ES-VA-5A

ES-UA-5A and ES-VA-5A E-Stop Safety Module Datasheet Model ES-UA-5A for 12 to 24 V DC/115 AC operation; model ES-VA-5A for 12 to 24 V DC/230 AC operation • • • • • • • • Monitors emergency stop devices, such as palm buttons and rope/cable pulls, and positiveopening safety switches used for guard/gate interlocking The safety inputs can monitor: ◦ Hard/relay contacts in a dual-channel hookup using terminals S11-S12 and S21S22, or ◦ A +24 V DC source switched by hard/relay contacts in single-channel hookup Four normally open output switching channels for connection to control-reliable power interrupt circuits and three auxiliary output channels Automatic reset or monitored manual reset Design complies with standards ANSI B11.19, UL991, ISO 13850 (EN418), and ISO 13849-1 (EN954-1) (Safety Category 4) For use in functional stop category 0 applications per ANSI NFPA 79 and IEC/EN60204-1 6 amp safety output contacts; 5 amp aux. output contacts Plug-in terminal blocks Models Supply Voltage Outputs Output Rating ES-UA-5A 12 to 24 V DC or 115 V AC 4 Normally open safety N.O. Safety Outputs: 6 A 1 Normally closed aux. N.C. Aux. Outputs: 5 A 2 Solid-state aux. SS Aux. Outputs: 100 mA ES-VA-5A 12 to 24 V DC or 230 V AC WARNING: • Not a stand-alone safeguarding device • Failure to properly safeguard hazards according to a risk assessment, local regulations, and applicable standards might lead to serious injury or death. • This Banner Engineering Corp device is considered complementary equipment that is used to augment safeguarding that limits or eliminates an individual's exposure to a hazard without action by the individual or others. Important: Read This First The user is responsible for satisfying all local, state, and national laws, rules, codes, and regulations relating to the use of this product and its application. Banner Engineering Corp. has made every effort to provide complete application, installation, operation, and maintenance instructions. Please contact a Banner Applications Engineer with any questions regarding this product. The user is responsible for making sure that all machine operators, maintenance personnel, electricians, and supervisors are thoroughly familiar with and understand all instructions regarding the installation, maintenance, and use of this product, and with the machinery it controls. The user and any personnel involved with the installation and use of this product must be thoroughly familiar with all applicable standards, some of which are listed within the specifications. Banner Engineering Corp. makes no claim regarding a specific recommendation of any organization, the accuracy or effectiveness of any information provided, or the appropriateness of the provided information for a specific application. Applicable U.S. Standards ANSI B11 Standards for Machine Tools Safety ANSI B11.19 Performance Criteria for Safeguarding Contact: Safety Director, AMT – The Association for Manufacturing Technology, 7901 Jones Branch Drive, Suite 900, McLean, VA 22102-4206 USA, www.amtonline.org NFPA 79 Electrical Standard for Industrial Machinery Contact: National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02169-7471 USA, www.nfpa.org/ ANSI/RIA R15.06 Safety Requirements for Industrial Robots and Robot Systems Contact: Robotic Industries Association, 900 Victors Way, Suite 140, Ann Arbor, MI 48108 USA, www.robotics.org Applicable International Standards EN ISO 12100 Safety of Machinery – Basic Concepts, General Principles for Design EN 60204-1 Electrical Equipment of Machines Part 1: General Requirements IEC 61508 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems Original Document 122365 Rev. G 10 August 2021 122365 ES-UA-5A and ES-VA-5A E-Stop Safety Module IEC 62061 Functional Safety of Safety-Related Electrical, Electronic and Programmable Control Systems EN ISO 13849-1 Safety-Related Parts of Control Systems ISO 13850 (EN 418) Emergency Stop Devices, Functional Aspects – Principles for Design Contact: IHS Markit (Global Engineering Documents), 15 Inverness Way East, Englewood, CO 80112 USA, https://global.ihs.com/ Overview An Emergency Stop Safety Module is used to increase the control reliability of an emergency stop circuit. As shown in the wiring drawings, the models ES-UA-5A and ES-VA-5A E-Stop Safety Modules (the Safety Modules) are designed to monitor a 1-channel or 2-channel E-stop switch. A 2-channel E-stop switch has two electrically isolated contacts. Figure 1. Features and Terminals S31 S32 S33 A1 A2 B1 B2 13 14 23 24 Y30 Y31 Y32 S34 S32 S35 S11 S12 S21 S22 33 34 Y35 43 51 44 52 Safety Circuit Integrity and EN ISO 13849-1 Safety Circuit Principles Safety circuits involve the safety-related functions of a machine that minimize the level of risk of harm. These safety-related functions can prevent initiation, or they can stop or remove a hazard. The failure of a safety-related function or its associated safety circuit usually results in an increased risk of harm. The integrity of a safety circuit depends on several factors, including fault tolerance, risk reduction, reliable and well-tried components, well-tried safety principles, and other design considerations. Depending on the level of risk associated with the machine or its operation, an appropriate level of safety circuit integrity (performance) must be incorporated into its design. Standards that detail safety performance levels include ANSI B11.19 Performance Criteria for Safeguarding and EN ISO 13849-1 Safety-Related Parts of a Control System. Safety Circuit Integrity Levels The safety circuits in International and European standards have been segmented into categories, depending on their ability to maintain their integrity in