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Safety Lockout System

1. MAIN PANEL EQUIPMENT GROUNDING CONDUCTOR EN EN Lee ee EY GRD i 7 T 3 BUS EN we v poA p SOS ZI 1 m Y MI Mi DC ON Hi He H3 I INCOMING LINES I 24VDC I DN 480V 60HZ F PRIMARY DR PREND eae I u PAPAS Fuses I PPS A 400V 50Hz I SO WATT I bi ES x do Gay i Li L2 43 INCL N Gan Nc I ne I I LN TRANS E I TILL IN 1 2 I I I 34 41 42 43 4 4422 26 27 10 WHITE D amas 1 Su Iakbder klod Ton kidsis jis s3j 11 Ug AIST DES tens mm 3 I P ATA Pl 440R ZBL220Z24 440R ZBL 220724 gens IA eng SAFETY RELAY SAFETY RELAY I SUPERVISION ISR pl SR I I RELAY l I 1L3 11 I I E S I E I 14 24 34 42 ER N INx A2 I TU MOTION BUS ep duech dee sase ck 34 44 i I m E EN 2 sagga a v y4 ys J TT T TT 8 35 4 5 26 32 40 3 33 7 8 91 EE all lid il alalela al2 o olo o a a a a 9 a a a 4 4 4 Wb 2 2j a 4 5 7 e 9 0 1j2 3 4 5j6 7 8j9 0j4 5 6 7 8 9 1 2 3 4 5 E nr KR i e Qu I IQ Dien I 15 10 19 Gy 2 I 44 I 18 l 350 l 37 l 43 719 re i 4219 Ca 2 sisi SLS2 SLS4 l I IEA AS el AAN uO Qe 10 Qe Qe Ot I I I I I 364 Qe 28 O 2 2940 O es 246 30 l I I I I I si Ors20 Gs ali Gs s Gies l I I I l 34449 Oj Sri Qu tO Qm Ga l I l l I l 39 7 r
2. gt is Il ae see oer ce Re y me lie ne E EE SAN min il In H KI 1 AA i Ver Cae I xS Se ie A des z S i N ut Um ee l i 7 OTE KEE EE i I I jl I I oo vf Lo i n i gt gt re gt I I Pek ra 1 1 1 i 1 1 lo li 1 1 I 1 i i i L Ze ES Ee i UT UA O r O een SAFE PILOT LIGHT O PHENOLIC NAMEPLATE O 4 44 BASE COVER SPECIAL INSTRUCTIONS 16 GREEN YELLOW GROUND WIRE 16 BLUE 8 32 TAPPED HOLE IN STAND OFF AND CORRESPONDING 136 DIA TO PREVENT TURNING NOTE ADD 187 DIA HOLE IN MTG RAIL 1 Publication 1000 UM 001B US P J uly 2000 Certification Documentation A 7 Table A D Composite Assembly of a Bulletin 194E SLS Switch Item Description Part Number Amount 1 Encl w M tg Pit Ref 32267 132 51 Eng Data 1 Ref 32267 133 01 2 194R Operating Handle Black 194R HS4 1 3 Phenolic Nameplate H 26553 1 3A 44 40 x 0 187 Pan Hd Stain St Screw 28010 068 01 2 4 800H Pilot Light 800H QR24W 1 4A 800H Nameplate Engrv SAFE 800H W 100E 1 5 194E 25 A Load Switch 194E A25 1753 1
3. Item Description Part Number Amount 8 Primary Fuses Kldr 0 75 A 25183 272 11 2 9 Secondary Fuse Block 1492 FB1C30 L 1 10 Secondary Fuse Kldr 0 75 A 25183 272 11 1 11 50 W Idec Power Supply PS5R D24 1 12 1005 85 A MCS Contactor 1005 C85D04C 1 12A IMCS Surge Suppressor 100 FSC280 1 128 MCS Auxiliary 2 N O 100 SA20 1 13 Pilz Relay PU3Z 24V 1 14 Timing Relay 100 FEA1SU22 1 15 Safety Relay 440R ZBL220724 2 16 MCS Relay 700 CF220D 1 16A Protective Cover 100 SCCA 1 16B IMCS Surge Suppressor 100 FSC280 1 17 Terminal Blocks 1492 H1 39 18 End Barrier 1492 N36 1 19 End Anchors 1492 N23 2 20 LED Terminal Blocks 1492 HM 2V24 3 21 End Barrier 1492 NM 40 3 22 Harting Insert Screw 09330102601 4 23 Harting Insert Screw 09330102701 4 24 Harting Hood 09300100422 4 25 Harting Base 09300100301 4 26 Sealcon CD21AAGY 4 26A Sealcon CD29AAGY 1 27 Harting M ale Insert Screw 09330242601 1 28 Harting Female Insert Screw 09330242701 1 29 Harting Hood 09300240421 1 30 Harting Base 09300240301 1 31 A B Logo 40009 100 52 1 32 Wiring Diagram Y 155798 Rev M 1 33 User Manual Pub 1000 UM 001A US P 1 34 LED Explanation Sheet 49000 082 01 1 35 Warning Label 32005 374 01 1 Publication 1000 UM 001B US P J uly 2000 Certification Documentation A 6 Figure A 3 Composite Assembly of a Bulletin 194E SLS Switch
4. 14 13 o lI II o Ko Kt ail SS LEGEND K3 34 33 d O x IN SLS BOX 44 F 43 O Publication 1000 UM 001B US P J uly 2000 Figure A 6 Test Panel Schematic Certification Documentation IN TEST PANEL SLS SWITCH 24V DC SEPARATE CONTROL z ab de CONTROL POWER OFF ON ms 16 im s fi de rer i O OK gt 31 Be H amp d4 1455 I I o I I SLS BOX I x I OFF DN SR i I I 14 Ok gt gt 13 14 lt i a7 gt TA de I j H I I i 15 I I O OK 1 23 24H ds Esa tapia T 0 uc i ON T IC b ae 43 d x C DRIVE DN 10 de 8 x C i IC OFF 7 8 gt l lt D e cen 22 x i BIET uH gt lt Y 42 CO x PILZ SLSI OFF ON o y SLS1 ON 5 i 3 gt O O lt r 5 3 A SLS2 OFF ON 9 h I SLS2 ON 2 i 1 G O o D a A SLS3 OFF ON o a SLS3 ON 9 i 10 gt O OK e 403 A SLS4 OFF ON 9 y I SLS4 DN 11 6 Oo OK ZK aD PLC PIN NUMBERS E LEGEND IN SLS BOX A 11 Publication 1000 UM 001B US P J uly 2000 A 12
5. 4 SLS switch expansion box Y 156773 Consult your r local 10 SLS switch expansion box Y 157131 Allen Bradley 4 SLS dimensions Sales Office 10 SLS dimensions 7 LED explanation sheet 49000 082 01 Rev A Publication 1000 UM 001B US P J uly 2000 A 2 Certification Documentation 5 54 i Am ALLEN BRADLEY l I L 3 SAFE Y l 4 44 n l lt O PHENDLIC NAMEPLATE O ex l 3 l I lt C gt l I I I i J l Daya E 2 COVER NOTE ADD 1187 DIA HOLE IN MTG RAIL ITEM 7A AND CORRESPONDING 136 DIA 8 3e TAPPED HOLE IN STAND OFF ITEM 7 TH PREVENT TURNING Diagrams Publication 1000 UM 001B US P J uly 2000 7F 7 75 6 6B 6C Figure A 1 Bulletin 194E SLS Sw itch Renewal Parts l l e yr 7C 7D 7B 7E in Oy ll V N Mo ELITE S i II I 6A x mi I I 3 li lt In Ine I I e I l I l l Certification Documentation A 3 Table A B Bulletin 194E SLS Switch Renewal Parts Item Description PartNumber Amount 2 A B Mounting Plate 32267 133 01 1 3 194R Operating Handle Black 194R HS4 1 4
6. Certification Documentation Figure A 7 Safety Lockout System Box Schematic TO PE EQUIPMENT TERMINAL IN GROUNDING o GRD BUS MAIN PANEL CONDUCTOR HJE D a EE i l E M gn T 1 l INCOMING LINES Fi ne EE A0DV 50H ar E 1 a tras t BUS 4B V 60Hz EO m 1 i I a y I I 13 1D ES fs I D BLACK CS 0 BLACK ais L PRIMARY KLDR LH Fuses GRD En CIO 0 WHITE i GRD Pe da da a E pa x LA Vos elu nv Gelz zl 1 1 a aB I I I A A I I I A B 44DR ZELZ2UZ2A I PILZ CATA PUBZ I I I L__SAFETY RELAY SUP I VOLTAGE SUPERVISION I I I i RELAY K1 AUX I a ee e A ed i aah L LER PUSE I a m YN A 1 K AUX SUP 43 Mj 4B 440R zeLeanze4 LLL SAFETY RELAY SR t CAS ES AA Jean RED IG ON VITE I l L a 1 uo a
