440R-ZBR520AZ1 Allen-Bradley Controller module

Description

440R-ZBR520AZ1 Allen-Bradley Controller module

Product Dimensions：

Product Description

The Allen-Bradley Guardmaster 440R-ZBR520AZ1 is a zero-speed monitoring safety relay that provides a safe output when a monitored machine has reached a standstill or fallen below a pre-defined low-speed threshold. It utilizes proximity sensors (or other suitable sensors like encoders) to detect rotation. The “ZBR” in its catalog number indicates it’s a Zero-Speed/Brake Monitor relay. This device is critical for applications where personnel access to moving parts is necessary, but only when those parts are completely stopped and safe. It’s often used in conjunction with safety interlock switches to ensure guards cannot be opened until the monitored machinery is static.

Product Parameters

Here are the key specifications for the 440R-ZBR520AZ1:

• Catalog Number: 440R-ZBR520AZ1
• Series: Guardmaster Zero-Speed Monitor (ZSM) / ZBR Series
• Function: Zero-Speed and/or Low-Speed Monitoring Safety Relay
• Inputs:
  • Sensor Inputs: Designed for proximity sensors (e.g., inductive proximity sensors) or encoders. Requires two sensor inputs for redundant monitoring.
  • Start/Reset Input: Manual or Automatic Reset.
• Outputs:
  • Safety Outputs: 2 NO (Normally Open) safety outputs, designed to be connected in series to the machine control circuit (e.g., to control contactors or safety interlock switches).
  • Auxiliary Outputs: 1 NC (Normally Closed) auxiliary output, typically for status indication.
• Power Supply: 24V AC/DC
• Monitored Speed Range: Adjustable threshold for zero-speed and low-speed detection.
• Response Time: Fast response time to detect standstill conditions.
• Terminal Type: Removable screw terminals for easy wiring.
• Mounting: DIN Rail mountable.
• Ingress Protection (IP) Rating: IP20 (terminal protection), typically housed within an enclosure.
• Operating Temperature: -5 °C to +55 °C (+23 °F to +131 °F)
• Safety Category/Performance Level: Designed to meet high safety integrity levels (e.g., PLe / Cat. 4 per EN ISO 13849-1, SIL 3 per IEC 61508) when used in a correctly designed safety system. Always verify the exact safety rating from the official datasheet for compliance.
• Dimensions (Approximate): Typically compact, fitting into standard control cabinets.

Product Advantages

• Enhanced Machine Safety: Crucial for applications where movement must be completely stopped before safe access is permitted, significantly reducing the risk of injury.
• Reliable Standstill Detection: Provides dependable monitoring of machinery speed, preventing hazardous access to moving parts.
• Dual Sensor Input: Utilizes two sensor inputs for redundancy, increasing the reliability and safety integrity of the monitoring function.
• Versatile Sensor Compatibility: Can work with various types of proximity sensors or encoders, offering flexibility in application.
• Adjustable Threshold: Allows for fine-tuning of the zero-speed or low-speed detection threshold to suit specific machine requirements.
• Easy Integration: Designed for DIN rail mounting and features removable terminals, simplifying installation and wiring into control panels.
• Compact Design: Saves space within control cabinets.
• High Safety Standards: Engineered to meet stringent international safety standards, contributing to overall machine safety compliance.

Precautions

• Sensor Selection and Installation: The performance of the ZSM relay heavily relies on the correct selection, placement, and alignment of the proximity sensors (or encoder). Ensure sensors are robust and accurately detect rotation.
• Proper Wiring: Strictly follow the wiring diagrams provided in the product manual. Incorrect wiring can lead to dangerous conditions or damage to the device.
• Safety Circuit Design: This relay is a component of a larger safety system. Ensure the entire safety system (including actuators, interlocks, E-stops, and control logic) is designed and validated by qualified personnel to meet required safety standards.
• Power Supply: Use a stable 24V AC/DC power supply within the specified voltage range.
• Commissioning and Testing: Thoroughly test the zero-speed monitoring function during commissioning and periodically thereafter, as part of your safety system’s validation and maintenance plan.
• Bypassing: Never attempt to bypass or defeat the safety functions of the relay, as this could lead to serious injury or death.
• Environmental Conditions: While designed for industrial environments, ensure the operating temperature and other environmental factors (e.g., excessive vibration, moisture) are within the specified limits.

Product Applications

The Allen-Bradley Guardmaster 440R-ZBR520AZ1 zero-speed monitoring safety relay is essential in applications where machinery must be at a complete standstill (or below a safe speed) before human intervention or access is allowed. Common applications include:

• Machine Guarding: Used in conjunction with guard locking interlock switches to prevent the opening of safety gates or access doors until the guarded machinery (e.g., conveyors, presses, robotic cells, mixers) has stopped rotating.
• Motor Control: Monitoring the speed of motors to ensure they are de-energized and stopped before maintenance or access.
• Conveyor Systems: Ensuring conveyors have stopped before personnel can clear jams or perform maintenance.
• Wind Turbines / Generators: Monitoring rotation for safe maintenance access.
• Any rotating machinery where a “zero-speed” condition is a critical safety requirement for access.

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