Safety Lockout System Bulletin 1000 User Manual
Important User Information Because of the variety of uses for the products described in this publication, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.
European Communities (EC) Directive Compliance If this product has the CE mark it is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives.
Notes:
Table of Contents Preface Purpose of the Safety Lockout System . . . . . . . . . . . . . . . . . . . Safety Requirements and Guidelines . . . . . . . . . . . . . . . . . . . . . Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simplified Wiring Diagram and Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application . . . . . . . . . . . .
Table of Contents ii Notes: Publication 1000-UM001B-US-P - July 2000
Preface Purpose of the Safety Lockout System The purpose of the Safety Lockout System (SLS) is to provide a highly reliable and long-lived system for the isolation of a multi-motor machine (or portion thereof) with such isolation operable from multiple remote locations. Safety Requirements and Guidelines The SLS is one subsystem in the machine control system. As is true in installing any machine control system, it is necessary to follow the instructions that accompany the control system.
Preface 2 Description of Use The SLS switch should not be used to initiate normal stopping of the system. The normal system stop function(s) should be used to stop the system and then, when necessary, the remote SLS switch can be used to initiate the isolation of the system. When the SLS switch is operated for the purpose of isolation, a white SAFE light will illuminate when the system is isolated.
Preface 3 Figure P.
Preface 4 Figure P.
Preface Application 5 The SLS is an isolation system designed to provide disconnection and isolation. This means that the SLS provides the isolation necessary for work on machine elements electrically powered through the SLS and for work on the electrical equipment powered by SLS. However, the forgoing speaks to the capability of the SLS, not necessarily its use as assigned by management for a given purpose.
Preface 6 G. Construction The SLS box enclosure is primarily provided to prevent tampering with the SLS components and circuitry and, as such, is designed and listed per UL 508A to be installed inside another enclosure. The SLS box is constructed with a large transparent viewing window in the cover necessary to easily observe the status of the LED indicators. Both the SLS box and the SLS switch are provided with special holes placed to accommodate tamper-resistant sealing. H.
Chapter 1 Installation Instructions A. The SLS box enclosure has no environmental rating. Its purpose is to prevent tampering with the safety system and allow viewing of the components. The SLS box shall be mounted in a parent enclosure of suitable environmental rating with sufficient space to allow free opening of its door and convenient wiring of its connectors. B.
1-2 Installation Instructions Note: If the Class J fuses protecting the SLS box are smaller than that specified, the equipment grounding conductor may be reduced to that as shown in Table 250-95 of the NEC. E. This SLS box has Harting connectors for four SLS switches with safe light (Cat. No. 1000-NXSLS). If less than that four are needed for an installation, jumper out the unneeded SLS switches in the male end of the Harting connector. Refer to wiring diagram Y-155798.
Chapter 2 Commissioning Box and Switch This procedure is to be followed at first time startup and any subsequent SLS service. A. Inspection 1. Visually inspect enclosure and components for damage that may have occurred in installation or shipment. Look for loose wires or damaged components. 2. For first time installation, remove adhesive protective paper cover from SLS box window. 3. Check incoming and outgoing three phase power lines for proper selection and sizing.
2-2 Commissioning Box and Switch B. Verification of SLS operation 1. Turn all SLS switches to the ON position. 2. Check the machine to see that damage or injury will not occur if the machine is started. 3. Energize the motion bus that the SLS box contactor controls. 4. Check for machine operation and by operating with the normal start and stop functions. Check to see that the signals to the PLC and drive are correct. Leave machine in the stopped mode. 5.
Chapter 3 Operational Procedure The machine operator should not use the SLS to perform a normal stop function. The SLS should only be used to isolate the system. Machine access is allowed only after the SLS switch is locked and tagged in the OFF position and the white SAFE light is illuminated to verify that the system is indeed isolated. If the white SAFE light fails to illuminate when the SLS switch is turned to the OFF position, the machine cannot be considered isolated nor safe.
3-2 Operational Procedure Table 3.A SLS Box (Continued) Component Cat. No. Source Description Repairable Function Pilz relay PU3Z 24VDV Pilz Voltage supervision and contactor monitoring safety relay No Monitors position of contactor and voltage on load side of contactor. Safety relay SR 700-ZBL220Z24 Allen-Bradley 24V safety relay No Checks for cable integrity and for operation of the SLS switch. Allen-Bradley 24V safety relay Yes Serves as E-stop, pilot relay, and PLC interface.
Operational Procedure Servicing 3-3 A. Servicing is only to be performed by qualified SLS technician. B. Due to the nature of this controller and the type of equipment used, most all components are deemed non-repairable and should be replaced (not repaired) if they are not functioning properly. C. Refer to Allen-Bradley wiring diagram Y-156594. This is a schematic for the 700-ZBL220Z24 and should aid in further understanding of the operation of the SLS switches and the safety relays. Refer to Appendix A.