the event of a failure. The most recognized standard that details safety circuit integrity levels is ISO 13849-1 (EN954-1), which establishes five levels: Categories B, 1, 2, 3, and 4 (most strict). In the United States, the typical level of safety circuit integrity is called control reliability. Control reliability typically incorporates redundant control and self-checking circuitry and is relatively similar to ISO 13849-1 Categories 3 and 4 (see CSA Z432 and ANSI B11.19). Perform a risk assessment to determine the appropriate category to make sure that the expected risk reduction is achieved to implement the requirements described by ISO 13849-1. This risk assessment must also take into account the national regulations, such as U.S. control reliability or European "C" level standards, to comply with the mandated minimum levels of performance. WARNING: • Determine the safety category • The design and installation of the safety devices and the means of interfacing of those devices could greatly affect the level of safety circuit integrity. • Perform a risk assessment to determine the appropriate safety circuit integrity level or safety category, as described by ISO 13849-1, to ensure that the expected risk reduction is achieved and that all applicable regulations and standards are met. 2 www.bannerengineering.com - Tel: + 1 888 373 6767 P/N 122365 Rev. G ES-UA-5A and ES-VA-5A E-Stop Safety Module Fault Exclusion An important concept within the category requirements of EN ISO 13849-1 is the probability of the occurrence of the failure, which can be decreased using the "fault exclusion" method. This method assumes that the possibility of certain well-defined failure(s) can be reduced to a point where the resulting fault(s) can be disregarded. Fault exclusion is a tool a designer can use during the development of the safety-related part of the control system and the risk assessment process. It allows the designer to eliminate the possibility of various failures and justify it through the risk assessment process to meet the requirements of Categories 2, 3, or 4. See EN ISO 13849-1/-2 for further information. Monitoring of Safety Devices Requirements vary widely for the level of control reliability or safety category per ISO 13849-1 (EN954-1) in safety applications. While Banner Engineering always recommends the highest level of safety in any application, it is the responsibility of the user to safely install, operate and maintain each safety system and comply with all relevant laws and regulations. Although only a few applications are listed, the Module can monitor a variety of devices as long as the input requirements are complied with (see Electrical Installation and Specifications). The Safety Module does not have 500 ms simultaneity between inputs and thus cannot be used for monitoring a two-hand control. In all cases, the safety performance (integrity) must reduce the risk from identified hazards as determined by the machine's risk assessment. WARNING: • Do not mute or bypass any emergency stop device • Muting or bypassing the safety outputs renders the emergency stop function ineffective. • ANSI B11.19, NFPA 79 and IEC/EN 60204-1 require that the emergency stop function remains active at all times. Emergency Stop Push Buttons and Rope/Cable Pull Switches The safety inputs can be interfaced with positive-opening switches to monitor an emergency-stop (E-stop) push button or rope/cable pull. The switch must provide one or two contacts for safety which are closed when the switch is armed. Once activated, the E-stop switch must open all its safety-rated contacts, and must require a deliberate action (such as twisting, pulling, or unlocking) to return to the closed-contact, armed position. The switch must be a "positive-opening" (or direct-opening) type, as described by IEC 60947-5-1. Standards ANSI NFPA 79, ANSI B11.19,, IEC/EN60204-1, and ISO 13850 specify additional emergency stop switch device requirements, including the following: • Emergency-stop push buttons shall be located at each operator control station and at other operating stations where emergency shutdown is required. • Stop and emergency-stop push buttons shall be continuously operable and readily accessible from all control and operating stations where located. Do not mute or bypass E-stop buttons or rope/cable pulls. • Actuators of emergency-stop devices shall be colored red. The background immediately around the device actuator shall be colored yellow (where possible). The actuator of a push-button-operated device shall be of the palm or mushroom-head type. • The emergency-stop actuator shall be a self-latching type. In addition, for Rope/Cable Pull Installations Only: • The wire rope should be easily visible and readily accessible along its entire length. Red markers or flags may be fixed on the rope to increase its visibility. • The rope or cable pull must provide constant tension and must have the capability to react to a force in any direction. • Mounting points, including support points, must be rigid. • The rope should be free of friction at all supports. Pulleys are recommended. • The switch must have a self-latching function that requires a manual reset after actuation Some applications may have additional requirements; comply with all relevant regulations. See the device manufacturer installation instructions for complete information (such as SSA-EB1..