Cattron Holdings, Inc., or any of its affiliates or agents shall not be liable for incidental or consequential damages of any kind. All Cattron products are sold pursuant to the Terms and Conditions of Sale, a copy of which will be furnished upon request. When used as a tradename herein, Cattron means Cattron Holdings, Inc.
Safe-E-Stop™ User Guide Contents 1. Introduction Terminology Warnings and Cautions MSD wiring Verification of correct device Verification of correct linking Placement of PSD in charger No serviceable parts Regulatory Compliance Awareness of PSD range and Hazards around the machine The system may cause an unexpected stop of the machine The safety analysis shall consider the reaction time of the system 2.10...
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Safe-E-Stop™ User Guide MSD Configuration 2.19 Configuration Part Number PSD Configuration MSD Configuration PSD Overview PSD Status Indications 6.2.1 PSD LEDs 6.2.1.1 PSD LCD 6.2.1.2 Radio signal level Monitoring 6.2.1.3 Battery Monitoring 6.2.1.4 General Status Monitoring Joining an E-Stop Group Normal Operation 6.4.1...
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Safe-E-Stop™ User Guide MSD Status Indicators MSD LEDs MSD LCD MSD Operational States MSD Information and Setup MSD Ethernet Address Configuration 8.6.1 Ethernet Telegram Content MSD Operation MSD Installation 8.8.1 Safety Instructions for Installation 8.8.2 MSD Installation Notes on Enclosure 8.8.2.1...
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Safe-E-Stop™ User Guide Band F (902-927MHz) Band F Channel Spacing Rules Band J (929MHz) Band J Channel Spacing Rules Appendix C: Approvals and Compliance Notifications FCC Caution EU Caution Equipment Rating Declaration of Conformity Appendix D: Ethernet Configuration & Data Mapping...
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Safe-E-Stop™ User Guide Appendix H: Safety Manual for Safe-E-Stop Functions Failure Modes Operational Constraints Appendix I: Safety Performance Level Version 17...
Safe-E-Stop™ User Guide 1. Introduction This manual provides guidance to installers and users of the Cattron Safe-E-Stop Personal Safety System. Terminology The following represent important acronyms and long form used in this document: Personal Safety Device (the unit worn by a machine operator)
Safe-E-Stop™ User Guide Warnings and Cautions WARNING and CAUTION statements are strategically placed throughout all text prior to operating or maintenance procedures, practices, or conditions considered essential to the protection of personnel or equipment and property. Before starting any task, review and understand the WARNINGS or CAUTIONS included in the text.
2.5 No serviceable parts WARNING There are no user serviceable parts in this PSD / MSD system; please return damaged units to Cattron or a Cattron authorized service center for service and do not attempt to repair these units. Unauthorized repairs will void the unit’s safety rating and could compromise the unit’s ability 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.
2.11 Frequency Change WARNING Selection of the correct operating frequency is entirely the responsibility of the user and Cattron accepts no responsibility for incorrect frequency selection and configuration. The frequency selected must strictly conform to channel setting rules shown in section 4 of this manual or the system may not function correctly.
▪ Product modifications may not be carried out. ▪ Only original spare units from Cattron must be used. ▪ Periodical inspections either required by law or prescribed in this user manual shall be carried out within the prescribed intervals.
Safe-E-Stop™ User Guide 2.16 Equipment rating warning CAUTION Damage of the device The PSD is rated at IP67 and an operating temperature range of -20°C to +60°C; do not use the PSD for conditions beyond these limits. The PSD battery cannot be charged if its temperature exceeds 40°C.
Safe-E-Stop™ User Guide Operating Principle 3.1 General The MSD has two safety relays that are wired in series with an external hard-wired E-Stop circuit that provides a machine with the ability to run. The MSD safety relays are changeover types that are held energized in normal (non-e-stop/run) operation.
Safe-E-Stop™ User Guide 3.3 Telegram Security The transmitted telegram contains several security features. 3.3.1 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.
If any other systems (including other Safe-E-Stop systems) are operating within 10m of the location that the Safe-E-Stop will be used, then a frequency that is at least as far away as is shown in the ‘CH SPACING Separation’ column should be chosen.
Safe-E-Stop™ User Guide Table 2: Frequencies That Are Not Supported VOID REQUENCIES 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...
The PSD will show the frequency configuration on the LCD when first turned on. As an additional aid to visual identification and differentiation, the following is available as an option: ▪ A sheet of labels of various colors of Cattron logo as a user installation item. Version 17...
