AB Safety Products Catalog

Safety Products

Presence Sensing Safety DevicesInterlock SwitchesSafety RelaysTrapped Key Interlock SwitchesEmergency Stop DevicesPosition (Limit) SwitchesSafety PLCsContactors & Control RelaysIEC Load SwitchesTwo-Hand Control DevicesSafety Isolation SystemsApplied Safety SolutionsConnection SystemsHazardous Location SwitchesMobileView Guard Terminal

New in this Catalogue

Ensign 3Interlock Switches

Page 3-74

Safety Wired T-Port &Distribution Box

Connection Systems15-4, 15-5, 15-8

Minotaur MSR238Safety Relays

Page 4-82

Minotaur MSR132ESafety Relays

Page 4-60

440G-MTInterlock Switches

Page 3-36

STFProApplied Safety

Solutions13-7

Compact PressMasterApplied Safety

Solutions13-8

Machine Safety ServicesApplied Safety

Solutions13-2

StamProApplied Safety

Solutions13-5

FeederProApplied Safety

Solutions13-6

Small Plastic SenatorPosition (Limit)

SwitchesPage 7-2

Large Metal SenatorPosition (Limit)

SwitchesPage 7-8

SafeEdgePresence Sensing

Safety DevicesPage 2-94

SafeZonePresence Sensing


Slamlock ElectricalProsafe TrappedInterlock Switches

Page 5-26

GuardShieldPresence Sensing


ElectroGuardSafety Isolation System

Page 12-2

Atlas 5Interlock Switches

Page 3-32

Lifeline 4Emergency Stop

DevicesPage 6-8

Products included in the Safety Products Catalog Supplement (S114-CA002A-EN-P) and IEC Load Switchesalso published in the Industrial Control catalogue (A113 March 2000).

Minotaur MSR30RT/RTPSafety Relays

Page 4-26

Plus

General

GeneralSafety Guidelines and Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Terms and Conditions of Sale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Maintenance of Industrial Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7IEC Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9NEMA Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Safety Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Presence Sensing Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Interlock Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Prosafe Trapped Key Interlock Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Emergency Stop Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Position (Limit) Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety PLCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Contactors & Control Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

IEC Load Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Two-Hand Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety Isolation Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Applied Safety Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Connection Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Hazardous Location & Pneumatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . 16

MobileView Guard Terminal Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Safeguarding Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Catalogue Number Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Comprehensive Product Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Sales Offices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

ImportantUser 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 supplement are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Rockwell Automation does not assume responsibility or liability including intellectual property liability, for actual use based upon the examples shown in this publication.

Related Safety Information

The installer is responsible for the safety of the entire installed control system and for meeting all applicable laws, codes, and safety requirements.

Terms and Conditions

For applicable "Terms and Conditions of Sale" please refer to page General-4.

IMPORTANT

Rockwell Automation reserves the right to make revisions to the material contained in this catalogue and specifically disclaims all liability for any incidental or consequential damages resulting from the furnishing, performance or use of this material.

ATTENTION: As the installer of this control system, you must be knowledgeable of other applicable standards pertaining to safety recommendations related to:

Machine Construction

General Electrical

Machine Guarding

Point of Operation guards, safety light curtains, mechanical guards, two-hand controls, and safety monitoring relays

In addition to local laws and codes, you are responsible for the safety recommendations detailed in all applicable codes and standards including:

National Electric Code

OSHA Regulations

ANSI Standards

General-3

General

Safety Guidelines and Warranties/Metric Conversions

Application ConsiderationsSelection of Equipment Because of the variety of uses for the products described in this catalogue, 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 and layout examples shown in this catalogue are intended solely for purposes of example. Because 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 SGI-1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid-state Control (available from your local Allen-Bradley Sales Office) describes some important differences between solid-state equipment and electromechanical devices which should be taken into consideration when applying products such as those described in this catalogue.

Service and Installation Conditions Unless otherwise noted, the products described in this catalogue are designed to meet usual service and installation conditions as defined in NEMA (National Electrical Manufacturers Association) Standards Publication Part ICS 1-108. Open style devices must be provided with environmental protection by proper mounting in enclosures designed for specific application conditions.

See pages 1-7 and 1-9 of this catalogue for information on enclosures and an explanation of the degrees of protection provided by the different types, based on NEMA Standards Publication 250 and IEC Publication 529, as applicable.

Performance Data Performance data given in this catalogue is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent the result of accelerated testing at elevated stress levels, and the user should correlate it to actual application requirements. Actual performance is subject to Allen-Bradley WARRANTY and LIMIT OF LIABILITY (see Allen-Bradley Terms and Conditions of Sale on page 1-4).

! Conversion Formula: 5/9 (F 32F) = C

" Conversion Formula: 9/5 (C) + 32F = F

Metric Conversion FactorsFrom To Multiply by

LengthInches (in.) Millimetres (mm) 25.4Inches (in.) Centimetres (cm) 2.54Feet (ft) Meters (m) 0.305Yards (yd.) Meters (m) 0.914Millimetres (mm) Inches (in.) 0.0394Centimetres (cm) Inches (in.) 0.394Meters (m) Feet (ft.) 3.28Meters (m) Yards (yd.) 1.09

Area

Square inches (in.2) Square millimetres (mm2) 645.0

Square inches (in.2) Square centimetres (cm2) 6.45

Square feet (ft.2) Square meters (m2) 0.0929

Square yards (yd.2) Square meters (m2) 0.836

Square millimetres (mm2) Square inches (in.2) 0.00155

Square centimetres (cm2) Square inches (in.2) 0.155

Square meters (m2) Square feet (ft.2) 10.8

Square meters (m2) Square yards (yd.2) 1.20

WeightOunces (oz.) Grams (g) 28.3Pounds (lb) Kilograms (kg) 0.454Grams (g) Ounces (oz.) 0.0353Kilograms (kg) Pounds (lb) 2.20

Volume

Cubic inches (in.3) Cubic centimetres (cm3) 16.4

Cubic feet (ft.3) Cubic meters (m3) 0.0283

Cubic inches (in.3) Litres (L) 0.0164

Cubic feet (ft.3) Litres (L) 28.3

Gallons (Imp) Litres (L) 4.55Gallons (US) Litres (L) 3.79

Cubic centimetres (cm3) Cubic inches (in.3) 0.061

Cubic meters (m3) Cubic feet (ft.3) 35.3

Litres (L) Cubic inches (in.3) 61.0

Litres (L) Cubic feet (ft.3) 0.0353

Litres (L) Gallons (Imp) 0.220Litres (L) Gallons (US) 0.264

PressurePounds/square inch (psi) Kilopascals (kPa) 6.89Pounds/square inch (psi) Bars (Bar) 0.0689Kilopascals (kPa) Pounds/square inch (psi) 0.145Bars (Bar) Pounds/square inch (psi) 14.5

TorquePound inch (lb in.) Newton meters (Nm) 0.113Newton meters (Nm) Pound inch (lb in.) 8.85

TemperatureDegrees Fahrenheit (F) Degrees Celsius (C) !Degrees Celsius (C) Degrees Fahrenheit (F) "

General-4

General

Terms and Conditions of Sale

These general terms and conditions of sale only apply to direct sales by the manufacturer or its affiliates. Sales by appointed distributors and other independent authorized resellers will be subject to terms and conditions of sale as may be separately established by each such distributor or reseller. Sales outside of North America, as well as sales of other Rockwell Automation products and services, also may be subject to separate or supplemental terms and conditions of sale. For further information, please consult Rockwell Automation/Allen-Bradley Sales Office.

General These general terms and conditions of sale (along with any directly associated written Seller specification or quotation) exclusively will govern the sale or licensing by Seller of all goods and services (including without limitation, hardware, firmware and software products, training, programming, maintenance, engineering, parts and repair services collectively, the Products) furnished hereunder. No addition or modification to these terms and conditions will be binding on Seller unless agreed to in writing signed by an authorized representative at Sellers headquarters. Seller objects to other terms and conditions that may be proposed by the customer not otherwise consistent with these or other terms and conditions set forth in Sellers written specification, quotation or order acknowledgment.

Payment Terms Net thirty (30) days from date of invoice with ongoing approved credit as determined by Seller. Seller reserves the right to suspend any further performance under this agreement or otherwise in the event payment is not made when due. No payment by offset is permitted unless approved by Seller.

Delivery Terms Delivery terms are Ex Works with respect to shipping costs, risk of loss and title transfer, except that title to all intellectual property rights associated with the Products (e.g., software and firmware) remains with Seller (or its suppliers and licensors), and such Products are made available or licensed only for use by the customer pursuant to this agreement or other Seller license agreement. Acknowledged shipping dates are approximate only and based on prompt receipt of all necessary information from the customer.

