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9M02-8978-A002-EN
Version 14

Safe-E-

Stop™

User Guide

SAFE-E-STOP

™

Personal Safety System

User Guide

9M02-8978-A002-EN

Summary of Contents for Safe-E-Stop MSD

Page 1: ...1 9M02 8978 A002 EN Version 14 Safe E Stop User Guide SAFE E STOP Personal Safety System User Guide 9M02 8978 A002 EN ...

Page 2: ...2 9M02 8978 A002 EN Version 14 Safe E Stop User Guide Revision History VERSION DATE NOTES 13 1 28 2018 Added cautions updated Fault finding and simplified frequency selection 14 2 2021 Rebranded ...

Page 3: ...nsider the reaction time of the system 9 2 10 Ethernet may not be used for safety critical function 9 2 11 General Safety Information 9 2 12 Intended Use 10 2 13 Improper Use 10 2 14 Equipment rating warning 11 3 Operating Principle 12 3 1 General 12 3 2 Radio Transmission 12 3 3 Telegram Security 13 4 Frequency Selection 14 4 1 Rules for Frequency selection 14 4 2 Site Planning 15 5 PSD and MSD C...

Page 4: ...net Address Configuration 37 8 7 MSD Operation 40 8 8 MSD Installation 40 9 System Commissioning 46 10 System Decommissioning 47 11 Parts Lists 48 11 1 System Part Numbers 48 11 2 Accessory Parts Lists 49 12 Maintenance 50 12 1 PSD Maintenance 50 12 2 MSD Maintenance 50 Appendix I Part Number Unit Configuration 52 Appendix II RF Channel Number vs Operating Frequency 54 Band B 433 434MHz 54 Band D ...

Page 5: ...ne operator MSD Machine Safety Device the unit connected into the hard wired E Stop wiring and monitoring systems PSS Personal Safety System the entire E Stop System PLC Programmable Logic Controller MASTER ADDRESS The Primary address used by the system to ensure adjacent systems is unique and will not cross talk SUB ADDRESS The appended address used to identify specific PSDs within a system COMM ...

Page 6: ... in the text All WARNINGS and CAUTIONS appearing in this manual are included below W A R N I N G S Y M B O L Meaning CAUTION Function Indicates that caution is necessary relative to the associated content and that the current information must be followed in order to avoid undesirable consequences 2 1 MSD wiring warning W A R N I N G The MSD must be hard wired in series with at least one E stop swi...

Page 7: ...s may result in no protection being provided to stop your machine which in turn could result in loss of ability to stop an impending emergency situation and may lead to injury or death 2 3 Verification of correct linking warning W A R N I N G After linking the PSD to the machine there should be a means for the operator to verify the connection several methods can be used including color coding num...

Page 8: ...bove may result in no immediate available protection being provided to stop your machine which in turn could result in loss of ability to stop an impending emergency situation and may lead to injury or death 2 5 No serviceable parts warning W A R N I N G There are no user serviceable parts in this PSD MSD system please return damaged units to Cattron or a Cattron authorized service centre for serv...

Page 9: ...rrounding hazards 2 8 The system may cause unexpected stop of the machine W A R N I N G The design of the machine shall consider the risk associated with an unexpected stop of the machine 2 9 The Safety analysis shall consider the reaction time of the system W A R N I N G The safety analysis of the application shall consider the reaction time of the system 2 10 Ethernet may not be used for safety ...

Page 10: ...authorized service center failure to comply will invalidate the warranty Only trained personnel may perform maintenance and repair on the product All repairs made by these authorized agents should be carried out in a suitably clean static safe environment free from contaminants such as metal filings water oil etc It is the user s responsibility to ensure that the product is maintained in good cond...

Page 11: ...lt in loss of ability to stop an impending emergency situation and may lead to injury or death C A U T I O N The choice of connection will be determined by the safety level required for the target application and machine To achieve SIL3 capable safety levels a dual channel connection approach will be required and is recommended but single channels are optional for lower safety levels and are also ...

Page 12: ... feature fully redundant hardware and safety critical software They individually and jointly meet the safety level of SIL3 according to ISO61508 The MSD polls the PSDs in turn and assigns a PSD an active slot if one is available The linked PSDs return the poll after each MSD poll forming a closed loop safety system 3 2 Radio Transmission The connection between the MSD and PSDs is performed by mean...