7. 14 AWG 4600 FT 115 0 16 AWG 2600 FT 115 0 18 AWG 1300 FT li5n COLOR CODING FOR INDIVIDUAL CONDUCTORS POSSIBLE SOURCE AND TYPE ALHPA WIRE XTRA GUARD 2 PART 825450 9 FOR 14 AVG 64 D 25440 9 FOR 16 AWG 61 OD amp 25430 9 FOR 18 AWG 55 OD FOR SLS SWITCHES SLS SWITCH CABLE SHOULD NOT BE RUN IN A LINE VOLTAGE WIRE WAY 2 4 5 e D 8 7 IC AND ICR HAVE POSITVELY GUIDED lt DIRECT DRIVE gt CONTACTS 8 SLS SWITCH CONTACT WIRED BETWEEN TERMINALS Sel AND B2 ON THE SAFETY RELAY MUST CLOSE BEFORE DR AT THE SAME TIME AS THE SLS SWICH CONTACT WIRED BETWEEN TERMINALS SIO AND Sil ON THE SAFETY RELAY SEE Y 156328 FOR SLS SWITCH WIRING DIAGRAM 9 TOP MOUNTED 100 FA04 AUXILIARY CONTACT IS NOT REMOVABLE to USE CDPPER WIRE ONLY SELECT FOR 75 C 85 AMP TORQUE LINE AND LOAD S2lto in MAX WITH 5 32 4mm ALLENWRENCH 30 AMP TORQUE LINE AND LOAD 3ltb in MAX PANEL TU BE SERVICED CERTIFIED AND SEALED FOR USE BY SAFETY LOCKOUT SYSTEM TECHNICIAN ONLY ia THIS PANEL CONSIDERED AN OPEN TYPE IT MUST BE HOUSED IN AN ADDITIONAL AND SUITABLE ENCLOSURE D NOTE THIS PANEL HAS AN EXTERNAL VOLTAGE OF MORE THAN ONE SOURCE THE GROUND TERMINAL lt GRD N OR Nx OF EACH COMPONENT MUST BE CONNECTED DIRECTLY TO THE GRD BUS WITH THE PROPERLY SIZED GREEN YELLOW OR WHITE WIRE DAISY CHAINING IS NOT PERMITTED E THIS SLS
8. ST 381 0 Md SF 88 fo ez KELAY S f mm 15 75 re hme 400 02 ER 35 og A m 1 e i mm PANEL CHANNEL L 542 5 i D I le H Bn bes d A S IIS IIS 3 LED TERMINALS E J d x y amp 3 amp 2 x 3 4 31 7 9 DIA D m D m D SE eget Eget iet EE MOUNTING HOLES E s l as ES Ke L S 3 S 3 CG ETT T E 1 CENCLOSURE SHOWN W DOOR REMOVED gt DOOR SHOWN IN OPEN POSITION CONDUIT HOLE W 163 DIA BUSHING 414 1 00 h 25 4 GENERAL NOTES 1 gt DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 2 ALL DIMENSIONS ARE APPROXIMATE AND NOT INTENDED FOR MANUFACTURING PURPOSES Publication 1000 UM 001B US P J uly 2000 A 16 Certification Documentation Figure A 11 SLS Switch NEMA Type 4 Stainless Dimension Drawing 45 31 7 9 DIA MOUNTING HOLES I 159 L 538 Y 40 45 136 7 37 Ba i LM LG SAFE DES QUE 1 pen PILOT LIGHT iHa Hoo WHITE m il PILOT LIGHT NE TD TR KEN i LENS D E opi Qu ROOM FOR o x EE H o PHENOLIC NAMEPLATE o ku FOR CUSTOMER S Ver ar IDENTIFICATIUN TES II 9 50 v il 8
9. Terminal Block On when the 24V DC power supply output is on 12 Terminal Block On when IC and 1CR are off PVSR output is closed and an SLS switch is off 10 Timing Relay TR On when time delay is complete and output N 0 contact is closed Publication 1000 UM 001B US P J uly 2000 A 20 Certification Documentation Notes Publication 1000 UM 001B US P J uly 2000 Appendix B References A NFPA 70E 1995 edition NFPA 79 1997 edition B IEC 947 60204 1 954 1 Publication 1000 UM 001B US P J uly 2000 B 2 References Notes Publication 1000 UM 001B US P J uly 2000 References B 3 Notes Publication 1000 UM 001B US P J uly 2000 B 4 References Notes Publication 1000 UM 001B US P J uly 2000 Reach us now at www rockwellautomation com Wherever you need us Rockwell Automation brings together leading brands in industrial automation including Allen Bradley controls Reliance Electric power transmission products Dodge mechanical power transmission components and Rockwell Software Rockwell Automation s unique flexible approach to helping customers achieve a competitive advantage is supported by thousands of authorized partners distributors and system integrators around the world Allen Bradley BRUN Doer EU o Americas Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 European Headquarters SA NV
10. 16B MCS Surge Suppressor 100 FSC280 1 17 Terminal Blocks 1492 H1 39 18 End Barrier 1492 N36 1 19 End Anchors 1492 N23 2 20 LED Terminal Blocks 1492 HM 2V24 3 21 End Barrier 1492 NM 40 3 22 Harting Insert Screw 09330102601 Eng Data 4 23 Harting Insert Screw 309330102701 Eng Data 4 24 Harting Hood 309300100422 Eng Data 4 25 Harting Base 409300100301 Eng Data 4 26 Sealcon CD21AAGY Eng Data 4 26A Sealcon CD29AAGY Eng Data 1 27 Harting M ale Insert Screw 09330242601 Eng Data 1 28 Harting Female Insert Screw 09330242701 Eng Data 1 29 Harting Hood 09300240421 Eng Data 1 30 Harting Base 09300240301 Eng Data 1 31 A B Logo 40009 100 52 1 32 ULLabel 40006 315 01 1 33 Wiring Diagram Y 155798 1 34 CEMark 44006 076 05 1 35 Category 4 per IEC 954 Label Ref 32005 371 01 Get from Eng 1 36 Ground Symbol Label Make at Assembly 1 37 Renewal Parts List 49000 063 01 1 38 User Manual Pub 1 1000 UM 001A US P 39 LED Explanation Sheet 49000 082 01 1 40 Warning Label Ref 32005 374 01 Get from Eng 1 Publication 1000 UM 001B US P J uly 2000 A 10 Certification Documentation Figure A 5 Bulletin 440R ZBL220 Safety Relay Schematic CS 24V DC SEPARATE CONTROL PTC OFF ON v S10 e SCH zu K1 O O OK Ke i si S33 OS C1 E r E ja i Lo SH sai s42 KI O Ox RES O RES O x x ce IC CR INA x Ke
11. Publication 1000 UM 001B US P J uly 2000 54 Troubleshooting Guide Publication 1000 UM 001B US P J uly 2000 10 One at a time check operation of SLS switches by turning to OFF position and check for the following a b C d e SAFE light on IC dropped out 1CR dropped out Safety relay SR dropped out VSR indicates safe condition IL VSR voltage sensing broken wire detection test a With power off remove one voltage sensing wire from the VSR Then with all SLS switches in the ON position apply power and turn a SLS switch off The result should be that the safe light does not illuminate after cycling an SLS switch and the system fault LED is on The VSR voltage hazard LED will now turn on Turn power off reconnect voltage sensing wire and repeat check with the VSR redundant voltage sensing circuit Each separately do the same test with the two N circuits No initial fault on VSR only when the SLS switch is turned to off does the system fault light come on D Safety relay cable shorting checks a With all power off install a shorting jumper on Allen Bradley safety relay 700 Z BL between terminals S10 and S11 Then power up the system with all SLS switches in the ON position Turn a SLS switch to the OFF position The SAFE light should not come on Observe that CH2 and K1 LEDs are off on the safety relay Turn off all power and remove shorting jumper With all power off install a sh
12. AB Allen Bradley Safety Lockout System Bulletin 1000 User Manual Automation Im portant 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 SG I 1 1 Saf ty Guiddines fartheA pdictiay Installation and Maintenancecf Sdid StateCantrd 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 products such as those described in this publication 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 conside