Warranty

A. Hardware: Seller warrants for a period of one (1) year from the date of invoice from Seller or its appointed distributor, as the case may be, that hardware Products furnished hereunder will be of merchantable quality, free from defects in material, workmanship and design. Repaired or replacement Products provided under warranty are similarly warranted for a period of six (6) months from the date of shipment to Customer or the remainder of the original warranty term, whichever is longer.

B. Software and Firmware: Unless otherwise provided in a Seller or third party license agreement, Seller warrants for a period of one (1) year from the date of invoice from Seller or its appointed distributor, as the case may be, that standard software or firmware Products furnished hereunder, when used with Seller-specified hardware, will perform in accordance with published specifications prepared, approved, and issued by Sellers headquarters. Seller makes no representation or warranty, express or implied, that the operation of the software or firmware Products will be uninterrupted or error free, or that the functions contained therein will meet or satisfy the Customer's intended use or requirements. Software and firmware corrections are warranted for a period of three (3) months from the date of shipment to Customer or the remainder of the original warranty term, whichever is longer.

C. Factory Repair and Field Exchange: Seller warrants for a period of six (6) months from the date of invoice from Seller or its appointed distributor, as the case may be, that billable or non-warranty factory-repaired or field-exchanged hardware Products furnished hereunder will be free from defects in material and workmanship. Products furnished on an exchange basis may be new or reconditioned.

D. Service: Seller warrants that Products comprised of services, including engineering and custom application programming services, whether provided on a fixed cost or time and material basis, will be performed in accordance with generally accepted industry practices to the extent such services are subject to written acceptance criteria agreed to in advance by Seller. All other warranties relative to provided services are disclaimed.

E. Customer Specifications: Seller does not warrant and will not be liable for any design, materials or construction criteria furnished or specified by Customer and incorporated into the Products or for Products made by or source from other manufacturers or vendors specified by Customer. Any warranty applicable to such Customer-specified Products will be limited solely to the warranty, if any, extended by the original manufacturer or vendor other than Seller to the extent permissible thereunder.

F. Remedies: Satisfaction of the above warranties will be limited, at Sellers option, to the replacement, repair, re-performance or modification of, or issuance of a credit for the purchase price of the Products involved, and where applicable, only after the return of such Products with Seller's consent. Replacement Products may be new or reconditioned. Any warranty service (consisting of time, travel and expenses related to such services) performed other than at Seller's factory, will be at Customer's expense.

G. General: Warranty satisfaction is available only if (a) Seller is promptly notified in writing and (b) Seller's examination discloses, to its satisfaction, that any alleged defect has not been caused by misuse; neglect; improper installation, operation, maintenance, repair, alteration or modification; accident; or unusual deterioration or degradation of the Products or parts thereof due to physical environment or electrical or electromagnetic noise environment.

H. THE ABOVE WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESSED, IMPLIED OR STATUTORY, INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR USE, OR PERFORMANCE OR APPLICATION WARRANTIES, AND EXTEND ONLY TO CUSTOMERS PURCHASING FROM SELLER OR ITS APPOINTED DISTRIBUTOR.

Limit of Liability IN NO EVENT WILL SELLER BE LIA-BLE FOR INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES OF ANY KIND. SELLERS MAXIMUM CUMULA-TIVE LIABILITY RELATIVE TO ALL OTHER CLAIMS AND LIABILITIES, INCLUDING THAT WITH RESPECT TO

General-5

General


DIRECT DAMAGES AND OBLIGATIONS UNDER ANY INDEMNITY, WHETHER OR NOT INSURED, WILL NOT EXCEED THE COST OF THE PRODUCTS GIVING RISE TO THE CLAIM OR LIABILITY. ANY ACTION AGAINST SELLER MUST BE BROUGHT WITHIN EIGHTEEN (18) MONTHS AFTER THE CAUSE OF ACTION ACCRUES. THESE DISCLAIMERS AND LIMITATIONS OF LIABILITY WILL APPLY REGARDLESS OF ANY OTHER CONTRARY PROVISION OF THE AGREEMENT AND REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT, TORT OR OTHERWISE, AND FURTHER WILL EXTEND TO THE BENEFIT OF SELLERS VENDORS, APPOINTED DISTRIB-UTORS AND OTHER AUTHORIZED RESELLERS AS THIRD-PARTY BENEFICIARIES. EACH PROVISION IN THE AGREEMENT WHICH PROVIDES FOR A LIMITATION OF LIABILITY, DISCLAIMER OF WARRANTY OR CONDITION OR EXCLUSION OF DAMAGES IS SEVERABLE AND INDE-PENDENT OF ANY OTHER PROVISION AND IS TO BE ENFORCED AS SUCH.

Intellectual Property Seller will defend any suit or proceeding brought against the customer based on a claim that the design or construction of the Products sold or licensed hereunder by Seller infringe any United States or Canadian Patent, Copyright or Mask Work Registration, provided that the customer promptly notifies Seller of any such claim and resulting suit or proceeding in writing and further provided that, at Seller's expense, (a) the customer gives Seller the sole right to defend or control the defence of the suit or proceeding, including settlement, and (b) the customer provides all necessary information and assistance for that defence. Except for any consequential damages, Seller will pay all costs and damages finally awarded or agreed upon by Seller that are directly related to any such claim. In the event of a charge of infringement Sellers obligation under the Agreement will be fulfilled if Seller, at its option and expense, either (i) procures for the customer the right to continue using such Products; (ii) replaces the same with non-infringing Products; (iii) modifies the same so as to make them non-infringing; or (iv) accepts the return of any infringing Products and refunds their purchase price. Notwithstanding the foregoing, Seller will have no liability with respect to any claim of infringement to the extent based on a configuration or modification incorporated in the Products at the request of the customer, on any process application into which the Products are integrated by the customer, or on use of the Products in combination with other equipment or products not supplied by Seller. THIS PARAGRAPH SETS FORTH SELLERS ENTIRE LIABILITY WITH RESPECT TO INTELLECTUAL PROPERTY AND INFRINGEMENT OF PATENTS BY ANY PRODUCTS (INCLUDING SOFTWARE PROGRAMS, EQUIPMENT OR PRODUCTS THEREOF) OR BY THEIR OPERATION, AND IS IN LIEU OF ALL WARRANTIES OR CONDITIONS RELATING TO INFRINGEMENT OR INTELLECTUAL PROPERTY, EITHER EXPRESS OR IMPLIED.

Licensed Software and Firmware Products comprised of soft-ware or firmware may be subject to additional terms and conditions set forth in separate Sellers license agreements that will control to the extent necessary to resolve any conflict with the terms and con-ditions stated herein. Such Products will not be delivered or made available until the customer also agrees to the terms and conditions of such separate license agreements.

Packing & Marking Customer-specified packing or marking may be subject to additional charges not otherwise included in the price of the Products.

Weights and Dimensions Published weights and dimensions are estimates or approximate only and are not warranted.

Quotations Written quotations are valid for 30 days from issue unless otherwise stated. Verbal quotations expire the same day they are made. All typographical and clerical errors are subject to correction.

Prices Prices and other information shown in any Seller publication (including product catalogues and brochures) are subject to change without notice and confirmation by specific quotation. Such publications are not offers to sell and are maintained only as a source of general information. The customer will pay or reimburse Seller for all sales, use, excise or similar taxes. Products comprised of time and material services will be provided in accordance with Sellers published service rates (including applicable overtime and travel expenses) in effect as of the date such services are provided, unless otherwise confirmed by Sellers written quotation or order acknowledgment. Billable service time includes travel time to and from the job site and all time Sellers representatives are available for work and waiting (whether on or off the job site) to perform the services.

Changes Customer-requested order changes, including those affecting the identity, scope and delivery of the Products, must be documented in writing and are subject to Sellers prior approval and adjustments in price, scheduling and other affected terms and conditions. In any event, Seller reserves the right to reject any change that it deems unsafe, technically inadvisable or inconsistent with established engineering or quality guidelines and standards, or incompatible with Seller's design or manufacturing capabilities.

Returns All returns of Products will be subject to prior Seller approval. Non-warranty returns of unused and salable Products for credit will be subject to Sellers return policies in effect at the time, including applicable restocking charges and other conditions of return. Products returned under warranty must be properly packed and shipped to Seller-specified locations. Shipping containers must be clearly marked per Sellers instruction and shipped freight prepaid by the customer.

