An Investment in Plant Floor Safety. 802C Safety Cable Pull Switches 802E Hinge Safety Interlock Switches 802F Safety Interlock Switches

Transcription

1 An Investment in Plant Floor Safety 802C Safety Cable Pull Switches 802E Hinge Safety Interlock Switches 802F Safety Interlock Switches

2 Notes 2

3 802C Cable Pull Safety Switches Safety and Application Safety through relying upon operational assurance of a stop switch is a relative term which depends upon the design of the switch as well as the application, installation and maintenance of the switch. While not the usual practice, ultimate operational assurance of a stop switch can be achieved by using redundant stop switches with checking for the purpose of identifying failure of the redundant stop switch. The following factors are significant to the safe operation of the stop switch and must be considered by those involved with the applications, installation and/or use of stop switches: 1. Use of proper system safety analysis for the application and installation of the stop switch, as well as the circuit for the stop switch. A system safety analysis should use applicable standards such as: OSHA 1910 Code of Federal Regulation. EN , Safety of Machinery Electrical Equipment of Machines. ANSI/NFPA 79, Electrical Standard for Industrial Machinery. ANSI B11, series of safety standards. EN 292, Safety of Machinery. Local applicable standards. 2. The application involving the stop switch should provide for a separate disconnect switch(es) with provision for lockout/tagout of the circuit. The stop switch must not be used as a disconnect switch. 3. The installation of a stop switch must be in accordance with the manufacturer s instructions, as well as good practice. 4. Follow the manufacturer s recommendations for short circuit protection in order to minimize the chance for welded contacts. 5. An effective and complete maintenance procedure and schedule must be established and implemented for the stop switch and its application utilizing: The Rockwell Automation/ Allen-Bradley Maintenance of Industrial Control Equipment found in the Rockwell Automation/ Allen-Bradley Industrial Control catalog. NEMA ICS 1.3, Preventative Maintenance of Industrial Control and Systems Equipment. NFPA 70B, Electrical Equipment Maintenance. NFPA 703, Part II (As Adopted by OSHA), Electrical Safety-Related Work Practice. It is the responsibility of the individual(s) who apply, install and/or use the stop switch to assure themselves that all the requirements for the application, installation and maintenance of the stop switch are satisfactorily met. Mounting Position the conduit entering the switch in such a manner that any fluid inside the conduit will not drain into the switch enclosure. Apply sealing compound to the conduit threads to prevent against the entry of fluids through the threads. The conduit threads in the body are metric Pg13.5 or Pg16. Adaptors are supplied to convert the conduit threads to 1/2 14 NPT. Clearance holes have been provided in the enclosure for mounting purposes. Use #10 (M5) screws for mounting. When mounting switches which have polymeric enclosures, it is recommended that washers be used under the mounting screw heads. Wiring The wiring terminals will accept #14 AWG (2.5mm 2 ) and smaller solid or stranded wire. For proper tightening, it is suggested that wires no smaller than #18 AWG (0.75mm 2 ) be used. If the switch is equipped with pressure plate type wiring terminals, strip the insulation approximately inch (9.5mm) before inserting the wire under the pressure plates. Be sure that all strands of the wire are retained by the pressure plate. If the switch is equipped with binding screw type terminals, strip the insulation approximately 1/2inch (12.7mm) before inserting the wire under the binding screw. Be sure that the wire is curved around the screw and that all strands of the wire are retained under the binding screw head.! ATTENTION: The normally open and normally closed contacts must be wired in series to detect cable breakage (see Figure 4A). A grounding screw is located inside the enclosure on those switches that have metal enclosures. Some of the metal enclosures may also have an untapped hole on the exterior of the enclosure near the conduit opening which can also be used for grounding purposes. 1

