Rockwell Automation 1000 User Manual

Safety Lockout
System

Bulletin 1000

User Manual

Important User Information

Because of the variety of uses for the products described in this publication,
those responsible for the application and use of this control equipment must
satisfy themselves that all necessary steps have been taken to assure that each
application and use meets all performance and safety requirements, including
any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this
guide are intended solely for purposes of example. Since there are many
variables and requirements associated with any particular installation,
Allen-Bradley does not assume responsibility or liability (to include intellectual
property liability) for actual use based upon the examples shown in this
publication.

Allen-Bradley publication SGI-1.1, Safety Guidelines for the Application, Installation
and Maintenance of Solid-State Control (available from your local Allen-Bradley
office), describes some important differences between solid-state equipment
and electromechanical devices that should be taken into consideration when
applying prod uct s such as tho se de sc ribe d in this pu blica tio n.

Reproduction of the contents of this copyrighted publication, in whole or part,
without written permission of Rockwell Automation, is prohibited.

Throughout this manual we use notes to make you aware of safety
considerations:

ATTENTION

Identifies infor matio n about practices or circumsta nces
that can lead to pers onal in jury or death, prop er ty d am age
or economic loss.

!

Attention st ate ment s hel p you to :

• identif y a hazard

• avoid a haza r d

• recognize the consequences

IMPORTANT

Allen-Bradley is a trademark of Rockwell Automation

Identifies informa tion that is critical for successful
application an d und ers ta ndin g of the pro du ct.

European Communities (EC) Directive Compliance

If this product has the CE mark it is approved for installation within the
European Union and EEA regions. It has been designed and tested to meet
the following directives.

EMC Directive

This product is tested to meet the Council Directive 89/336/EC
Electromagnetic Compatibility (EMC) by applying the following standards, in
whole or in part, documented in a technical construction file:

• EN 5008 1-2 EMC — Gen eric Emission S tandar d, Pa rt 2 — Indus trial

Environment

• EN 50082-2 EMC — Generic Immunity Standard, Part 2 — Industrial

Environment

This product is intended for use in an industrial environment.

Low Voltage Directive

This product is tested to meet Council Directive 73/23/EEC Low Voltage,
by applying the safety requirements of EN 61131-2 Programmable
Controllers, Part 2 — Equipment Requirements and Tests. For specific
information required by EN 61131-2, see the appropriate sections in this
publication, as well as the Allen-Bradley publication Industrial Automation
Wiring and Grounding Guidelines For Noise Immunity, publication 1770-4.1.

This equipment is classified as open equipment and must be mounted in an
enclosure duri ng op era tion to provide safety protec tio n.

Notes:

Table of Contents

Preface

Purpose of the Safety Lockout System . . . . . . . . . . . . . . . . . . . Preface-1

Safety Requirements and Guidelines. . . . . . . . . . . . . . . . . . . . . Preface-1

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preface-1

Description of Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preface-2

Simplified Wiring Diagram and

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preface-2

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preface-4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preface-4

Chapter 1 Installation Instructions

Chapter 2 Commissioning Box and Switch

Chapter 3 Operational Procedure

Component Function and Description. . . . . . . . . . . . . . . . . . . . . . . . 3-1

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Chapter 4 SLS Sequence of Operation

Chapter 5 Troubleshooting Guide

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SLS Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Appendix A Certification Documentation

Appendix B References

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Table of Con tents ii

Notes:

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Preface

Purpose of the Safety Lockout System

Safety Requirements and Guidelines

Definitions

The purpose of the Safety Lockout System (SLS) is to provide a highly reliable
and long-lived system for the isolation of a multi-motor machine (or portion
thereof) with such isolation operable from multiple remote locations.

The SLS is one subsystem in the machine control system. As is true in
installing any machine control system, it is necessary to follow the instructions
that accompany the control system. It is further necessary to follow the
requirements of the relevant regulatory bodies. These can include NFPA 70
(The National Electrical Code), NFPA 70E, NFPA 79, relevant OSHA
requirements and relevant State and Local codes.

• EN 50081-2 EMC — Generic Emission Standard, Part 2 — Industrial

Environment

• EN 50082-2 EMC — Generic Immunity Standard, Part 2 — Industrial

Environment

Safety lockout system (SLS) — Isolation system designed to meet lockout/
tagout requirements by the use of remote lockout switches, voltage
super visi on m onit or an d an isola ti on con tac tor havi ng po sit ive gu ide d aux ili ar y
contacts.

SLS box — SLS enclosure and components other than the SLS switches.
SLS swit c h — rem o te lo c kou t sw itch with ver if ic ati on light.
Expansion box — provisions for more than four (4) SLS switches.