Order Cancellation An order may be cancelled by the customer prior to shipment only by written notice and upon payment to Seller of reasonable cancellation and restocking charges, including reimbursement for direct costs, plus allowances for disruption. Cancellation charges associated with orders for custom Products or Products specifically manufactured to the customers specification may equal the actual selling price of the Products. Seller has the right to cancel an order for cause at any time by written notice, and Seller will be entitled to cancellation and restocking charges as identified above. No termination by the customer for cause will be effective unless and until Seller has failed to correct such alleged cause within forty-five (45) days after receipt of the customers written notice specifying such cause.

Force Majeure Seller will not be liable for any loss, damage or delay arising out of its failure to perform hereunder due to causes beyond its reasonable control, including without limitation, acts of God or the customer, acts of civil or military authority, fires, strikes, floods, epidemics, quarantine restrictions, war, riots, delays in transportation, or transportation embargoes. In the event of any such delay, Sellers performance date(s) will be extended for that length of time as may be reasonably necessary to compensate for the delay.

Government Clauses and Contracts No government contract regulations or clauses will apply to the Products or this agreement or act to bind Seller unless specifically agreed to by Seller in writing at Sellers headquarters. Products sold or licensed hereunder are not intended to be used, nor should they be used, in any nuclear-related application either as a Basic Component under 10 CFR 21 (United States NRC) or otherwise under similar nuclear laws and regulations of this or any other country.

General-6

General


Export Control Products and associated materials supplied or licensed under this agreement may be subject to various export laws and regulations. It is the responsibility of the exporter to comply with all such laws and regulations.

Disputes The parties will attempt in good faith promptly to resolve any dispute arising out of this agreement by negotiations between representatives who have authority to settle the controversy. If unsuccessful, the parties further will attempt in good faith to settle the dispute by non-binding third-party mediation, with fees and expenses of such mediation apportioned equally to each side. Any dispute not so resolved by negotiation or mediation may then be submitted to a court of competent jurisdiction in accordance with the terms of this agreement. These procedures are the exclusive procedures for the resolution of all such disputes between the parties.

Governing Law This agreement and all disputes arising thereunder will be governed by and interpreted in accordance with the internal laws of the state, province or other governmental jurisdiction in which Sellers principal place of business resides, but specifically excluding the provisions of the 1980 UN Convention on Contracts for the International Sales of Goods.

Assignment This agreement may not be assigned by either party without the written consent of the other, however, consent will not be required for internal transfers and assignments as between Seller and its parent corporations, subsidiaries or affiliates as part of a consolidation, merger or other form of corporate reorganization.

Language The parties acknowledge that they have required that this agreement be drawn up in English. Les parties reconnaissent avoir exig la rdaction en anglais du Contrat. In the event of a conflict between the English and other language versions of this agreement, the English version will prevail.

General-7

General

Maintenance of Industrial Control Equipment

Periodic Inspection Industrial control equipment should be inspected periodically. Inspection intervals should be based on environmental and operating conditions and adjusted as indicated by experience. An initial inspection within 3 to 4 months after installation is suggested. See National Electrical Manufacturers Association (NEMA) Standard No. ICS 1.3, Preventive Maintenance of Industrial Control and Systems Equipment, for general guidelines for setting-up a periodic maintenance program. We suggest that a periodic maintenance program is set up. Some specific guidelines for Allen-Bradley products are listed below.

Contamination If inspection reveals that dust, dirt, moisture or other contamination has reached the control equipment, the cause must be eliminated. This could indicate an incorrectly selected or ineffective enclosure, unsealed enclosure openings (conduit or other) or incorrect operating procedures. Replace any improperly selected enclosure with one that is suitable for the environmental conditions refer to NEMA Standard No. 250, Enclosures for Electrical Equipment for enclosure type descriptions and test criteria. Replace any damaged or embrittled elastomer seals and repair or replace any other damaged or malfunctioning parts (e.g., hinges, fasteners, etc.). Dirty, wet or contaminated control devices must be replaced unless they can be cleaned effectively by vacuuming or wiping. Compressed air is not recommended for cleaning because it may displace dirt, dust, or debris into other parts or equipment, or damage delicate parts.

Cooling Devices Inspect blowers and fans used for forced air cooling. Replace any that have bent, chipped, or missing blades, or if the shaft does not turn freely. Apply power momentarily to check operation. If unit does not operate, check and replace wiring, fuse, or blower or fan motor as appropriate. Clean or change air filters as recommended in the product manual. Also, clean fins of heat exchangers so convection cooling is not impaired.

Hazardous Location Enclosures

Location Enclosures NEMA Types 7 & 9 enclosures require careful handling so machined flanges do not get damaged. For removable covers, remove the cover and set aside with machined surface up. For hinged covers, open the cover fully and restrain in the full open position if necessary. Clean and examine the flanges on both the body and cover before re-assemble. If there are scratches, nicks, grooves or rust on the mating surfaces, replace the body or cover as necessary. Examine all bolts and replace any that have dam-aged threads. Also check mating threads for damage and replace enclosure if necessary. Covers and bodies of some enclosures are manufactured as matched sets (not interchangeable). The manufac-turer should be consulted before replacing a cover or body unless it is specified by the manufacturer as interchangeable.

ATTENTION: Explosion hazard. Always disconnect power before opening enclosures in hazardous locations. Close and secure such enclosures before re-applying power.

ATTENTION: Servicing energized Industrial Control Equipment can be hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of controlled equipment. Recommended practice is to disconnect and lockout control equipment from power sources, and release stored energy, if present. Refer to National Fire Protection Association Standard No. NFPA70E, Part II and (as applicable) OSHA rules for Control of Hazardous Energy Sources (Lockout/Tagout) and OSHA Electrical Safety Related Work Practices for safety related work practices, including procedural requirements for lockout/tagout, and appropriate work practices, personnel qualifications and training requirements where it is not feasible to de-energize and lockout or tagout electric circuits and equipment before working on or near exposed circuit parts.

Operating Mechanisms Check for proper functioning and freedom from sticking or binding. Replace any broken, deformed or badly worn parts or assemblies according to individual product renewal parts lists. Check for, and re tighten securely, any loose fasteners. Lubricate if specified in individual product instructions.

Note: Allen-Bradley magnetic starters, contactors and relays are designed to operate without lubrication do not lubricate these devices because oil or grease on the pole faces (mating surfaces) of the operating magnet may cause the device to stick in the ON mode. Some parts of other devices are factory-lubricated if lubrication during use or maintenance of these devices is needed, it will be specified in their individual instructions. If in doubt, consult your local Allen-Bradley Sales Office for information.

Contacts Check contacts for excessive wear and dirt accumulations. Vacuum or wipe contacts with a soft cloth if necessary to remove dirt. Contacts are not harmed by discoloration and slight pitting. Contacts should never be filed, as dressing only shortens contact life. Contact spray cleaners should not be used as their residue on magnet pole faces or in operating mechanisms may cause sticking, and on contacts can interfere with electrical continuity. Contacts should only be replaced after silver has become badly worn. Always replace contacts in complete sets to avoid misalignment and uneven contact pressure.

Vacuum Contactors Contacts of vacuum contactors are not visible, so contact wear must be checked indirectly. Vacuum bottles should be replaced when:

The estimated number of operations equals one million, or

The contact life line indicator shows need for replacement, or

The vacuum bottle integrity tests show need for replacement.

Replace all vacuum bottles in the contactor at the same time to avoid misalignment and uneven contact wear. If the vacuum bottles do not require replacement, check and adjust overtravel to the value listed on the maintenance instructions.

Terminals Loose connections in power circuits can cause overheating that can lead to equipment malfunction or failure. Loose connections in control circuits can cause control malfunctions. Loose bonding or grounding connections can increase hazards of electrical shock and contribute to electromagnetic interference (EMI). Check the tightness of all terminals and bus bar connections and tighten securely any loose connections. Replace any parts or wiring damaged by overheating, and any broken wires or bonding straps.

Arc Hoods Check for cracks, breaks, or deep erosion. Arc hoods and arc chutes should be replaced if damaged or deeply eroded.

General-8

General

Maintenance of Industrial Control Equipment

Coils If a coil exhibits evidence of overheating (cracked, melted or burned insulation), it must be replaced. In that event, check for and correct overvoltage or undervoltage conditions, which can cause coil failure. Be sure to clean any residue of melted coil insulation from other parts of the device or replace such parts.

Batteries Replace batteries periodically as specified in product manual or if a battery shows signs of electrolyte leakage. Use tools to handle batteries that have leaked electrolyte; most electrolytes are corrosive and can cause burns. Dispose of the old battery in accordance with instructions supplied with the new battery or as specified in the manual for the product.

Pilot Lights Replace any burned out lamps or damaged lenses.

Photoelectric Switches The lenses of photoelectric switches require periodic cleaning with a soft dry cloth. Reflective devices used in conjunction with photoelectric switches also require periodic cleaning. Do not use solvents or cleaning agents on the lenses or reflectors. Replace any damaged lenses and reflectors.