4 802C Cable Pull Safety Switches After wiring has been completed, check that all wires are placed in such a manner that they will not interfere with the switch portion of the device or with the proper positioning of the cover gasket. Recheck all wiring terminal screws for tightness. Replace and securely tighten or latch the cover and check for proper mechanical action before applying power to the switch. Actuation A cable is attached to the actuator. The switch is actuated by pulling on the cable. Some switches are spring return while others are maintained position switches that will remain in the operated position until a reset button on the switch is pressed.! ATTENTION: The contacts of MAINTAINED POSITION SWITCHES will change state electrically before the mechanical latch or maintained action takes place. The actuator must be moved a distance sufficient to cause the maintained action to occur or the system could restart upon release of the actuation cable (see adjustment). On three wire control systems, the premature release of the actuating cable, before mechanical latch, would allow the system to be restarted from any start station without any reset action at the pull switch. IF THERE IS A CONCERN, PROCEDURES SHALL BE PUT IN PLACE TO ASSURE THAT THE SWITCHED LATCH HAS OPENED, E.G., A GENTLE PULL ON THE CABLE. Normally the installation is such that the actuating cable is positioned in a horizontal plane. See Figure 1A, the Typical Installation Example diagram. Care must be taken to insure that the cable does not become too slack, preventing proper actuation. Too much slack could cause delayed response and/or require excessive motion by the operator to effect switch action. If the cable is too tight, however, false actuation of the switch might occur especially in installations that are subject to wide variations in temperature. If the switch is installed in such a manner that the weight of the actuating cable is supported by the actuator, be sure that the cable weight does not cause false operation of the switch.! ATTENTION: The system should be tested after installation by actuating the cable. The circuit should perform as intended with a minimum of effort on the cable. Be sure that the switch will reset properly when the reset button is depressed. Cable tension and/or cable size should be adjusted as necessary to obtain proper operation. Installation Recommendations Cable pull switches have two main requirements for operation. One requirement is direct opening action contacts. The second requirement is overlapping contacts to monitor the cable tension. It is important to follow the installation instructions as well as the applicable codes and standards for these types of switches. Cable Installation Adjustment: 802C B, 802C C, and 802C E During adjustment of the switch the cable is stressed using a turnbuckle until the normally open contact closes. Once the normally open contact is closed and the normally closed contact remains closed, the switch is adjusted properly. Adjustment: 802C H, 802C J During adjustment of the switch the cable is stressed using a turnbuckle until the normally open contact closes. This is easily accomplished by adjusting the turnbuckle until the mark on the shaft aligns with the edge of the housing. At this point both the normally open and the normally closed contact are closed, and the switch is adjusted properly. Cable Length Where the cable is freely stressed the standard cable length is outlined in the product selection guide in the catalog. When installing a switch with a cable run between the standard length and the maximum length, the following shall be considered: Pulleys are used for all supports, The ambient temperature will not vary by any more than 10C (18F), A spring is installed at the anchoring end of the cable. It is recommended that the cables be installed on a straight run (see Figure 1A). However, if the installation requires the cable to be installed around corners, pulleys shall be used (see Figure 1B). Figure 1B ÇÇÇÇÇÇÇ Ç Ç Ç Ç ÇÇÇÇÇÇ Ç The switching distance (distance to operate contacts) must be taken into account when determining the operating distance X. This distance must be greater than the operating travel of the switch. This will assure there is sufficient room to move Figure 1A Typical Installation Example Note: When installing a switch with a cable run between the standard length and the maximum length, a spring shall be installed at the anchoring end (see Figure 3 for spring installation). 2

5 802C Cable Pull Safety Switches the cable and operate the switch. The maximum distance the cable can be freely stressed (distance between supports) is 5m (16.4ft). Care should be taken to assure that the cable will slide freely through all supports. It is important not to exceed the maximum length of cable as specified in the selection guide and assure that the cable properly operates the switch. Attach the red PVC coated cable to the switch, turnbuckle, eye stiffener, clamps, and eye loop as shown in Figures 1 and 2. Attach the turnbuckle about halfway along the cable span, then attach the other half in a similar manner. Figure 2 Typical Installations of 802C N Switches For installations with large ambient temperature variation or cable runs up to 50m (150ft) (25m (75ft) on each side of switch) the cable pull switch 802C N should be used. The operation of this switch is by means of connecting a cable and two tension springs to an operating lever (see Figure 3 for details). The cable configuration is shown in Figure 3. The cable is connected to the turnbuckle, eye loops and spring as outlined in Figure 2. Figure 3 mm (inches) Temperature Effects on Cable The normal operating temperature range is 30 o C to 80 o C ( 22 o F to 176 o F). The supplied cable will expand and contract at a rate of 6.89 x 10 6 inches per degree per inch (3µm per meter per degree). Operation When the cable is pulled the normally closed contacts will open, interrupting the circuit (see Figure 4C). If the cable breaks or becomes slack the normally open contact will reopen (see Figure 4B) and interrupt the control circuit. Maintained Some of the cable pull switches are also available with a latch feature and manual reset. This requires the operator to manually reset the switch after the problem has been cleared.! ATTENTION: After actuation and before resetting the maintained switch, the machinery should be inspected in order to detect the reason for activation. 3