-.. p/n 162275, or RP-RM83F.. p/n 141245 datasheets). WARNING: • Do not mute or bypass any emergency stop device • Muting or bypassing the safety outputs renders the emergency stop function ineffective. • ANSI B11.19, NFPA 79 and IEC/EN 60204-1 require that the emergency stop function remains active at all times. Interlocked Guards (Gates) The safety inputs can be interfaced with positive-opening safety switches to monitor the position of an interlock guard or gate. Each switch must provide electrically isolated contacts: at minimum, one normally closed (N.C.) contact from each individually mounted switch. The contacts must be of "positive-opening" (direct-opening) design, as described by IEC60947- 5-1, with one or more normally closed contacts rated for safety. In addition, the switches must be mounted in a "positive mode," to move/disengage the actuator from its home position and open the normally closed contact when the guard opens. The design and installation of the interlocked guard and the safety switches should comply with ANSI B11.19, ISO14119, ISO 14120, and/or other applicable standards. See the device manufacturer installation instructions for complete information (such as GM-FA-10J p/n 60998, SI-LS83/-LS100 p/n 59622, or SI-HG63 p/n 129465 datasheets). P/N 122365 Rev. G www.bannerengineering.com - Tel: + 1 888 373 6767 3 ES-UA-5A and ES-VA-5A E-Stop Safety Module In higher levels of safety performance, the design of a dual-channel coded magnetic switch typically uses complementary switching, in which one channel is open and one channel is closed at all times. The inputs of the Safety Module do not support complementary switching, and thus should not be used with coded magnetic safety switches. Mechanical Installation The ES-xA-5A E-Stop Safety Module must be installed inside an enclosure. It is not designed for exposed wiring. It is the user’s responsibility to house the ES-xA-5A E-Stop Safety Module in an enclosure with NEMA 3 (IEC IP54) rating, or better. The ES-xA-5A E-Stop Safety Module mounts directly to standard 35 mm DIN rail. Heat Dissipation Considerations: For reliable operation, ensure that the operating specifications are not exceeded. The enclosure must provide adequate heat dissipation, so that the air closely surrounding the ES-xA-5A E-Stop Safety Module does not exceed the maximum operating temperature stated in the Specifications. Methods to reduce heat build-up include venting, forced airflow (for example, exhaust fans), adequate enclosure exterior surface area, and spacing between modules and other sources of heat. Electrical Installation WARNING: • Risk of electric shock • Use extreme caution to avoid electrical shock. Serious injury or death could result. • Always disconnect power from the safety system (for example, device, module, interfacing, etc.), guarded machine, and/or the machine being controlled before making any connections or replacing any component. Lockout/tagout procedures might be required. Refer to OSHA 29CFR1910.147, ANSI Z244-1, or the applicable standard for controlling hazardous energy. • Make no more connections to the device or system than are described in this manual. Electrical installation and wiring must be made by a Qualified Person 1 and must comply with the applicable electrical standards and wiring codes, such as the NEC (National Electrical Code), NFPA 79, or IEC 60204-1, and all applicable local standards and codes. It is not possible to give exact wiring instructions for a Safety Module that interfaces to a multitude of machine control configurations. The following guidelines are general in nature. The Safety Module has no delay function. Its output relay contacts open within 25 milliseconds after a safety input opens. This classifies the Safety Module as a functional stop "Category 0" control, as defined by ANSI NFPA 79 and IEC/EN 60204-1. The Safety Module is powered by either a 12-24 V DC supply at 4 W or an AC supply (115 V AC, model ES-UA-5A, or 230 V AC, model ES-VA-5A) at 7 VA. The safety inputs can be connected to: • • A +24 V DC source that is switched by a hard/relay contact in single-channel hookup configuration, or Hard/relay contacts in a dual-channel wiring configuration using terminals S11-S12 and S21-S22. Safety Input Device Wiring Options The operation of all dual-channel wiring options is concurrent, meaning that input channel 1 and input channel 2 must be in the same state in both the STOP and RUN condition, but with no simultaneity (timing) requirement between the channels. The dual-channel wiring configuration is able to detect certain failures and faults, such as short circuits, that could result in a loss of the safety function. Once such a failure or fault is detected, the Safety Module will turn OFF (open) its safety outputs until the problem is fixed. This circuit can meet ISO 13849-1 Category 2, 3, or 4 requirements, depending on the safety rating and the installation of the safety input device. This circuit can detect a short circuit between channels or to another source of power, at a minimum, when the device is actuated. A single device with redundant outputs that can fail in such a manner to lose the safety function, such as a single safety interlocking switch, can typically meet only a Category 2. See below for means to eliminate or minimize the possibility of failures and faults that could result in the loss of the safety function(s). The single-channel wiring configuration cannot detect short circuits to secondary sources of +24 V DC or detect the loss of the switching function of the safety input device (that is, it is not redundant) and thus this circuit typically can meet only ISO 13849-1 Category 2. It is recommended that in all circumstances the installation of the Safety Module and its associated safety input devices are installed to eliminate or minimize the possibility of failures and faults that could result in the loss of the safety function(s). Methods to eliminate or minimize the possibility of these failures include, but are