Allen-Bradley 440F-C4000P MatGuard Safety Mat Controller
The 440F-C4000P is a dedicated controller for pressure-sensitive safety mats, part of the Rockwell Automation MatGuard system. It monitors one or two safety mats (4-wire resistive type) and provides two redundant safety outputs (force-guided relays) for stopping hazardous machine motion. The controller meets ISO 13849-1 PL d and IEC 61508 SIL 2 requirements. It can also be used with safety edges or bumpers of the same technology.
Technical Specifications
Number of Mat Inputs: 2 independent channels (4-wire resistive mat)
Response Time: < 20 ms (from activation to output switching)
Safety Outputs: 2 N.O. relay contacts (6 A at 250 VAC / 30 VDC)
Auxiliary Outputs: 1 N.C. solid-state (24 VDC, 100 mA)
Power Supply: 24 VDC (19.2–28.8 V), 50 mA typical
Protection Degree: IP20 (controller), suitable for cabinet mounting
Monitoring and Diagnostics
The controller continuously checks the mat's internal resistance, wire integrity, and cross-circuit shorting. Any fault (open circuit, short circuit, or loss of contact) will cause the safety outputs to open and the "Fault" LED to blink a diagnostic code. A manual reset input (N.O. pushbutton) is required to restart after a mat activation or power cycle. The controller also features an auto-reset mode (selectable via DIP switch) for non-safety applications.
Configuration and Indicators
DIP switches set: two-mat or single-mat operation, reset type (manual/auto), and mat sensitivity (low/high). Five LEDs indicate: Power, Mat status (activated or not), Output status (OK), Fault, and Reset request. The controller includes a removable terminal block with 12 positions. Maximum cable length to mat: 100 meters using 22 AWG shielded cable.
Physical and Environmental
Dimensions: 114 mm × 99 mm × 45 mm (H × W × D). Weight: 0.2 kg. Mounting: DIN rail (35 mm) or panel. Operating temperature: -10°C to +55°C; storage: -40°C to +85°C. Humidity: 10–90% non-condensing. Vibration: 1g at 10–55 Hz. The controller is UL 508 listed, CSA certified, and meets EN 954-1 Category 3.
Compatible Mats
Works with Allen-Bradley 440F-M series mats (e.g., 440F-M2125, 440F-M2242) as well as other 4-wire resistive mats from Tapeswitch, Schmersal, and Omron. The controller can be cascaded with other safety devices (e.g., light curtains) via its dual-channel input loop. Typical applications include robotic workcells, assembly stations, and press brakes.