3-4 Operational Procedure Notes: Publication 1000-UM001B-US-P - July 2000
Chapter 4 SLS Sequence of Operation The following is the sequence of operation for the SLS box and the SLS switch as shown on Y-155798 Rev. M and Y-156328 Rev. B. The intention is to provide an understanding of circuit operation and equipment function. This will be an aid in troubleshooting because if the sequence stops or is incomplete, the suspected part or failure may be narrowed down and identified.
4-2 SLS Sequence of Operation D. If an operator moves the SLS switch from ON to OFF, the following will happen: 1. The safety relay circuit between terminals S10 and S11, and S21 and S2 will open up to de-energize the safety relay, causing the safety contacts terminals #13 and #14 between wires #1 and #3 to open up. In addition, safety relay auxiliary contacts between terminals #33 and #34 and #43 and #44 will open dropping out 1CR. This will cause IC to open up.
SLS Sequence of Operation 4-3 F. If the SLS switch is moved back to the ON position the following will happen: 1. The SLS switch contacts between the safety relay terminals S10 and S11, and S21 and B2 will close to energize the safety relay. This causes the safety contacts between terminals #13 and #14 between wires #1 and #3 to close. Note: The SLS switch contacts must close at approximately the same time or the safety relay will lock up. This may denote an SLS switch or cable failure.
4-4 SLS Sequence of Operation Notes: Publication 1000-UM001B-US-P - July 2000
Chapter 5 Troubleshooting Guide Troubleshooting Guide Table 5.A SLS Box Problem Component Possible Cause Check • Low voltage on secondary • Low voltage on primary Control transformer Loose connections, System voltage Primary wired for proper Replace if nothing suspicious voltage found. No Primary wired wrong Voltage on input Replace if nothing suspicious found.
5-2 Troubleshooting Guide Table 5.A SLS Box (Continued) Problem Component Safety relay SR Safety contacts between terminals #13 and #14 will not close Safety relay 1SR Won’t pick up 1CR Won’t drop out Publication 1000-UM001B-US-P - July 2000 Possible Cause Check Suggested Action Repairable? Bad SLS switch SLS switch Replace SLS switch. No Fault, opens or short in SLS cable SLS cable Repair or replace cable. No 1CR jammed on 1CR for operation Replace if necessary.
Troubleshooting Guide 5-3 Table 5.B SLS Switch Problem Component Possible Cause Check Does not illuminate with all other circuitry checking OK Pilot light Burned out bulb Loose connections Connections Contacts do not operate properly SLS switch Bad switch Continuity and operation Replace. No Handle mechanism For operation Replace. No Contacts do not operate properly SLS switch auxiliary contact Bad contact Continuity and operation Replace.
5-4 Troubleshooting Guide 10. One at a time, check operation of SLS switches by turning to OFF position, and check for the following: a. SAFE light on. b. IC dropped out. c. 1CR dropped out. d. Safety relay SR dropped out e. VSR indicates safe condition. 11. VSR voltage sensing broken wire detection test. a. With power off, remove one voltage-sensing wire from the VSR. Then, with all SLS switches in the ON position, apply power and turn a SLS switch off.
Troubleshooting Guide 5-5 13. IC contactor monitoring test. a. With all power off disconnect wire #7 on the IC auxiliary terminal #81. b. Apply power with all SLS switches in the ON position. Turn one SLS switch to OFF. The safe light should not come ON because the VSR contacts K2 and K1 between terminals #13 and #14 should not close. The VSR will not show a fault light. c. Turn off power and reconnect wire # 7 at terminal #81 on the IC contactor auxiliary. d.
5-6 Troubleshooting Guide Notes: Publication 1000-UM001B-US-P - July 2000
Appendix A Certification Documentation A. Listed as an open type controller per UL508A B. TUV Reinland verification of FMEA = checking condition of the SAFE light C. Declaration of conformity = CE marked. Self-certified to meet EN 60204-1: 1997 D. SUVA letter stating that MCS control devices 1CR and IC have positively guided auxiliary contacts that meet the requirements of IEC 947-5-1 E.
A-2 Certification Documentation Diagrams Figure A.
Certification Documentation A-3 Table A.B Bulletin 194E SLS Switch Renewal Parts Item Description Part Number Amount 1 A-B Enclosure 32267-132-51 1 2 A-B Mounting Plate 32267-133-01 1 3 194R Operating Handle — Black 194R-HS4 1 4 Phenolic Nameplate H-26553 1 4A #4-40 x 0.187 Pan Hd. Stain. St. Screw 28010-068-01 2 5 800H Pilot Light 800H-QR24W 1 5A 800H Nameplate Engrv. SAFE 800H-W100E 1 6 194E 25 A Load Switch 194E-A25-1753 1 6A 194E Auxiliary Contact 1 N.O. - 1 N.C.