not limited to: • Physically separating interconnecting control wires from each other and from secondary sources of power. • Routing interconnecting control wires in separate conduit, runs, or channels. • Locating all elements (modules, switches, and devices under control) within one control panel, adjacent to each other, and directly connected with short wires. • Properly installing multi-conductor cabling and multiple wires through strain-relief fittings. (Over-tightening of a strain-relief can cause short circuits at that point.) • Using positive-opening components as described by IEC 60947-5-1 that are installed and mounted in a positive mode. 1 4 A person who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training and experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work. www.bannerengineering.com - Tel: + 1 888 373 6767 P/N 122365 Rev. G ES-UA-5A and ES-VA-5A E-Stop Safety Module • Periodically checking the functional integrity / safety function and training operators, maintenance personnel, and others associated with the operation of the machine to recognize and immediately correct such failures. If you have any questions about your intended use, please contact a Banner applications engineer. Connection of Multiple Switches Connect the poles of multiple switches, such as E-Stop switches, as shown in the following hookup figures. The switches are shown in the "armed" position with both contacts closed. Multiple switches connected to one Safety Module must be series connected. Figure 2. Series connection of multiple E-stop switches E-Stop S11 S21 E-Stop S22 S12 WARNING: • Test multiple safety devices individually • Failure to test each safety device individually could result in undetected faults and create an unsafe condition that could result in serious injury or death. • When two or more safety devices are used, individually actuate each device, causing a stop or opencontact condition, then reset/rearm the safety module (if using manual reset mode). This allows the monitoring circuits to check each device and its wiring to detect faults. Note: The minimum amount of time for the Module to detect a STOP condition is 15 milliseconds. This "recovery time" (OFF state) is required for the internal integrity tests to complete, allowing a reliable reset to occur. A lockout may occur if the Module is cycled too quickly. To clear the lockout, the inputs must be re-cycled, meeting the minimum recovery time requirements. Connection of Safety Switches The Safety Module may be used to monitor safety interlocking switches that determine the position of a guard or gate. To achieve Category 4 operation per ISO 13849-1 (EN 954-1), two positiveopening safety switches must operate concurrently when the guard or gate is opened. The Safety Module verifies concurrent opening of two contacts – one from each safety switch. Reset of the Safety Module is not possible if one switch fails to open or if a short circuit between the safety interlocking switches occurs. Figure 3. Wiring using contacts from two safety switches S11 P/N 122365 Rev. G Safety Gate or Guard with end-of-travel stops and two individually mounted Safety Interlocking Switches OPEN www.bannerengineering.com - Tel: + 1 888 373 6767 S21 S22 S12 5 ES-UA-5A and ES-VA-5A E-Stop Safety Module Connection of Reset Switch The reset circuit switch can be any mechanical switch, such as a normally open momentary switch, or a two-position key switch. The reset switch must be capable of reliably switching 12 to 30 V DC at 20 to 50 milliamps. As shown in the wiring diagrams, the reset switch connects between Safety Module terminals S33 and S34. The reset switch must be located outside of – and not be accessible from – the area of dangerous motion, and must be positioned so that any area of dangerous motion may be observed by the switch operator during the reset procedure. See warning below. WARNING: • Install reset switches properly • Failure to properly install reset switches could result in serious injury or death. • Install reset switches so that they are accessible only from outside, and in full view of, the safeguarded space. Reset switches cannot be accessible from within the safeguarded space. Protect reset switches against unauthorized or inadvertent operation (for example, through the use of rings or guards). If there are any hazardous areas that are not visible from the reset switches, provide additional safeguarding. Automatic Reset Mode The Safety Module may be configured (via hookup) for automatic reset. Leave terminals S33 and S34 open and install a jumper between terminals S32 and S35 (see hookups). The Safety Module will reset (and its outputs energize) as soon as the switch returns to its armed (closed-contact) position. Automatic reset is useful for some automated processes. However, if automatic reset is used, it is necessary to provide a means of preventing resumption of hazardous machine motion, until an alternate reset procedure is performed. The alternate procedure must include a reset/restart switch, located outside the area of dangerous motion and positioned so that any area of dangerous motion may be observed by the switch operator during the reset procedure. WARNING: • Reset routine required • Failure to prevent the machine from restarting without actuating the normal start command/device can create an unsafe condition that could result in serious injury or death. • Do not allow the machine to restart without actuating the normal start command/device. Perform the reset routine after clearing the cause of a stop condition, as required by U.S. and international standards. Connection to the Machine to be Controlled The machine hookup diagram shows a generic