Banner ES-TA-3F1 Operating Instructions Manual

Ten-Input Emergency Stop Safety Module

Model ES-TA-3F1 with DeviceNet

™

Contents

Section 1 Product Description . . . . . . 3

Section 2 Emergency Stop Switch . . . 4

Requirements . . . . . . . . . . .

Section 3 Mounting the E-Stop . . . . . 5

Safety Module

Section 4 Electrical Hookup . . . . . . . . 6

and Initial Checkout

Section 5 Operating Instructions . . . 10

Section 6 Troubleshooting . . . . . . . . 13

Section 7 Repairs . . . . . . . . . . . . . . 15

Section 8 DeviceNet . . . . . . . . . . . . 17

Section 9 Product Specifications . . . 20

Features

• Monitors up to ten normally-closed Emergency Stop switch circuits for a
contact failure or wiring fault

• Diverse-redundant input monitoring circuit

• DeviceNet

™

monitoring of status and diagnostic information

• Auto reset or monitored manual reset

•Two output switching channels for connection to control-reliable power
interrupt circuits

• Designed to comply with standards UL991, EN418, and
EN954-1 (Safety Category 4)

• For use in functional stop category 0 applications per NFPA 79
and EN418

• Plug-in terminal blocks and replaceable circuit boards

• LED indicators for status of all inputs and outputs

• Manual MAC ID Address switches and LED

• Autobaud

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E-Stop Safety Module – Model ES-TA-3F1

Important ... read this page before proceeding!

Banner Engineering Corp. has made every effort to provide complete application, installation, operation, and maintenance instructions. In addition,
any questions regarding the use or installation of Banner model ES-TA-3F1 Emergency Stop Safety Module should be directed to the factory
applications department at the telephone numbers or address shown on back cover.

The user must ensure that all machine operators, maintenance personnel, electricians, and supervisors are thoroughly familiar with and understand
all instructions regarding the installation, maintenance, and use of the model ES-TA-3F1 Emergency Stop Safety Module, and with the machinery it
controls.

The user and any personnel involved with the installation and use of the model ES-TA-3F1 Emergency Stop Safety Module must be thoroughly
familiar with all applicable ANSI/NFPA standards. The standards, listed below, directly address the use of emergency stop systems. 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.

The user has the responsibility to ensure that all local, state, and national laws, rules, codes, and regulations relating to the use of this Emergency
Stop Safety Module in any particular application are satisfied. Extreme care is urged that all legal requirements have been met and that all installation
and maintenance instructions contained in this manual are followed.

U. S. Standards Applicable to Use of Emergency Stop Safety Modules

ANSI B11 Standards for Machine Tools “Safety Requirements for the Construction, Care and Use”

Available from: Safety Director

AMT – The Association for Manufacturing Technology
7901 Westpark Drive
McLean, VA 22101-4269
Phone: [phone]

NFPA79 “Electrical Standard for Industrial Machinery (1997)”

Available from: National Fire Protection Association

1 Batterymarch Park, P.O. Box 9101
Quincy, MA 02269-9101
Phone: [phone]

ANSI/RIA R15.06 “Safety Requirements for Industrial Robots and Robot Systems”

Available from: Robotic Industries Association

900 Victors Way, P.O. Box 3724
Ann Arbor, MI 48106
Phone: [phone]

European Standards Applicable to Use of Emergency Stop Safety Modules

EN292-1 “Safety of Machinery – Basic Concepts, General Principles for Design

Part 1: Basic Terminology, Methodology”

EN292-2 “Safety of Machinery – Basic Concepts, General Principles for Design

Part 2: Technical Principals and Specifications”

EN60204-1 “Electrical Equipment of Machines: Part 1: General Requirements”

Also, request a type “C” standard for your specific machinery.

EN418 “Safety of Machinery – Emergency Stop Equipment Functional Aspects, Principles for Design”

Available from: Global Engineering Documents

15 Inverness Way East
Englewood, CO 80112-5704
Phone: [phone]

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E-Stop Safety Module – Model ES-TA-3F1

SECTION 1 – Product Description

The purpose of the model ES-TA-3F1 Emergency Stop (E-stop) Safety Module is to
increase the control reliability of a multiple-input Emergency Stop circuit. The ANSI
B11.19 standard states:

“Control reliability of electrical, electronic, or pneumatic systems

frequently consists of multiple, independent parallel or series
circuitry or components so arranged that any single failure . . .

either sends a stop command to the machine tool or prevents a
successive cycle from being initiated.”