Solid State Devices

Solid-state devices require little more than a periodic visual inspection. Discoloured, charred or burned components may indicate the need to replace the component or circuit board. Necessary replacements should be made only at the PC board or plug-in component level. Printed circuit boards should be inspected to determine whether they are properly seated in the edge board connectors. Board locking tabs should also be in place. Solid-state devices must also be protected from contamination, and cooling provisions must be maintained refer to paragraphs titled CONTAMINATION and COOLING DEVICES on previous page. Solvents should not be used on printed circuit boards.

ATTENTION: Use of other than factory-recommended test equipment for solid-state controls may result in damage to the control or test equipment or unintended actuation of the controlled equipment. Refer to paragraph titled HIGH VOLTAGE TESTING.

High Voltage Testing High voltage insulation resistance (IR) and dielectric withstanding voltage (DWV) tests should not be used to check solid-state control equipment. When measuring IR or DWV of electrical equipment such as transformers or motors, a solid-state device used for control or monitoring must be disconnected before performing the test. Even though no damage is readily apparent after an IR or DWV test, the solid-state devices are degraded and repeated application of high voltage can lead to failure.

Locking and Interlocking Devices Check these devices for proper working condition and capability of performing their intended functions. Make any necessary replacements only with Allen-Bradley renewal parts or kits. Adjust or repair only in accordance with Allen-Bradley instructions.

Maintenance After a Fault Condition Opening of the short circuit protective device (such as fuses or circuit breakers) in a properly coordinated motor branch circuit is an indication of a fault condition in excess of operating overload. Such conditions can cause damage to control equipment. Before restoring power, the fault condition must be corrected and any necessary repairs or replacements must be made to restore the control equipment to good working order. Refer to NEMA Standards Publication No. ICS-2, Part ICS2-302 for procedures.

Replacements Use only replacement parts and devices recommended by Allen-Bradley to maintain the integrity of the equipment. Make sure the parts are properly matched to the model, series and revision level of the equipment.

Final Check Out After maintenance or repair of industrial controls, always test the control system for proper functioning under controlled conditions that avoid hazards in the event of a control malfunction.

For additional information, refer to NEMA ICS 1.3, PREVENTIVE MAINTENANCE OF INDUSTRIAL CONTROL AND SYSTEMS EQUIPMENT, published by the National Electrical Manufacturers Association, and NFPA70B, ELECTRICAL EQUIPMENT MAINTENANCE, published by the National Fire Protection Association.

General-9

General

IEC Enclosures

Degree of ProtectionIEC Publication 529 describes standard Degrees of Protection that enclosures of a product are designed to provide when properly installed.

SummaryThe publication defines degrees of protection with respect to:

Persons Equipment within the enclosure Ingress of water

It does not define:

Protection against risk of explosion Environmental protection (e.g. against humidity, corrosive

atmospheres or fluids, fungus or the ingress of vermin)

Note: The IEC test requirements for Degrees of Protection against liquid ingress refer only to water. Those products in this catalogue, which have a high degree of protection against ingress of liquid, in most cases include Nitrile seals. These have good resistance to a wide range of oils, coolants and cutting fluids. However, some of the available lubricants, hydraulic fluids and solvents can cause severe deterioration of Nitrile and other polymers. Some of the products listed are available with seals of Viton or other materials for improved resistance to such liquids. For specific advice on this subject refer to your local Rockwell Automation Sales Office see Section 21of this catalogue.

IEC Enclosure ClassificationThe degree of protection is indicated by two letters (IP) and two numerals. International Standard IEC 529 contains descriptions and associated test requirements that define the degree of protection each numeral specifies. The table on the right indicates the general degree of protection refer to the Abridged Descriptions of IEC Enclosure Test Requirements starting below. For complete test requirements refer to IEC 529.

Abridged Descriptions of IEC Enclosure Test Requirements(Refer to IEC 529 for complete test specifications e.g., test apparatus configuration; tolerances; etc. For Metric Conversion factors see page 1-3.)

Tests for Protection Against Access to Hazardous Parts (first characteristic numeral)

The first characteristic numeral of the IP number indicates compliance with the following tests for the degree of protection against access to hazardous parts. It also indicates compliance with tests as shown in the next section for the degree of protection against solid foreign objects.

The protection against access to hazardous parts is satisfactory if adequate clearance is kept between the specified access probe and hazardous parts. For voltage less than 1000V AC and 1500V DC, the access probe must not touch the hazardous live parts. For voltage exceeding 1000V AC and 1500V DC, the equipment must be capable of withstanding specified dielectric tests with the access probe in the most unfavourable position.

! The IEC standard permits use of certain supplementary letters with the characteristic numerals. If such letters are used, refer to IEC 529 for the explanation.

IP0_ No test required.

IP1_ A rigid sphere 50 mm in diameter shall not completely pass through any opening. Force = 50 N.

IP2_ A jointed test finger 80 mm long and 12 mm in diameter may penetrate to its 80 mm length, but shall have adequate clearance as specified above, from hazardous live parts, in every possible position of the test finger as both joints are bent through an angle up to 90. Force = 10 N.

IP3_ A test rod 2.5 mm in diameter shall not penetrate and adequate clearance shall be kept from hazardous live parts (as specified in table above). Force = 3 N.

IP4_ A test wire 1 mm in diameter shall not penetrate and adequate clearance shall be kept from hazardous live parts (as specified in table above). Force = 1 N.

First Numeral ! Second Numeral !

Protection of persons against access to hazardous parts and protection against penetration of solid foreign objects.

Protection against ingress of water under test conditions specified in IEC 529.

0 Non-protected 0 Non-protected1 Back of hand; objects greater

than 50 mm in diameter2 Vertically falling drops of

water

3 Finger; objects greater than 12.5 mm in diameter

4 Vertically falling drops of water with enclosure tilted 15

5 Tools or objects greater than 2.5 mm in diameter

6 Spraying water

7 Tools or objects greater than 1.0 mm in diameter

8 Splashing water

9 Dust-protected (dust may enter during specified test but must not interfere with operation of the equipment or impair safety)

10 Water jets

11 Dusttight (no dust observable inside enclosure at end of test)

12 Powerful water jets13 Temporary submersion14 Continuous submersion

Example: IP41 describes an enclosure that is designed to protect against the entry of tools or objects greater than 1 mm in diameter and to protect against vertically dripping water under specified test conditions.

Note: All first numerals and second numerals up to and including characteristic numeral 6, imply compliance also with the requirements for all lower characteristic numerals in their respective series (first or second). Second numerals 7 and 8 do not imply suitability for exposure to water jets (second characteristic numeral 5 or 6) unless dual coded; e.g., IP_5/IP_7.

General-10

General

IEC Enclosures

IP5_ A test wire 1 mm in diameter shall not penetrate and adequate clearance shall be kept from hazardous live parts (as specified in table above). Force = 1 N.

IP6_ A test wire 1 mm in diameter shall not penetrate and adequate clearance shall be kept from hazardous live parts (as specified in table on page 1-9). Force = 1 N.

Tests for Protection Against Solid Foreign Objects(first characteristic numeral)

For first numerals 1, 2, 3, and 4 the protection against solid foreign objects is satisfactory if the full diameter of the specified probe does not pass through any opening. Note that for first numerals 3 and 4 the probes are intended to simulate foreign objects which may be spherical. Where shape of the entry path leaves any doubt about ingress or a spherical object capable of motion, it may be necessary to examine drawings or to provide special access for the object probe. For first numerals 5 and 6 see test descriptions below for acceptance criteria.

IP0_ No test required.

IP1_ The full diameter of a rigid sphere 50 mm in diameter must not pass through any opening at a test force of 50 N.

IP2_ The full diameter of a rigid sphere 12.5 mm in diameter must not pass through any opening at a test force of 30 N.

IP3_ A rigid steel rod 2.5 mm in diameter must not pass through any opening at a test force of 3 N.

IP4_ A rigid steel wire 1 mm in diameter must not pass through any opening at a test force of 1 N.

IP5_ The test specimen is supported inside a specified dust chamber where talcum powder, able to pass through a square-meshed sieve with wire diameter 50 mm and width between wires 75 mm, is kept in suspension.

Enclosures for equipment subject to thermal cycling effects (category 1) are vacuum pumped to a reduced internal pressure relative to the surrounding atmosphere: maximum depression = 2 kPa; maximum extraction rate = 60 volumes per hour. If extraction rate of 40 to 60 volumes/hr. is obtained, test is continued until 80 volumes have been drawn through or 8 hr. has elapsed. If extraction rate is less than 40 volumes/hr. at 20 kPa depression, test time = 8 hr.

