Banner ES-UA-5A, ES-VA-5A Instruction

ES-U A-5A and ES-VA-5A E-Stop Safety

Emergency
Stop
Devices
29YL

0 122365 1

Modules

Model ES-UA-5A for 12-24V dc/115V ac operation; Model ES-

VA-5A for 12-24V dc/230V ac operation

Original Instructions

• Monitors emergency stop devices, such as palm buttons and rope/cable
pulls, and positive-opening saf ety switches used f or guard/gate interlock­ing

• The safety inputs can monitor:

• Hard/relay contacts in a dual-channel hookup using terminals S11-S12

and S21-S22, or

• A +24V dc source switched by hard/relay contacts in single-channel

hookup

• Four normally open output switching channels for connection to control­reliable 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

Output RatingOutputsSupply VoltageModel

12-24V dc

ES-UA-5A

or

115V ac

12-24V dc

ES-VA-5A

or

230V ac

WARNING . . . Not a Point-of-Operation Guarding Device

This Safety Module is not a point-of-operation guarding device, as defined by OSHA regulations. It is necessary
to install point-of-operation guarding devices, such as saf ety light curtains 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.

N.O. Safety Outputs: 6 A4 Normally open safety
N.C. Aux. Outputs: 5 A1 Normally closed aux.
SS Aux. Outputs: 100 mA2 Solid-state aux.

5/2010P/N 122365 rev. C

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

Important ... read this before proceeding!

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 direct any questions regarding the use or
installation of this product to the factory applications department at the telephone numbers or address shown on
back cover.

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 involv ed with the installation and
use of this product must be thoroughly familiar with all applicable standards , some of which are listed below. Banner
Engineering Corp. mak es no claim regarding a specific recommendation of any organization, the accur acy or eff ec­tiveness of any information provided, or the appropriateness of the provided information for a specific application.

Applicable U.S. Standards

ANSI B11 General Safety Requirements
ANSI B11.19 Performance Criteria for Safeguarding
Contact: Safety Director , AMT – The Association for Manufacturing T echnology , 7901 W estpark Drive, McLean,

VA 22102, Tel.: [phone]

ANSI NFPA79, Electrical Standard for Industrial Machinery
Contact: National Fire Protection Association,1 Batterymarch Park, P.O. Box 9101, Quincy, MA 02269-9101,

Tel.: [phone]

ANSI/RIA R15.06, Safety Requirements for Industrial Robots and Robot Systems
Contact: Robotic Industries Association, 900 Victors Way, P.O. Box 3724, Ann Arbor, MI 48106, Tel.: 734-994-

6088

Applicable International Standards

ISO 12100-1 (EN292-1), Safety of Machinery – Basic Concepts, General Principles for Design, P art 1: Basic T ermi-

nology, Methodology
ISO 12100-2 (EN292-2), Safety of Machinery – Basic Concepts, General Principles for Design, Part 2: Technical

Principals and Specifications

IEC 60204-1, Electrical Equipment of Machines: General Requirements
IEC 61508, Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems
IEC 62061, Safety of Machinery – Functional Safety of Safety-Related Electrical, Electronic and Programmable

Electronic Control Systems
ISO 13849-1 (EN954-1), Safety of Machinery – Related Parts of Control Systems: Part 1 General Principles for

Design

ISO 13850 (EN418), Emergency Stop Devices
Contact: Global Engineering Documents, 15 Inverness Way East, Englewood, CO 80112-5704, Tel.: 800-854-

7179

2

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S34 S32 S35

S11 S12 S21 S22

S31 S32 S33

A1 A2 B1 B2

Y30 Y31 Y32

13 14 23 24

Y35 51

52

33 34 43 44

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

Overview

An Emergency Stop Safety Module is used to increase the control
reliability of an emergency stop circuit. As shown in the hookup
drawings, the models ES-UA-5A and ES-VA-5A E-Stop Safety
Modules (the Safety Modules) are designed to monitor a 1­channel or 2-channel E-stop switch. A 2-channel E-stop switch
has two electrically isolated contacts.

