Cattron Safe-E-Stop PSD User Manual
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Cattron Safe-E-Stop PSD User Manual

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Safe-E-Stop™
User Guide
SAFE-E-STOP
9M02-8978-A002-EN
Version 14
Personal Safety System
User Guide
9M02-8978-A002-EN
™
1

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  • Page 1 Safe-E-Stop™ User Guide ™ SAFE-E-STOP Personal Safety System User Guide 9M02-8978-A002-EN 9M02-8978-A002-EN Version 14...
  • Page 2 Safe-E-Stop™ User Guide Revision History VERSION DATE NOTES 1/28/2018 Added cautions, updated Fault finding and simplified frequency selection 2/2021 Rebranded 9M02-8978-A002-EN Version 14...

  • Page 3: Table Of Contents

    Safe-E-Stop™ User Guide Contents Introduction ............................5 Terminology........................... 5 Warnings and Cautions.......................... 6 MSD wiring warning........................6 Verification of configuration warning ....................7 Verification of correct linking warning ..................... 7 Placement of PSD in charger warning ................... 8 No serviceable parts warning ......................8 Regulatory warning.........................
  • Page 4 Safe-E-Stop™ User Guide PSD Belt Clip..........................25 Battery Chargers ..........................26 General Information ........................26 Caution ............................26 Single Bay Charger ........................27 Six-Bay Charger .......................... 27 Battery Charger Status and Indicators ..................28 MSD ..............................29 MSD Overview ..........................29 MSD Connections ........................

  • Page 5: Introduction

    Failure Modes ............................62 Operational Constraints ........................... 62 Safety Performance Level ........................64 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:...

  • Page 6: Warnings And Cautions

    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.

  • Page 7: Verification Of Configuration Warning

    Safe-E-Stop™ User Guide Verification of configuration warning W A R N I N G More than one PSD may be used in, around, or nearby your machine; therefore before using any PSD, you must ensure by checking the configuration ID or other means of identification that the correct unit has been selected and that it matches the machine being protected.

  • Page 8: Placement Of Psd In Charger 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 service and do not attempt to repair these units.

  • Page 9: Regulatory Warning

    Safe-E-Stop™ User Guide Regulatory warning W A R N I N G Observe the statutory regulations and directives applicable for the intended purpose, e.g.: ▪ Accident prevention regulations ▪ Safety rules and directives ▪ Standards ▪ Generally applicable statutory and other binding regulations for accident prevention and environmental protection, and general safety and health requirements.

  • Page 10: Intended Use

    ▪ 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.

  • Page 11: Equipment Rating Warning

    Safe-E-Stop™ User Guide 2.14 Equipment rating warning C A U T I O N 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.

  • Page 12: Operating Principle

    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 normally open types: if the MSD power were removed, the relays would open and the machine would be brought to a halt as though an E- Stop had been pressed.

  • Page 13: Telegram Security

    Safe-E-Stop™ User Guide 3.2.2 Radio Interference Signals from other RF-emitting sources might interfere with the radio communication between the MSD and PSD. If the radio link reliability is affected by interference, changing the RF channel or even the RF band may be necessary. 3.3 Telegram Security The transmitted telegram contains several security features.

  • Page 14: Frequency Selection

    902,600,000 927,500,000 2 (200kHz) Table 1 defines the six operating bands; currently Cattron have only released the B, D, and F bands. ▪ In North America, the D band is licensed and the F band is license exempt. ▪ Europe and many other regions including Brazil use the license exempt band B.

  • Page 15: Site Planning

    921,400,000 912,000,000 921,500,000 Cattron can supply support and help with frequency selection if they are provided with a list of frequencies in use in the immediate operating location. 4.2 Site Planning As far as is practical RF systems frequency separation should be at least as shown in the last column of table below.

  • Page 16: Psd And Msd Configuration Parameters

    Safe-E-Stop™ User Guide PSD and MSD Configuration Parameters The factory set system parameters— include the selected RF Band, Primary RF channel, Secondary RF channel (if any), System master address, and the PSD specific sub-address. Each system’s configuration is identified in clear text on its labelling. A system of one MSD and one or more PSDs must have a correct set of configuration parameters to be able to operate.