Positive guidance — per IEC 947-5-1 is a performance relationship between
contacts o f diff e rent types (i. e ., N.O . and N.C.)

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Preface 2

Description of Use

Simplified Wiring Diagram and Sequence of Operation

The SLS switch shou ld not be us ed to initiat e norma l stop pin g of the system.
The normal system stop f unc tio n(s) s hou ld be us ed to sto p the syst em and
then, when necessary, the remote SLS switch can be used to initiate the
isolation of the system. When the SLS switch is operated for the purpose of
isolation, a white SAFE light will illuminate when the system is isolated. The
illumination of the SAFE light is the control indication that the electrical
power to the equipment on the machine fed through the SLS is de-energized
and isolat ed.

An SLS service technician must investigate, correct and log any abnormality.

After using the normal stop function, the machine operator can turn the SLS
switch from the ON to the OFF position and then lock the SLS switch in the
OFF position. This will cause the isolation contactor (IC) to drop out and arm
the SAFE pilot light. The voltage supervision relay ( V S R) will then monitor
the load side of the isolation contactor for voltages greater than 10V and will
monitor the posit ion of the isolatio n cont act or th rou gh it s norm a lly clos ed
positively guided auxiliary contact. If the voltage check is OK and the IC
auxiliary contact is closed, the VSR’s safety contacts will close, illuminating the
SAFE pilot light.

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Figure P.1 Typical SLS System Layout

IC

Preface 3

INCOMING

LINES

MOTION BUS

OR

HAZARD

PVSR

IC

SLS SW

PVSR

OFF

ON

SAFE

IC

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Preface 4

Figure P.2 Typical SLS System Layout

MAIN
ENCLOSURE

PLC

GRD INCOMING LINES

P
E

MAIN
DISC

SLS BOX

SLS EXPANSION
BOX

T
O

S
L
S

S
W
I
T
C
H
E
S

DRIVE DRIVE DRIVE

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TO MOTION BU S ON

MACHINE OR HAZARD

S
T
A
R
T
E
R

S
T
A
R
T
E
R

TO NON-MOTION BUS
ON MACHINE OR
NON-HAZARD

S
T
A
R
T
E
R

Preface 5

Application

Specifications

The SLS is an isolation system designed to provide disconnection and
isolation. This means that the SLS provides the isolation necessary for work on
machine elements electrically powered through the SLS and for work on the
electrical equipment powered by SLS. Howeve r, the forgoing speaks to the
capability of the SLS, not necessarily its use as assigned by management for a
given purpose.

Since the SLS illuminates the SAFE light, it is imperative that the SLS be
applied only where it disables all forms of energy and after a risk analysis has
been performed.

A. Electrical Ratings

• Supply Voltage 480V, 60 Hz and 400V, 50 Hz

• Contactor Ampacity 30, 85

(in conformance with clause 5.7.1 of NFPA 79: 1997, and
clause 4.3.2 of EN 602 04 -1: 1997)

B. Estimated system life

• SLS box

– Electrical 1,000,000 operations
– Mechanical 10,000,000 operations

• SLS switch

– Electrical 200,000 operations
– Mechanical 200,000 operations

C. Environmental

• Storage temperature –30…+85°C

• Operating temperature, Ambient –10…+40°C

• Relative humidity, Non-Condensing 90% RH

D. Electromagnetic Interference

Compliant with EMC Directives

E. Reliability

Syste m re li abilit y is in dicate d by F M E A an a ly s is.

F. Safety Lo ckout Sys t em

Certified by TUV (Northbrook, IL) for category 4 EN 954-1: 1996, and
EN 60204-1

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Preface 6

G. Construction

The SLS box enclosure is primarily provided to prevent tampering with
the SLS components and cir c uitry and, as such, is designed and listed
per UL 508A to be inst alled insi de another encl os ur e. The SLS box is
constr u c ted wi th a la rg e tra ns pa re n t viewing wind ow in the cover
necessary to easily observe the status of the LED indicators. Both the
SLS box and the SLS switch are provided with special holes placed to
accommodate tamper-resistant sealing.

H. Construction Rating (for SLS switch only)

NEMA4/IP65

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Chapter

Installation Instruc tio ns

A. The SLS box enclosure has no environmental rating. Its purpose is to

prevent tampering with the safety system and allow viewing of the
components. The SLS box shall be mounted in a parent enclosure of
suitable environmental rating with sufficient space to allow free opening
of its door a nd conv enient wiring of i t s connectors.

B. After installation the SLS system must be tested for proper operation

and certified as such by a SLS trained service technician, who then seals
the SLS box and the SLS switches. The engineer responsible for the
process or machine shall keep a service logbook of this and all future
servicing. Servicing is to be performed only by SLS qualified technicians.