6 802C Cable Pull Safety Switches Figure 4A Cable Stressed at Rated Force Figure 4B Cable Broken or Slack, Stop Signal Would Be Initiated Figure 4C Cable Pulled to Initiate Stop Signal Maintenance The stop switch, cable, and application must be inspected periodically to evaluate the operability of the stop switch and cable assembly. An initial inspection must be made within 3 to 4 months after installation. If inspection reveals contamination has reached the stop switch or cable assembly, the cause must be eliminated. Replace the stop switch and/or cable assembly when any damaged, broken, deformed, or badly worn parts (including contacts) or assemblies are found to be a part of the stop switch and/or cable assembly. The pulleys and other moving parts associated with the cable should be periodically lubricated. In the event any short circuit protection device in the circuit (such as a fuse or circuit breaker) should trip, the stop switch must be inspected for damage before restoring power and replaced if the switch is damaged. In any event, the stop switch and cable assembly should be replaced at specified intervals based upon the environment and operating conditions. Replacement of the stop switch and cable assembly should be considered no later than 500,000 operations. Always test the control system for proper functioning under control conditions to avoid hazards in the event of control malfunction after maintenance or replacement of the stop switch. For additional information, refer to the maintenance section of this catalog and the installation instruction for the safety switch. 4

7 Specifications Safety Switches 802C Cable Pull Safety Switches Description 802C cable pull switches are intended for applications such as material handling conveyors, transfer machines, painting lines, etc. These switches are typically wired in a control circuit to interrupt the machine operation when an operator pulls a cable. These switches comply IEC , CSA, UL, DIN VDE 0660 T200. The switches are available in many mounting configurations. Features Enclosure rating IP65 (IEC 529), NEMA 1, 2, 3, 4, and 12 Overlapping contacts to monitor cable tensions Positive opening NC contacts per IEC Contacts rated NEMA A300/P300 Conduit entries available are 1/2 NPT (with Pg to 1/2 NPT conduit adaptor), Pg 11, Pg 13.5 and Pg 16 depending on the control (metric to U.S. conduit adaptor available) Available with or without reset CSA certified, UL listed, and CE marked for applicable directives Variable pull forces available for different lengths of cable 5

8 802C Cable Pull Safety Switches Selection Guide mm (inches) 6

9 802C Cable Pull Safety Switches Selection Guide mm (inches) 7

10 8 Dimensions mm (inches) Figure 1 Figure 3 Figure 4 Figure 2 802C Cable Pull Safety Switches

11 9 Dimensions mm (inches) (continued) Figure 5 Figure 6 Figure 7 Figure 8 802C Cable Pull Safety Switches

12 802C Cable Pull Safety Switches Dimensions mm (inches) (continued) Figure 9 Figure 10 10