connection of the Safety Module's redundant output circuits to the master stop control elements (MSCs). An MSC is defined as an electrically powered device, external to the Safety Module, which stops the machinery being controlled by immediately removing electrical power to the machine and (when necessary) by applying braking to dangerous motion. This stopping action is accomplished by removing power to the actuator of either MSC. External Device Monitoring To satisfy the requirements of Control Reliability (OSHA and ANSI), Category 3 and 4 of ISO 13849-1 (EN 954-1), the Machine Primary Control Elements (MPCEs) must each offer a normally closed, forced-guided (mechanically linked) monitor contact. Connect one normally closed monitor contact from each Machine Primary Control Element as shown in the appropriate hookup drawing (circuit between terminals S31 and S32, jumper if no MSC contacts are monitored). In operation, if one of the switching contacts of either MPCE fails in the energized condition, the associated monitor contact will remain open. Therefore, it will not be possible to reset the Primary Safety Device. If no MPCE-monitor contacts are monitored, it is the user's responsibility to ensure that any single failure will not result in a hazardous condition and will prevent a successive machine cycle. 6 www.bannerengineering.com - Tel: + 1 888 373 6767 P/N 122365 Rev. G ES-UA-5A and ES-VA-5A E-Stop Safety Module Wiring Drawings Figure 4. Wiring for 2-Channel E-Stop Applications Auto Reset Manual Reset AC Power shown DC Power shown dc common +V 115 ac or 230V ac (depending on model) A1 12-24V dc ES-UA-5A A2 ES-VA-5A B2 AC or DC power connections shown are valid for either auto or manual reset. 115V ac B1 A1 ES-UA-5A A2 ES-VA-5A B2 12-24V dc B1 230V ac 12-24V dc E-Stop Switch E-Stop Switch S11 S11 S21 S21 MSC1 MSC3 S22 MSC1 MSC3 S22 S31 S12 S34 S31 MSC Monitor Contacts or Jumper for No Monitoring S32 Reset Switch MSC Monitor Contacts or Jumper for No Monitoring S32 S12 S34 MSC2 MSC4 S33 MSC2 MSC4 S33 Jumper S32 S32 Jumper Machine Master Stop Control Elements S35 6A max. L1 K1A K2B 23 24 34 33 43 Non-safety Auxiliary Monitor Contact 44 K1E * 34 Arc Suppressors (see WARNING ) Non-safety Auxiliary Monitor Contact 44 K1E P/N 122365 Rev. G * 52 * Arc Suppressors (see WARNING ) K2E Y30 100 mA max. each Output Non-safety Monitor Outputs Y35 Y32 Power Supply Fault Outputs Energized 12-24V dc +V MSC4 5A max. 51 Y31 100 mA max. each Output Non-safety Monitor Outputs Y32 * K2D 43 Y30 Outputs Energized MSC3 6A max. K2E Y31 * K2C K1D * 52 MSC2 6A max. K1C 33 MSC4 5A max. 51 24 * K2D K2B 23 MSC3 6A max. K1D * 6A max. Machine Control Circuits L2 MSC1 14 K1B * K2C K2A 13 MSC2 6A max. K1C K1A * 6A max. K1B 6A max. L1 MSC1 14 Machine Control Circuits L2 K2A 13 Machine Master Stop Control Elements S35 Y35 Power Supply Fault 12-24V dc dc common +V www.bannerengineering.com - Tel: + 1 888 373 6767 dc common 7 ES-UA-5A and ES-VA-5A E-Stop Safety Module Figure 5. Wiring for 1-Channel E-Stop Applications Auto Reset Manual Reset AC Power shown DC Power shown +V 115V ac or 230V ac (depending on model) dc common 12-24V dc E-Stop Switch A1 ES-UA-5A A2 ES-VA-5A B2 E-Stop Switch AC or DC power connections shown are valid for either auto or manual reset. 115V ac B1 230V ac A1 ES-UA-5A A2 ES-VA-5A B2 12-24V dc B1 12-24V dc ES-UA-5A 12-24V dc/115V ac ES-VA-5A S11 12-24V dc/230V ac ES-UA-5A 12-24V dc/115V ac ES-VA-5A S11 12-24V dc/230V ac S21 S21 MSC1 MSC3 S22 MSC1 MSC3 S22 S31 S31 MSC Monitor Contacts or Jumper for No Monitoring S32 S12 S34 Reset Switch MSC Monitor Contacts or Jumper for No Monitoring S32 S12 S34 MSC2 MSC4 S33 MSC2 MSC4 S33 Jumper S32 S32 Jumper Machine Master Stop Control Elements S35 6A max. L1 K1A K2A 13 K2B 24 23 Machine Control Circuits 34 43 Non-safety Auxiliary Monitor Contact 44 K1E 24 * Arc Suppressors (see WARNING ) Non-safety Auxiliary Monitor Contact 44 K1E 8 * 52 * Arc Suppressors (see WARNING ) K2E Y30 100 mA max. each Output Non-safety Monitor Outputs Y35 Y32 Power Supply Fault Outputs Energized 12-24V dc +V MSC4 5A max. 51 Y31 100 mA max. each Output Non-safety Monitor Outputs Y32 * K2D 43 Y30 Outputs Energized MSC3 6A max. K2E Y31 * K2C 34 K1D * 52 MSC2 6A max. K1C 33 MSC4 5A max. 51 K2B 23 Machine Control Circuits * K2D * 6A max. MSC3 6A max. K1D MSC1 14 K1B L2 K2A 13 * K2C 33 K1A MSC2 6A max. K1C 6A max. L1 * 6A max. K1B L2 MSC1 14 Machine Master Stop Control Elements S35 Y35 Power Supply Fault 12-24V dc dc common +V www.bannerengineering.com - Tel: + 1 888 373 6767 dc common P/N 122365 Rev. G ES-UA-5A and ES-VA-5A E-Stop Safety Module WARNING: • Properly install arc or transient suppressors • Failure to follow these instructions could result in serious injury or death. • Install any suppressors as shown across the coils of the machine primary control elements. Do not install suppressors directly across the output contacts of the safety or interface module. In such a configuration, it is possible for suppressors to fail as a short circuit. WARNING: • Interfacing master stop controls • Failure to follow these instructions could result in serious injury or death. • Unless the same degree of safety is maintained, never wire an intermediate device(s) (PLC, PES, PC) between the safety module outputs and the master stop control element it switches such that a failure causes a loss of the safety stop command or the failure allows the safety function to be suspended, overridden, or defeated. • When forced-guided, mechanically linked relays are added as intermediate switching devices, a normally closed (N.C.) forced-guided monitor contact from each relay must be added to the series feedback loop or properly wired external device