1

C. SLS cable and cable installation specification

1. Cable must be installed so that it is protected from physical damage.
This may require conduit.

2. Cable must have a shield with a drain wire co nn ected to ground at
the SLS box .

3. Cable insulated for 600V is recommended.

4. Cable shall have copper conductors only.

5. Maximum SLS switch circuit length (total length of wire run):

2

#14 AWG (2.5 mm
#16 AWG (1.5 mm
#18 AWG (0.75 mm

6. Individual conductors within a cable shall be color coded or
otherwise clearly marked.

Suggested source and type of cable:

For SLS switches — Alpha wire Xtra-Guard 2 Part #25450/9 for
#14 AWG 0.64" O.D., Part #25440/9 for #16 AWG 0.61" O.D.,
and Part #25430/9 for #18 AWG 0.55" O.D.
(SLS switch cable must not be run with power conductors.)

) = 4600 ft (1403 m)

2

) = 2600 ft (793 m )

2

) = 1300 ft (397 m)

D. SLS box ground bus must be bonded to the system ground bus in the

main enclosure as follows:

1. For 85 A SLS box with Pilz relay (Cat. No. 1000-NXSLSV85) use

2

#8 AWG (10 mm

2. For 30 A SLS box with Pilz relay (Cat. No. 1000-NXSLSV30) use
#10 AWG (6 mm

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).

2

).

1-2 Installation Instructions

Note: If the Class J fuses protecting the SLS box are smaller than that
specified, the equipment grounding conductor may be reduced to that as
shown in Tab le 25 0- 95 of the N E C.

E. This SLS box has Harting connectors for four SLS switches with safe

light (Cat. No. 1000-NXSLS). If less than that fou r are needed for an
installation, jumper out the unneeded SLS switches in the male end of
the Harting connector. Refer to wiring diagram Y-155798.

Example: If SLS #4 is not needed, remove the hood on the male
Harting SLS connector and install a jumper between pins #3 and #8 on
the insert and install another jumper between pins #4 and #9 on the
insert. This will jumper out the missing SLS switch #4. Re-install the
hood and clamp the male Harting connector back in the SLS #4
position.

F. If an installation requires more than four SLS switches, an expansio n

box(es) can be installed to in crea se the tota l num ber of SLS swi tche s.
Refer to drawings Y-156773 and Y-157131.

G. The SLS enclosure must be bolted to the mounting plate of an enclosure

in the vertical position. Refer to dra wi ng YD-24475 for mounting
dimensions.

H. The SLS box must be protected upstream from the isolation contactor

by a Class J time delay fuse. Maximum available fault current is 42 KA at
480V. In order to ensure IEC 947-4-1 Type 2 or better protection, fuses
are to be sized per NEC Article 430 part D, but shall not exceed the
following:

85 A cont actor size = 100 A max.
30 A contactor size = 30 A max.

I. Power wire size and terminal torque

Table 1.A

SLS Rating Cat. No. Power Wire Size Terminal Torque

30 A with P i lz relay 1000-NXSLSV30 #14…#6 AWG

(2.5…16 mm

85 A with P i lz relay 1000-NXSLSV85 #14…#2 AWG

(2.5…50 mm

2

)

2

)

31 lb-in. (3.5 Nm)
+0%…5%

52 lb-in. (6 Nm)
+0%…5%

J. SLS switch in stallation

1. Mount in the vertical plane per drawing YD-24492.

2. Use conduit and hub or strain relief cord grip.

3. Connect SLS cable to terminal blocks that correspond to the pin
numbers on the Harting connectors per drawing Y-156328.

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Chapter

2

Commiss ioning Box and Switch

This procedure is to be followed at first time startup and any subsequent SLS
service.

A. Inspection

1. Visually inspect enclosure and components for damage that may
have occurred in installation or shipment. Look for loose wires or
damaged components.

2. For first time ins t allati on, rem o ve adh e sive pro tect iv e pape r cover
from SLS box wind ow .

3. Check incoming and outgoing three phase power lines for proper
selection and siz ing. Sel ect per NEC arti cle 43 0 par t B and size per
NEC tabl e 310-16 , 75°C column. Note that the preferred wire,
MTW, is rated 90°C, but it must be size d per th e 75°C column.

4. Check incoming and outgoing lines along with associated line voltage
control wires that attach to the isolation contactor for proper torque.
Refer to wirin g dia gra m fo r va lue s. Also c heck tha t the lug s do not
crimp down on the wire insulation.

5. Check to see that the proper class J time delay fuse is installed ahead
of the SLS box. Refer to wiring diagram notes and see item H under
“Installation Instructions”.

6. Check to see that the proper size grounding conductor has been
installed between the ground bus in the main enclosure and the
ground bus in the SLS box (refer to item D under “Installation

Instructions”). Refer to NEC Table 250-66 for sizing.