As indicated in Figure 3, a typical Emergency Stop switch offers two redundant
switching contacts. In a properly designed machine stop circuit, the opening of either of
the two Emergency Stop contacts immediately removes electrical power from the
machine control elements which react to stop hazardous machine motion and/or any
other machine hazard. This redundancy of stopping control offered by a two-pole
Emergency Stop switch is the first step towards control reliability. However, failure or
defeat of one of the switch contacts to a short-circuit will go undetected, thereby
removing the redundancy, and leaving the Emergency Stop circuit prone to eventual
failure.

The model ES-TA-3F1 E-Stop Safety Module connects up to ten Emergency Stop
switches to the machine Emergency Stop control elements. The Emergency Stop
switches become the inputs to the Safety Module, which monitors the condition of both
contacts of each E-stop switch connected to it. The output of the E-stop Safety Module
consists of two redundant output switching channels, each of which is the series
connection of two force-guided relay contacts (K1 and K2 in Figure 3).

As recommended by the Control Reliability section of ANSI B11.19, outputs of the
E-Stop Safety Module consist of two contacts (K1 and K2). These contacts are
mechanically linked, force-guided contacts, allowing the Safety Module to monitor the
outputs for failures. If the Safety Module detects failure of any contact of either the input
E-stop switches or the output relays, the Safety Module output is disabled and cannot
be reset. The two switching output circuits of the Safety Module are rated for up to
250V ac at up to 4 amps (resistive load).

The model ES-TA-3F1 E-Stop Safety Module also provides a selectable (automatic or
manual) reset function.

Key to Categories

• A Functional Stop Category (0, 1 or 2),
per EN60204-1 and NFPA79, refers to the

type of stopping action required by the
guarded machine in question. Some
machines may be stopped safely,
immediately following a stop command
(removal of power); others, due to their
high speed, mass or momentum, would
run on following an immediate stop
command. These machines require power
to be provided to the guarded machine’s
braking system for a specified delay time,
to effect a controlled stop.
Category 0 Stop: immediate removal of
power, uncontrolled stop
Category 1 Stop: controlled stop with a
delay before power is removed from
guarded machine
Category 2 Stop: controlled stop with
power left available to the guarded machine
actuators

• A Safety Category (B, 1, 2, 3 or 4), per
EN954-1, refers to “the performance of a

safety related part of a control system (or
circuit) with respect to the occurrence of
faults...” Of the many factors involved when
selecting an appropriate safety category,
hazard analysis, risk assessment and risk
reduction are among the most important.
The level of risk is based on the severity of
a potential harm and its probability of
occurring, which is used to determine the
appropriate performance of a control
system or circuit. Typically, as described in
Annex B of EN954-1, in cases where
serious injury is possible:

- Safety Category 2 would be selected

only if exposure to a hazard is
infrequent, and of a short duration.

- Safety Category 4 would be selected

if exposure to a hazard is frequent to
continuous, or if exposure is for a long
duration.

For more information, refer to standards
EN954-1, EN418, NFPA 79, EN60204-1 and
British Standard 5304:(1988).

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E-Stop Safety Module – Model ES-TA-3F1

The Safety Module has indicators for input power, E-Stop inputs, monitor inputs, reset
input and output relay status (see Figure 1). A selector for Auto or Manual Reset is
located under the control panel cover (see page 8 for instructions). See Sections 6 and
7 for information regarding troubleshooting and repairs.

Figure 1. ES-TA-3F1 status indicators

SECTION 2 – Emergency Stop Switch Requirements

As shown in Figure 3, each Emergency Stop switch must provide two contacts which
are closed when the switches are in the “ready” position. Once activated, the
Emergency Stop switch must open both contacts. The switch may be returned to the
closed-contact position only by a deliberate action (such as twisting, pulling or
unlocking). Additionally, NFPA79, section 13.2 Emergency Stop Devices specifies the
following switch (“stop control”) requirements:

• Emergency Stop push buttons must be located at each operator control station
and at other operating stations where emergency shutdown is required.

• Stop and Emergency Stop push buttons must be continuously operable from all
control and operating stations where located.

• Actuators of Emergency Stop devices must be colored RED. The background
immediately around the device actuator must be colored YELLOW. The actuator
of a push-button-operated device must be of the palm or mushroom-head type.

• The Emergency Stop actuator must be either a momentary or self-latching type.

NOTE: Some applications may have additional requirements. The user must refer to all

relevant regulations.

WARNING. . .