Figure 1: Features and terminals

Safety Circuit Integrity and ISO 13849-1 Safety Circuit Principles

Safety circuits inv olv e the safety-related functions of a machine that minimiz e the le v el of risk of harm.These safety­related 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 sev eral f actors, including f ault toler ance, risk reduction, reliable and w ell­tried 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
performance (i.e., integrity) must be incorporated into its design. Standards that detail safety performance levels
include ANSI/RIA R15.06, ANSI B11 and B11.19, OSHA 29CFR1910.217, and ISO 13849-1 (EN954-1).

Safety Circuit Integrity Levels

Safety circuits in international and European standards are segmented into categories, depending on their ability to
maintain their integrity in the event of a failure.The most recognized of these standards is ISO 13849-1 (EN954-1),
which establishes five levels: Categories B, 1, 2, 3, and the most stringent, Category 4.

In the United States, the typical level of safety circuit integrity has been called "control reliability." Control reliability
typically incorporates redundant control and self-checking circuitry and has been loosely equated to ISO 13849-1
Categories 3 and 4 (see CSA Z432 and ANSI B11.TR4).

If the requirements described by ISO 13849-1 are to be implemented, a risk assessment must first be performed to
determine the appropriate category , in order to ensure that the e xpected risk reduction is achiev ed.This risk assess­ment must also take into account national regulations, such as U .S. control reliability or European "C" le vel standards,
to ensure that the minimum mandated level of performance is complied with.

WARNING . . . Safety Categories

The level of safety circuit integrity can be greatly impacted by the design and installation of the saf ety devices and
the means of interfacing of those devices .A risk assessment must be performed to determine the appropriate

safety circuit integrity level or safety category as described by ISO 13849-1 (EN 954-1) to ensure that the
expected risk reduction is achieved and that all relevant regulations and standards are complied with.

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ES-UA-5A and ES-VA-5A E-Stop Safety Modules

Fault Exclusion

An important concept within the category requirements of ISO 13849-1 is the "probability of the occurrence of the
failure," which can be decreased using a technique termed "fault exclusion." The rationale assumes that the possi­bility of certain well-defined failure(s) can be reduced to a point where the resulting fault(s) can be, f or the most part,
disregarded – that is, "excluded."

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. Fault exclusion allows the designer to design out the possibility of various failures
and justify it, through the risk assessment process, to meet the intent requirements of Category 2, 3 or 4. See 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 saf ety system and comply with all relev ant la ws
and regulations.

While only two applications are listed below , 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 can not 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 . . . Emergency Stop Functions

Do not mute or bypass any emergency stop device. ANSI NFPA79 and IEC/EN 60204-1 require that the
emergency stop function remain active at all times.Muting or bypassing the Safety Outputs will render the
emergency stop function ineffective.

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, IEC/EN 60204-1, 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.

For Rope/Cable Pull installations only:

• The wire rope should be easily accessible and visible along its entire length. Markers or flags may be fixed on the
rope to increase its visibility.

• Mounting points, including support points, must be rigid.

• The rope should be free of friction at all supports. Pulleys are recommended.

4

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ES-UA-5A and ES-VA-5A E-Stop Safety Modules

Some applications may have additional requirements; comply with all relevant regulations. See the device man­ufacturer installation instructions for complete information (such as SSA-EB..-.. p/n 111880, or RP-RM83F.. p/n
141245 installation data sheets).

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 IEC 60947- 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.

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.

The design and installation of the interlocked guard and the safety switches should comply with ANSI B11.19,
ISO14119, and other applicable standards. See the device manufacturer installation instructions for complete infor­mation (such as SI-LS83/-LS100 p/n 59622, or SI-HG63 p/n 129465 installation data sheets).