Page 13: ... equipment in use 3 3 2 System Address Your Personal Safety System uses 32 768 unique Master Addresses and 15 Sub Addresses per MSD one per each possible associated PSD This system address is contained in every telegram sent between the MSD and PSD The data is considered valid only when the address combination matches This is a safety measure to ensure that the MSD will act only upon its assigned ...

Page 14: ...uipment on site Selection of an appropriate operating frequency requires both knowledge of RF channels in use and the application of the rules set out below Table 1 Frequency Spacing by RF band BAND START FREQ HZ END FREQ HZ CH SPACING KHZ START CHANNEL END CHANNEL CH SPACING A 418 000 000 B 433 077 500 434 777 500 25 A00 A68 2 50kHz C 447 000 000 D 450 000 000 470 000 000 12 5 A00 Q00 4 50kHz E 8...

Page 15: ...hannel Spacing for Adjacent Systems BAND START FREQ HZ END FREQ HZ CH SPACING KHZ START CHANNEL END CHANNEL CH SPACING A 418 000 000 B 433 077 500 434 777 500 25 A00 A68 2 50kHz C 447 000 000 D 450 000 000 470 000 000 12 5 A00 Q00 4 50kHz E 868 000 000 F 902 600 000 927 500 000 100 A00 C49 2 200kHz NB channels are identified on the equipment by a three digit identity xnn see columns 5 and 6 above ...

Page 16: ...st match exactly only the Sub Address the first C in the example below must be different between PSDs but will be included in the range of Sub Addresses that the MSD is capable of using In summary A PSD only has ONE Sub Address and each PSD must have a different Sub Address An MSD has a range of Sub Addresses Both PSDs and MSD have a number of other parameters that must match exactly 5 1 PSD Confi...

Page 17: ...il Figure 2 MSD Configuration Label Figure 2 shows the labelling on the MSD the configuration example shown identifies this MSD as having a configuration of A 23 00 AO CB6A referring to Table 4 Band A 418MHz single channel 23 in that band Sub Address range A thro O and Master Address CB6A In this example the MSD is capable of operating with the PSD in Figure 1 above because the PSD has a matching ...

Page 18: ... F PSD 1 A R A 1 1 0 0 A 0 0 0 1 1 B B B 1 2 A 0 0 B 1 C G C 6 4 B 0 0 C 1 D O 0 4 2 6 K C B 6 A 1 E R Y 7 6 Y 0 0 L 1 F R Z 9 9 Z 0 0 O MSD 1 A A 1 1 A 0 0 A O 1 B B 1 2 B 0 0 A O 1 C C 6 4 C 0 0 A O 1 D 0 5 0 0 A O 1 E Y 7 6 Y 0 0 A O 1 F Z 9 9 Z 0 0 A O E F F F Table 5 Frequency Bands BAND FREQ MHZ TYPICALLY USED IN A 418 China B 433 EU Other C 447 EU Licensed D 450 NA and Other Licensed E 869 ...

Page 19: ...the PSDs E Stop switches Up to five out of a total of fifteen PSDs can be linked to an MSD at any one time If a PSD is linked to the MSD the MSD E Stop Safety Relays are then also subject to additional rules relating to the RF communication link between the PSD and MSD being uncorrupted and continuous as well as the PSD E Stop switch remaining out Corruption loss of the RF link or an E Stop switch...

Page 20: ...ime there is a change of displayed message and the backlight will remain on for 10 seconds 6 2 1 2 Radio signal level Monitoring The RF signal level is monitored and displayed on the PSD using a graphic icon as shown in Figure 4 More bars mean more signal Very low signal will be accompanied by the icon flashing Figure 4 RF Signal Level Monitoring 6 2 1 3 Battery Monitoring The estimated battery le...

Page 21: ...ED ERROR LED HAPTIC FEEDBACK DISPLAY PSD UNLINKED STATE PSD unlinked ESTOP pressed ESTOP Red 3 short pulses REL ESTOP PSD unlinked 1 short pulse LINK HOLD I Automatic 30 sec shutdown 3 short pulses SHUTDOWN Manual shutdown Follow Unlink process then press O for 3 sec 3 short pulses SHUTDOWN Links full Red 3 short pulses LINKS FULL MSD not seen Red Flashing Orange 3 short pulses MSD NOT SEEN When r...