Model ES-TA-3F1
Emergency Stop Safety

Module is not a point-of­operation guarding device, as defined
by OSHA regulations. It is necessary to

install point-of-operation guarding
devices, such as safety light screens
and/or hard guards, to protect
personnel from hazardous machinery.

Failure to install point-of-operation
guards on hazardous machinery can
result in a dangerous condition which
could lead to serious injury or death.

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E-Stop Safety Module – Model ES-TA-3F1

SECTION 3 – Mounting the E-Stop Safety Module

Mount the ES-TA-3F1 E-Stop Safety Module inside a lockable enclosure which has a
minimum rating of NEMA3 (IP54). The model ES-TA-3F1 E-Stop Safety Module is not
designed for exposed wiring. It is the user’s responsibility to house the Safety
Module in an enclosure with NEMA 3 (IEC IP54). For security reasons, the key to the
lockable enclosure should be in the possession of a Qualified Person (see section 5.1,
Security Protocol).

The Safety Module housing may be mounted onto standard 35 mm DIN rail or may be
mounted directly to the backplate of the lockable enclosure, using the supplied
hardware. Leave a minimum 1 cm (1/4") gap between the Safety Module housing and
adjacent housings, to allow room for potential board replacement at a later date.

The ES-TA-3F1 E-Stop Safety Module should be configured before initial checkout and
use (see section 4.4 and 4.5).

Figure 2. ES-TA-3F1 Safety Module dimensions

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7.1 mm
(0.28")

7.4 mm
(0.29")

60.8 mm
(2.40")

149.0 mm
(5.87")

134.2 mm
(5.28")

DIN Mounting Tab

(Supplied)

110.0 mm
(4.33")

35.0 mm
(1.38")

DIN Mounting Slot

Slot for Screws (2)
M3.5 x 0.6 mm (2)

75.0 mm
(2.93")

Combo Head (Phillips/Slotted) Screws
M3.5 x 0.6 mm x 14 mm (2) (#6 x 0.5" equivalent) (Supplied)

M3.5 mm Washers (2) (#6 equivalent) (Supplied)
M3.5 mm x 0.6 mm Nuts (2) (#6 equivalent) (Supplied)

Recommended torque is
16-20 in-lbs on mounting screws

E-Stop Safety Module – Model ES-TA-3F1

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SECTION 4 – Electrical Hookup and Initial Checkout

It is not possible to give exact wiring instructions for a device such as the model
ES-TA-3F1 E-Stop Safety Module which interfaces to a multitude of machine control
configurations. The following guidelines are general in nature.

The E-Stop Safety Module has no delay function. The output relay contacts open within
25 milliseconds from the time that any Emergency Stop switch contact opens. This
classifies the E-Stop Safety Module as a functional “Category 0” Emergency Stop
control as defined by NFPA 79 (National Fire Protection Association Standard for
Industrial Machinery) and EN418 (European Standard: “Safety of Machinery,
Emergency Stop Equipment, Functional Aspects – Principles of Design”).

4.1 Connection of Emergency Stop Switches

Connect the two poles of each Emergency Stop switch as shown in Figure 3. The
switches in Figure 3 are shown in their “ready” position with both contacts closed. See
Product Specifications on page 20 for E-stop switch input requirements.

NOTE: Jumper any unused inputs to simulate an emergency stop switch in the

closed-contact position.

4.2 Connection of Reset Switch

The circuit Reset switch can be any mechanical switch, such as a normally open
momentary switch, or a two-position key switch. The Reset switch must meet the
requirements listed in the Product Specifications on page 20. The Reset switch

connects between terminals 22 and 50 of the Safety Module.

The Reset switch must be located outside and not 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 operation. Any areas not
in full view must use supplemental guarding to detect personnel.

CAUTION . . .

Electrical Hazard

Always disconnect power

from the ES-TA-3F1 E-Stop
Safety Module and all power from the
machine being controlled before
making or removing any wire
connections.

Electrical installation and wiring must be
made by qualified personnel and must
comply with the NEC (National Electrical
Code), IEC 60204-1 and -2, and all
applicable local standards and codes.

CAUTION . . .

Do Not Use As A Safety

!

Safety Module is not to be used as a gate
or interlocking switch monitor. The use of
input devices other than emergency stop
switches (see section 2) may result in a
reduction in the safety category as
described by EN 954-1.

Switch (Interlock) Monitor

The ES-TA-3F1 E-Stop

WARNING . . .

Do Not Use Jumpers to

!

Bypass an E-stop circuit.