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

Tel: [phone]

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

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.

P/N 122365 rev. C

Tel: [phone]

3Banner Engineering Corp. - Minneapolis, MN USA - www.bannerengineering.com

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

Tel: [phone]

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

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.

P/N 122365 rev. C

Tel: [phone]

5Banner Engineering Corp. - Minneapolis, MN USA - www.bannerengineering.com

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

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

Tel: [phone]