Mechanical Installation

The Safety Module must be installed inside an enclosure. It is not designed for exposed wiring.It is the user’s re-
sponsibility to house the Safety Module in an enclosure with NEMA 3 (IEC IP54) rating, or better.

The Safety Module mounts directly to standard 35 mm DIN rail; see Dimensions.

Heat Dissipation Considerations

For reliable operation, ensure that the oper ating specifications are not exceeded.The enclosure must provide adequate
heat dissipation, so that the air closely surrounding the Module does not exceed the maximum operating temperature
stated in the Specifications. Methods to reduce heat build-up include venting, forced airflow (e.g., exhaust fans),
adequate enclosure exterior surface area, and spacing between modules and other sources of heat.

Electrical Installation

WARNING . . . Shock Hazard

Always disconnect power fr om the Safety Module and all po wer fr om the mac hine being contr olled bef ore
making any connections or replacing any component. Electrical installation and wiring muct by made by

qualified personnel and must comply with the NEC (National Electrical Code), ANSI NFPA79 or IEC 60204-1, and
all applicable local standards and codes.

It is not possible to give exact wiring instructions for a Safety Module which 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" E-stop control, as defined by ANSI NFPA
79 and IEC/EN 60204-1.

The Safety Module is powered by either a 12-24V dc supply at 4W or an ac supply (115V ac, model ES-UA-5A, or
230V ac, model ES-VA-5A) at 7VA.The safety inputs can be connected to:

• A +24V dc source that is switched by a hard/relay contact in single-channel hookup configuration, or

• Hard/relay contacts in a dual-channel hookup configuration using terminals S11-S12 and S21-S22.

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S12S22S11 S21

E-Stop E-Stop

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

Safety Input Device Hookup Options

The operation of all dual-channel hookup 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 (i.e. timing) requirement
between the channels.

The dual-channel hookup 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 fix ed.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 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 hookup configuration can not detect short circuits to secondary sources of +24V dc or detect
the loss of the switching function of the safety input de vice (i.e ., 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 de vices
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, installed and mounted in a positive mode.

• 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 at the
numbers listed on the last page.

Connection of Multiple Switches

Connect the poles of multiple switches, such as E­Stop 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 (see figure at right and the warning,
Multiple Switching Devices).

6

Figure 2: Series connection of multiple E-stop s witches

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S12S22

S11

S21

Safety Gate or Guard with end-of-travel stops and two
individually mounted Safety Interlocking Switches

OPEN

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

WARNING . . . Multiple Safety Devices

When two or more safety devices are used, each device must be individually actuated, causing a ST OP or
open-contact condition, then reset/rearmed and the Safety Module reset (if using manual reset mode).This
allows the monitoring circuits to check each device and its wiring to detect faults. Failure to test each device in­dividually in this manner could result in undetected faults and create an unsafe condition which could result
in serious injury or death.

NOTE:The minimum amount of time for the Module to detect a STOP condition is 15 ms .This "recovery time" (OFF­state) 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
positive-opening safety s witches must operate concurrently when
the guard or gate is opened (see figure at right).

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: Hookup using contacts from two
safety switches

Connection of Reset Switch

The reset circuit switch can be any mechanical s witch, such as a normally open momentary switch, or a two-position
key switch.The reset switch must be capable of reliably switching 12 to 30V dc at 20 to 50 milliamps. As shown in
the hookup drawings, 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 . . . Reset Switch Location

The reset switch must be accessible only from outside, and in full view of, the hazardous area. Reset
switches must also be out of reach from within the safeguarded space, and must be protected against
unauthorized or inadvertent operation (e.g., through the use of rings or guards). If any areas are not visib le from
the reset switch(es), additional means of safeguarding m ust be provided.Failure to do so could result in serious
bodily injury or death.

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ES-UA-5A and ES-VA-5A E-Stop Safety Modules

WARNING . . . Reset Routine Required

U.S. and international standards require that a reset routine be performed after clearing the cause of a stop condition
(e.g., arming an E-stop button, closing an interlocked guard, etc.).Allowing the machine to restart without ac-

tuating the normal start command/device can create an unsafe condition which could result in serious injury
or death.