  • Page 17: Msd Configuration Detail

    As an aid to visual identification and differentiation, the following are available as options: ▪ A sheet of labels of various colors of Cattron Logo as a user installation item. ▪ Differently colored rubber bumpers as a factory installed item.
  • Page 18 Safe-E-Stop™ User Guide Table 4: Configuration Parameter Examples HARDWARE SECTION CONFIGURATION SECTION EXAMPLES EXAMPLES 1st RF Channel RF Channel Sub Address Master Address Chan Chan Chan Chan Band Version of unit unit Start (MSB) (LSB) MSD/PSD Color Band Band A − Z A −...

  • Page 19: Psd

    Safe-E-Stop™ User Guide 6.1 PSD Overview PSDs can be considered as 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;...
  • Page 20 Safe-E-Stop™ User Guide 6.2.1 PSD LEDs Referring to Figure 3 above, there are four LEDs above the E-Stop switch. These are: STATUS This will be flashing: GREEN: Normal operation ORANGE: Conditions that require the user to be aware RED: Conditions that require the user to take corrective action COMM LOSS Illuminates if this PSD loses communication...

  • Page 21: Joining An E-Stop Group

    Safe-E-Stop™ User Guide Figure 5: Battery Level Monitoring 6.2.1.4 General Status Monitoring The main LCD display 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. Ensure the PSD is in good physical condition and that the E-Stop switch is in the released position.
  • Page 22 Safe-E-Stop™ User Guide PSD LINKED STATE Green 1 short pulse (at PSD # linked (flashing) state transition ACTIVE to PSD linked – (normal operation see PSD Linking mode) above) 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: Table 9: Linked Operational States BUTTON...

  • Page 23: Normal Operation

    Safe-E-Stop™ User Guide BUTTON COMM ERRO HAPTIC STATUS LED DISPLAY PRESSED LOSS BATT R LED FEEDBACK Low battery Red Flashing Orange 3 short pulses PSD # level every 10 sec. ACTIVE flashing ERROR The Status LED generally has the following meaning: Table 10: PSD Status LED General Meaning GREEN Normal operation...

  • Page 24: Leaving An E-Stop Group

    Safe-E-Stop™ User Guide As part of the recovery process, it is important that all users are accounted for. 6.4.4 Issuing an E-Stop In normal operation, the E-Stop switch can be pressed at any time. This results in the MSD E-Stop Safety Relays opening within 500mS, bringing the machine to a safe state.

  • Page 25: Psd Belt Clip

    PSD including temperature; very low temperatures will significantly reduce available battery capacity; at -20°C the capacity will be approximately 30% lower than at 25°C. Cattron recommends that the customer estimate the usage of their PSDs so they can plan for a battery replacement after 500 charge/ discharge cycles.

  • Page 26: Battery Chargers

    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 its battery may explode if exposed to fire or excessive heat.

  • Page 27: Single Bay Charger

    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 3 hours. Figure 9: Single Slot Charger Features and Power Cord Power supply (input 100V – 240V AC). DC plug (9V DC output).

  • Page 28: Battery Charger Status And Indicators

    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. NOTE: Additional reference information for charge status LEDs is located on bottom of charger.

  • Page 29: Msd

    Safe-E-Stop™ User Guide AMBER SOLID Low temperature condition. Battery temperature is <0°C (below freezing) and cannot be charged. Charger will monitor battery temperature for two hours and begin charging once it rises above 0°C. Remove battery from charger if not charging after two hours. AMBER ONE FLASH Under charged condition.
  • Page 30 Safe-E-Stop™ User Guide ▪ INPUTS 2 & 4 are unused (polarity reversible) ▪ RJ45 Ethernet port ▪ Antenna port TNC ▪ 24Vdc power input (9-36Vdc) ▪ E-Stop Safety Relay outputs R1 & R2 ▪ COMM Loss Safety Relay outputs R3 & R4 ▪...
  • Page 31 Safe-E-Stop™ User Guide Figure 12: MSD Typical Single Channel Connections When Using the COMM LOSS Relays 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.
  • Page 32 Safe-E-Stop™ User Guide Figure 13: MSD Typical Single Channel Connections When Not Using the COMM LOSS Relays 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.
  • Page 33 Safe-E-Stop™ User Guide Figure 14: MSD Typical Dual Channel Connections When Not Using the COMM LOSS Relays 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.
  • Page 34 Safe-E-Stop™ User Guide Figure 15: MSD Typical Dual Channel Connections When Using the COMM LOSS Relays 9M02-8978-A002-EN Version 14...