Page 22: ...s to normal operation if no 2nd press within 5 seconds PSD ACTIVE Unlink PSD stage 2 within 5 seconds Press O again for 1 second Green flashing fast to off 1 short pulse at state transition to PSD unlinked Changes to PSD unlinked state above ESTOP pressed ESTOP Red flashing 3 short pulses ESTOP ESTOP pressed other PSD Red flashing 3 short pulses ESTOP ESTOP re opened Reopen ESTOP Green flashing 1 ...

Page 23: ... linked PSD is always available As this is not ideal the PSD warns the user if the signal is getting too low by flashing the status LED Red requiring action by the user changing the COMM LOSS LED to Orange displaying REDUCE RANGE on the display and Haptic vibration in groups of 3 pulses The user must move closer to the machine or risk causing an E Stop by COMM LOSS If a PSD moves out of range and ...

Page 24: ...dure that informs the MSD that the PSD user wants to leave the group in a controlled and safe way The user simply needs to press and hold the O button for 1 second until the Status LED starts to flash fast then release the O button for 0 5 seconds and then press the O button again for 1 second then the PSD will unlink from the MSD Note that if the O button is not pressed a second time within 5 sec...

Page 25: ...t clip provides a secure means to wear the PSD so that the E Stop switch is presented with the best possible aspect for immediate access in a safety critical application this is far superior to an end mounted switch that may even require a two handed approach to activate the switch Figure 6 PSD Belt Clip The Belt clip should be attached to a belt that is no wider than 1 5 inches 38mm to ensure tha...

Page 26: ...re or positioned so that the E Stop switch faces toward a wall and away from personnel Always fully charge the PSD before initial use the PSD s battery may be charged when it is partially discharged It is neither necessary nor advantageous to fully discharge the battery before recharging Return the PSD to Cattron for service or recycling and do not discard unwanted PSDs in the trash or incinerate ...

Page 27: ...40V AC 2 DC plug 9V DC output 3 DC power connection back of charger 4 Charging slot for PSD 1 x 5 Charger base 6 Charge status and power on LEDs 7 4 Six Bay Charger A six bay charger can charge up to 6 PSDs at a time Each PSD will fully charge within 3 hours Figure 10 Six Slot Charger Features 1 DC power connection 2 Charge status and power on LEDs 3 Quick reference information for charge status L...

Page 28: ...luminate RED to confirm the battery is charging normally When charging is complete and after removing the PSD the charge status LED will illuminate ORANGE for a few seconds Allow the charge status LED to go off before placing another PSD in the charging pod Table 12 Battery Charger Status indication TOP LED COLOR FLASH PATTERN MEANING GREEN FLASHING Battery s capacity is over 80 charged It is reco...

Page 29: ...that the PSD is on and linked to that machine NOTE 1 The MSD does not need a PSD to be connected in order to keep its E Stop Safety Relays closed as long as power is connected to the MSD and it has no faults these relays are held closed and the hard wired E Stop circuit is maintained only the COMM LOSS relays will be open without a PSD connected NOTE 2 The COMM LOSS relays are an automatic functio...

Page 30: ... provided by the E Stop relays in a single channel configuration If a single PSD is always to be used then use of the COMM LOSS relays will also provide additional status information Once one PSD is LINKED it is placed into service as an additional E Stop and the COMM LOSS relays are closed If a user fails to link their PSD and confirm that it is linked it will not be detected and the machine coul...

Page 31: ...ed by the E Stop relays Where a strong process is in place that ensures the users confirm that the PSD is LINKED before starting to work the use of the COMM LOSS relays may not be needed The Ethernet bus may also provide a way to give visual feedback of PSD status total number of PSDs Linked or using the Green button to light a lamp etc This then makes it possible to run the machine with the hard ...

Page 32: ...ers confirm that the PSD is LINKED before starting to work the use of the COMM LOSS relays may not be needed The Ethernet bus may also provide a way to give visual feedback of PSD status total number of PSDs Linked or using the Green button to light a lamp etc This then makes it possible to run the machine with the hard wired E Stop switch in use and no PSD in use The dual channel connection metho...