Automatic Reset Mode

The Safety Module may be configured (via hookup) for automatic reset. If no MSC contacts are monitored, 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 hazar dous machine motion, until an alternate reset pr ocedure
is performed. The alternate procedure must include a reset/restart switch, located outside the area of dangerous

motion, which is positioned so that any area of dangerous motion may be observed by the switch operator during
the reset procedure. See Warning.

Connection to the Machine to be Controlled

The machine hookup diagrams show 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.

In operation, if one of the switching contacts of either MPCE f ails 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 haz-

ardous condition and will prevent a successive machine cycle.

8

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*

*

*

*

MSC1

E-Stop Switch

MSC3

MSC2

MSC Monitor

Contacts

or Jumper for No

Monitoring

MSC Monitor

Contacts

or Jumper for No

Monitoring

L2

MSC1

MSC2

Machine

Master Stop

Control Elements

K1

A

6A max.

6A max.

6A max.

K2

A

K1

B

K2

B

K1CK2

C

MSC3

13

14

23

24

33

34

S32

S31

S21

S11

S12

S22

L1

Machine

Control

Circuits

MSC4

S34

S33

S32

S35

*

Arc Suppressors
(seeWARNING)

6A max.

K1DK2

D

MSC4

43 44

5A max.

K1

E

K2

E

51 52

Non-safety

Auxiliary Monitor

Contact

Y31

Y30

Non-safety

Monitor Outputs

100 mA max.

each Output

Outputs

Energized

PowerSupply

Fault

Outputs

Energized

PowerSupply

Fault

dc common

+V

12-24V dc

Y32 Y35

Jumper

*

*

MSC1 MSC3

MSC2

L2

MSC1

Machine

Master Stop

Control Elements

K1

A

6A max.

6A max.

6A max.

K2

A

K1

B

K2

B

K1CK2

C

13 14

23

24

33

34

S32

S31

S21

S11

S12

S22

L1

Machine

Control

Circuits

MSC4

S34

S33

S32

S35

*

Arc Suppressors
(seeWARNING)

6A max.

K1DK2

D

43

44

5A max.

K1

E

K2

E

51

52

Non-safety

Auxiliary Monitor

Contact

Y31

Y30

Non-safety

Monitor Outputs

100 mA max.

each Output

dc common

+V

12-24V dc

Y32 Y35

Jumper

*

*

Reset Switch

MSC2

MSC3

MSC4

E-Stop Switch

115 ac or 230V ac

B2

B1

AC Power shown

A1 A2

(depending on model)

B2B1

dc

common

+V

DC Power shown

12-24V dc

A1

A2

ES-UA-5A

115V ac

ES-VA-5A

230V ac

ES-UA-5A

12-24V dc

ES-VA-5A

12-24V dc

AC or DC power
connections shown
are valid for either
auto or manual reset.

Auto Reset Manual Reset

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

Hookup Drawings

Figure 4: Hookup: 2-Channel E-stop applications

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*

*

*

*

MSC1 MSC3

MSC2

MSC Monitor

Contacts
or Jumper for
No Monitoring

MSC Monitor

Contacts
or Jumper for
No Monitoring

L2

Machine

Master Stop

Control Elements

K1

A

6A max.

6A max.

6A max.

K2

A

K1

B

K2

B

K1CK2

C

13 14

23

24

33

34

S32

S31

S21

S11

S12

S22

L1

Machine

Control
Circuits

MSC4

S34

S33

S32

S35

*

Arc Suppressors
(seeWARNING)

6A max.

K1DK2

D

43 44

5A max.