13. Publication 1000 UM 001B US P J uly 2000 Certification Documentation Figure A 8 Safety Lockout System Box Schematic Continued REMOTE 24VDC A 13 FOR PLL INTERFACE AND E STOP 2 m PLC vi Ka PLC 45 113 HHH 14 h gt 17 ae REMOTE SAFETY RELAY CONTACTS PLC x ki Ke PLC 43 i o 123 I 24 19 20 SLD s21 81 x e 454 Xr LED s sas LS 42 x PLC PLO o3dd la rel 45 eS A B 44DR ZBL 220724 lt SAFETY RELAY qo d45 STATUS TO PLC 38 PLC 1SR STATUS TO DRIVE PLC 36 I 37 PLC PLC gt qu lt gt 6 lt a Ge SEN is 45 PLC gt ar Nes lt 21 285 ZO Gm Continued on next page Publication 1000 UM 001B US P J uly 2000 A 14 Certification Documentation Figure A 9 Safety Lockout System Box Connection Diagram TU PE TERMINAL IN
14. TERMINALS PLUS 1 GROUND 241 3 F SN Fe educi 875 i 222 3 IN uu I 1 17 A n Lee i c gt i na 194E 25 AMP d NE 1 EE n DIE Li r3 Pp 1 Il E ors quee a H Jo M EI og d uU or La Y HOLES FOR WIRE LEAD SEAL 1 26 2 00 32 0 50 8 5 04 128 0 BLACK HANDLE LOCKABLE IN THE OFF POSITION WHEN LOCKED OUT ENCLOSURE CANNOT BE OPENED n i 112 DIA HOLE FOR 3 4 CONDUIT GENERAL NOTES 2 63 D DIMENSIONS IN PARENTHESES ARE IN MILLIMETERS 66 72 2 ALL DIMENSIONS ARE APPROXIMATE AND NOT 2 00 50 85 Publication 1000 UM 001B US P J uly 2000 INTENDED FOR MANUFACTURING PURPOSES Certification Documentation A 17 Figure A 12 Safety Lockout System Switch Connection Diagram U SLS BOX CONNECTOR PIN NUMBERS 10 346 7 8 SGRD AUTE 3 R D e CTF 3 L2 S L3 N 13 1 FF o ena 4 TO 6 T3 l 2e Publication 1000 UM 001B US P J uly 2000 Certification Documentation A 18 Figure A 13 LED Explana
15. avenue Herrmann Debroux 46 1160 Brussels Belgium Tel 32 2 663 06 00 Fax 32 2 663 06 40 Asia Pacific Headquarters 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Automation Publication 1000 UM 001B US P J uly 2000 1999 Rockwell International Corporation Printed in the U S A
16. the motion bus that the SLS box contactor controls 4 Check for machine operation and by operating with the normal 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 SLS box for the following conditions Power supply DC ON on VSR POWER on Safety relay 1SR POWER ON CH1 CH2 K1 K2 on Safety relay SR POWER ON CH1 CH2 EL K2 on LED terminal blocks PLUS on 12 off MINUS on 6 All SLS switch SAFE lights should be off 7 Check voltage on secondary of CCT 8 Measure DC voltage on power supply output If necessary adjust to 27V 9 One at atime check the operation of each SLS switch by turning it to the OFF position Then check for the following e SAFE light on e IC dropped out e 1CR dropped out refer to cross bar e Safety relay dropped out LED POWER ON on CH1 CH2 K1 K2 off e VSR indicates safe condition LED POWER on six phase voltages off e LED T B PLUS on 12 on MINUS on To provide an indication of tampering seal the 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 A service log shall be kept for each SLS box that keeps track of the following 1 Serial number of SLS box Date of commissioning Nam
17. 1000 UM 001B US P J uly 2000 Preface 4 Figure P 2 Typical SLS System Layout 2 MAIN H a ENCLOSURE INCOMING LINES SLS BOX SLS EXPANSION BOX TO MOTION BUS ON MACHINE OR HAZARD TO NON MOTION BUS ON MACHINE OR NON HAZARD Publication 1000 UM 001B US P J uly 2000 Application Specifications Preface A 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 However 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 e Supply Voltage A80V 60 Hz and 400V 50 Hz e Contactor Ampacity 30 85 in conformance with clause 5 7 1 of NFPA 79 1997 and clause 4 3 2 of EN 60204 1 1997 B Estimated system life e SLS box Electrical 1 000 000 operations Mechanical 10 000 000 operations e SLS switch Electrical 200 000 operations Mechanical 200 000 operations C Environmental e Storage temperature 30 85 C e Operating temperature Ambient 10 40 C e Relative humidity Non Condensing 90 RH D Electromagnetic Interference Complia
18. 2 70 12 f I 1 d LA 4 LA 1 A oat L bd BOTTOM OF ENCLOSURE INSIDE VIEW NOTES 6 iH 1 WITH CONTROL POWER ON OUTPUT IS OPEN IF MEASURED VOLTAGE IS GREATER THAN LOVAC AND Y4 Y5 IS OPEN CLOSED IF MEASURED VOLTAGE IS LESS THAN 10VAC AND Y4 Y5 IS CLOSED REMOTE DEVICE 3 THIS SAFETY RELAY CHECKS FOR OPERATION OF THE SLS SWITCH AND CHECKS SLS CABLE FOR A FAILURE THE OUTPUT CONTACTS ARE REDUNDANT AND SELF MONITORING THEY WILL PREVENT THE ISOLATION CONTACTOR FROM ENERGIZING IN THE EVENT OF A FAILURE IN THE SLS SWITCH CIRCUITS OR THE SLS SWITCH 4 HI He H3 gt gt amp 8 erger gt gt a 3 8 x3 xe DI 5 THIS PANEL SHALL BE PROTECTED BY A TIME DELAY CLASS J FUSE 85 AMP ISOLATION CONTACTOR SIZE 100 AMP MAX 30 AMP ISOLATION CONTACTOR SIZE 40 AMP MAX MAX AVAILABLE FAULT CURRENT 42KA e 480V DISCONNECTING MEANS PROVIDED BY OTHERS AND IS LOCATED INSIDE THE MAIN CONTROL PANEL WHERE THE SLS PANEL IS ALSO LOCATED Publication 1000 UM 001B US P J uly 2000 SLS SWITCH CABLE SPECIFICATIONS 1 WHEN INSTALLED CABLE MUST BE PROTECTED FROM PHYSICAL DAMAGE THIS MAY REQUIRE CONDUIT MUST HAVE SHIELD WITH DRAIN VIRE 600 VOLT INSULATION RECOMMENDED COPPER CONDUCTORS MAXIMUM SLS SWITCH CIRCUIT LENGTH BETWEEN SLS SW AND SLS BOX OUT AND BACK 4 TIMES MAX WIRE LENGTH DIVIDED BY 8 lt TOTAL LENGTH DF WIRE
19. 5 26 a s I N T L 1 a amp 3 a Pe SLSI suse sss sis 1 Le e gt Table A E Composite Assembly of a Bulletin 100 85 A SLS Box with Pilz Relay Cat No 1000 NXSLSV85 Item Description Part Number Amount 1 End w M tg Plt Ref 32267 121 51 Eng Data 1 Ref 32267 122 02 2 Nameplate 49103 449 01 1 3 Panel Channel Panduit E 5x2W H6 Eng Data 1 3A Cover Panduit C 5W H6 Eng Data 1 4 Heyco Bushing SB 200 26 Eng Data 2 5 Ground Bus N70 12 1 Eng Data 1 6 Micron Transformer B075 1017 GA Eng Data 1 7 Primary Fuse Block 1492 FB2C30 L 1 Publication 1000 UM 001B US P J uly 2000 Certification Documentation A 9 Table A E Composite Assembly of a Bulletin 100 85 A SLS Box with Pilz Relay Cat No 1000 NXSLSV85 Continued Item Description Part Number Amount 8 Primary Fuses Kldr 0 75 A 25183 272 11 2 9 Secondary Fuse Block 1492 FB1C30 L 1 10 Secondary Fuse Kldr 0 75 A 25183 272 11 1 11 50 W Idec Power Supply PS5R D24 Eng Data 1 12 1005 85 A MCS Contactor 1005 C85D04C 1 12A MCS Surge Suppressor 100 FSC280 1 128 MCS Auxiliary 2 N O 100 SA20 1 13 Pilz Relay PU3Z Eng Data 1 14 Timing Relay 700 FEA1SU22 1 15 Safety Relay 440R ZBL220Z24 2 16 IMCS Relay 700 CF220D 1 16A Protective Cover 100 SCCA 1