Enclosures for equipment not subject to thermal cycling effects and designated category 2 in the relevant product standard are tested for 8 hr. without vacuum pumping.

Protection is satisfactory if talcum powder has not accumulated in a quantity or location such that, as with any other kind of dust, it could interfere with the correct operation of the equipment or impair safety; and no dust has been deposited where it could lead to tracking along creepage distances.

IP6_ All enclosures are tested as category 1, as specified above for IP5_. The protection is satisfactory if no deposit of

dust is observable inside the enclosure at the end of the test.

Tests for Protection Against Water(second characteristic numeral)

The second characteristic numeral of the IP number indicates compliance with the following tests for the degree of protection against water. For numerals 1 through 7, the protection is satisfactory if any water that has entered does not interfere with satisfactory operation, does not reach live parts not designed to operate when wet, and does not accumulate near a cable entry or enter the cable. For second numeral 8 the protection is satisfactory if no water has entered the enclosure.

IP_0 No test required.

IP_1 Water is dripped onto the enclosure from a drip box having spouts spaced on a 20 mm square pattern, at a rainfall rate of 1 mm/min. The enclosure is placed in its normal operating position under the drip box. Test time = 10 min.

IP_2 Water is dripped onto the enclosure from a drip box having spouts spaced on a 20 mm square pattern, at a rainfall rate of 3 mm/min. The enclosure is placed in 4 fixed positions tilted 15 from its normal operating position, under the drip box. Test time = 2.5 min. for each position of tilt.

IP_3 Water is sprayed onto all sides of the enclosure over an arc of 60 from vertical, using an oscillating tube device with spray holes 50 mm apart (or a hand-held nozzle for larger enclosures). Flow rate, oscillating tube device = 0.07 l/min. per hole x number of holes; for hand-held nozzle = 10 l/min. Test time, oscillating tube = 10 min.; for hand-held nozzle = 1 min./m2 of enclosure surface area, 5 min. minimum.

IP_4 Same as test for IP_3 except spray covers an arc of 180 from vertical.

IP_5 Enclosure is sprayed from all practicable directions with a stream of water at 12.5 l/min. from a 6.3 mm nozzle from a distance of 2.5 to 3 m. Test time = 1 min./m2 of enclosure surface area to be sprayed, 3 min. minimum.

IP_6 Enclosure is sprayed from all practicable directions with a stream of water at 100 l/min. from a 12.5 mm nozzle from a distance of 2.5 to 3 m. Test time = 1 min./m2 of enclosure surface area to be sprayed, 3 min. minimum.

IP_7 Enclosure is immersed in water in its service position for 30 min. Lowest point of enclosures less than 850 mm tall = 1000 mm below surface of water. Highest point of enclosures more than 850 mm tall = 150 mm below surface of water.

IP_8 Test conditions are subject to agreement between manufacturer and user, but shall be at least as severe as those for IP_7

General-11

General

NEMA Enclosures

Specify the Correct Enclosure for Your Motor Controls

Type 1General Purpose Surface MountingType 1 enclosures are intended for indoor use primarily to provide a degree of protection against contact with the enclosed equipment in locations where unusual service conditions do not exist. The enclosures are designed to meet the rod entry and rust-resistance design tests. Enclosure is sheet steel, treated to resist corrosion.

Type 1Flush MountingType 1 Flush mounting enclosures for installation in machine frames and plaster wall. These enclosures are for similar applications and are designed to meet the same tests as Type 1 surface mounting.

Type 3Rainproof DusttightType 3 enclosures are intended for outdoor use primarily to provide a degree of protection against windblown dust, rain and sleet; and to be undamaged by the formation of ice on the enclosure. They are designed to meet rain !, external icing ", dust, and rust-resistance design tests. They are not intended to provide protection against conditions such as internal condensation or internal icing.

Type 3RRainproofType 3R enclosures are intended for outdoor use primarily to provide a degree of protection against falling rain, and to be undamaged by the formation of ice on the enclosure. They are designed to meet rod entry, rain # external icing ", and rust-resistance design tests. They are not intended to provide protection against conditions such as dust, internal condensation, or internal icing.

Type 4WatertightType 4 enclosures are intended for indoor or outdoor use primarily to provide a degree of protection against windblown dust and rain, splashing water, and hose-directed water; and to be undamaged by the formation of ice on the enclosure. They are designed to meet hosedown, dust, and external icing tests ". They are not intended to provide protection against conditions such as internal condensation or internal icing.

Type 4XNon-Metallic,Corrosion-Resistant Type 4X enclosures are intended for indoor or outdoor use primarily to provide a degree of protection against corrosion, windblown dust and rain, splashing water, and hose-directed water; and to be undamaged by the formation of ice on the enclosure. They are designed to meet the hosedown, dust, external icing ", and corrosion-resistance design tests. They are not intended to provide protection against conditions such as internal condensation or internal icing.

! Evaluation criteria: No water has entered enclosure during specified test." Evaluation criteria: Undamaged after ice buildup during specified test has melted

(Note: Not required to be operable while ice-laden.# Evaluation criteria: No water shall have reached live parts, insulation or

mechanisms.

Type 6PFor Prolonged Submersion at a Limited DepthType 6P enclosures are intended for indoor or outdoor use primarily to provide a degree of protection against the entry of water during prolonged submersion at a limited depth; and to be undamaged by the formation of ice on the enclosure. They are designed to meet air pressure, external icing !, hosedown and corrosion-resistance design tests. They are not intended to provide protection against conditions such as internal condensation or internal icing.

Type 7For Hazardous Gas LocationsType 7 enclosures are for indoor use in locations classified as Class I, Groups C or D, as defined in the U.S. National Electrical Code. Type 7 enclosures are designed to be capable of withstanding the pressures resulting from an internal explosion of specified gases, and contain such an explosion sufficiently that an explosive gas-air mixture existing in the atmosphere surrounding the enclosure will not be ignited. Enclosed heat generating devices are designed not to cause external surfaces to reach temperatures capable of igniting explosive gas-air mixtures in the surrounding atmosphere. Enclosures are designed to meet explosion, hydrostatic, and temperature design tests. Finish is a special corrosion-resistant, gray enamel.

Type 9For Hazardous Dust LocationsType 9 enclosures are intended for indoor use in locations classified as Class II, Groups E, F, or G, as defined in the U.S. National Electrical Code. Type 9 enclosures are designed to be capable of preventing the entrance of dust. Enclosed heat generating devices are designed not to cause external surfaces to reach temperatures capable of igniting or discolouring dust on the enclosure or igniting dust-air mixtures in the surrounding atmosphere. Enclosures are designed to meet dust penetration and temperature design tests, and aging of gaskets. The outside finish is a special corrosion-resistant gray enamel.

Type 12Dusttight Industrial UseType 12 enclosures are intended for indoor use primarily to provide a degree of protection against dust, falling dirt, and dripping non-corrosive liquids. They are designed to meet drip ", dust, and rust-resistance tests. They are not intended to provide protection against conditions such as internal condensation.

Type 13 OiltightType 13 enclosures are intended for indoor use primarily to provide a degree of protection against dust, spraying of water, oil, and non corrosive coolant. They are designed to meet oil exclusion and rust-resistance design tests. They are not intended to provide protection against conditions such as internal condensation.

General-12

General

NEMA Enclosures

Selection Criteria

Enclosures for Non hazardous Locations

! See page 1-13 for abridged description of NEMA enclosure test requirements. Refer to NEMA Standards Publication No. 250 for complete test specifications." Non hazardous materials, not Class III ignitable or combustible.

Enclosures for Hazardous Locations (Division 1 or 2) !

! For indoor locations only, unless catalogued with additional NEMA Type enclosure number(s) suitable for outdoor use as shown in the table on this page. Some control devices (if so listed in the catalogue) are suitable for Division 2 hazardous location use in enclosures for non-hazardous locations. For explanation of CLASSES, DIVISIONS and GROUPS, refer to the National Electrical Code.Note: Classifications of hazardous locations are subject to the approval of the authority having jurisdiction. Refer to the National Electrical Code.

" See abridged description of test requirements on page 1-13. For complete requirements, refer to UL Standard 698, compliance with which is required by NEMA enclosure standards.

# For listing of additional materials and information noting the properties of liquids, gases and solids, refer to NFPA 497M-1991, Classification of Gases, Vapours, and Dustsfor Electrical Equipment in Hazardous (Classified) Locations.

$ UL 698 does not include test requirements for Class III. Products that meet Class II, Group G requirements are acceptable for Class III.

For a Degree of Protection Against:Designed to Meet

Tests No.!