monitoring channel. Overvoltage Category II and III Installations (EN 50178 and IEC 60664-1) The ES-xA-5A E-Stop Safety Module is rated for Overvoltage Category III when voltages of 1 V to 150 V AC/DC are applied to the output relay contacts. It is rated for Overvoltage Category II when voltages of 151 V to 250 V AC/DC are applied to the output relay contacts and no additional precautions are taken to attenuate possible overvoltage situations in the supply voltage. The ES-xA-5A EStop Safety Module can be used in an Overvoltage Category III environment (with voltages of 151 V to 250 V AC/DC) if care is taken either to reduce the level of electrical disturbances seen by the ES-xA-5A E-Stop Safety Module to Overvoltage Category II levels by installing surge suppressor devices (for example, arc suppressors), or to install extra external insulation in order to isolate both the ES-xA-5A E-Stop Safety Module and the user from the higher voltage levels of a Category III environment. For Overvoltage Category III installations with applied voltages from 151 V to 250 V AC/DC applied to the output contact(s): the ES-xA-5A E-Stop Safety Module may be used under the conditions of a higher overvoltage category where appropriate overvoltage reduction is provided. Appropriate methods include: • An overvoltage protective device • A transformer with isolated windings • A distribution system with multiple branch circuits (capable of diverting energy of surges) • A capacitance capable of absorbing energy of surges • A resistance or similar damping device capable of dissipating the energy of surges When switching inductive AC loads, it is good practice to protect the ES-xA-5A E-Stop Safety Module outputs by installing appropriately-sized arc suppressors. However, if arc suppressors are used, they must be installed across the load being switched (for example, across the coils of external safety relays), and never across the ES-xA-5A E-Stop Safety Module’s output contacts. Auxiliary Monitor Contact/Solid-State Monitor Outputs Connection The action of the auxiliary monitor contact, terminals 51-52, inversely "follows" the action of the safety outputs. Two additional solidstate monitor outputs (at terminals Y32 and Y35) each are capable of switching up to 100 mA at 12- 24 V dc. The output at terminal Y32 follows the action of the output circuits (K1 and K2); the output at terminal Y35 opens (low signal) when there is a loss of power or a fault is detected. These outputs are to be used only for nonsafety functions (typically, to communicate the status of the Safety Module to a programmable logic controller). See the appropriate figure for wiring information. Initial Checkout Procedure CAUTION: • Disconnect power prior to checkout • Dangerous voltages might be present along the module wiring barriers whenever power to the machine control elements is on. • Before performing the initial checkout procedure, disconnect all power from the machine to be controlled. Exercise extreme caution whenever machine control power is or might be present. Always disconnect power to the machine control elements before opening the enclosure housing of the module. 1. Remove power from the machine primary control elements. 2. Ensure the safety device is in a STOP or "open-contact" state (for example, actuate the E-stop switch to open its contacts). 3. Apply power to the Safety Module at terminals A1 and A2 or B1 and B2.Verify that only the Input Power indicator is ON. If either input channel 1 or input channel 2 indicators are ON at this point, disconnect the input power and check all wiring. Return to step 2 after the cause of the problem has been corrected. 4. Reset or otherwise cause the safety device to reach an ON or "closed-contact" state (for example, arm the E-stop switch to close its contacts). 5. Manual Reset mode: Ch1 and Ch2 indicators should be flashing. Close and reopen the Reset switch. 6. Verify that the Ch1 and Ch2 indicators both come ON. If only one indicator comes ON or if any indicator is flashing, refer to the Troubleshooting section for more information. Return to step 2 after correcting the problem. P/N 122365 Rev. G www.bannerengineering.com - Tel: + 1 888 373 6767 9 ES-UA-5A and ES-VA-5A E-Stop Safety Module 7. Cause the safety device to generate a STOP or "open-contact" state (for example, actuate the E-stop switch to open its contacts). The Ch1 and Ch2 indicators should turn OFF simultaneously. If either indicator remains ON, disconnect the input power and check all wiring. Return to step 2 after the cause of the problem has been corrected. Refer to the Troubleshooting section for more information. 8. If more than one safety device is series-connected to the Safety Module, run the above checkout procedure individually for EACH device. 9. Close and secure the enclosure in which the Safety Module is mounted. Apply power to the machine control elements and perform the Periodic Checkout Procedure. WARNING: • Test multiple safety devices individually • Failure to test each safety device individually could result in undetected faults and create an unsafe condition that could result in serious injury or death. • When two or more safety devices are used, individually actuate each device, causing a stop or opencontact condition, then reset/rearm the safety module (if using manual reset mode). This allows the monitoring circuits to check each device and its wiring to detect faults. Specifications Supply Voltage and Current AI-A2: 115 V AC (model ES-UA-5A) or 230 V ac (model ES-VA-5A) ±15% , 50/60 Hz BI-B2: 11 V DC to 27.6 V DC Power consumption: approx. 