20. 5A 194E Auxiliary Contact 1 N O 1 N C 194E A P11 1 5B 194E Adapter Kit 194E G3675 1 5C Operating Shaft 31013 314 01 1 6 Terminal Block Stand Off See Note 40164 416 01 1 6A Terminal Block M tg Rail See Note 1492 DR3 1 6B Terminal Blocks 1492 W M3 8 6C Grounding Terminal Block 1492 W M G3 1 6D End Barrier 42164 017 01 1 6E Partition Plate 1492 PPM 3 1 DE End Anchor 1492 EA15 1 7 Cap Plug 28470 007 01 1 8 Nameplate Stamp w Serial No H 25932 1 9 Trademark Plate H 18742 1 10 Wiring Diagram Y156328 1 11 Renewal Parts List 49000 064 01 1 Publication 1000 UM 001B US P J uly 2000 A 8 Certification Documentation Figure A 4 Composite Assembly of a Bulletin 100 85 A SLS Box with Pilz Relay Cat No 1000 NXSLSV85 WINDOW l ja 2 88 40 ENCLOSURE DOOR poor 4 E y 4 00 4 00 187 DIA 187 DIA 59 25 me Ta 125 DIA RS a DOOR MODIFICATION BASE MODIFICATION LEVER MODIFICATION 2 34 35 MOUNTED Y INSIDE 12 12A 12B Se Se B B Ses s Ee ne is 264 27 28 z 2 29 30 ENCLOSURE BASE Bai SES 5 N 22 23 24 2
21. Allen Bradley Protective cover No Prevents manual operation Terminal blocks 1492 H1 Allen Bradley Terminal blocks No Provides connections LED terminal 1492 HM 2V24 Allen Bradley LED terminal blocks No Provides indication of voltage blocks presence Harting connectors See Renewal Parts Harting Plug in connectors Yes Provides quick connection and List indication of tampering if sealed Table 3 B SLS Switch Component Cat No Source Description Repairable Function Enclosure 32267 132 51 Allen Bradley NEMA Type 4 SS Provides protection for SLS enclosure components Allows for tamper indication if sealed Mounting plate 32267 133 01 Allen Bradley M ounts components Operating handle 194R HS4 Allen Bradley Lockable position No Operates and provides for indicating operating lockout Enclosure cannot be handle opened when locked out Pilot light 800H QR24W Allen Bradley White 24V DC pilot light Yes Signals SAFE SLS switch 194E A25 1753 Allen Bradley 3 pole disconnect switch No Provides redundant signal through safety relay SLS switch 194E A P11 Allen Bradley Auxiliary contact No Provides SLS status to PLC auxiliary contact Publication 1000 UM 001B US P J uly 2000 Servicing Operational Procedure 3 3 Servicing is only to be performed by qualified SLS technician Due to the nature of this controller and the type of equipment used most all components are deemed non repairable and should be replaced
22. D s 8 5 VA a F I S 8 GLUBALTRAN amp e 15 Al FEWER SUPPLI GR 400V 50 HZ el 50 WATT Al 480v 60 Hz 5 i PRIMARY J y i E I PANEL CHANNEL 13 S NT gt 12 124 128 16 164 168 R K pa o d i I NES S s ES N SE ye a PILZ RELAY pen S y I SC SE IAN ge s El 1 35 35 ooo a E E EN PANEL CHANNEL 14 19 h BR H M NOR AL i H H a K N 7 lg 9 20 2 y y y g D x x D D SBz 2Bz us 9525 ges Boe ss Epae Sie c e Sixz sil Esp B sch s 882 EN EN EN ERN 26A 27 28 x 22 23 24 30 25 26 LIT E ENCLOSURE BASE SLSI SLS2 SLS4 SLS3 4 Ae amp BOTTOM Table A C Bulletin 100 85 A SLS Box with Pilz Relay Cat No 1000 N XSLSV85 Renewal Parts Item Description Part Number Amount 1 A B Enclosure 32267 121 51 1 2 A B Mounting Plate 32267 122 02 1 3 Panduit Panel Channel E 5x2W H6 1 3A Panduit Cover C 5WH6 1 4 Heyco Bushing SB 200 26 2 5 Ground Bus N70 12 1 1 6 Micron Transformer B075 1017 GA 1 7 Primary Fuse Block 1492 FB2C30 L 1 Publication 1000 UM 001B US P J uly 2000 Certification Documentation A 5 Table A C Bulletin 100 85 A SLS Box with Pilz Relay Cat No 1000 NXSLSV85 Renewal Parts Continued
23. PANEL IS CONFIGURED FOR 4 SLS SWITCHES THE NUMBER OF SLS SWITCHES MAY BE INCREASED BY THE USE OF SLS EXPANSION BOXES SEE Y 156773 FOR 4 AND Y 157131 FOR 10 ADDITIONAL SWITCHES AND INSTUCTIONS 22 SLS SWITCHES MAXIMUM TOTAL Certification Documentation A 15 Figure A 10 SLS Box with Pilz Relay 30 A Cat No 1000 NXSLSV30 and 85 A Cat No 1000 NXSLSV85 Dimension Drawing CONDUIT HOLE W 163 DIA BUSHING 41 45 16 00 406 4 200 12 00 50 8 304 8 37 ee Q4 BLOWN FUSE 7 00 11 9 4 INDICATOR 1 FUSE BLOCKS 177 8 2 8 i i t I s i X al a 0 0 D al 75 VA N S GLOBALTRAN amp POWER SOPFE alte 400V 50 HZ 30 WATT amp 480V 60 HZ Ie primary EOS J x PANEL CHANNEL 8 m H a ka HOLE FOR WIRE LEAD SEAL i loo u d xi d effet 3 15 00 RE
24. Phenolic Nameplate H 26553 1 4A 4 40 x 0 187 Pan Hd Stain St Screw 28010 068 01 2 5 800H Pilot Light 800H QR24W 1 5A 800H Nameplate Engrv SAFE 800H W 100E 1 6 194F 25 A Load Switch 194E A25 1753 1 6A 194E Auxiliary Contact 1 N O 1 N C 194E A P11 1 6B 194E Adapter Kit 194E G3675 1 6C A B Operating Shaft 31013 314 01 1 7 Terminal Block Stand Off See Note 40164 416 01 1 7A Terminal Block M tg Rail See Note 1492 DR3 1 7B Terminal Blocks 1492 W M 3 8 7C Grounding Terminal Block 1492 W M G3 1 TD End Barrier 42164 017 01 1 TE Partition Plate 1492 PPM 3 1 7F End Anchor 1492 EA15 1 8 Cap Plug 28470 007 01 1 9 Trademark Plate H 18742 1 10 Wiring Diagram Y 156328 Rev B 1 Publication 1000 UM 001B US P J uly 2000 A 4 Certification Documentation Figure A 2 Bulletin 100 85 A SLS Box with Pilz Relay Cat No 1000 NXSLSV85 Renewal Parts AB SS Allen Bradley a Em WINDOW E AAN QQG 7 8 6 ENCLOSURE DOOR A O CAES EE Al ERA RA PEO 4 f I X F Z Bg n I al 10 I