  • Page 35: Msd Status Indicators

    Safe-E-Stop™ User Guide 8.3 MSD Status Indicators With both LED and LCD displays, the MSD provides an overview of operational status. The Ethernet/IP port can provide detailed operational status of linked wireless E-Stops to operations personnel. This information includes: ▪ The number and identity of linked PSDs ▪...

  • Page 36: Msd Operational States

    Safe-E-Stop™ User Guide 8.3.2 MSD LCD The MSD LCD gives guidance to the current operational state as detailed in Table The LCD display also provides additional information when using the five-button cluster to the left. The MSD LCD remains illuminated. # represents the PSD sub-address 8.4 MSD Operational States Table 13: MSD Operational States...

  • Page 37: Msd Ethernet Address Configuration

    Safe-E-Stop™ User Guide ▪ Change the dip switches to the new address, where X is the variable being set ▪ (Add values to achieve the required value between 1 and 255.) ▪ On the MSD, navigate to the MSD ‘IP Address’ display page using the up or down arrows ▪...
  • Page 38 Table 15: Ethernet/IP Device Identity information CLASS: IDENTITY OBJECT (01H) INSTANCES #1 ATTRIBUTES Access Name Type Value Vendor ID UINT 1367 (Cattron) Device Type UINT 12 (Communication Adapter Profile) Product Code UINT Revision Struct of: Firmware revision number Major Revision...
  • Page 39 Safe-E-Stop™ User Guide Table 17: Input (to Remote Device) Telegram Content BYTE # FIELD TYPE DESCRIPTION / VALUE Message Format Revision USINT (0-255) Revision of the Message Format Definition. Set to 1 Message Update Counter USINT (0-255) Free running counter; Increments each time the Ethernet/IP message content is updated inside the MSD.

  • Page 40: Msd Operation

    Safe-E-Stop™ User Guide BYTE # FIELD TYPE DESCRIPTION / VALUE PSD1 – RSSI SINT Received signal strength of last telegram received, in dBm (-128 to 127) 20-22 PSD2 Status bytes (same structure as PSD1) 1-2 & RSSI 23-25 PSD3 Status bytes (same structure as PSD1) 1-2 &...
  • Page 41 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 is helpful to allow local users to better understand its operational status by reference to the MSD LEDs and LCD, also all required information can be obtained from the Ethernet port.
  • Page 42 Safe-E-Stop™ User Guide 8.8.2.2 Secondary Enclosure Option Kit (2OPT-8637-A102) Dimensions Figure 19: Secondary Enclosure Dimensions 9M02-8978-A002-EN Version 14...
  • Page 43 The MCU is designed for DIN rail mounting, is rated at IP30, and must be protected from moisture and dust. Mount the MCU on a DIN rail in a secondary enclosure (see 9.8.2) (a suitable 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.
  • Page 44 Before installing the MSD, prepare an electrical wiring diagram that defines all electrical interface connections between the system and the equipment being controlled. Cattron also advises you to first read the following topics of discussion at the same time; you should locate and refer to the example mainline drawing provided.
  • Page 45 ▪ Coaxial cable should be type RG58AU, 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.

  • Page 46: System Commissioning

    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.

  • Page 47: System Decommissioning

    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.

  • Page 48: Parts Lists

    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.

  • Page 49: Accessory Parts Lists

    Safe-E-Stop™ User Guide 11.2 Accessory Parts Lists Table 21: Individual Accessory Part Numbers DESCRIPTION PART NUMBER ITEM SPARE PSD, must identify band (X) Color (Y) and master PSD-1-X-Y Spare or additional PSD address (nnnn) of target system if ordered after main system SPARE MSD, must identify band (X) and master address MSD-1-X Spare MSD...