Page 33: ...us total number of PSDs Linked or using the Green button to light a lamp etc This then makes it possible to run the machine with the hard wired E Stop switch in use and no PSD in use The dual channel connection method below ensures a high level of reliability and monitoring is imposed provided the safety PLC inputs are OR d no single channel wiring fault will be possible Additionally if the machin...

Page 34: ...34 9M02 8978 A002 EN Version 14 Safe E Stop User Guide Figure 15 MSD Typical Dual Channel Connections When Using the COMM LOSS Relays ...

Page 35: ...igure 16 MSD Status Indicators 8 3 1 MSD LEDs The Status of the four Safety relays is indicated by the four red LEDs above the LCD display When the LED is on the NO terminal will be closed and when the LED is off and in all cases when the MSD has no power the NC terminals will be closed The four LEDs to the right of the LCD display relate more to operational status as follows STATUS POWER shows th...

Page 36: ...8 5 MSD Information and Setup The MSD LCD display in combination with the five pushbuttons to the left allow access to three different screens plus the bootup screen that shows the current firmware revision you can cycle around the screens by using the up down buttons on the MSD the screens are The default status screen See the table above The Ethernet IP Address Setting screen see the next sectio...

Page 37: ...s If the top center cover is removed from the MSD a dip switch can be found that is used to set the IP address Figure 17 IP Address Setting IP Address Setting is as follows To set Dynamic Address Selection DHCP Set all DIP switches to 0 To set a Static IP address the following process should be followed Unlink and turn off all PSDs Re boot the MSD by removing and re applying power The MSD has a pa...

Page 38: ...SINT co controller firmware revision 1st segment Minor Revision USINT co controller firmware revision 2nd segment 5 Get Status WORD Status summary of the device 6 Get Serial Number UDINT Serial number of HMS ABIC 7 Get Product Name SHORT_STRING Safe E Stop Table 16 Device Status Attribute 5 as Provided by the HMS ABIC BITS NAME VALUE DESCRIPTION 0 Owned 1 Module has an owner 1 Reserved Read as 0 2...

Page 39: ...ntly linked to MSD up to 5 PSD 0 empty field 1 15 PSD ID 16 255 not used 7 PSD2 ID Same 8 PSD3 ID Same 9 PSD4 ID Same 10 PSD5 ID Same 11 Offending PSD ID USINT 0 255 PSD ID broadcasted by the MSD to all other PSDs after an ESTOP or COMLOSS event to be shown on the PSD displays 0 no PSD event if MSD status is zero MSD wired ESTOP button if MSD ESTOP field is 1 1 15 Offending PSD ID 16 255 not used ...

Page 40: ...mits as directed and maintained in good order As long as the MSD remains powered on the only interaction that may be required will be the result of one or more PSDs going out of RF range resulting in communication loss for longer than 30 seconds This condition requires the remaining if any users to confirm that the user of the offending PSD was not subject to an accident To enforce this check all ...

Page 41: ...te protection level for the environment in which it is installed and also maintain the MSD within its stated operating parameters see appendix The enclosure should provide suitable mechanical rigidity IP rating etc the wiring should carry a suitable rating for voltage current insulation temperature rating etc The objective being the protection from fire and electrical hazards of the persons expose...

Page 42: ...42 9M02 8978 A002 EN Version 14 Safe E Stop User Guide 8 8 2 2 Secondary Enclosure Option Kit 2OPT 8637 A102 Dimensions Figure 19 Secondary Enclosure Dimensions ...

Page 43: ...option kit is available from Cattron Select a location to minimize any possible interference from RF sources such as motors Ideally install the MSD enclosure close to the area where the hard wired E Stop is located and where it can be viewed easily by users and maintainers An approved enclosure with a window is ideal All wiring entering the enclosure must be terminated inside the enclosure To prev...

Page 44: ...ce when using the external power supply this should also have a 1A overload protective device The Safety inputs are rated at 24Vdc 4Vdc Omni directional non polarized 8 8 5 MSD Terminals The MSD is fitted with spring clamp terminals to ensure reliable connections are continuously maintained These terminals require the use of a size 3 screwdriver to open the clamp for release CAUTION do not press t...

Page 45: ...similar or lower loss appropriate cables are available from Cattron and may have been provided with your system If the coaxial cable is going to an antenna remote from the MSD location keep it separate from any power carrying conductors and mount it within a metallic conduit system for protection If the MSD is mounted within a secondary enclosure correctly mount any metallic conduit with earth bon...