K1

E

K2

E

51 52

Non-safety

Auxiliary Monitor

Contact

Y31

Y30

Non-safety

Monitor Outputs

100 mA max.

each Output

Outputs

Energized

PowerSupply

Fault

dc common

+V

12-24V dc

Y32 Y35

Jumper

*

*

MSC1 MSC3

MSC2

L2

Machine

Master Stop

Control Elements

K1

A

6A max.

6A max.

6A max.

K2

A

K1

B

K2

B

K1CK2

C

13 14

23

24

33 34

S32

S31

S21

S11

S12

S22

L1

Machine

Control

Circuits

MSC4

S34

S33

S32

S35

*

Arc Suppressors
(seeWARNING)

6A max.

K1DK2

D

43 44

5A max.

K1

E

K2

E

51

52

Non-safety

Auxiliary Monitor

Contact

Y31

Y30

Non-safety

Monitor Outputs

100 mA max.

each Output

Outputs

Energized

PowerSupply

Fault

dc common

+V

12-24V dc

Y32 Y35

Jumper

*

*

Reset Switch

MSC1

MSC2

MSC3

MSC4

MSC1

MSC2

MSC3

MSC4

ES-UA-5A

12-24V dc/115V ac

ES-VA-5A

12-24V dc/230V ac

ES-UA-5A

12-24V dc/115V ac

ES-VA-5A

12-24V dc/230V ac

E-Stop
Switch

E-Stop
Switch

115V ac or 230V ac

B2

B1

AC Power shown

A1

A2

(depending on model)

B2B1

dc

common

+V

DC Power shown

12-24V dc

A1 A2

ES-UA-5A

115V ac

ES-VA-5A

230V ac

ES-UA-5A

12-24V dc

ES-VA-5A

12-24V dc

AC or DC power
connections shown
are valid for either
auto or manual reset.

Auto Reset Manual Reset

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

Figure 5: Hookup: 1-Channel E-stop applications

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ES-UA-5A and ES-VA-5A E-Stop Safety Modules

Overvoltage Category II and III Installations (EN 50178 and IEC 60664-1)

The Safety Module is rated f or Overvoltage Category III when voltages of 1V to 150V ac/dc are applied to the output
relay contacts. It is rated for Overvoltage Category II when voltages of 151V to 250V 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 Module can be used in an Overvoltage Category III environment (with voltages of 151V to 250V ac/dc)
if care is taken either to reduce the level of electrical disturbances seen by the Module to Overvoltage Category II
levels by installing surge suppressor devices (e.g., arc suppressors), or to install extra external insulation in order
to isolate both the Safety Module and the user from the higher voltage levels of a Category III environment.

Overvoltage Category III Installations

When output contact voltage 151V to 250V ac/dc is applied to the output contact(s): the 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 a multiplicity of 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 install appropriately-sized arc suppressors to protect the
Safety Module outputs. However , if arc suppressors are used, the y must be installed across the load being s witched
(e. g., across the coils of external safety relays), and never across the Safety Module's output contacts (see
WARNING, "Wiring of Arc Suppressors").

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 .There
are also two solid-state monitor outputs, each capable of s witching up to 100 mA at 12-24V dc. One output at terminal
Y32 follows the action of the output circuits (K1 and K2); the other output at terminal Y35 opens (low signal) when
there is a loss of power or a fault is detected. A typical use for these outputs is to communicate the status of the
Safety Module to a programmab le logic controller (PLC). See hookups for more information.These outputs are to

be used only for control functions that are NOT safety-related.

WARNING . . .Wiring of Arc Suppressors

If arc suppressors are used, they MUST be installed as shown across the actuator coil of the Master Stop
Control Elements (MSC1 to MSC4). NEVER install suppressors directly across the output contacts of the
Safety Module. It is possible for suppressors to f ail as a short circuit. If installed directly across the output contacts
of the Safety Module, a short-circuited suppressor will create an unsafe condition which could result in se­rious injury or death.