  • Page 50: Maintenance

    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.
  • Page 51 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: Appendix I: Part Number Unit Configuration

    Safe-E-Stop™ User Guide Appendix I: Part Number Unit Configuration Table 22: RF Bands BAND START FREQ HZ END FREQ HZ TYPICALLY USED IN 418,000,000 China 433,077,500 434,777,500 EU, Brazil, Many Others unlicensed 447,000,000 EU Licensed 450,000,000 470,000,000 North America & Other Licensed 868,000,000 EU unlicensed 902,600,000...
  • Page 53 Safe-E-Stop™ User Guide Table 24: System Configuration Examples ORDERING NUMBER CONFIGURATION DETAIL, EXAMPLE EXAMPLES FACTORY DEFINED CONFIGURATIONS Band Color Band Chan (MSB) (LSB) # of Chan Band Chan Chan Version PSDs Start A − Z A − F A − Z 0 −...

  • Page 54: Appendix Ii: Rf Channel Number Vs Operating Frequency

    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), then select a frequency at least 50KHz (2 channels) away from other frequencies in use.
  • Page 55 Safe-E-Stop™ User Guide Table 27: Unavailable Frequencies AVOID FREQUENCIES 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 9M02-8978-A002-EN Version 14...

  • Page 56: Appendix Iii: Approvals And Compliance Notifications

    (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. 9M02-8978-A002-EN...

  • Page 57: Appendix Iv: Troubleshooting

    MSD Radio is Faulty If the items above have been eliminated as possibilities, the radio in the MSD may be faulty. This can be checked by returning the MSD to Cattron for analysis and repair. 9M02-8978-A002-EN Version 14...

  • Page 58: Psd

    User Guide Error Light is On The Error LED will be flashing. Generally, if switching the PSD off and back on does not resolve the problem, return the device to Cattron or an authorized service facility. Error 1 Shown on LCD The Main controller has an error.

  • Page 59: Msd

    If only one PSD has the problem, the PSD is faulty; return to Cattron or an authorized service facility. Error Light is On Generally, if switching the MSD off and back on does not resolve the problem, return to Cattron or an authorized service facility. No Power If all lights are off, request the services of an authorized and trained service agent to conduct the following analysis and repair.

  • Page 60: Appendix V: Technical Data And Specifications Psd And Msd

    Safe-E-Stop™ User Guide Appendix V: Technical Data and Specifications PSD and MSD ELECTRONIC DATA MECHANICAL DATA Functions E-Stop, Link (activate), Unlink (deactivate) and dual-step Permissive functions. Digital Circuitry Dual-processor self-monitoring safety Weight Approx. 200g (8oz.) technology 162 x 109 x 61mm Dimensions 138 x 65 x 54mm (6.4 x 4.3 x 2.4 in.)

  • Page 61: Appendix Vi: Technical Data And Specifications Battery Charger

    Safe-E-Stop™ User Guide Appendix VI: Technical Data and Specifications Battery Charger CHARGER MODEL 1PRT-8778-A001 1PRT-8779-A001 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 20.0 x 5.8 x 3.7 inches Weight (Charger Only) 290 g / 0.64 lbs.

  • Page 62: Appendix Vii: Safety Manual For Safe-E-Stop

    Safe-E-Stop™ User Guide Appendix VII: Safety Manual for Safe-E-Stop Functions The Safe-E-Stop product has been designed to provide a wireless Emergency Stop function. Since 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.
  • Page 63 Safe-E-Stop™ User Guide The input contacts INPUT 2 and INPUT 4 have no assigned function and SHALL NOT BE CONNECTED. They are reserved for future use. Several warnings and cautions have been inserted in the manual and needs consideration, they are found in chapter 2, sections as follows: MSD wiring warning Verification of configuration warning...
  • Page 64 Safe-E-Stop™ User Guide 9M02-8978-A002-EN Version 14...

  • Page 65: Safety Performance Level

    For remote and communication control systems support, parts and repair, or technical support, visit us online at: www.cattron.com/Contact Safe-E-Stop™ is manufactured at the following location: Cattron North America Inc., 655 N River Rd NW, Suite A, Warren, OH 44483 9M02-8978-A002-EN Version 14...

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