25. Power supply LED is on Pilz PU3Z power LED on All SLS switch SAFE lights are off All safety relay LEDs are on ICR is energized refer to cross bar Blown fuse pilot lights are off TB LEDs between and are on Co Do H gt CO N IC is open B The remote 24V DC signal is applied to 1SR at TB 34 and TB 35 causing it to close the circuit between wires 4 and 5 C Since the safety relay 1SR is energized and its contacts between 13 and 14 are closed IC will be energized actuating the IC auxiliary contacts and sending power to the motion bus Publication 1000 UM 001B US P J uly 2000 42 SLSSequence of Operation Publication 1000 UM 001B US P J uly 2000 D If an operator moves the SLS switch from ON to OFF the following will happen 1 The safety relay circuit between terminals S10 and S11 and S21 and S2 will open up to de energize the safety relay causing the safety contacts terminals 13 and 14 between wires 1 and 3 to open up In addition safety relay auxiliary contacts between terminals 33 and 34 and 43 and 44 will open dropping out 1CR This will cause IC to open up Note If one of the contacts on the SLS switch does not open or if there is a short in the cable to the SLS switch only one of the safety relay contacts K 1 or K2 will drop out IC But the safety relay will lock up and not allow a re start Now since one of the safety relay auxiliary contacts K 1 or K2 will remain
26. ble A F LED Explanation Item 1 Description Power Supply Indicator LED Certification Documentation A 19 Explanation DC on when 120V is applied 2 Control Transformer Sec Fuse Blown Fuse On when fuse is blown Control Transformer 2 Pri Fuses Blown Fuse On when fuse is blown Safety Relay 1SR LED e POWER on when 24V DC is applied e CH1 on when circuit 10 to 511 is closed e CH2 on when circuit 21 to B2 is closed e Kl on when internal relay K1 is energized e K2 on when internal relay K2 is energized Safety Relay SR e POWER on when 24V DC is applied e CH1 on when circuit 10 to S11 is closed because all SLS switches are in the ON position e CH2 on when circuit 10 to S11 is closed because all SLS switches are in the ON position e Kl on when internal relay K1 is energized e K2 on when internal relay K2 is energized Pilz Relay PVSR e POWER on when 24V DC is applied e VL1 L2 on voltage L1 to L2 is above 10V e VL2 L3 on voltage L2 to L3 is above 10V e VL1 L3 on voltage L1 to L3 is above 10V e VLI N on voltage L1 to ground is above 10V e VL2 N on voltage L2 to ground is above 10V e VL3 N on voltage L3 to ground is above 10V e SYSTEM FAILURE on when one of the eight voltage sensing connections is open or there is an internal fault in the PU3Z e VOLTAGE HAZARD on when measured voltage is greater than 10V Terminal Block On when the timer contact is closed
27. ch is moved back to the ON position the following will happen 1 The SLS switch contacts between the safety relay terminals S10 and S11 and S21 and B2 will close to energize the safety relay T his causes the safety contacts between terminals 13 and 14 between wires 1 and 3 to close Note The SLS switch contacts must close at approximately the same time or the safety relay will lock up This may denote an SLS switch or cable failure Also the contacts IC and 1CR between terminals S41 and S42 must be closed or the safety relay will not energize T his may indicate a failure of IC 1CR the SLS switch or the cable Plus safety relay auxiliary contacts between terminals 33 and 34 and 43 and 3 44 will close energizing 1CR 2 Since 1SR between wires 4 and 5 is closed along with 1CR between wires 3 and 4 and the safety relay SR output contacts between terminals 13 and 14 are also closed IC will close its output power contacts 3 The PVSR will detect a voltage and see that the circuit between terminals Y 4 and Y 5 is open causing the safety contacts between terminals 13 and 14 PVSR to open 4 All contacts in series with the SAFE light should now be open and the SAFE light will now be off The TB led between wire 12 and will be off Publication 1000 UM 001B US P J uly 2000 44 SLS Sequence of Operation Notes Publication 1000 UM 001B US P J uly 2000 Troubleshooting Guide Table 5 A SLS Box Troublesh
28. closed 1CR will remain energized preventing the SAFE pilot light from illuminating Also if the contacts IC and 1CR between terminals S41 and S42 on the safety relay have not re closed the safety relay will not allow a restart 2 After IC has dropped out the VSR will check for voltages greater than 10V on the load side of IC through its redundant and broken wire sensing circuit The VSR will also check to see that the N C positively guided auxiliary contact between wire 7 and 8 on IC is closed If these two conditions are met the VSR will close the safety contacts between its terminals 13 and 14 3 Since the auxiliary contact of IC between and wire 10 is closed the 1CR contact between wires 10 and 11 is closed the safety contacts between wire 11 and 12 are closed and the SLS switch contact between wire 12 and the SAFE pilot light is closed the SAFE pilot light will illuminate The TB led between wire 12 and is on E The SAFE pilot light will not come on with the SLS switch in the off position if 1 The VSR detects a voltage greater than 10V on the load side IC 2 The VSR detects that the positively guided N C auxiliary IC contact between wires 7 and 8 has not re closed 3 A safety relay auxiliary contact does not allow 1CR to drop out and close circuit between wires 10 and 11 4 The IC auxiliary contact between wires PLUS and 10 does not re close SLS Sequence of Operation 4 3 F Ifthe SLS swit
29. e of SLS commissioning technician Name of the SLS service technician Description of service performed Date of service D O1 H gt FA Operational Procedure Chapter 3 The machine operator should not use the SLS to perform a normal 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 O FF position and the white SA FE 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 isolated nor safe The operator should not enter the machine but should contact a SLS qualified service technician Component Function and 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 M ounting plate 32267 122 02 Allen Bradley M ounts equipment Control B075 1017 GA Micron 480 400 120 110V No Provides 120V for control circuit transformer Primary fuse block 1492 FB2C30 L Allen Bradley Class CC rejection type No Secures fuse and indicates with blown fuse indication status Primary fuses KLDR Allen Bradley Class CC fuse No Protects CCT primary or Littlefuse Secondary fuse 1492 FB1C30 L Allen Bradley Class CC rejec