4 W/7 VA The Safety Module should be connected only to a SELV (safety extra-low voltage, for circuits without earth ground) or a PELV (protected extra-low voltage, for circuits with earth ground) power supply. Supply Protection Circuitry Protected against transient voltages and reverse polarity Overvoltage Category Output relay contact voltage of 1 V to 150 V AC/DC: category III Output relay contact voltage of 151 V to 250 V AC/DC: category III, if appropriate overvoltage reduction is provided (see Overvoltage Category III Installations). Pollution Degree 2 Required Overcurrent Protection WARNING: Electrical connections must be made by qualified personnel in accordance with local and national electrical codes and regulations. Overcurrent protection is required to be provided by end product application per the supplied table. Overcurrent protection may be provided with external fusing or via Current Limiting, Class 2 Power Supply. Supply wiring leads < 24 AWG shall not be spliced. For additional product support, go to www.bannerengineering.com. Required Overcurrent Protection (Amps) Supply Wiring (AWG) 20 5.0 22 3.0 24 2.0 26 1.0 28 0.8 30 0.5 Relay Outputs Relay Outputs 4 normally open (N.O.) output channels and 1 normally closed (N.C.) auxiliary output Contacts: AgNi, 5 μm gold-plated Each normally open output channel is a series connection of contacts from two forcedguided (mechanically linked) relays, K1-K2. The normally closed Aux. output channel is a parallel connection of contacts from two forced-guided relays, K1-K2. Low Current Rating: The 5 μm gold-plated contacts allow the switching of low current/low voltage. In these low-power applications, multiple contacts can also be switched in series (for example, “dry switching”). To preserve the gold plating on the contacts, do not exceed the following max. values at any time: Min. Max. Voltage 1 V AC/DC 60 V Current 5 mA AC/DC 300 mA Power 5 mW (5 mVA) 7 W (7 VA) 10 www.bannerengineering.com - Tel: + 1 888 373 6767 P/N 122365 Rev. G ES-UA-5A and ES-VA-5A E-Stop Safety Module Relay Outputs High Current Rating: If higher loads must be switched through one or more of the contacts, the minimum and maximum values of the contact(s) changes to: Minimum Maximum Voltage 15 V AC/DC Current 250 mA AC/DC Power 5 W (5 VA) N.O. Safety Contacts (13-14, 23-24, 33-34, 43-44): 250 V AC / 24 V DC, 6 A resistive B300, Q300 (UL508) N.C. Auxiliary Contact (51-52): 250 V AC/ 24 V DC, 5 A resistive B300, Q300 (UL508) Minimum Maximum — IEC60947-5-1 Voltage 15V AC/DC Current 250 mA AC/DC Power 5 W (5 VA) N.O. Safety Contacts: AC-1: 250 V AC, 6 A; DC-1: 24 V DC, 6 A AC-15: 230 V AC, 3 A; DC-13: 24 V DC, 4 A N.C. Auxiliary Contact: AC-1: 250 V AC, 5 A; DC-1: 24 V DC, 5 A AC-15: 230 V AC, 2 A; DC-13: 24 V DC, 4 A Mechanical Life > 50,000,000 operations Note: Transient suppression is recommended when switching inductive loads. Install suppressors across load. Never install suppressors across output contacts (see Warning, Wiring of Arc Suppressors). Electrical Life 150,000 cycles at 1500 VA 1,000,000 cycles at 450 VA 2,000,000 cycles at 250 VA 5,000,000 cycles at 125 VA Solid-State Outputs Two non-safety solid-state DC outputs Output circuits require application of +12 to 24 V DC ± 15% at terminal Y31; dc common at Y30. Max. switching current: 100 mA at 12 to 24 V DC Output Response Time 35 ms max. (25 ms typical) Both outputs are protected against short circuits. Output at Y32 monitors state of outputs – conducts (output high) when both K1 and K2 are energized. Output at Y35 conducts (output high) when in normal operation (no lockout). I/O General Input Requirements E-stop switch: must have normally closed contacts each capable of switching 20 to 50 mA at 12 to 30 V DC; and must be open longer than 15 ms for a valid stop command. Maximum input resistance 250 ohms per channel at 24 V DC supply voltage. Maximum input resistance 25 ohms per channel at 12 V DC supply voltage. Reset switch: must have one normally open contact capable of switching 20 to 50 mA at 12 to 30 V DC. Indicators 3 green LED indicators: Power ON , Channel 1, Channel 2 1 red LED indicator: indicates a fault condition (see Troubleshooting) OFF-State Recovery Time 350 ms maximum Construction Polycarbonate housing. Rated NEMA 1, IEC IP20 Mounting Mounts to standard 35 mm DIN rail track. Safety Module must be installed inside an enclosure rated NEMA 3 (IEC IP54), or better. Operating Conditions Standards and Certifications Vibration Resistance 10 to 60 Hz at 0.35 mm peak displacement per UL 991 60 to 150 Hz at 5 g max. Design Standards Cat. 4 PL e per EN ISO 13849-1; SIL 3 per IEC 61508 and IEC 62061 Environment Temperature: 0 °C to +50 °C (+32 °F to +122 °F), (surrounding air) 90% at +50 °C maximum relative humidity (non-condensing) P/N 122365 Rev. G www.bannerengineering.com - Tel: + 1 888 373 6767 11 ES-UA-5A and ES-VA-5A E-Stop Safety Module Dimensions 84 mm (3.3") 118.0 mm (4.6") 45 mm (1.8") All measurements are listed in millimeters [inches], unless noted otherwise. Product Support and Maintenance Troubleshooting Module will not reset Indicator Status Possible Causes and Solutions Power LED ON Fault LED OFF Ch1 LED Flashing Ch2 LED Flashing Waiting for manual reset: • EDM monitoring contacts are not closed. Check MSCs. • Check jumper at S32-S35 (auto reset) or S32-S33 (manual reset). • Check reset button connection. No Fault Indicated Indicator Status Possible Causes and Solutions Power LED ON Fault LED OFF Ch1 LED OFF Ch2 LED OFF E-stop button open: • Connector loose. • Re-arm E-stop button. Power LED ON Fault LED OFF Ch1 LED OFF Ch2 LED ON Ch.1 open; Ch. 2 closed: • Check wiring to S11-S12. • Check switch. • Check connectors are properly seated. Power LED ON Fault LED OFF Ch1 LED ON Ch2 LED OFF Ch.1 closed; Ch. 2 open: • Check wiring to S21-S22. • Check switch. • Check connectors are properly seated. 