WARNING . . . Interfacing MSCs

NEVER wire an intermediate device(s) (e.g., PLC, PES, PC) between the Safety Module outputs and the
Master Stop Control Element it switches in such a manner that in the event of a failure there is a loss of
the safety stop command, OR in such a manner that the saf ety function can be suspended, overridden, or
defeated, unless accomplished with the same or greater degree of safety.

Whenever forced-guided, mechanically linked relays are added as intermediate switching devices, a normally
closed forced-guided monitor contact from each relay must be added to the series feedback loop between Safety
Module terminals S31 and S32.

P/N 122365 rev. C

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11Banner Engineering Corp. - Minneapolis, MN USA - www.bannerengineering.com

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

Initial Checkout Procedure

CAUTION . . . Disconnect Power Prior to Checkout

Before performing the initial chec kout procedure, make certain all power is disconnected fr om the machine
to be controlled.

Dangerous voltages may be present along the Safety Module wiring barriers whenever power to the machine
control elements is ON. Exercise extreme caution whenever machine control power is or may be present.

Always disconnect power to the machine control elements before opening the enclosure that houses the
Safety Module.

1. Remove power from the machine primary control elements.

2. Ensure the safety de vice is in a ST OP or "open-contact" state (e.g., actuate the E-stop switch to open its contacts).

3. Apply power to the Saf ety Module at terminals A1 and A2 or B1 and B2.Verify that only the Input P o wer indicator
is ON. If either input channel 1 or input channel 2 indicators are ON at this point, disconnect the input po wer and
check all wiring. Return to step 2 after the cause of the problem has been corrected.

4. Reset or otherwise cause the safety de vice to reach an ON or "closed-contact" state (e .g., 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.

7. Cause the safety device to generate a STOP or "open-contact" state (e.g., 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 chec kout 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 . . . Multiple Safety Devices

When two or more safety devices are used, each device must be individually actuated, causing a ST OP or
open-contact condition, then reset/rearmed and the Safety Module reset (if using manual reset mode).This
allows the monitoring circuits to check each device and its wiring to detect faults. Failure to test each device in­dividually in this manner could result in undetected faults and create an unsafe condition which could result
in serious injury or death.

The functioning of the Safety Module and the device(s) connected to it must be verified on a regular periodic basis
to ensure proper operation (see also the machine manufacturer’s recommendations).

1. With the machine running, cause the safety device to generate a STOP or "open-contact" state (e.g., actuate
the E-stop switch to open its contacts).Verify that the machine stops.

2. Reset or otherwise cause the safety device to reach an ON or "closed-contact" state. Verify that the machine
does not restart.

3. If using manual reset mode, close and then open the reset switch within 2 seconds.Verify that the machine
can be restarted by normal initiation.

12

Periodic Checkout Procedure

P/N 122365 rev. CBanner Engineering Corp. - Minneapolis, MN USA - www.bannerengineering.com

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ES-UA-5A and ES-VA-5A E-Stop Safety Modules

4. If more than one safety device is series-connected to the Safety Module, run the above chec kout procedure

individually for EACH device.

Repairs

CAUTION . . . Abuse of 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 by a physical impact to the housing. An internal relay ma y have f ailed in such a manner that its replace-

ment is required.

If the Module is not immediately replaced or repaired, m ultiple simultaneous failures may accum ulate such
that the safety function can not be guaranteed.

Do not attempt any repairs to the Module. It contains no field-replaceable components. Return it to the fac­tory for warranty repair or replacement: Contact Banner Factory Application Engineering at the address or the

numbers listed on the back page.They will attempt to troubleshoot the system from your description of the problem.
If they conclude that a component is defective, they will issue a return merchandise authorization (RMA) number
for your paperwork, and give you the proper shipping address.

Pack the Module carefully. Damage which occurs in return shipping is not covered by warranty.

Supply V oltage and Current

Overvoltage Category

Relay Outputs

Specifications

SpecificationCategory

AI-A2: 115V ac (model ES-UA-5A) or 230V ac (model ES-VA-5A) ±15% , 50/60Hz
BI-B2: 11V dc – 27.6V dc
Power consumption:approx. 4W/7VA
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.