13 802C Accessories Cable Pull Safety Switches 11

14 802C Accessories Cable Pull Safety Switches 12

15 802E Hinge Safety Interlock Switches Safety and Application Safety through relying upon operational assurance of each safety interlock switch is a relative term which depends upon the design of the switch, as well as the application, installation, and maintenance of the switch. The application of each safety interlock switch must use redundant interlock switches, as well as a checking circuit. The following factors are significant to the safe operation of a safety interlock switch and must be considered by those involved with the application, installation and/or use of safety interlock switches: 1. Use of a proper system safety analysis for the application and installation of each safety interlock switch, as well as the circuit for each of the switches. Such a system safety analysis should use applicable standards such as: EN , Safety of Machinery Electrical Equipment of Machines. ANSI/NFPA/79, Electrical Standard for Industrial Machinery. ANSI B11 Series, Machine Safety Standards including B11.19 Control Reliability. EN, 292, Safety of Machinery. Other local applicable standards. 2. The application of each safety interlock switch must use redundant interlock switches with a checking circuit which identifies any malfunction or improper sequencing of any switch (whether an intermittent, momentary, or permanent malfunction) and, thereupon, initiates a pre-determined corrective action (i.e., stopping or preventing further operation of the control equipment) to include a maintenance procedure for replacement of the failed interlock switch before further use of the controlled equipment. 3. The installation of the safety interlock switch must be in accordance with the manufacturer s instructions, as well as good practice. Refer to NEMA Standard ICS 5 Clause 9 Part Follow the manufacturer s recommendations for short circuit protection in order to minimize the chance for welded contacts. 5. An effective and complete maintenance procedure and schedule must be established and implemented for the safety interlock switch and its application utilizing: The Rockwell Automation/ Allen-Bradley Maintenance of Industrial Control Equipment found in the Rockwell Automation/ Allen-Bradley Industrial Control catalog. NEMA ICS 1.3, Preventative Maintenance of Industrial Control and Systems Equipment. NFPA 70B, Electrical Equipment Maintenance. NFPA 703, Part II (As Adopted by OSHA), Electrical Safety-Related Work Practice. Only qualified individuals should apply, install, use, and/or maintain the safety interlock switch; it is the responsibility of such individuals to see that the requirements for the application, installation, use, and/or maintenance of the safety interlock switch are satisfactorily met. Installation Recommendations The switch shall not be used as a mechanical stop. Application consideration must be given to the maximum listed travel capabilities of the switch. For reliable contact operation, the actuator should be adjusted to provide overtravel beyond the operating point, but not damage the switch by excessive overtravel. Installation Consideration IEC Direct Opening Action Contacts The safety interlock switch has an IEC direct opening action feature. The actuator must move a distance beyond the trip point to engage the IEC direct opening action feature. For proper operation of the IEC direct opening action system, the switch actuator must be adjusted to provide at least 3.5 of overtravel beyond the trip point. 13

16 802E Hinge Safety Interlock Switches Maintenance The interlock switch and application must be inspected periodically to evaluate the operability of the switch. An initial inspection must be made within 3 to 4 months after installation. If inspection reveals contamination has reached the interlock switch, the cause must be eliminated. Replace the interlock switch when any damaged, broken, deformed, or badly worn parts (including contacts) or assemblies are found to be a part of the interlock switch. In the event any short circuit protection device in the circuit (such as a fuse or circuit breaker) should trip, the interlock switch must be inspected for damage before restoring power and replaced, if the switch is damaged. In any event, the interlock switch should be replaced at specified intervals based upon the environment and operating conditions. Replacement of the interlock switch should be considered no later than 500,000 operations. Always test the control system for proper functioning under control conditions to avoid hazards in the event of control malfunction after maintenance or replacement of the interlock switch. For additional information, refer to the maintenance section of this catalog and the installation instruction for the safety switch. 14

17 802E Hinge Safety Interlock Switches Specifications Description Rockwell Automation/Allen-Bradley hinge safety interlock switches are intended for interlocking applications and are usually permanently mounted on machine guards, covers and doors to verify that they are in the proper position. These switches are typically wired in a control circuit to interrupt the machine operation when the door is opened, or when the hinge actuator is moved. These switches comply with GS ET 15, IEC, EN The switches are available in three mounting configurations. Type B housing is glass fiber-reinforced thermoplastic. Type B switches are available in both lever type and rotating shaft type actuators. Type E and R housings are die-cast aluminum and available in lever type actuators only. Features Enclosure rating IP65 (IEC529), NEMA 1, 2, 3, 4, 12, and 13 Direct acting normally closed contacts per IEC, EN and DIN VDE 0660 Contacts rated NEMA A300, P300 Conduit entries available are 1/2 NPT (conduit adaptor supplied with the switch), Pg11 and Pg13.5 depending on the control (metric to US conduit adaptor available) The profile of the operator head provides a high degree of tamper resistance for the switch CSA certified, UL listed, CE marked for all applicable directives and BG pending Actuator head can be rotated in 90 increments. 15

18 16 Selection Guide mm Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á ÁÁÁÁÁ Á Á 802E Hinge Safety Interlock Switches

19 17 Selection Guide mm Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á 802E Hinge Safety Interlock Switches