12 www.bannerengineering.com - Tel: + 1 888 373 6767 P/N 122365 Rev. G ES-UA-5A and ES-VA-5A E-Stop Safety Module Fault Indicator Status Possible Causes and Solutions Power LED ON Fault LED ON* Ch1 and Ch2 LED flashing alternately Input concurrency fault: Both inputs did not open concurrently. Both inputs are now closed. • Check switches/wiring at both inputs. • Open both inputs to clear the fault. Power LED ON Fault LED ON* Ch1 LED OFF Ch2 LED Flashing Input concurrency fault: Ch1 opened and closed and is now open while Ch2 remained closed. • Check switches/wiring at both inputs. • Open both inputs to clear the fault. Power LED ON Fault LED ON* Ch1 LED Flashing Ch2 LED OFF Input concurrency fault: Ch1 remained closed while Ch2 opened and closed and is now open. • Check switches/wiring at both inputs. • Open both inputs to clear the fault. Power LED ON Possible input fault: Ch1 and Ch 2 are closed and are (or were) shorted together. • Check wiring at both inputs. • Open both inputs to clear the fault. Possible internal fault: Return to factory for repair or replacement Fault LED ON* Ch1 LED ON Ch2 LED ON All LEDs OFF Possible fault in machine control or wiring to module: • Check input power connections or external fuses. • Check connectors are properly seated. Dim LEDs Dim Power LED: • Check power supply capacity and load. Other LEDs dim: • May glow during power-up (normal). • Check power supply load and capacity. * Fault LED Flickers This is normal while the Fault LED is ON. MSCs Do Not Energize Indicator Status Possible Causes and Solutions Power LED ON Fault LED OFF Ch1 LED ON Ch2 LED ON Possible fault in machine control or an open circuit between machine control and MSCs: • Check continuity of safety outputs (e.g. between terminals 13 and 14). • Check control wires and connectors. • Check MSCs. Repairs Contact Banner Engineering for troubleshooting of this device. Do not attempt any repairs to this Banner device; it contains no field-replaceable parts or components. If the device, device part, or device component is determined to be defective by a Banner Applications Engineer, they will advise you of Banner's RMA (Return Merchandise Authorization) procedure. Important: If instructed to return the device, pack it with care. Damage that occurs in return shipping is not covered by warranty. WARNING: • Do not abuse the module after failure—If an internal fault has occurred and the module will not reset, do not tap, strike, or otherwise attempt to correct the fault with a physical impact to the housing. • Failure to follow these instructions could result in serious injury or death. • An internal relay might have failed in such a manner that its replacement is required. If the module is not immediately replaced or repaired, multiple simultaneous failures might accumulate such that the safety function cannot be guaranteed. EU Declaration of Conformity (DoC) Banner Engineering Corp. herewith declares that these products are in conformity with the provisions of the listed directives and all essential health and safety requirements have been met. For the complete DoC, please go to www.bannerengineering.com. P/N 122365 Rev. G www.bannerengineering.com - Tel: + 1 888 373 6767 13 ES-UA-5A and ES-VA-5A E-Stop Safety Module Product Directive ES-UA-5A and ES-VA-5A Emergency Stop Module for industrial 2006/42/EC control Representative in EU: Peter Mertens, Managing Director, Banner Engineering BV. Address: Park Lane, Culliganlaan 2F, bus 3,1831 Diegem, Belgium. Banner Engineering Corp. Limited Warranty Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year following the date of shipment. Banner Engineering Corp. will repair or replace, free of charge, any product of its manufacture which, at the time it is returned to the factory, is found to have been defective during the warranty period. This warranty does not cover damage or liability for misuse, abuse, or the improper application or installation of the Banner product. THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED (INCLUDING, WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), AND WHETHER ARISING UNDER COURSE OF PERFORMANCE, COURSE OF DEALING OR TRADE USAGE. This Warranty is exclusive and limited to repair or, at the discretion of Banner Engineering Corp., replacement. IN NO EVENT SHALL BANNER ENGINEERING CORP. BE LIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR ANY EXTRA COSTS, EXPENSES, LOSSES, LOSS OF PROFITS, OR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE PRODUCT, WHETHER ARISING IN CONTRACT OR WARRANTY, STATUTE, TORT, STRICT LIABILITY, NEGLIGENCE, OR OTHERWISE. Banner Engineering Corp. reserves the right to change, modify or improve the design of the product without assuming any obligations or liabilities relating to any product previously manufactured by Banner Engineering Corp. Any misuse, abuse, or improper application or installation of this product or use of the product for personal protection applications when the product is identified as not intended for such purposes will void the product warranty. Any modifications to this product without prior express approval by Banner Engineering Corp will void the product warranties. All specifications published in this document are subject to change; Banner reserves the right to modify product specifications or update documentation at any time. Specifications and product information in English supersede that which is provided in any other language. For the most recent version of any documentation, refer to: www.bannerengineering.com. For patent information, see www.bannerengineering.com/patents. © Banner Engineering Corp. All rights reserved