Safe-E-Stop™ User Guide 5.2 MSD Configuration Your MSD has been manufactured to operate in a specific RF band and is fitted with a specific Ethernet option. Within that band all users can configure the specific RF channel. ● Authorized users can set the System master address.
Safe-E-Stop™ User Guide Table 4: Frequency Bands BAND FREQ MHZ TYPICALLY USED IN China EU & Other EU Licensed NA and Other Licensed Japan 2.19 Configuration Part Number PSD Configuration PSD-2-X-Y Where 2 is the current version Where X is the RF Band...
Safe-E-Stop™ User Guide 6.1 PSD Overview PSDs can be considered a set of wireless E-Stop switches that are dynamically linked to the MSD on an as- needed basis. The MSD does not need a PSD to be connected in order to keep its E-Stop Safety Relays closed;...
Safe-E-Stop™ User Guide 6.2.1 PSD LEDs Referring to above, there are four LEDs above the E-Stop switch. These are: Figure 3 This will be flashing: GREEN: Normal operation STATUS ORANGE: Conditions that require the user to be aware RED: Conditions that require the user to take corrective action...
Safe-E-Stop™ User Guide Figure 5: Battery Level Monitoring 6.2.1.4 General Status Monitoring The main LCD area gives general status as defined in the tables below. 6.3 Joining an E-Stop Group For a PSD to link to a group: Verify that the PSD has the correct configuration for the MSD to be joined.
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Safe-E-Stop™ User Guide Flashing 3 short MSD NOT MSD not seen Orange pulses SEEN When ready to join the group, ensure that you are in the work area and press and hold the ‘|’ button for longer than half a second. Monitor the PSD display for information on linking status. The PSD returns a status message depending on several factors as displayed in the following table.
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Safe-E-Stop™ User Guide Once a PSD has joined and become an active member of the E-Stop group, the PSD displays its current status as indicated in the following table, where # is the current ID of this or another PSD:...
Safe-E-Stop™ User Guide The Status LED generally has the following meaning: Table 9: PSD Status LED General Meaning Normal operation REEN Items of note RANGE Action is required to correct a problem The Haptic feedback (vibration) generally has the following meaning:...
Cattron recommends that the customer estimate the usage of their PSDs in order to plan for a battery replacement after 500 charge/ discharge cycles. The battery is not user serviceable. The PSD must be returned to Cattron or an authorized agent for service. Version 17...
Safe-E-Stop™ User Guide 6.8 PSD Belt Clip The PSD belt 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 superior to an end-mounted switch that may require a two-handed approach to activate.
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Safe-E-Stop™ User Guide To detach the PSD from the clip, press the tab away from the PSD, as shown in Figure 8. Figure 8: PSD Belt Clip Detachment Version 17...
It is neither necessary nor advantageous to fully discharge the battery before recharging. Return the PSD to Cattron for service or recycling. Do not discard unwanted PSDs in the trash or incinerate. The battery may explode if exposed to fire or excessive heat.
Safe-E-Stop™ User Guide 7.3 Single Bay Charger A single-bay charger can charge one PSD at a time. A PSD will fully charge within approximately 3 hours. Figure 9: Single Slot Charger Features and Power Cord Power supply (input 100V – 240V AC).
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Safe-E-Stop™ User Guide Figure 11: Six Bay Charger, Side View and Power Cord DC power connection for power supply (included). DC power connection for optional 12V-24V kit. DC plug (12V DC output). Power supply (input 100V – 240V AC). AC cord for power supply.
Safe-E-Stop™ User Guide 7.5 Battery Charger Status and Indicators The Battery charger LEDs indicate the current charging state. The bottom LED illuminates Green when the unit is connected to power. The top LED is the status LED and conforms to the Table 11.
SIL3 performance level. NOTE 4: "If the machine will at times be used without any of the Safe-E-Stop PSDs in use the MSD COMM LOSS relays will be open; therefore the COMM LOSS relays cannot be wired in series with the E-Stop relays because the hard-wired machine E-Stop circuit will never be closed;...
Safe-E-Stop™ User Guide 8.2 MSD Connections The MSD features multiple interface ports for various connections: ▪ COMM LOSS reset switch connects to inputs 1 and 3 (polarity reversible) ▪ INPUTS 2 & 4 are unused (polarity reversible) ▪ RJ45 Ethernet port ▪...
Safe-E-Stop™ User Guide 8.2.1 Single Channel Connections Example when using the COMM LOSS Relays The following configuration combines the SIL3 function of the COMM LOSS relays with the systematic capability of 3 provided by the E-Stop relays in a single channel configuration.
