxiliary Output (Lock Status) |
| 2 | Brown | 24V DC+ (Power Supply) |
| 3 | Green | Lock Command |
| 4 | Yellow | Safety B+ (OSSD Input) |
| 5 | Gray | Safety A (OSSD Output) |
| 6 | Pink | Safety B (OSSD Output) |
| 7 | Blue | Ground/0V |
| 8 | Red | Safety A+ (OSSD Input) |
Application Scenarios and Industry Use Cases
The 440G-TZS21UPRH serves critical safety functions across diverse industrial sectors. Understanding the optimal application scenarios helps engineers and plant managers select the appropriate guard locking solution.
Food and Beverage Industry
With its IP69K rating, the TLS-Z GD2 switch withstands high-pressure washdown and chemical cleaning procedures essential in food processing environments. The corrosion-resistant glass-filled PBT housing maintains integrity through repeated sanitation cycles, while the RFID-coded actuator prevents tampering that could compromise hygiene safety. Packaging machines, filling lines, and conveyor systems benefit significantly from this switch’s reliability.
Pharmaceutical Manufacturing
Cleanroom requirements demand switches that eliminate particle generation and withstand gamma radiation sterilization. The 440G-TZS21UPRH’s sealed construction prevents contamination, and its compliance with international pharmaceutical safety standards (IEC 61508, ISO 13849-1) satisfies regulatory requirements for validated manufacturing processes.
Semiconductor Fabrication
The IP67 rating protects against moisture and particulate contamination in semiconductor cleanrooms. The switch’s fast response time and diagnostic capabilities support the tight process control required in wafer fabrication facilities, where unexpected equipment access can compromise expensive batches.
Heavy Machinery and Presses
Machines with high inertia or stored energy—hydraulic presses, power presses, CNC machining centers—require guard locking that maintains protection until dangerous motion ceases completely. The 2000N holding force ensures guards remain secured even under significant mechanical stress, while the power-to-release configuration provides fail-safe operation.
Robotic Work Cells
Collaborative robot applications require sophisticated safety monitoring that coordinates guard status with robot speed and mode changes. The 440G-TZS21UPRH’s auxiliary output provides real-time lock status feedback to the robot controller, enabling safe speed and separation monitoring functions per ISO 10218-2.
Power-to-Release vs Power-to-Lock: Making the Right Choice
The 440G-TZS21UPRH operates on the power-to-release principle, meaning the guard unlocks when energized and remains locked during power loss. This configuration provides inherent fail-safe behavior—the guard cannot remain locked if power fails or is interrupted. For most personnel protection applications, power-to-release is the recommended approach per EN ISO 14119 and IEC 60947-5-3.
Consider the alternative 440G-TZS21UPLH (power-to-lock) only after a comprehensive risk assessment demonstrates that power-to-release creates greater hazards—for example, in applications where unexpected guard release could cause product damage or process disruption rather than personnel injury.
Competitive Model Comparison
When evaluating the 440G-TZS21UPRH against alternatives, consider the following comparison with similar products from leading manufacturers:
| Feature | 440G-TZS21UPRH | Schmersal AZM400 | Pilz PSENmlock |
|---|---|---|---|
| Holding Force | 2000N | 10,000N | 7500N |
| Safety Level | PLe / SIL 3 | PLe / SIL 3 | PLe / SIL 3 |
| Coding Method | RFID Unique | Transponder | RFID |
| IP Rating | IP69K | IP67 | IP67 |
| Connection | M12 8-pin QD | M23 / Cable | M12 / M23 |
| Diagnostics | OSSD + Aux | OSSD + Status | OSSD + Door |
While competitors offer higher holding forces suitable for heavy press and stamping applications, the 440G-TZS21UPRH excels in washdown environments and integrates optimally within Allen Bradley/rockwell Automation control architectures.
Installation Best Practices
Proper installation ensures the 440G-TZS21UPRH delivers its designed safety performance throughout its operational life. Follow these essential guidelines:
- Mechanical Mounting: Use non-removable fasteners (tamper-proof screws) to secure the switch and actuator. Apply tamper-evident varnish to mounting screws after commissioning. Position guard stops to prevent overtravel that could damage the switch body.