TypeFor Indoor Use Outdoor Use Indoor or Outdoor

1 12 13 3R 3 4 4X 6PIncidental contact with enclosed equipment 6.2 % % % % % % % %Falling dirt 6.2 % % % % % % % %Rust 6.8 % % % % % % % %Circulating dust, lint, fibres and flyings " 6.5.1.2 (2) % % % % % %Windblown dust 6.5.1.1 (2) % % % %Falling liquids and light splashing 6.3.2.2 % % % % % %Rain (Test evaluated per 6.4.2.1) 6.4.2.1 % % % % %Rain (Test evaluated per 6.4.2.2) 6.4.2.2 % % % %Snow and sleet 6.6.2.2 % % % % %Hosedown and splashing water 6.7 % % %Occasional prolonged submersion 6.11 (2) %Oil and coolant seepage 6.3.2.2 % %Oil or coolant spraying and splashing 6.12 %Corrosive agents 6.9 % % % % %

For a Degree of Protection AgainstAtmospheres Typically Containing: #

Designed toMeet Tests "

Class (NationalElectrical

Code)

7, Class I Group 9, Class II Group

A B C D E F G

Acetylene Explosion Test I %

Hydrogen, Manufactured GasHydrostatic Test

I % %

Diethyl Ether, Ethylene, Hydrogen Sulfide I %

Acetone, Butane, Gasoline, Propane, Toluene Temperature Test I % %

Metal dusts and other combustible dusts with resistivity of less than 105 -cm.

Dust Penetration Test

Temperature Test with Dust Blanket

II %

Carbon black, charcoal, coal or coke dusts with resistivity between 102108 -cm II %

Combustible dusts with resistivity of 105 -cm or greater

II %

Fibres, flyings $ III %

ENCLOSURESRefer to the brief descriptions below for the various types of enclosures offered by Allen-Bradley. See page 1-13 for selection criteria. For definitions, descriptions and test criteria, see National Electrical Manufacturers Association (NEMA) Standards Publication No. 250. Also see individual product listings within the Allen-Bradley catalogue for available enclosure types and for any additional information relating to these descriptions.

NOTE: Enclosures do not normally protect devices against conditions such as condensation, icing, corrosion or contamination that may occur within the enclosure or enter via the conduit or unsealed openings. Users must make adequate provisions to safe-guard against such conditions and satisfy themselves that the equipment is properly protected.

General-13

General

NEMA Enclosures

Selection Criteria

Abridged Description of NEMA Enclosure Test Requirements6.2 Rod Entry Test A 3.18 mm (.125 in.) diameter rod must not be able to enter enclosure except at locations where nearest live part is more than 102 mm (4 in.) from an opening such opening shall not permit a 13 mm (.5 in.) diameter rod to enter.

6.3 Drip Test Water is dripped onto enclosure for 30 minutes from an overhead pan having uniformly spaced spouts, one every 12,900 mm2 (20 sq. in.) of pan area, each spout having a drip rate of 20 drops per minute.

Evaluation 6.3.2.2: No water shall have entered enclosure.

6.4 Rain Test Entire top and all exposed sides are sprayed with water at a pressure of 0.35 kg/cm2 (5 psi) from nozzles for one hour at a rate to cause water to rise 457 mm (18 in.) in a straight-sided pan beneath the enclosure.

Evaluation 6.4.2.1: No water shall have reached live parts, insulation or mechanisms.

Evaluation 6.4.2.2: No water shall have entered enclosure.

6.5.1.1 (2) Outdoor Dust Test (Alternate Method) Enclosure and external mechanisms are subjected to a stream of water at 170.5 litres (45 gallons) per minute from a 25.4 mm (1 in.) diameter nozzle, directed at all joints from all angles from a distance of 3 to 3.7 meters (10 to 12 feet). Test time is 48 seconds times the test length (height + width + depth of enclosure in feet), or a minimum of 5 minutes. No water shall enter enclosure.

6.5.1.2 (2) Indoor Dust Test (Alternate Method) Atomized water at a pressure of 2.11 kg/cm2 (30 psi) is sprayed on all seams, joints and external operating mechanisms from a distance of 305 to 381mm (12 to 15 in.) at a rate of 11 litres (3 gallons) per hour. No less than 142 gms (5 oz) of water per linear foot of test length (height + length + depth of enclosure) is applied. No water shall enter enclosure.

6.6 External Icing Test Water is sprayed on enclosure for one hour in a cold room +2C (36F); then room temperature is lowered to approximately 5C (23F) and water spray is controlled so as to cause ice to build up at a rate of 6.4 mm (.25 in.) per hour until 19 mm (.75 in.) thick ice has formed on top surface of a 25.4 mm (1 in.) diameter metal test bar, then temperature is maintained at 5C (23F) for 3 hours.

Evaluation 6.6.2.2: Equipment shall be undamaged after ice has melted (external mechanisms not required to be operable while ice-laden).

6.7 Hosedown Test Enclosure and external mechanisms are subjected to a stream of water at 246 litres (65 gallons) per minute from a 25.4 mm (1 in.) diameter nozzle, directed at all joints from all angles from a distance of 3 to 3.7 meters (10 to 12 ft). Test time is 48 seconds times the test length [height + width + depth] of enclosure in meters (ft.), or a minimum of 5 seconds. No water shall enter enclosure.

6.8 Rust Resistance Test (Applicable Only to Enclosures Incorporating External Ferrous Parts) Enclosure is subjected to a salt spray (fog) for 24 hours, using water with five parts by weight of salt (NaCI), at 35C (95F), then rinsed and dried. There

shall be no rust except where protection is impractical (e.g., machined mating surfaces, sliding surfaces of hinges, shafts, etc.).

6.9 Corrosion Protection Sheet steel enclosures are evaluated per Underwriters Laboratories (UL) 50, Part 13 (test for equivalent protection as G-90 commercial zinc coated sheet steel). Other materials per Underwriters Laboratories (UL) 508, 6.9 or 6.10.

6.11 (2) Air Pressure Test (Alternate Method) Enclosure is sub-merged in water at a pressure equal to water depth of 2 meters (6 ft), for 24 hours. No water shall enter enclosure.

6.12 Oil Exclusion Test Enclosure is subjected to a stream of test liquid for 30 minutes from a 9.5 mm (.375 in) diameter nozzle at 7.57 litres (2 gallons) a minute. Water with 0.1% wetting agent is directed from all angles from a distance of 305 to 457 mm (12 to 18 in.), while any externally operated device is operated at 30 operations per minute. No test liquid shall enter the enclosure.

Abridged Description of UL Standard 698 Test Requirements

Explosion Test During a series of tests in which gas-air mixtures of the specific gas, over its range of explosive concentrations, are ignited inside the enclosure, the enclosure shall prevent the passage of flame and sparks capable of igniting a similar gas-air mixture surrounding the enclosure. In addition, there shall be no mechanical damage to enclosed electrical mechanisms or the enclosure.

Hydrostatic Test The enclosure shall withstand for 1 minute a hydrostatic test based on the maximum internal explosion pressure developed during the explosion tests, as follows: cast metal, four times the explosion pressure without rupture or permanent deformation; fabricated steel, twice the explosion pressure without permanent deformation and three times the explosion pressure without rupture. Exception: Hydrostatic tests may be omitted if calculations show safety factor of 5:1 for cast metal and 4:1 for fabricated steel.

Temperature Test The enclosed device is subjected to a temperature test to determine maximum temperature at any point on the external surface. The device must be marked with a temperature code based on the result only if the temperature exceeds +100C (+212F).

Dust Penetration Test The device is operated at full rated load until equilibrium temperatures are attained, then allowed to cool to ambient (room) temperature, through six heating and cooling cycles covering at least 30 hours, while continuously exposed to circulating dust of specified properties in a test chamber. No dust shall enter the enclosure.

Temperature Test with Dust Blanket This test is conducted as described for the Dust Penetration test except that the re circulating dust nozzles are positioned so that the dust is not blown directly on the device under test. The device is operated at full rated load (and under abnormal conditions for equipment subject to overloading) until equilibrium temperatures are attained. Dust in contact with the enclosure shall not ignite or discolour from heat, and the exterior temperatures based on +40C (+104F) ambient shall not exceed:

Group Normal Operation Abnormal OperationE +200C (+392F) +200C (+392F)F +150C (+302F) +200C (+392F)G +120C (+248F) +165C (+329F)

General-14

General

Notes

Safety Principles

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

EU Directives and Legislation. . . . . . . . . . . . . . . . . . . . 1-4

EU Harmonized European Standards . . . . . . . . . . . . . 1-9

Choice of Protective Measures . . . . . . . . . . . . . . . . . . 1-13

Safety Strategy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Safety Related Control Systems. . . . . . . . . . . . . . . . . 1-22

Further Considerations and Examples . . . . . . . . . . . 1-25

Reset Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Control Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Safety Light Curtains. . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

U.S. Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . 1-45

Organizations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49

Australian Safety Regulations . . . . . . . . . . . . . . . . . . . 1-49

1-2

Safety Principles

Important 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 catalogue are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Rockwell Automation does not assume responsibility or liability including intellectual property liability, for actual use based upon the examples shown in this publication.