Safe-E-Stop™ User Guide 8.2.2 Single-Channel Connections Example when not using the COMM LOSS Relays The following configuration does not use the SIL3 function of the COMM LOSS relays but does use the systematic capability of 3 provided by the E-Stop relays.
Safe-E-Stop™ User Guide 8.2.3 Dual-Channel Connections Example when not using the COMM LOSS Relays The following configuration provides the systematic capability of 3 provided by the E-Stop relays in a dual channel configuration. 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.
Safe-E-Stop™ User Guide 8.2.4 Dual-Channel Connection Example using E-Stop relays and the COMM LOSS relays The following configuration combines the SIL3 function of the COMM LOSS relays with the systematic capability of 3 provided by the E-Stop relays in a dual channel configuration.
Safe-E-Stop™ User Guide 8.3 MSD Status Indicators The MSD provides an overview of operational status with both LED and LCD. The Ethernet port can provide detailed operational status of linked wireless E-Stop’s to operations personnel. This information includes: ▪ The number and identity of linked PSDs The activation state of each PSD’s green enable button...
Safe-E-Stop™ User Guide MSD LEDs The Status of the four Safety relays is indicated by the four red LEDs above the LCD. 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.
Safe-E-Stop™ User Guide 8.5 MSD Information and Setup The MSD LCD, in combination with the five buttons to the left, allow access to three different screens, plus the bootup screen, that shows the current firmware revision. The screens may be cycled by using the up and down buttons on the MSD.
Safe-E-Stop™ User Guide 8.6 MSD Ethernet Address Configuration o program the IP address on an MSD it is first necessary to download a third-party tool which is freely available from HMS, the manufacturer of the Anybus EtherNet modules used in the MSD.
8.8.2 MSD Installation Notes on Enclosure The MSD must be housed in a secondary enclosure for protection; a suitable option kit (2OPT-8637-A102) is available from Cattron. This enclosure provides visibility to the MSD. This allows local users to better understand Version 17...
It is suggested that an enclosure approved for use by a recognized authority, such as UL, CSA, Intertek, TUV, etc., be selected. The optional enclosure (Cattron Part Number 2OPT-8637-A102) provides a suitable level of protection for most generic industrial and commercial environments.
Safe-E-Stop™ User Guide The secondary enclosure kit comprises the enclosure, an internal backplate with DIN rail mounted, and three 25mm conduit connection points: one for the antenna and two for the remainder of the wiring. Metallic conduit must be bonded together and grounded. The backplane must also be grounded if a 110Vac supply is used or switched by the MSD.
The supply voltage is 24Vdc nominal (9-36Vdc), maximum current is 1A, nominal current at 24V is 250mA. The MSD is fitted with a protective fuse next to the DC input terminal (Cattron part number PRT-0001852) rated at 1A. An optional wide range (85-264VAC 47-63Hz 1A) power supply is available from Cattron.
The antenna extension (coaxial) cable must be no longer than required, being at most 50 feet in length (without further reference to your supplier). ▪ Coaxial cable should be type RG58AU, similar or lower loss; appropriate cables are available from Cattron and may have been provided with your system. ▪...
Safe-E-Stop™ User Guide System Commissioning When the system has been installed, the functionality should be tested thoroughly as follows: Charge the PSDs. Verify that the MSD is in a protective secondary enclosure suitably rated for the environment. Inspect all wiring to ensure it is correct, secure, and neatly restrained according to good engineering practice and compliant with all local and national rules.
Safe-E-Stop™ User Guide 10. System Decommissioning If the system is to be decommissioned it is important to ensure 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.
The following part numbers must be specified with the RF Band letter in place of the ‘X1’ according to the following frequency chart. If you are unsure of the band you require, contact Cattron or your authorized distributor for advice.
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Safe-E-Stop™ User Guide Table 17: Accessory Part Numbers UMBER ESCRIPTION MSD Secondary Enclosure Enclosure IP66, NEMA 4, Clear hinged locking lid with 2OPT-8637-A102 DIN rail with 3 Cable glands Power Supply 100-264Vac to Power supply 110Vac – 24Vdc 2OPT-8637-A103 24Vdc 1A DIN Rail mount...
The Safe-E-Stop personal safety system is a safety-critical device that is designed, built, and maintained to the strictest of standards. There are no user-serviceable parts within either the PSD or MSD. For any repairs that may be required to these units, return to Cattron or an authorized service agent is required. 12.1 PSD Maintenance Each time the PSD is put into operation, examine it for any obvious physical damage that may affect safe and reliable operation.