Protected against transient voltages and reverse polaritySupply Protection Circuitry

Output relay contact voltage of 1V to 150V ac/dc: category III
Output relay contact voltage of 151V to 250V ac/dc:category III, if appropriate

overvoltage reduction is provided (see Ov ervoltage Category III Installations on page

11).
2Pollution Degree

4 normally open (N.O.) output channels and 1 normally closed (N.C.) auxiliary output
Each normally open output channel is a series connection of contacts from two

forced-guided (mechanically linked) rela ys , K1-K2.The normally closed Aux. output
channel is a parallel connection of contacts from two forced-guided relays, K1-K2.

Contacts: AgNi, 5 µm gold-plated
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

P/N 122365 rev. C

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Emergency
Stop
Devices
29YL

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

SpecificationCategory
switched in series (e.g., “dry switching”).To preserve the gold plating on the

contacts, do not exceed the following max. values at any time:

Min. voltage: 1V ac/dc
Min. current: 5 mA ac/dc
Min. power: 5 mW (5 mVA)

Max. voltage: 60V
Max. current: 300 mA
Max. power: 7 W (7 VA)

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:
Voltage: 15V ac/dc
Current: 250 mA ac/dc
Power: 5 W (5 VA)

Maximum
N.O. Safety Contacts (13-14, 23-24, 33-

34, 43-44): 250V ac / 24V dc, 6A resistive

B300, Q300 (UL508)
N.C. Auxiliary Contact (51-52): 250V ac

/ 24V dc, 5A resistive
B300, Q300 (UL508)

Minimum:
Voltage: 15V ac/dc

Maximum — IEC60947-5-1
N.O. Safety Contacts:
AC-1: 250V ac, 6A;DC-1: 24V dc, 6ACurrent: 250 mA ac/dc
AC-15: 230V ac, 3A;DC-13: 24V dc, 4APower: 5 W (5 VA)

Solid-State Outputs

N.C. Auxiliary Contact:
AC-1: 250V ac, 5A;DC-1: 24V dc, 5A
AC-15: 230V ac, 2A;DC-13: 24V dc, 4A

Mechanical life: > 50,000,000 operations
Electrical life: 150,000 cycles @ 1500 VA; 1,000,000 cycles @ 450 VA; 2,000,000

cycles @ 250 VA; 5,000,000 cycles @ 125 VA

NOTE:Transient suppression is recommended when switching inductive
loads. Install suppressors acr oss load. Never install suppressor s across output
contacts (see Warning,Wiring of Arc Suppressors).

Two non-safety solid-state dc outputs
Output circuits require application of +12-24V dc ± 15% at terminal Y31; dc common

at Y30.
Max. switching current: 100 mA at 12-24V dc
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).

35 ms max. (25 ms typical)Output Response Time

14

Tel: [phone]

P/N 122365 rev. CBanner Engineering Corp. - Minneapolis, MN USA - www.bannerengineering.com

Emergency
Stop
Devices
29YL

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

SpecificationCategory

Input Requirements

Indicators

Mounting

Vibration Resistance

Operating Conditions

E-stop switch: must have normally closed contacts each capable of switching 20

to 50 mA @ 12 to 30V dc; and must be open > 15 ms for a valid stop command.
Maximum input resistance 250 ohms per channel @ 24V dc supply voltage.
Maximum input resistance 25 ohms per channel @ 12V dc supply voltage.
Reset switch: must have one normally open contact capable of switching 20 to 50

mA @ 12 to 30V dc.
350 ms max.OFF-State Recovery Time

3 green LED indicators: Power ON , Channel 1, Channel 2
1 red LED indicator: indicates a fault condition (see Troubleshooting)

Polycarbonate housing. Rated NEMA 1, IEC IP20Construction

Mounts to standard 35 mm DIN rail track. Safety Module must be installed inside an
enclosure rated NEMA 3 (IEC IP54), or better.