30. fuse is installed ahead of the SLS box Refer to wiring diagram notes and see item H under Installation Instructions 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 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 Inspect SLS cable installation for protection against damage Refer to item C under Installation Instructions 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 note 4 on wiring diagram Y 155798 Refer to Appendix A Publication 1000 UM 001B US P J uly 2000 2 2 Commissioning Box and Switch Publication 1000 UM 001B US P J uly 2000 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 Energize
31. 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 e EN 50081 2 EMC Generic Emission Standard Part 2 Industrial Environment e 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 supervision monitor and an isolation contactor having positive guided auxiliary contacts SLS box SLS enclosure and components other than the SLS switches SLS switch remote lockout switch with verification light Expansion box provisions for more than four 4 SLS switches Positive guidance per IEC 947 5 1 is a performance relationship between contacts of different types De NO and N C Publication 1000 UM 001B US P J uly 2000 Preface 2 Description of Use Simplified Wiring Diagram and Sequence of Operation Publication 1000 UM 001B US P J u
32. ly 2000 The SLS switch should not be used to initiate normal stopping of the system The normal system stop function s should be used to stop the system 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 SA FE 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 isolated 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 VSR will then monitor the load side of the isolation contactor for voltages greater than 10V and will monitor the position of the isolation contactor through its normally closed 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 Preface 3 Figure P 1 Typical SLS System Layout HAZARD INCOMING EE MOTION BUS OR e 0 PVSR SLS SW OFF ON SAFE PVSR i H o j 7 I O OK IC Se d Publication
33. mponent Possible Cause Check Suggested Action Repairable Does not Pilot light Burnedoutbulb Connections Replace bulb Yes illuminate with all Loose Tighten connections other circuitry connections checking OK Contacts do not SLS switch Bad switch Continuity and operation Replace No operaie propery Handle For operation Replace No mechanism Contacts do not SLS switch Bad contact Continuity and operation Replace No operate properly auxiliary contact SLS Test Procedure If an SLS box needs to be removed from the main control panel it can be tested as follows Wiring diagram Y 155798 Rev M SLS box Y 156328 Rev B SLS switch Y 156386 Rev B test procedure control panel In addition to the normal Allen Bradley test procedure the following should also be done 1 D MS w I Connect test control panel per Y 156386 Rev B at PLC connector and power test panel with 24V D C separate control Connect four SLS switches wired per Y 156328 Rev B Apply 480V or 400V three phase to line side of isolation contactor Turn the four SLS switches to ON position Energize 1SR with selector switch on test control panel Observe all LEDs in SLS box for condition O bserve pilot lights on test control panel for condition SR 1SR IC and 1CR should be energized All SLS switch SAFE lights should be off Measure D C voltage on power supply output If necessary adjust to 27V Check voltage on secondary of CCT
34. nductor may be reduced to that as shown in Table 250 95 of the NEC E This SLS box has Harting connectors for four SLS switches with safe light Cat No 1000 NX SLS If less than that four 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 expansion box es can be installed to increase the total number of SLS switches 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 drawing Y D 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 contactor size 100 A max 30 A contactor size 30 A max I Power wire size and terminal torque Table LA SLS Rating Cat No Po
35. not repaired if they are not functioning properly Refer to Allen Bradley wiring diagram Y 156594 This is a schematic for the 700 ZBL220Z 24 and should aid in further understanding of the operation of the SLS switches and the safety relays Refer to Appendix A Reference to renewal parts list For renewal parts identification and placement refer to Allen Bradley document 49103 063 01 SLS box and 49000 064 01 SLS switch Refer to Appendix A Refer to Allen Bradley drawaing Y 156386 for test set up The entire SLS box may be returned to the factory for repair and or testing Consult your local Allen Bradley Sales O ffice regarding a Product Service Report PSR to initiate a factory repair Publication 1000 UM 001B US P uly 2000 3 4 Operational Procedure Notes Publication 1000 UM 001B US P J uly 2000 Chapter 4 SLS Sequence of Operation The following is the sequence of operation for the SLS box and the SLS switch as shown on Y 155798 Rev M and Y 156328 Rev B The intention is to provide an understanding of circuit operation and equipment function This will be an aid in troubleshooting because if the sequence stops or is incomplete the suspected part or failure may be narrowed down and identified Assumptions are made that the SLS has been installed properly no fuses are blown power is on all equipment is functioning correctly and all SLS switches are in the ON position A Status 1
36. nt with EMC Directives E Reliability System reliability is indicated by FMEA analysis E Safety Lockout System Certified by TUV Northbrook IL for category 4 EN 954 1 1996 and EN 60204 1 Publication 1000 UM 001B US P J uly 2000 Preface 6 G Construction The SLS box enclosure is primarily provided to prevent tampering with the SLS components and circuitry and as such is designed and listed per UL 508A to be installed inside another enclosure The SLS box is constructed with a large transparent viewing window 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 Publication 1000 UM 001B US P J uly 2000 Chapter 1 Installation Instructions 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 and convenient wiring of its 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