Cable and conduit entry points must be kept in good condition. If the MSD is damaged or faulty, return it to Cattron or an authorized service agent for repair. If the enclosure housing the MSD is damaged, it should be repaired to prevent damage to the MSD.
A.2 Benefits of using the configuration tool Frequency Change The Safe-E-Stop system must have an interference-free operating RF channel to reliably maintain a machine in the running state, as interference could block the signal and lead to false E-Stop events. Having the configuration tool makes it possible for a user to change the operating frequency in the event that another system on or off site is causing interference on the current channel.
Safe-E-Stop™ User Guide A.3 Installing the Configuration Tool The application should be installed on a PC with a Bluetooth® adapter. The PC must be running Windows 10 version 1709 or newer. The application can be downloaded from this link: https://www.estopconfig.com/app In order to install the application, it is necessary to allow side-loaded applications as described on the opening page.
Safe-E-Stop™ User Guide A.4 Using the Configuration Tool Launch Application Launch the application and set the supervisor password. Note that if this password is lost, the application will need to be re-installed. Log in. Configuring Devices (Frequency) The configure device screen will appear. Power up the PSD or MSD.
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Safe-E-Stop™ User Guide Select the device from the list shown and pair with it. If multiple devices have been powered on (or have reset) in the last 30 seconds, be sure to select the correct device. To set the frequency, click on the ‘Set Freq’ box, enter the new value (compliant with the frequency setting rules of section 4 of this manual) and click ‘Apply’.
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Safe-E-Stop™ User Guide A ‘Verify Device Configuration’ box will appear asking you to check the PSD or MSD to ensure the ● device is showing a changed configuration message. If successfully applied, a confirmation will appear. Click ‘Acknowledge’ to continue.
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Configuration of address requires that the PC is connected to the internet so that login to the online address management database and authorized user management is available. User login information will have been pre-assigned by Cattron. If this page is not visible, it can be switched to by clicking the arrows icon next to the Bluetooth icon.
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Safe-E-Stop™ User Guide Authorizing Devices When a device is authorized, the master address and sub-address for PSDs will be automatically assigned. Authorizing a Primary MSD Unless an MSD is a spare, the ‘Make Spare’ selection should be left unselected. When making a spare MSD or a PSD, see the next section first.
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Safe-E-Stop™ User Guide Authorizing a Spare MSD When making (authorizing) a spare MSD, it is necessary to select ‘Make Spare’ and then ‘Select Associated MSD’ from the drop-down list on the Authorization tab (below left). This ensures that both units share the same master address.
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Safe-E-Stop™ User Guide Applying Configuration to a unit Once the required units are on the ‘Authorized’ tab, the PC can be taken offline if necessary to ● program the specific unit (by serial number, e.g. 50C-12011023) requiring configuration. ● The process is somewhat like programming the frequency above. The frequency will be the only parameter that must be entered manually for the frequency determined for use on this system.
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Safe-E-Stop™ User Guide ● Click the Bluetooth icon at the top of the screen. ● then switch it on. It will show on the screen (below left). Click the ‘Configure’ button and confirm as prompted. ● Version 17...
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Safe-E-Stop™ User Guide Select the correct device configuration from the available devices. It is possible to click the ‘End User ● Company’ drop-down and choose the correct serial number, or click the ‘Serial Number’ drop-down and select the correct serial number to match the device to be programmed.
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Safe-E-Stop™ User Guide De-commissioning and marking units as Destroyed Decommissioning a unit If a unit is no longer required on a given system, it can be decommissioned and made available again for use on another system. This can be achieved by selecting units from the ‘Authorized’ tab and clicking the ‘Decommission’ button. Confirm and acknowledge as prompted.
Channel A00 will be 433.0775MHz. Channel A68 will be 434.7775MHz. Band B Channel Spacing Rules If the MSD is to be installed less than 100m (330’) from another RF system (Cattron or other), select a frequency at least 50KHz (2 channels) away from other frequencies in use.
Channel A00 will be 429.250Hz. Channel A39 will be 429.7375MHz. Band J Channel Spacing Rules If the MSD is to be installed less than 100m (330’) from another RF system (Cattron or other), select a frequency at least 50KHz (2 channels) away from other frequencies in use.
(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 follows the essential requirements and other relevant provisions of Directive 2014/53/EC. Equipment Rating The PSD is rated at IP67 and an operating temperature range of -20°C to +60°C;...