7. Verify that the SLS switches are connected to the SLS box and that
unneeded SLS switches are jumpered out in the Harting connectors
as per item E under “Installation Instructions”.

8. Inspect SLS cable installation for protection against damage. Refer to

item C under “Installation Instructions”.

9. If required, check to see that white phenolic nameplate on the SLS
switch cover is engraved as specified. Also check to see that screws
that secure this nameplate to cover are resealed on the inside of cover
when nameplate is replaced. This is to ensure NEMA Type 4 (IP65)
watertight construction.

10.Verify that the control transformer primary and secondary is
connected per the system voltage per not e #4 on wiring diagram
Y-155798. Refer to Appendix A.

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2-2 Commissioning Box and Switch

B. Verification of SLS operation

1. Turn all SLS switches to the ON position.

2. Check the machine to see that damage or injury will not occur if the
machine is started.

3. En e rgi ze the motion bu s tha t the SLS box con tactor controls.

4. Check for machine operation an d by operating with the norma l start
and stop functions. Check to see that the signals to the PLC and
drive are correct. Leave machine in the stopped mode.

5. Observe LEDs in SL S box for the following conditions:

• Power suppl y DC ON = on.

• VSR — POWER = on .

• Safety relay 1SR — POWER ON, CH1, CH2, K1, K2 = on.

• Safety relay SR — POWER ON, CH1, CH2, K1, K2 = on.

• LED termina l blo cks — PL US = on, 12 = of f, MI NU S = on.

6. All SLS switch SAFE lights should be o ff.

7. Check voltage on secondary of CCT.

8. Measure DC voltage on power supply output. If necessary, adjust to
27V.

9. One at a time, check the operation of each SLS switch by turning it
to the OFF position. Then check for the following:

• SAFE light on.

• IC dropped out.

• 1CR dropped out (refer to cross bar).

• Safety relay dropped out, LED — POWER ON = on, CH1, CH2,

K1, K2 = off.

• VSR indicates saf e condit io n. LE D — POWER = on, six phase

voltages = off.

• LED T.B. — PLUS = on, 12 = on, MINUS = on

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C. To provide an indicat ion of tamper in g, seal th e SLS box, the

SLS switches and the Harting connectors with a tamper-resistant
indicating seal. There are holes in the right hand side of the enclosures
for this and in the Harting connectors.

D. A service log shall be kept for each SLS box that keeps track of the

following:

1. Serial number of SLS box

2. Date of commissioning

3. Name of SLS commissioning technician

4. Name of the SLS service technician

5. Description of service performed

6. Date of ser vi ce

Component Function and

Chapter

3

Operational Procedure

The machine operat or shou ld not use the SLS to perfor m a norm al stop
function. The SLS should only be used to isolate the system. Machine access is
allowed only after the SLS switch is locked and tagged in the OFF position and
the white SAFE light is illuminated to verify that the system is indeed isolated.
If the white SAFE light fails to illuminate when the SLS switch is turned to the
OFF position, the machine cannot be considered isol ated nor safe. The
operator should not enter the machine, but should contact a SLS qualified
service technician.

Description

Table 3.A SLS Box

Component Cat. No. Source Description Repairable Function

Enclosure 32267-121-51 Allen-Bradley See-through cover Provides segregation and

protection of the SLS

components.
Mounting plate 32267- 122-02 Allen-Bradley Mounts equipment.
Control

transformer
Primary fuse block 1492-FB2C30-L Allen-Bradley Class CC rejection type

Primar y fuses KLDR Allen-Bradley

Second ary fuse
block

Second ary fuse KLDR Allen-Bradley

Power su pply PS5R-C/50W 24 V IDEC Current limiting 24VDC

Safety contactor 100S-C85D04C Allen-Bradley 85 A IEC safety contactor,

B075-1017-GA Micron 480/400 – 120/110V No Provides 120V for control circuit.

No Secures fuse and indicates

with blown fuse indication
Class CC fuse No Protec ts CCT primary.

or Littlefuse

1492-FB 1C30-L Allen-Bradley Class CC rejection type

with blown fuse indication
Class CC fuse No Protec ts CCT sec ondary.

or Littlefuse

with LED

120V coil

No Secures and indicates status.

No Provides current limited 24V DC

No Provides isola tion and s tatus

status.

for SLS circuit.

throug h N.C. pos itive guid ed

auxiliary.
2 N.O. auxiliary 100-SA20 Allen-Bradley 2 N.O. auxiliary No Provides control circuits with

positive guidance and

monito ring of power poles.
Surge suppressor 100-FSC280 Allen-Bradley 120V RC type No Absorbs coil spikes.

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