Related Safety Information

You are responsible for the safety of the entire installed control system and for meeting all applicable laws, codes, and safety requirements.

Terms and Conditions

For applicable Terms and Conditions of Sale please refer to page 1-4 in this catalogue.

IMPORTANT

Rockwell Automation reserves the right to make revisions to the material contained in this catalogue and specifically disclaims all liability for any incidental or consequential damages resulting from the furnishing, performance or use of this material.

ATTENTION: As the installer of this control system, you must be knowledgeable of other applicable standards pertaining to safety recommendations related to:

Machine Construction General Electrical Machine Guarding Point of Operation guards, safety light curtains,

mechanical guards, and two-hand controls, and safety monitoring relays

In addition to local laws and codes, you are responsible for the safety recommendations detailed in all applicable codes and standards including:

National Electric Code OSHA Regulations ANSI Standards NFPA CSA

1-3

Safety Principles

Overview

A FAST TRACK GUIDE TO CONTENTS IN RELATIONTO MACHINERY SAFETY LEGISLATION IN EU

THE MACHINERY DIRECTIVENew machinery supplied within the EC

must satisfy the Essential Health and Safety Requirements.

See: Directives & Legislation and Harmonized European Standards.

THE USE OF WORK EQUIPMENT DIRECTIVE

Employers must ensure that all work equipment provided is suitable and safe.

See: Directives & Legislation and Harmonized European Standards.

RISK ASSESSMENT Determine the machines operating characteristics and limits.

Identify the hazards. Estimate the risk.See: Safety Strategy.

RISK REDUCTION Take any measures required to eliminate the hazards or reduct the risk to an

acceptable level.See: Choice of Protective Measures. Safety Related Control Systems.

Further Considerations and Examples. Interlocking Devices.

TECHNICAL FILE Ensure the availability of information required to check the conformity of

the machine.See: Directives & Legislation.

Employers must ensure that all work equipment is safe, maintained in efficient

working order and in good repair.

APPROVED BODIES Where necessary (Annex IV machines)

take appropriate action with anApproved Body.

See: Directives & Legislation.

Employers must ensure that suitable instruction and training is available together with adequate health and

safety information.

DECLARATION Prepare a Declaration of Conformity

or a Declaration of Incorporation. Where appropriate affix the CE mark.

See: Directives & Legislation.

Manufacturers and employers may need to satisfy other EC Directives in addition to those discussed in this book.Affixation of the CE mark is intended to indicate compliance with all relevant EC Directives.

1-4

Safety Principles

EU Directives and Legislation

The purpose of this section is to act as a guide for anyone concerned with machine safety, especially guarding and interlocking protective systems. It is intended for designers and users of industrial equipment.

In order to promote the concept of an open market within the EC and EFTA all member countries are obliged to enact legislation that defines essential safety requirements for machinery and its use. Machinery that does not meet these requirements cannot be sold into or within EC and EFTA countries.

EU Directives and LegislationThere are two European Directives that are of direct relevance to the safety of industrial machinery and equipment. These are:

1. The Machinery Directive 2. The Use of Work Equipment by Workers at Work Directive

These two Directives are directly related as the Essential Health and Safety Requirements (EHSRs) from the Machinery Directive can be used to confirm the safety of equipment in the Use of Work Equipment Directive.

This section deals with aspects of both directives and it is strongly recommended that anyone concerned with the design, supply, purchase or use of industrial equipment within the EC and EFTA countries familiarize themselves with their requirements. Most suppliers and users of machinery will simply not be allowed to operate in the EC unless they conform to these directives.

There are several other European Directives, either active or in preparation, with relevance to industrial safety. Most of them are fairly specialized in their application and are therefore left outside the scope of this section but it is important to note that, where relevant, their requirements must be met. Examples are: The Low Voltage DirectiveThe EMC DirectiveThe Prevention of explosion due to hazardous atmospheres Directive.

The Machinery Directive (see Figure 9)

89/392/EEC as amended by 91/368/EEC and 93/44/EEC has been consolidated in a new directive 98/37/EC. This Directive covers the supply of new machinery and other equipment including safety components. In most cases it is an offense to supply

Figure 1machinery unless it complies with the Directive. This means that it must satisfy wide ranging essential safety requirements contained in

Annex I of the Directive, a correct conformity assessment must be carried out and a Declaration of Conformity must be given.

The Directive came into full force for machinery on January 1st, 1995 and for Safety Components on January 1st, 1997. A two year transition period was allowed whereby either existing national regulations could be used or the new Directive regime could be followed. It is the responsibility of the manufacturer, importer or end supplier of the equipment to ensure that equipment supplied is in conformity with the Directive.

Essential Health & Safety Requirements(referred to as EHSRs)

Figure 2The Directive gives a list of EHSRs to which machinery must comply where relevant. The purpose of this list is to ensure that the machinery is safe and is designed and constructed so that it can be used, adjusted and maintained throughout all phases of its life without putting persons at risk.

The directive also provides a hierarchy of measures for eliminating the risk:

(1) Inherently Safe DesignWhere possible the design itself will prevent any hazards.

Where this is not possible (2) Additional Protection Devices, e.g., Guards with interlocked access points, non-material barriers such as light curtains, sensing mats etc., should be used.

Any residual risk which cannot be dealt with by the above methods must be contained by (3) Personal Protective Equipment and/or Training. The machine supplier must specify what is appropriate.

Suitable materials should be used for construction and operation. Adequate lighting and handling facilities should be provided. Controls and control systems must be safe and reliable. Machines must not be capable of starting up unexpectedly and should have one or more emergency stop devices fitted. Consideration must be given to complex installations where processes upstream or downstream can effect the safety of a machine. Failure of a power supply or control circuit must not lead to a dangerous situation. Machines must be stable and capable of withstanding foreseeable stresses. They must have no exposed edges or surfaces likely to cause injury.

Guards or protection devices must be used to protect risks such as moving parts. These must be of robust construction and difficult to

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bypass. Fixed guards must be mounted by methods that can only be undone with tools. Movable guards should be interlocked. Adjustable guards should be readily adjustable without the use of tools.

Electrical and other energy supply hazards must be prevented. There must be minimal risk of injury from temperature, explosion, noise, vibration, dust, gases or radiation. There must be proper provisions for maintenance and servicing. Sufficient indication and warning devices must be provided. Machinery shall be provided with instructions for safe installation, use, adjustment etc.

Conformity Assessment

Figure 3The designer or other responsible body must be able to show evidence that proves conformity with the EHSRs. This file should include all relevant information such as test results, drawings, specifications, etc., as shown below.

Where equipment is designed to specific harmonized European standards, it simplifies the task of showing conformity. These standards are not legally required, however, their use is strongly recommended since proving conformity by alternative methods can be an extremely complex issue. The structure of these standards, which are produced by CEN (the European Committee for Standardization) and CENELEC (the European Committee for Electrotechnical Standardization) support the Machinery Directive. Together CEN and CENELEC form the Joint Institute for Standardization in Europe.

A thorough, documented risk assessment must be conducted to ensure that all potential machine hazards are addressed.

Technical File

The person responsible for a declaration of conformity must ensure that the following documentation will be available on the premises for inspection purposes.A A technical file including:

Overall drawings of the equipment including control circuit drawings.

Detailed drawings, calculation notes, etc. required for checking the conformity of the machinery with the EHSRs.

TEST RESULTS-------------

----------------

---------------

----------------

STANDARDS

A list of:1. The EHSRs relevant to the equipment.2. Applicable Harmonized European Standards.3. Other applicable standards.4. Technical design specifications.

A description of methods adopted to eliminate hazards presented by the machinery.

If desired, any technical report or certificate obtained from an approved body (test house) or laboratory.

If conformity is declared with a Harmonized European Standard, any technical report giving test results for it.

A copy of instructions for the machinery.B For series manufacture, details of internal measures (quality systems, for example) to ensure that all machinery produced remains in conformity:

The manufacturer must carry out necessary research or tests on components, fittings or the completed machinery to determine whether by its design and construction it is capable of being erected and put into service safely.

The technical file need not exist as a permanent single file but it must be possible to assemble it to make it available in a reasonable time. It must be available for ten years following production of the last unit. Failure to make it available in response to a substantiated request by an enforcement authority may constitute grounds for doubting the conformity.