Safe-E-Stop™ User Guide Appendix D: Ethernet Configuration & Data Mapping EtherNet/IP Table 21: Configuration Parameters for the EtherNet/IP Telegram: ARAMETER SSEMBLY NSTANCE IN BYTES Input (T->O) Output (O->T) Configuration Table 22: EtherNet/IP Device Identity information (01H) LASS DENTITY BJECT #1 A...
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Safe-E-Stop™ User Guide Table 24: Input (to Remote Device) Data Mapping IELD ESCRIPTION ALUE Message Format Revision USINT (0-255) Revision of the Message Format Definition. Set to 1 Free running counter; Increments each time the Ethernet/IP message content is updated inside the MSD.
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Safe-E-Stop™ User Guide Bit 7: TILT indicator BOOL SINT PSD1 – RSSI Received signal strength of last telegram received, in dBm (-128 to 127) PSD2 Status bytes 20-22 (same structure as PSD1) 1-2 & RSSI PSD3 Status bytes 23-25 (same structure as PSD1) 1-2 &...
Safe-E-Stop™ User Guide Modbus TCP Configuration The MSD implements a Modbus TCP server that provides access to the I/O Data. The Modbus TCP server is available on both the EtherNet/IP and PROFINET versions. ● The server is accessible over TCP port 502 ●...
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Safe-E-Stop™ User Guide The Input registers follow the same structure as the EtherNet/IP messages, where the 64 bytes from the EtherNet/IP messages are mapped to 32 Modbus 16-bit registers. Table 27: Input Registers ODBUS EGISTER EFERENCE THER MESSAGES BYTES DDRESS...
Safe-E-Stop™ User Guide PROFINET Configuration PROFINET protocol handling is done by a PROFINET communication module from HMS (Anybus-IC AB6005). This module implements real-time (RT) PROFINET I/O in accordance with PROFINET Conformance Class A (CC-A). This module is pre-certified if using the default settings of all parameters and is using the original GSD (general station descriptor) file provided by HMS.
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Safe-E-Stop™ User Guide Bit 0: ESTOP BOOL Set to 1 when the MSD is in ESTOP state (a PSD ESTOP is pressed or a PSD sends a TILT indication) Bit 1: COMLOSS BOOL Set to 1 when the MSD is in COM LOSS state...
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Safe-E-Stop™ User Guide PSD5 Status bytes 29-31 (same structure as PSD1) 1-2 & RSSI Reserved Future use. Set to 0 Free running counter; increments each time a RF transaction is MSD transactions counter USINT (0-255) initiated by the MSD. Free running counters; each counter increment for each valid...
If RF interference is suspected, an audit of other wireless systems in the area should be conducted. If a problem is found, remove the source of interference. Otherwise, the Safe-E-Stop system frequency will need to be reprogrammed at Cattron or an authorized service facility.
30%. A battery that has been charged more than 500 times will have lost 20% of its capacity. This can be rectified by having a new battery installed by Cattron or an authorized service facility. Cannot Link to MSD If 5 PSDs are already linked to the MSD, it will not be possible to link another PSD.
PSD is faulty. Return to Cattron or an authorized service facility. Error Light is Flashing If switching the MSD off and back on does not resolve the problem, return to Cattron or an authorized service facility.
Safe-E-Stop™ User Guide Appendix F: Technical Data and Specifications PSD and MSD *Refer to current datasheet at www.Cattron.com Appendix G: Technical Data and Specifications Battery Charger 1PRT-8778-A001 1PRT-8779-A001 HARGER ODEL 101 x 137 x 81 mm 509 x 148 x 94 mm Dimensions (W x L x H) 3.9 x 5.4 x 3.2 inches...
Appendix H: Safety Manual for Safe-E-Stop Functions The Safe-E-Stop product has been designed to provide a wireless emergency stop function. Because it is a wireless system, any loss of communication between the machine safety device (MSD) and any of the linked personal safety devices (PSDs) will result in the machine stopping.
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Safe-E-Stop™ User Guide The input contacts INPUT 2 and INPUT 4 have no assigned function and should not be connected. They are reserved for future use. HIS MANUAL CONTAINS MANY IMPORTANT WARNINGS AND CAUTIONS THAT SHOULD BE REVIEWED PRIOR TO...
PFH = 1.90565e-09 After manual activation For detailed information on the failure modes, failure rates and safe failure fraction, please contact Cattron division and ask for “parameter for failure rate determination.” Due to continuous product improvement, the information provided in this document is subject to change without notice.
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