- Environmental Protection: Verify that conduit entries use appropriate IP-rated fittings. Apply thread sealant to threaded entries in washdown applications. Ensure the rotatable head’s unused actuator slot uses the provided blanking plug.
- Wiring Integrity: Route wiring through protected conduits to prevent damage from moving guards or production equipment. Use the specified 8-pin M12 cordset (889D-F8AB-x) for reliable connections. Maintain wire segregation between safety circuits and auxiliary outputs.
- Functional Testing: Verify correct operation after installation—confirm that the guard cannot open without unlock signal, OSSD outputs energize when locked, and auxiliary status reflects actual lock condition. Document test results for safety compliance records.
Maintenance Requirements
The 440G-TZS21UPRH requires minimal maintenance when installed correctly, but regular inspection extends service life and ensures continued safety performance:
- Weekly Inspections: Check for signs of abuse, missing screws, or damage affecting sealing integrity. Verify guard alignment and actuator insertion depth remain within specifications.
- Functional Testing: Test unlock/lock sequences and verify safety outputs respond correctly. Confirm auxiliary status output reflects lock condition accurately.
- Cleaning: Use only approved cleaning agents compatible with PBT housing. Avoid high-pressure water jets directed at conduit entries.
- Replacement: If malfunction or damage occurs, replace the complete unit—do not attempt repair. The sealed construction prevents internal component replacement.
Standards and Certifications Compliance
The 440G-TZS21UPRH meets stringent international safety standards essential for industrial machinery compliance:
| Standard | Description | Application |
|---|---|---|
| EN ISO 13849-1 | Safety of machinery – Safety-related parts of control systems | PLe performance level certification |
| IEC 61508 | Functional safety of electrical/electronic/programmable electronic safety-related systems | SIL 3 capability demonstration |
| IEC 62061 | Safety of machinery – Functional safety | Safety integrity level allocation |
| ISO 14119 | Interlocking devices associated with guards | Type 4 interlocking device requirements |
| IEC 60947-5-3 | Control circuit devices – Requirements for proximity devices | PDDB (Defined Behavior under Fault Conditions) |
| IEC 60204-1 | Safety of machinery – Electrical equipment | Machine electrical safety requirements |
Purchasing Guide and Recommendations
When sourcing the Allen Bradley 440G-TZS21UPRH, consider these practical factors to ensure you receive genuine Rockwell Automation products with full warranty support:
- Verify Authenticity: Purchase from authorized Rockwell Automation distributors or certified channel partners. Check the manufacturer’s warranty and request certification documentation.
- Bundle Accessories: Order compatible M12 cordsets (889D-F8AB-5 for 5m length), emergency override keys (440G-A36026), and dust covers (440K-A17183) with your switch order for complete installation.
- Consider Alternatives: If IP69K washdown is unnecessary, evaluate the standard TLS-GD2 series for cost optimization. For higher holding force requirements, consider the 440G-TZS21UPLH with alternative actuator configurations.
- Stock Planning: For critical production equipment, maintain spare switches and actuators in inventory. The M12 quick-disconnect enables rapid replacement without rewiring.
Conclusion
The Allen Bradley 440G-TZS21UPRH Guardmaster TLS-Z GD2 Guard Locking Switch delivers exceptional safety performance for industrial machinery guarding applications. Its combination of RFID-coded actuation, solid-state OSSD outputs, IP69K environmental protection, and PLe/SIL 3 safety certification makes it the preferred choice for demanding applications in food processing, pharmaceutical, semiconductor, and general manufacturing sectors.
When integrated correctly with compatible safety relays and controllers, the 440G-TZS21UPRH provides reliable protection that satisfies international standards while offering simplified installation through its M12 quick-disconnect interface. For organizations pursuing the highest levels of machine safety and regulatory compliance, this switch represents a sound investment in personnel protection and operational reliability.