20 18 Dimensions mm (inches) Figure 2 Figure 1 Figure 4 Figure 3 802E Hinge Safety Interlock Switches

21 19 Dimensions mm (inches) Figure 6 Figure 5 802E Hinge Safety Interlock Switches

22 20 Dimensions mm (inches) Figure 7 Figure 8 802E Hinge Safety Interlock Switches

23 802F Key Safety Interlock Switches Safety and Application Safety through relying upon operational assurance of each safety interlock switch is a relative term which depends upon the design of the switch, as well as the application, installation, and maintenance of the switch. The application of each safety interlock switch must use redundant interlock switches, as well as a checking circuit. The following factors are significant to the safe operation of a safety interlock switch and must be considered by those involved with the application, installation and/or use of safety interlock switches: 1. Use of a proper system safety analysis for the application and installation of each safety interlock switch, as well as the circuit for each of the switches. Such a system safety analysis should use applicable standards such as: EN , Safety of Machinery Electrical Equipment of Machines. ANSI/NFPA/79, Electrical Standard for Industrial Machinery. ANSI B11 Series, Machine Safety Standards including B11.19 Control Reliability. EN, 292, Safety of Machinery. Other local applicable standards. 2. The application of each safety interlock switch must use redundant interlock switches with a checking circuit which identifies any malfunction or improper sequencing of any switch (whether an intermittent, momentary, or permanent malfunction) and, thereupon, initiates a predetermined corrective action (i.e., stopping or preventing further operation of the control equipment) to include a maintenance procedure for replacement of the failed interlock switch before further use of the controlled equipment. 3. The installation of the safety interlock switch must be in accordance with the manufacturer s instructions, as well as good practice. Refer to NEMA Standard ICS 5 Clause 9 Part Follow the manufacturer s recommendations for short circuit protection in order to minimize the chance for welded contacts. 5. An effective and complete maintenance procedure and schedule must be established and implemented for the safety interlock switch and its application utilizing: The Allen-Bradley Maintenance of Industrial Control Equipment found in the Allen-Bradley Industrial Control catalog. NEMA ICS 1.3, Preventative Maintenance of Industrial Control and Systems Equipment. NFPA 70B, Electrical Equipment Maintenance. NFPA 703, Part II (As Adopted by OSHA), Electrical Safety-Related Work Practice. Only qualified individuals should apply, install, use, and/or maintain the safety interlock switch; and it is the responsibility of such individuals to see that the requirements for the application, installation, use, and/or maintenance of the safety interlock switch are satisfactorily met. Installation Recommendations The switch shall not be used as a mechanical stop. Application consideration must be given to the maximum listed travel capabilities of the switch. For reliable contact operation, the actuator key should be adjusted to provide overtravel beyond the operating point, but not damage the switch by excessive overtravel. Installation Consideration IEC Direct Opening Action Contacts The safety interlock switch has an IEC direct opening action feature. The actuator must move a distance beyond the point to engage the IEC direct opening action feature. For proper operation of the IEC direct opening action system, the switch actuator must be adjusted to provide at least 1mm (0.4in) of overtravel beyond the trip point. 21

24 802F Key Safety Interlock Switches Maintenance The interlock switch and application must be inspected periodically to evaluate the operability of the switch. An initial inspection must be made within 3 to 4 months after installation. If inspection reveals contamination has reached the interlock switch, the cause must be eliminated. Replace the interlock switch when any damaged, broken, deformed, or badly worn parts (including contacts) or assemblies are found to be a part of the interlock switch. In the event any short circuit protection device in the circuit (such as a fuse or circuit breaker) should trip, the interlock switch must be inspected for damage before restoring power and replaced if the switch is damaged. In any event, the interlock switch should be replaced at specified intervals based upon the environment and operating conditions. Replacement of the interlock switch should be considered no later than 500,000 operations. Always test the control system for proper functioning under control conditions to avoid hazards in the event of control malfunction after maintenance or replacement of the interlock switch. For additional information, refer to the maintenance section of this catalog and the installation instruction for the safety switch. 22

