Using the Safety Distribution ‘R’ Box

Safety Application Example

Using the Safety Distribution `R' Box

Summary of Changes

Summary of Changes ...............................................................................1 Introduction ...............................................................................................2 Important User Information......................................................................2 General Safety Information ......................................................................3 Description ................................................................................................4 SensaGuard Connections ........................................................................8 Tongue Interlock and Cable ...................................................................11 Pull Switch Connections ........................................................................11 Guardlocking Connections ....................................................................14 Mixed Device Connections.....................................................................21 Additional Resources .............................................................................26

This publication contains new and updated information as indicated in the following table.

Topic Updated wiring diagrams.

Pages Throughout

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Introduction

This safety application note describes the basic features of the safety distribution `R' box and provides typical connection examples. The `R' box complements the existing Rockwell Automation safety distribution boxes by adding circuitry to accommodate SensaGuardTM interlock switches and guardlocking interlock switches.

Important User Information

Solid state equipment has operational characteristics differing from those

of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at ) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

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

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Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

General Safety Information

IMPORTANT

This application example is for advanced users and assumes that you are trained and experienced in safety system requirements.

ATTENTION: A risk assessment should be performed to make sure all task and hazard combinations have been identified and addressed. The risk assessment may require additional circuitry to reduce the risk to a tolerable level. Safety circuits must take into consideration safety distance calculations which are not part of the scope of this document.

Contact Rockwell Automation to find out more about our safety risk assessment services.

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Description

This new passive safety distribution `R' box helps facilitate quick installation of safety systems by using quick disconnect (QD) patchcords that eliminate individual wiring to specific terminals inside the interlocks. The new `R' box offers more connectivity functions than the existing distribution boxes. With a 4-port and an 8-port option, the new passive distribution safety box easily accommodates simple to complex safety systems. Some of the key features are shown below.

8-port `R' Distribution Box

Green Enunciation LED Power to the Block 8 Port Connections M12 QD with 8 Pins

Main Connection M23 QD with 19 Pins

Amber Enunciation LED 1 per Port

Labels for Each Port

This distribution box is designed to accommodate SensaGuard interlock switches, tongue-operated interlock switches, the LifelineTM cable pull switches, and tongue-operated guardlocking interlock switches.

The table below summarizes the differences in the safety distribution boxes offered by Rockwell Automation. This application note describes ways to use the 898D-P84RT-M19 (4-port) and the 898D-P88RT-M19 (8-port) distribution boxes.

Cat. No.

898D-44LT-DM4 898D-48LT-DM4 898D-44KT-DM4 898D-48KT-DM4 898D-P44JT-A5 898D-P44JT-A10 898D-P48JT-A5 898D-P48JT-A10 898D-P68MT-A5 898D-P68MT-A10 898D-P84RT-M19 898D-P88RT-M19

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Safety Circuit

Enunciation Power,

Signal

Ground, and

Lock/Shield

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This distribution box has three types of circuits: cascaded safety circuits, enunciation circuits, and power, ground and lock/shield circuits on all ports.

Cascaded Dual-channel Safety Circuit

The cascaded dual-channel safety circuit passes through each port. The block can be applied in single-channel applications that use only one circuit, or dual-channel applications that use both circuits. The circuits must be completed by the devices connected to each port or by a shorting plug. When the circuits are complete, the safety system interprets this to mean that the safety gates are closed. The safety system can then energize its safety outputs. The safety circuit consists of two signals that pass through each port. You must supply +24V DC to the A+ and B+ signals. Then devices connected to the ports complete the connection from 4 to 6 and 8 to 5. The signal exits pins 3 and 17, through the gray and pink wires of the mating 19-wire cordset.

The illustrations below show the connection of a typical port to a SensaGuard switch or an interlock switch with voltage-free contacts to complete the safety circuit. The SensaGuard switch receives the safety A+ power from pin 8 and the safety B+ power from pin 4. Diagnostic testing is performed on the safety power signals, and if OK, the output transistors are powered. The safety A output is pin 5 and the safety B output is pin 6. Interlock switches with voltage-free contacts make a direct connection from pin 8 to pin 5 and from pin 4 to pin 6 to complete the safety circuit.

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