The technical file does not need to include detailed plans or any other specific information regarding sub-assemblies used for the manufacture of the machinery unless they are essential to verify conformity with the EHSRs.

Figure 4

Conformity Assessment for Annex IV Machines

Certain types of equipment are subject to special measures. This equipment is listed in Annex IV of the Directive and includes dangerous machines such as some woodworking machines, presses, injection moulding machines, underground equipment, vehicle servicing lifts, etc.Annex IV also includes certain safety components such as light curtains and two-hand control units.

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Figure 5For Annex IV machines in conformity with Harmonized European Standards there are three procedures to choose from:

1. Send the technical file to an approved body who will acknowledge receipt of the file and keep it.

Note: NOTE: With this option there is no assessment of the file. It may be used as reference at a later date in the event of a problem or a claim of noncompliance.

2. Send the technical file to an approved body who will verify that the Harmonized Standards have been correctly applied and will issue a certificate of adequacy for the file.

3. Submit an example of the machinery to an approved body (test house) for EC type examination. If it passes, the machine will be given a EC type examination certificate.

For Annex IV machines not in conformity with a standard or where no relevant Harmonized European Standard exists, an example of the machinery must be submitted to an approved body (test facility) for EC type examination.

Approved Bodies

A network of approved bodies who will communicate with each other and work to common criteria is being set up throughout the EC and EFTA countries. Details of test houses and laboratories with approved body status can be obtained from the United Kingdom Accreditation Service, Audley House, 13 Palace Street, London SW1E 5HS.

Figure 6

TEST RES

ULTS

------------- --------

--------STANDA RDS

Techn

ical

File

EC Type Examination

For an EC type examination the approved body will require a technical file and access to the machine to be examined. They will check that the machine is manufactured in accordance with its technical file and that it satisfies the applicable EHSRs. If the examination is successful an EC type examination certificate will be issued. A body that refuses to issue a certificate must inform the other approved bodies.

Figure 7

Declaration of Conformity Procedure

The responsible person must draw up an EC Declaration of Conformity and affix the CE (see Figure 7) mark to all machines supplied. The machines should also be supplied with the Declaration of Conformity.

Note: NOTE: Safety components should have a Declaration of Conformity but not a CE mark with respect to the Machinery Directive (although they may be CE marked with respect of the EMC or Low Voltage Directives).

The CE mark represents self-certification but it is an offense to apply the CE mark unless the machine satisfies the EHSRs and it is, in fact, safe. It is also an offense to apply a mark that may be confused with the CE mark to machinery.

Note: NOTE: The use of the CE mark also indicates compliance with any other European directives to which the machinery may be subject.

EC Declaration of Conformity

The certificate forming the declaration of conformity must include details of the manufacturer and responsible person, machine details (make, serial number, etc.), details of the approved body, (if appropriate), details of any standards used and the details of the person empowered to sign the declaration certificate. It must state conformity with the EHSRs or with the example of the machinery that underwent EC type examination (see Figure 8).

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Figure 8

EC Declaration of Incorporation

Where the equipment is supplied for assembly with other items to form a complete machine at a later date, the responsible person may issue a DECLARATION OF INCORPORATION with it (instead of a declaration of conformity). The CE mark should NOT be applied. The declaration should state that the equipment must not be put into service until the machine into which it has been incorporated has been declared in conformity (see Figure 9).This option is not available for equipment which can function independently or which modifies the function of a machine.

Maykit Wright Ltd.

Declaration of ConformityIn respect of the following Directives: European Machinery Directive (89/392 EEC as amended by 91/368 EEC and 93/44 EEC).Any other Directives relevant to the machine (e.g., the EMC Directive) should also be included.

Company: Maykit Wright Ltd. Main Street Anytown Industrial Estate Anytown, England AB1 2DC Tel: 00034 000890. Fax: 00034 000567

Machine: Meat Packaging Machine.

Type: Vacustarwrap 7D

Serial Number: 00516

Conforming to standards: All relevant Harmonized European Standards used and, where appropriate, any national standards and specifications.

If the machine is covered by Annex IV (Schedule 4) it would be necessary at this point to include either: The name and address of the Approved Body and the number of the Type Examination Certificate.or The name and address of the Approved Body which has drawn up a Certificate of Adequacy for the technical file.or The name and address of the Approved Body to which the technical file has been forwarded.

This is to declare that the above machine conforms with the relevant Essential Health and Safety Requirements of the European Machinery Directive (89/392 EEC as amended by 91/368 EEC and 93/44 EEC). Signed for Maykit Wright Ltd.

G.V. WrightG.V. WrightG.V. WrightManaging Director Issued 18th January 1996

The Use of Work Equipment by Workers at Work (Directive 89/655/EEC)

Whereas the Machinery Directive is aimed at suppliers, this Directive is aimed at users of machinery. It covers all industrial sectors and it places general duties on employers together with minimum requirements for the safety of work equipment. All EU countries are enacting their own forms of legislation to implement this Directive.

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Figure 9: Overview of procedures for the Machinery DirectiveIn the U.K., it has been implemented in the form of a collection of numbered regulations entitled The Provision and Use of Work Equipment Regulations 1992 (often abbreviated to P.U.W.E.R.). The form of implementation may vary between countries but the effect of the Directive is retained (see Figure 11).

The Directive was implemented on January 1st, 1993 and all new machines provided for use from that date must satisfy all the regulations.

All machinery must satisfy theEssential Health and Safety Requirements

Most machines & safety components (other than those listed in Annex IV)

Machines & safety components listed in

Annex IV

Must conform with relevant Harmonised

European standards

Must conform directly with the

EHSRs

If it DOES CONFORM with

relevant Harmonised

European standards

If it DOES NOT CONFORM with relevant Harmonised

European standards

OR

OR OR

Send the TECHNICAL

FILE to an approved body

which will acknowledge its

RECEIPT

Send the TECHNICAL FILE

to an approved body which will examine it and

issue a CERTIFICATE OF ADEQUACY for

the file

Send equipment to an approved body

for EC TYPE EXAMINATION

You must be able to assemble the TECHNICAL

FILE on request

It MUST be submitted to an

Approved Body for EC Type

Examination

FOR MACHINERYYou must issue a Declaration of Conformity and affix the CE mark or issue a Declaration of Incorporation.

FOR SAFETY COMPONENTSYou must issue a Declaration of Conformity.

For existing machines in use before this date regulations 1 to 10 must be satisfied but regulations 11 to 24 were not fully implemented until January 1, 1997.

Regulations 1 to 10

These regulations give details of which types of equipment and workplaces are covered by the Directive.

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EU Harmonized European Standards

They also place general duties on employers such as instituting safe systems of working and providing suitable and safe equipment that must be properly maintained. Machine operators must be given proper information and training for the safe use of the machine.

New machinery (and second hand machinery from outside the EC or EFTA) provided after January 1st, 1993 should satisfy any relevant product directives, e.g., The Machinery Directive (subject to transitional arrangements). Second hand equipment from within the EC or EFTA provided for the first time in the workplace must immediately satisfy regulations 11 to 24.

Figure 10

Note: NOTE: Existing or second hand machinery which is significantly overhauled or modified will be classified as new equipment so the work carried out on it must ensure compliance with the Machinery Directive (even if it is for a companys own use).

Regulation 5 Suitability of work equipment lies at the heart of the directive and it highlights the employers responsibility (under the Management of Health and Safety at Work Regulations 1992) to carry out a proper process of risk assessment.

Regulation 6 Maintenance requires machinery to be properly maintained. This will normally mean that there must be a routine and planned preventive maintenance schedule. It is recommended that a log is compiled and kept up to date. This is especially important in cases where the maintenance and inspection of equipment contributes to the continuing safety integrity of a protective device or system.

Regulations 11 to 24These regulations cover specific hazards and protective arrangements on machines.

They were not fully implemented until January 1st, 1997 for existing unmodified machines in use before January 1st, 1993. They applied immediately to other equipment. However, if the equipment conforms with relevant product directives, e.g., The Machinery Directive, they will automatically comply with the corresponding requirements of regulations 11 to 24 as they are similar in nature to the EHSRs of that Directive.

Of particular interest is Regulation 11, which gives a hierarchy of protection measures. These are:

A. Fixed enclosing guards.

B. Other guards or protection devices.

C. Protection appliances (jigs, holders, push sticks, etc.).

D. The provision of information, instruction, supervision and training.

These measures should be applied from the top (a) as far as practical and usually a combination of two or more will be required (see Figure 11).

EU Harmonized European StandardsThese standards are common to all EC and EFTA countries and are produced by the European Standardization bodies CEN and CENELEC. Their use is voluntary but designing and manufacturing equipment to them is t

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