Page 46: ... reset switch has been installed and is accessible to the operators 8 Verify the antenna is mounted correctly and in such a way that it has good line of sight to the operating area and that the cables are secure 9 Apply power and observe that the MSD powers up correctly and the LCD is displaying LINKED PSD NONE 10 Verify that the machine can be started as normal 11 Verify that each of the existing...

Page 47: ...re that the machine is left in a fully operational state and that any hard wired E Stop switches are fully functional Decommissioning must be carried out by competent and trained personnel Equipment removed should be disposed of in compliance with local and national rules related to disposal and recycling of electronic equipment and batteries ...

Page 48: ...a Table 20 System Part Numbers Examples PSS PART NUMBER DESCRIPTION PSS 1 A R 1 PSS version 1 for Band A One MSD One Red PSD PSS 1 B R 2 PSS version 1 for Band B One MSD Two Red PSDs PSS 1 C R 3 PSS version 1 for Band C One MSD Three Red PSDs PSS 1 D R 4 PSS version 1 for Band D One MSD Four Red PSDs PSS 1 E O 5 PSS version 1 for Band E One MSD Five Orange PSDs PSS 1 F B 6 PSS version 1 for Band F...

Page 49: ...ands A B C D Antenna mount and Ground plane kit 900 2OPT 8637 A201 KIT Antenna mount Ground Plane Bands E F Antenna Cable 25ft 2CAB 6861 A001 Coaxial Cable RG58 25ft 7 69m TNC male to N Type Male Antenna Cable Nft 2CAB 9110 A601 Coaxial Cable TNC male to N Type Male custom length N Antenna 406 440MHz PRT 0001814 Antenna 406 440MHz Band A B Antenna 430 490MHz PRT 0001715 Antenna 430 490MHz Band C D...

Page 50: ...it for repair The PSD may be cleaned with warm soapy water using common dish washing soaps Stubborn stains may be removed with a cloth dampened with isopropyl rubbing alcohol Do not use Heavy industrial cleaners Citrus or oil based cleaners Ethanol denatured alcohol methylated spirits Acetone and acetone based cleaners Chlorine based cleaners bleaches Do not store your PSDs at elevated temperature...

Page 51: ... if necessary Remove power from the MSD then F3 can be removed by carefully pulling the fuse straight out using tweezers or needle nose pliers Replacement is the reverse of the removal procedure F3 is a 1 5A 125V slow blow ceramic fuse Cattron part number PRT 0001852 No further maintenance of the MSD should be required ...

Page 52: ...le 23 PSD and MSD Configuration Examples HARDWARE SECTION EXAMPLES CONFIGURATION SECTION EXAMPLES Version of MSD PSD RF Band PSD Color 1st RF Channel 2nd RF Channel Sub Address Master Address 1st Sub Band Chan dec Chan unit 2nd Sub Band Chan dec Chan unit SAC Start SAC End MA1 MSB MA2 MA3 MA4 LSB A Z A Z 0 99 A Z or 0 99 A O A O 0 E 0 F 0 F 0 F PSD 1 A R A 1 1 0 0 A 0 0 0 1 1 B B B 1 2 A 0 0 B 1 C...

Page 53: ...1 0 1 4 Band 915MHz 10PSDs Red Dual Channel C05L18 PSDs SA A thru J Master Address 1010 1 D R 6 V 0 5 0 0 A F C B 6 A Band 450MHz 6PSDs Red Single Channel V05 PSDs SA A thru F Master Address CB6A 1 E R 8 Y 0 6 0 0 A H E F F F 1 F R 15 K 0 9 V 0 0 A O 0 1 F C Band 915MHz 15PSDs Red Single Channel K09 PSDs SA A thru O Master Address 01FC Table 25 Example System Contents EXAMPLE PART NUMBER ITEMS INC...

Page 54: ...ast 50KHz 2 channels away from other frequencies in use Band D 450 470MHz This band starts at 450 000MHz channel spacing is 12 5KHz There are 1600 channels available and channel frequency is coded with a letter and two digits Channel A00 will be 450 000MHz Channel B00 will be 451 250MHz Channel Q00 will be 470 000MHz Band D Channel Spacing Rules If the MSD is to be installed less than 100m 330 fro...