A-4 Certification Documentation Figure A.2 Bulletin 100, 85 A SLS Box with Pilz Relay (Cat. No. 1000-NXSLSV85) Renewal Parts Table A.C Bulletin 100, 85 A SLS Box with Pilz Relay (Cat. No. 1000-NXSLSV85) Renewal Parts Item Publication 1000-UM001B-US-P - July 2000 Description Part Number Amount 1 A-B Enclosure 32267-121-51 1 2 A-B Mounting Plate 32267-122-02 1 3 Panduit Panel Channel E.5x2WH6 1 3A Panduit Cover C.
Certification Documentation A-5 Table A.C Bulletin 100, 85 A SLS Box with Pilz Relay (Cat. No. 1000-NXSLSV85) Renewal Parts (Continued) Item Description Part Number Amount 8 Primary Fuses Kldr 0.75 A 25183-272-11 2 9 Secondary Fuse Block 1492-FB1C30-L 1 10 Secondary Fuse Kldr 0.75 A 25183-272-11 1 11 50 W Idec Power Supply PS5R-D24 1 12 100S-85 A MCS Contactor 100S-C85D04C 1 12A MCS Surge Suppressor 100-FSC280 1 12B MCS Auxiliary 2 N.O.
A-6 Certification Documentation Figure A.
Certification Documentation A-7 Table A.D Composite Assembly of a Bulletin 194E SLS Switch Item Description Part Number Amount 1 Encl. w/Mtg. Plt. (Ref. 32267-132-51) (Ref. 32267-133-01) Eng. Data 1 2 194R Operating Handle — Black 194R-HS4 1 3 Phenolic Nameplate H-26553 1 3A #4-40 x 0.187 Pan Hd. Stain. St. Screw 28010-068-01 2 4 800H Pilot Light 800H-QR24W 1 4A 800H Nameplate Engrv. SAFE 800H-W100E 1 5 194E 25 A Load Switch 194E-A25-1753 1 5A 194E Auxiliary Contact 1 N.O.
A-8 Certification Documentation Figure A.4 Composite Assembly of a Bulletin 100, 85 A SLS Box with Pilz Relay (Cat. No. 1000-NXSLSV85) Table A.E Composite Assembly of a Bulletin 100, 85 A SLS Box with Pilz Relay (Cat. No. 1000-NXSLSV85) Item Description Publication 1000-UM001B-US-P - July 2000 Part Number Amount 1 Encl. w/Mtg. Plt. (Ref. 32267-121-51) (Ref. 32267-122-02) Eng. Data 1 2 Nameplate 49103-449-01 1 3 Panel Channel (Panduit E.5x2WH6) Eng. Data 1 3A Cover (Panduit C.5WH6) Eng.
Certification Documentation A-9 Table A.E Composite Assembly of a Bulletin 100, 85 A SLS Box with Pilz Relay (Cat. No. 1000-NXSLSV85) (Continued) Item Description Part Number Amount 8 Primary Fuses Kldr 0.75 A 25183-272-11 2 9 Secondary Fuse Block 1492-FB1C30-L 1 10 Secondary Fuse Kldr 0.75 A 25183-272-11 1 11 50 W Idec Power Supply PS5R-D24 Eng. Data 1 12 100S-85 A MCS Contactor 100S-C85D04C 1 12A MCS Surge Suppressor 100-FSC280 1 12B MCS Auxiliary 2 N.O.
A-10 Certification Documentation Figure A.
Certification Documentation A-11 Figure A.
A-12 Certification Documentation Figure A.
Certification Documentation A-13 Figure A.
A-14 Certification Documentation Figure A.
Certification Documentation A-15 Figure A.10 SLS Box with Pilz Relay, 30 A (Cat. No. 1000-NXSLSV30) and 85 A (Cat. No.
A-16 Certification Documentation Figure A.
Certification Documentation A-17 Figure A.
A-18 Certification Documentation Figure A.
Certification Documentation A-19 Table A.F LED Explanation Item Description Indicator Explanation 1 Power Supply LED DC on when 120V is applied 2 Control Transformer Sec. Fuse Blown Fuse On when fuse is blown 3 Control Transformer (2) Pri.
A-20 Certification Documentation Notes: Publication 1000-UM001B-US-P - July 2000
Appendix B References A. NFPA 70E 1995 edition, NFPA 79 1997 edition B.
B-2 References Notes: Publication 1000-UM001B-US-P - July 2000
References B-3 Notes: Publication 1000-UM001B-US-P - July 2000
B-4 References Notes: Publication 1000-UM001B-US-P - July 2000
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Publication 1000-UM001B-US-P - July 2000 2 © 1999 Rockwell International Corporation. Printed in the U.S.A.