37. on Industrial Automation Wiring and G rounding G uidelines For Noise Immunity publication 1770 4 1 This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection Notes Preface Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Appendix Appendix B Table of Contents Purpose of the Safety Lockout System Preface 1 Safety Requirements and Guidelines Preface 1 Mulle Preface 1 Description of Use Preface 2 Simplified Wiring D iagram and Sequence of Operation Preface 2 Application AR ee ee ee ee ers Preface 4 Specificato hS cosi arais EA OR GEAL wow Pr RE rta Preface 4 Installation Instructions Commissioning Box and Switch Operational Procedure Component Function and Description 3 1 SENICI 145a ecdesia ri n e ee 3 3 SLS Sequence of Operation Troubleshooting Guide Troubleshooting Guide 5 1 SLS Test Procedure dans 5 3 Certification Documentation References Publication 1000 UM 001B US P J uly 2000 Table of Contents ii Notes Publication 1000 UM 001B US P J uly 2000 Purpose of the Safety Lockout System Safety Requirements and Guidelines Definitions Preface The purpose of the Safety Lockout System SLS is to provide a
38. on with wires removed on the contactor replace entire assembled device Safety contacts VSR Bad relay Refer to VSR literature Replace VSR No between terminal and LEDs on front of 13 and 14 will VSR for status not close and there is no voltage on load side of contactor and IC auxiliary is closed Publication 1000 UM 001B US P J uly 2000 5 2 Troubleshooting Guide Table 5 A SLS Box Continued Problem Component Possible Cause Check Suggested Action Repairable Safety contacts Safety relay SR Bad SLS switch SLS switch Replace SLS switch No ae Fault opens or SLS cable Repair or replace cable No not close short in SLS cable 1CR jammed on 1CR for operation Replace if necessary No IC jammed on For operation Replace entire contactor ass y No Powercircuitto Power LED off Reset power supply safety relay open Failed safety LEDs during operation Replace No relay Safety relay ISR Power circuitto Power LED off Reset power supply No safety relay open Failed safety LEDs during operation Replace No relay Won t pick up 1CR Open coil Flash light coil Replace No Open circuit to ES coil Welded contacts Replace No Won t drop out Welded contacts Replace No Foreign material Replace No Publication 1000 UM 001B US P J uly 2000 jam Table 5 B SLS Switch Troubleshooting Guide 5 3 Problem Co
39. ooting Guide Chapter 5 Problem Component Possible Cause Check Suggested Action Repairable e Low voltage on Control Loose Primary wired for proper Replace if nothing suspicious No secondary transformer connections voltage found e Low voltage on System voltage primary High voltage on Primary wired Voltage on input Replace if nothing suspicious No secondary wrong found Blown fuse Primary fuses Overload or short For correct wiring or Replace CCT if necessary and indicated in CCT fault in control circuit install correct size fuse as shown on the wiring diagram Blown fuse Secondary fuse Overload or short For correct wiring or Replace CCT if necessary and indicated in CCT fault in control circuit install correct size fuse as shown on the wiring diagram Low DC voltage on Power supply Overload low Adjust output voltage Replace if defective No oad side voltage on AC Check CCT voltage side output Does not pickup Contactor Low voltage Control voltage Open coil Flash light coil Replace entire assembled No contactor Open in coil Entire coil circuit circuit Foreign material Replace entire assembled No jam contactor Does not drop out Weldedcontact Coil voltage must be Replace entire assembled No or foreign zero contactor material jam Continuity or Auxiliary contacts Resistance of contacts Auxiliary contacts are locked No non operati
40. orting jumper on Allen Bradley safety relay 700 Z BL between terminals S21 and B2 Then power up the system with all SLS switches in the ON position Turn a SLS switch to the OFF position The SAFE light should not come on Observe that CH1 and K2 LEDs are off on safety relay Turn off all power and remove shorting jumper Troubleshooting Guide 5 5 13 IC contactor monitoring test a With all power off disconnect wire 7 on the IC auxiliary terminal 81 b Apply power with all SLS switches in the ON position Turn one SLS switch to O FF The safe light should not come ON because the VSR contacts K2 and K 1 between terminals 13 and 14 should not close The VSR will not show a fault light c Turn off power and reconnect wire 7 at terminal 81 on the IC contactor auxiliary d Apply power and cycle the 4 SLS switches to confirm system operation H Voltage sensing test The object is to determine whether the VSR contacts K2 and K 1 between terminals 13 and 14 remain open if a voltage is present on the load side of the contactor a To prepare remove 3 phase power primary and secondary fusing and apply 120V to wire 1 and 2 to power control circuit Also apply 3 phase voltage to load side of contactor b All SLS switches in ON position c Turn SLS switch s to off With voltage above 10V applied to the load side of contactor the VSR should show a voltage hazard LED and should not allow a SAFE light to come on Tes
41. rations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to e identify a hazard e avoid a hazard e recognize the consequences IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley is a trademark of Rockwell Automation European Communities EC If this product has the CE mark it is approved for installation within the Directive Compliance 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 e EN 50081 2 EMC Generic Emission Standard Part 2 Industrial Environment e 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 publicati