25 Specifications Safety Switches 802F Key Safety Interlock Switches Description Rockwell Automation/Allen-Bradley key interlock switches are intended for interlocking applications on machine guards, covers and doors to verify they are in the proper position. These switches are typically wired in a control circuit to interrupt the machine operation when the key is removed. These switches comply with GS ET 15, IEC The switches are available in three mounting configurations. Type S housing is thermoset polyester and type E and R housings are die-cast aluminum. Features Enclosure rating IP65 (IEC 529), NEMA 1, 2, 3, 4, 12, and 13. Separate actuator key. Direct opening action normally closed contacts per IEC and DIN VDE Contacts rated NEMA A300, P300. Conduit entries available are 1/2 NPT (conduit adaptor supplied with the switch), Pg 11 and Pg 13.5 depending on the control (metric to U.S. conduit adaptor available). Features (continued) High degree of tamper resistance due to the triple coding of the actuator key. Actuator protected against dismantle by one way notch on actuator cover (S Style). CSA certified, UL listed, CE marked for all applicable directives, and BG pending. Variable actuator approach direction with different actuator openings and the ability to rotate the head. Models are available with keys that allow for a high degree of misalignment. Replacement Keys! ATTENTION: Replacement keys are made available for replacement purposes only (mounting) and shall not be used for any other purposes such as defeating any other interlock switch. For replacement keys, please contact your local Rockwell Automation sales office. 23

26 802F Key Safety Interlock Switches Selection Guide mm Wiring 5-Pin Micro-Type Receptacle Pin Mini-Type Receptacle

27 802F Key Safety Interlock Switches Selection Guide mm 25

28 802F Key Safety Interlock Switches Selection Guide mm Wiring 2 Circuit Switches With LED

29 Specifications Safety Switches 802F Key Safety Interlock Switches Description The Magnetically Operated Key Interlock Switches are intended for safety interlocking applications requiring separate actuator key and interlocking mechanisms. These switches are typically used on machines to assure that protective guards will remain closed until an operating sequence is complete. The switches comply with GS ET 19, IEC , DIN VDE 0660 T200. Features Requires separate control signal to release key. Designed to assure the machine/ process cannot operate when the actuator key is not in the closed and locked position. Monitors the switch and the interlocking system. High-impact, heavy-duty die-cast aluminum housing. Compact/space saving design. Actuator key triple coded for prevention of false manipulation. Features (continued) Actuator approach can be turned in 90 increments. Mounting according to DIN EN Designed to IEC and GS ET 19. CSA certified, UL listed, CE marked for all applicable directives, and BG pending. Available with operating voltages 24V DC, 120V AC, 230V AC. Direct opening action contacts per IEC Replacement Keys! ATTENTION: Replacement keys are made available for replacement purposes only (mounting) and shall not be used for any other purposes such as defeating any other interlock switch. For replacement keys, please contact your local Rockwell Automation sales office. 27

30 802F Key Safety Interlock Switches The Key Operated Interlocking Switch (802F T) Comes With Two Types of Locking Methods: Mechanical Lock Mechanically locked solenoid unlocked. The key is locked in place after full insertion. The key is released when an operational voltage is applied to the solenoid. Solenoid Lock Solenoid locked mechanically unlocked. The key is locked in place when fully inserted and when an operational voltage is applied. Release of the key occurs when the operational voltage is removed from the solenoid. E1 E2 E1 E E1, E2 solenoid control safety contacts safety contacts auxiliary contacts auxiliary contacts 28

31 802F Key Safety Interlock Switches Selection Guide mm Mechanically Locked Solenoid Unlocked 29

32 802F Key Safety Interlock Switches Selection Guide mm Solenoid Locked Mechanically Unlocked 30

33 31 Dimensions mm (inches) 802F T 802F E60 Y X Y X Z Z 90 Standard Key Spring Loaded Key 802F Key Safety Interlock Switches

34 32 Dimensions mm (inches) 802F R60 802F E68 802F Key Safety Interlock Switches

35 802F Key Safety Interlock Switches Dimensions mm (inches) 2 and 3 Contact Switch 802F S Pivoting Operation Single N.C. Output Switch 802F S 33

36 802F Key Safety Interlock Switches Dimensions mm (inches) Thermoset Plastic and Stainless Steel Key Vertical Radius 34

37 802F Key Safety Interlock Switches Dimensions mm (inches) Horizontal Radius Universal Radius Key 35

38 Notes 36

39 Notes 37

40 38