Page 55: ...Band B Band D Band F 434 177 500 466 937 500 902 600 000 912 100 000 921 600 000 902 700 000 912 200 000 921 700 000 902 800 000 912 300 000 921 800 000 902 900 000 921 100 000 921 900 000 911 700 000 921 200 000 922 000 000 911 800 000 921 300 000 922 100 000 911 900 000 921 400 000 912 000 000 921 500 000 ...

Page 56: ...tion is subject to the following two conditions 1 This device may not cause harmful interference and 2 this device must accept any interference received including interference that may cause undesired operation EU Caution Hereby Cattron declares that the Safe E Stop system is in compliance with the essential requirements and other relevant provisions of Directive 2014 53 EC ...

Page 57: ...he antenna is securely attached to the ground plane If the above are correct check the resistance of the coaxial cable at the MSD between center and screen If it is short circuit the cable is faulty If it is open circuit then short circuit the connector at the antenna end and make sure that the connector at the MSD end now shows a short circuit If not the cable is faulty If all is OK remove the sh...

Page 58: ...hree times when the fault is initially detected The operator can unlink during this 30 seconds period to avoid a COMLOSS Return unit for service Battery Operating Time is Shorter than Expected The PSD operates for 14 hours on a fully charged battery at a temperature of around 20 C Very low temperatures will reduce this time and this is a feature of the battery technology and cannot be changed at m...

Page 59: ...in the MSD is faulty return to Cattron or an authorized service facility If the fuse no longer blows check all external wiring for an intermittent short circuit on the 24V line and correct Operating Range is Short If all PSDs have the same issue see System section above Cannot Reset Unit after a PSD Communication Loss Check the wiring and voltages between the reset input the external reset button ...

Page 60: ...on IEC60068 2 6 Free Fall IEC60068 2 64 Relay outputs 150VAC DC 10mA minimum to 6A maximum resistive load Overvoltage category II according to IEC60364 Humidity RH 10 95 non condensing Class 2 Altitude 2000m Ethernet IP port Full diagnostics data not safety rated Environment Pollution degree 3 Pollution degree 2 EMC MSD ETSI EN 301 489 3 V2 1 1 EN55032 Class A EN 61000 4 2 Level II EN 61000 4 3 30...

Page 61: ...bs Compatible Device PSD 1 x x PSD 1 x x Operating Temperature 0 C 32 C 32 F 104 F 0 C 40 C 32 F 104 F Storage Temperature 20 C 60 C 4 F 140 F 20 C 60 C 4 F 140 F Power Supply Input 100V 240V AC 50 60 Hz 0 58A max 100V 240V AC 50 60 Hz 2 2A max Charger Input 9V DC 2 2A 12V DC 7 0A DC port 12V 7 0A 24V 3 5A hardwire port Charger Output 4 2V DC 1 3A 4 2V DC 1 3A each position Charge Rate 1 3A 3 to 4...

Page 62: ...re Modes PSD Any failure of the PSD will lead to the PSD transitioning into a Safe State In Safe State the PSD will terminate all wireless communications the MSD will as a consequence detect a communication loss and open all the safety relays E Stop and COMM LOSS this will bring the machine to a safe state The display on the PSD will show ERROR 1 and the Error LED will flash MSD Any failure of the...

Page 63: ...ing 2 2 2 2 Verification of configuration warning 2 3 2 3 Verification of correct linking warning 2 4 Placement of PSD in charger warning 2 5 2 5 No serviceable parts warning 2 6 2 6 Regulatory warning 2 7 2 7 Awareness of PSD range and Hazards around the machine 2 8 2 8 The system may cause unexpected stop of the machine 2 9 2 9 The Safety analysis shall consider the reaction time of the system 2...

Page 64: ...64 9M02 8978 A002 EN Version 14 Safe E Stop User Guide ...

Page 65: ...UNCTION TYPE ACTION SAFETY PERFORMANCE LEVEL PROBABILITY OF FAILURE PER HOUR PFH Safety Function COMMUNICATION LOSS SIL3 PFH 1 58248e 09 ESTOP operation ESTOP SC3 SIL3 after initiating event PFH 1 90565e 09 Due to continuous product improvement the information provided in this document is subject to change without notice Cattron Support For remote and communication control systems support parts an...

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