42. t is complete Disconnect all power remove metering remove test SLS switches install Harting connectors for shipment remove test control panel re install primary and secondary fusing check for loose connections and check to see if all jumpers are removed Publication 1000 UM 001B US P J uly 2000 5 6 Troubleshooting Guide Notes Publication 1000 UM 001B US P J uly 2000 Appendix A Certification Documentation A Listed as an open type controller per UL508A B TUV Reinland verification of FMEA checking condition of the SAFE light C Declaration of conformity CE marked Self certified to meet EN 60204 1 1997 D SUVA letter stating that MCS control devices 1CR and IC have positively guided auxiliary contacts that meet the requirements of IE C 947 5 1 E TUV Reinland certified to meet the requirements of category 4 EN 954 1 1996 in relationship to the SAFE light Documents Table A A Description Allen Bradley Drawing Number Revision SLS box wiring diagram Y 155798 sheet 1 2 and 3 Rev M SLS box dimension drawing YD 24475 Rev 5 SLS box renewal parts list 49000 063 01 Rev 3 SLS switch wiring diagram Y 156328 Rev B SLS switch dimension drawing YD 24492 Rev 3 SLS switch renewal parts list 49000 064 01 Rev 3 Test procedure wiring diagram Y 156386 Rev B Allen Bradley schematic wiring Y 156594 Rev B diagram for 700 ZBL safety relay SLS box composite assembly 49103 588 01 Rev D
43. this and all future servicing Servicing is to be performed only by SLS qualified technicians 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 connected 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 14 AWG 2 5 mm 4600 ft 1403 m 16 AWG 1 5 mm2 2600 ft 793 m 18 AWG 0 75 mm 1300 ft 397 m 2 2 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 X tra G uard 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 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 NX SLSV 85 use 8 AWG 10 mm 2 For 30 A SLS box with Pilz relay Cat No 1000 NX SLSV 30 use 10 AWG 6 mm Publication 1000 UM 001B US P J uly 2000 12 Installation Instructions Publication 1000 UM 001B US P J uly 2000 Note If the Class J fuses protecting the SLS box are smaller than that specified the equipment grounding co
44. tion e C85 100S ABNIUTEXT V dvd NUA N34409 G 0 75 VA GLOBAL TRAN 400V 90 HZ PRIMARY _ U 480V 60 HZ 0 I 08I00 31 26 pl 1 0 2I8 4 671 ei POWER SUPPLY 50 WATT TANNVHD T3NVd NY PILZ RELAY 000 700 FE RELAY O 49 IFA ALIAVS p2Z099 HZ dNOrF AV 14a ALFIAVS pezo 14Z a0vy7 leo ANNEL m 10 PANEL CH L EN o PEA EWH S67 4o0 CF aaon JIVWiy 3 NN Nid 0 YOLIFNNOI ONILAVH 7 VA17 3 FIVW Nid 0 YOLIAFNNOI ONILAVH JIVWiy FIVW Nid 0 YOLIFNNOI ONILAVH J I9W37 3 3 NN Nid 0 AOL 2 3NNDS ONILISVH JIVW1i 8 3 VW Nid ve 901 D3NNDOD ONIL AV ENCLOSURE SHOWN W DOUR REMOVED Publication 1000 UM 001B US P J uly 2000 Ta
45. tion type No Secures and indicates status block with blown fuse indication Secondary fuse KLDR Allen Bradley Class CC fuse No Protects CCT secondary or Littlefuse Power supply PS5R C 50W 24V IDEC Current limiting 24V DC No Provides current limited 24V DC with LED for SLS circuit Safety contactor 100S C85D04C Allen Bradley 85 A IEC safety contactor No Provides isolation and status 120V coil through N C positive guided auxiliary 2 N 0 auxiliary 100 SA20 Allen Bradley 2 N O auxiliary No Provides control circuits with positive guidance and monitoring of power poles Surge suppressor 100 FSC280 Allen Bradley 120V RC type No Absorbs coil spikes Publication 1000 UM 001B US P J uly 2000 3 2 Operational Procedure Table 3 A SLS Box Continued Component Cat No Source Description Repairable Function Pilz relay PU3Z 24VDV Pilz Voltage supervision and No M onitors position of contactor contactor monitoring and voltage on load side of safety relay contactor Safety relay SR 100 ZBL220724 Allen Bradley 24V safety relay No Checks for cable integrity and for operation of the SLS switch Safety relay 1SR Allen Bradley 24V safety relay Yes Serves as E stop pilot relay and PLC interface 1CR 700 CF220D Allen Bradley 24V DC control relay Yes Keeps safe light out if the SR Safety relay faults Protective cover 100 SCCA
46. wer Wire Size Terminal Torque 30 with Pilzrelay 1000 NXSLSV30 14 AWG 31 lb in 3 5 Nm 2 5 16 mm 0 5 85 A with Pilzrelay 1000 NXSLSV85 14 2 AW 52 Ib in 6 Nm 2 5 50 mm 4096 5 J SLS switch installation 1 Mount in the vertical plane per drawing Y D 24492 2 Use conduit and hub or strein relief cord grip 3 Connect SLS cable to terminal blocks that correspond to the pin numbers on the Harting connectors per drawing Y 156328 Chapter 2 Commissioning 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 For first time installation remove adhesive protective paper cover from SLS box window Check incoming and outgoing three phase power lines for proper selection and sizing Select per NEC article 430 part B and size per NEC table 310 16 75 C column Note that the preferred wire MTW is rated 90 C but it must be sized per the 75 C column Check incoming and outgoing lines along with associated line voltage control wires that attach to the isolation contactor for proper torque Refer to wiring diagram for values Also check that the lugs do not crimp down on the wire insulation Check to see that the proper class J time delay
47. y 2 1 9 SD WATT Vg 24VDC LR CURRENT LIMITING 3 SEC POWER SUPPLY XH I i TR Mia agp eyl N 0 8 LH is L atts E L L BLUE W WHITE STRIP Bue ECH SLSL EN SLSe amp E TO SLS EXPANSION wa BOXES _ lt lt D SERA D Oss A m TZ RS x ei Re 17 A ae MANUAL VER tins Mas RESET i TERMINALS JE p 3 I a H kg eh PLC i T PLE AS at a shio e w I Ae I a I l i Sis SV HL DIE 1 d OFF oN Ic ICR d K KI Tr ee SLSL sen L L 1 i JL we ee cse n d 3 ED s SS SV GE i l OFF ON H vi use I de I PILZ CAT PUSZ i i nur Mya VOLTAGE SUPERVISION i a OFF on AE 1 RELAY I i i We I P se i Y 2 i entes SLS SV H E I I OFF UN sis4 i i 1 I T I TED GB e f i nt sist LSI I PLE 14 I i I 15 gt I i lt 5 e I as i i i roy PLE I suse sis2 PLE 16 H i 17 2 lt I I e Io i D FEB ia sLss aen as FUE as SLS STATUS T I o o I STATUS TO PLG oy i w 0 I om TO PLC PLE f i aan sia PLE 20 I i i el 2 T I lt a I I T m IE El El El O Suca stss Spese Ind s PLC La gt lt o gt li GRD o e o e e m m GRO ist LSE sisasiss sisasis sLs4 e Es ma gt E aT a 4 0 DITA 4 1 0 SLL g ees B say 8 Lea 6 H x i Resch 1 810 S21 su t I I 3L 3 eas A B 4AUR ZELZ2UZ24 i eo A e SAFETY RELAY Sek ICR I t 4 i Nes ji l m i d H i

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