10 to 60 Hz @ 0.35 mm peak displacement per UL 991
60 to 150 Hz @ 5 g max.

Temperature: 0° to +50°C (+32° to 122°F), (surrounding air)

Certifications

Max. Relative Humidity: 90% @ +50°C (non-condensing)
Cat. 4 PL e per EN ISO 13849-1; SIL 3 per IEC 61508 and IEC 62061Design Standards

P/N 122365 rev. C

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15Banner Engineering Corp. - Minneapolis, MN USA - www.bannerengineering.com

84 mm

(3.3")

45 mm

(1.8")

118.0 mm
(4.6")

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

Figure 6: Dimensions — in mm (inches)

Module will not reset

Fault LED OFF
Ch1 LED Flashing
Ch2 LED Flashing

No fault indicated

Fault LED OFF
Ch1 LED OFF
Ch2 LED OFF

No fault indicated

Power LED ON
Fault LED OFF
Ch1 LED OFF
Ch2 LED ON

Troubleshooting

Possible Causes / SolutionsIndicator StatusCondition
Waiting for manual reset:Power LED ON

• EDM monitoring contacts are not closed. Check MSCs.

• Check jumper at S32-S35 (auto reset) or S32-S33

• Check reset button connection.

E-stop button open:Power LED ON

• Connector loose.

• Re-arm E-stop button.

Ch.1 open; Ch. 2 closed:

• Check wiring to S11-S12.

• Check switch.

• Check connectors are properly seated.

(manual reset).

No fault indicated

Fault LED OFF

16

Ch.1 closed; Ch. 2 open:Power LED ON

• Check wiring to S21-S22.

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P/N 122365 rev. CBanner Engineering Corp. - Minneapolis, MN USA - www.bannerengineering.com

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

Ch1 LED ON • Check switch.
Ch2 LED OFF

Possible Causes / SolutionsIndicator StatusCondition

• Check connectors are properly seated.

Fault

Fault

Fault

Fault

Power LED ON
Fault LED ON*
Ch1 and Ch2 LED flashing alter-

nately
Power LED ON

Fault LED ON*
Ch1 LED OFF
Ch2 LED Flashing

Power LED ON
Fault LED ON*
Ch1 LED Flashing
Ch2 LED OFF

Power LED ON
Fault LED ON*
Ch2 LED ON
Ch1 LED ON

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.

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.

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 .

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

MSCs do not energize

All LEDs OFF

Dim LEDs

*Fault LED Flickers
Power LED ON

Fault LED OFF
Ch1 LED ON
Ch2 LED ON

Possible fault in machine control or wiring to mod­ule:

• Check input power connections or external fuses.

• Check connectors are properly seated.

Dim Power LED:

• Check power supply capacity and load.

Other LEDs dim:

• May glow during power-up (normal).

• Check power supply load and capacity.

This is normal while the Fault LED is ON.

Possible fault in machine contr ol 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.

P/N 122365 rev. C

Tel: [phone]

17Banner Engineering Corp. - Minneapolis, MN USA - www.bannerengineering.com

ES-UA-5A and ES-VA-5A E-Stop Safety Modules

EC Declaration of Conformity

Banner Engineering Corp. here with declares that ES-UA-5A and ES-V A-5A Emergency Stop Modules for industrial
control are in conformity with the provisions of the Machinery Directive (Directive 2006/42/EC), and all essential
Health and Safety Requirements have been met. Download the complete EC Declaration of Conformity as a PDF
file at http://www.bannerengineering.com/ESmodule

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Warranty: Banner Engineering Corp. will repair or replace, free of charge, any product
of its manufacture found to be def ective at the time it is returned to the f actory during
the warranty period.This warranty does not cover damage or liability f or the improper

application of Banner products.This warranty is in lieu of any other warranty either

expressed or implied.