SAFETY COMPONENTS. Easy Selection Guide SAFETY PRODUCTS. nhp.com.au nhp-nz.com

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1 SAFETY COMPONENTS Easy Selection Guide SAFETY PRODUCTS nhp.com.au nhp-nz.com

2 step 1 STEP 1: Input devices: Machine safety systems start with an input device. This device initiates the safety function to be completed. For example, an emergency stop pushbutton would be the input device for an emergency stop function. Safety functions are split into two categories; each category has associated input devices: 1. Primary safeguarding These are safety functions that provide the primary protection for the user of the machine. These would generally be interlocked guards or presence sensing systems. Primary safeguards are responsible for minimising the risk to the user when interacting with the equipment. Common Input devices: Mechanical interlock switches Interlock switches without locking function Interlock switches with locking function Non-Contact interlock switches Safety limit switches 2. Complementary measures These safety functions are supporting measures used to complement the primary safeguarding. For example, an emergency stop function isn t generally used as the primary safety measure however it is used to provide a safety function when the primary safeguard has been ineffective. Common Input devices: Emergency stop operators Emergency pullwire switches Enabling switches step 2 STEP 2: Safety relay device (Controller): Input devices are generally monitored by a safety relay, sometimes referred to as a safety controller. The safety relay monitors the state of the input device and initiates the appropriate behaviour when the input device is activated. Why is a safety relay required? Safety control systems are designed to relevant safety standards. In Australia, AS can be used as a guide for designing safety control systems for machine applications. In this standard, safety control systems are designed to an appropriate safety category. Safety categories set requirements related to the system s ability to perform the following: Fault tolerance Can the system perform the function even when a failure has occurred? Generally the components need to have redundant channels to achieve this. For example, if one channel fails, the redundant channel can still perform the function. Safety relays are redundant devices, thus if a failure occurs in the safety relay it will still perform the function correctly. Diagnostics Can the system detect a fault when it occurs? If the system can detect faults when they occur the system will become more reliable. Safety relays provide diagnostic ability to the safety system by monitoring that the components are working correctly. 2

3 step 3 STEP 3: Output/switching devices: Output devices are used to switch the source of the hazard on and off. These devices are controlled by the outputs of the safety relay or controller. The output or switching device has a combination of contacts (NO/NC) which are forcibly guided or positively driven. By monitoring the state of these contacts the safety controller or PLC can determine if a fault has occurred. Safety category summary: Category B Category 1 Category 2 Category 3 Category 4 Requirements Components should be selected in accordance with relevant standards and using basic safety principles. Reference Appendix A-D of AS for list of Basic Safety Principles, for example; environmental conditions, transient suppression, etc. Requirements of Category B Well-tried safety components should be used, reference Appendix A-D of AS for requirements of well-tried safety components. Well-tried safety principles should be used, reference Appendix A-D of AS for a list, for example; Use of mechanically linked contacts, over-dimensioning, etc. Requirements of Category B and well-tried safety principles. Safety function must be checked at suitable times by the control system. Requirements of Category B and well-tried safety principles. A single fault doesn t lead to loss of safety function. Whenever reasonably practicable the single fault is detected. Reference Appendix A-D of AS for a list of common faults to consider. Requirements of Category B and well-tried safety principles. A single fault doesn t lead to the loss of safety function. The single fault is detected if possible, an accumulations of faults can t lead to the loss of safety function. Reference Appendix A-D of AS for a list of common faults to consider. System behaviour The occurrence of a fault can lead to loss of the safety function. The occurrence of fault can lead to loss of safety function, but the probability of fault is reduced due to well-tried components and well-tried safety principles The occurrence of a fault between checks may lead to a loss of safety function. The fault is detected. When a single fault occurs the safety function is performed. Some but not all faults are detected, an accumulation of faults can lead to a loss of the safety function. When a single fault occurs the safety function is performed. Accumulation of faults can t lead to a loss of safety function. 3

4 INPUT DEVICES: Product selection: Primary safeguarding Mechanical interlock switches: Non-locking These devices are designed for use on sliding, hinged or lift-off guard doors and offer electrical interlocking of the machine control circuit to the guard door. Operation of these devices requires physical contact from the actuator and allows immediate opening of the guard door. Type Safety contacts Auxiliary contacts 1 NC 2 NC 1 NO Miniature tongue operated interlock switch Versatile tongue operated interlock switch Elf Elf Trojan 5 Trojan 5 GD2 440K-E K-E K-T K-T11147 Accessories Non-locking Elf Trojan Flat actuator 440K-A º actuator 440K-A21006 Standard actuator 440G-A27011 Mechanical interlock switches: Locking These devices are designed for use on sliding, hinged or lift-off guard doors and offer electrical interlocking of the machine control circuit to the guard door. Operation of these devices requires physical contact from the actuator and only allows opening of the guard door after a signal has been given to the device. These units are ideal for applications that require the guard door to remain locked closed until potential hazards have stopped and a safe condition exists. Type Locking force [N] Power to release Safety contacts Auxiliary contacts Solenoid contacts Solenoid voltage 2 NC 1 NO 2 NO 1 NC 1 NO 2 NC 24V AC/DC Versatile guard locking interlock switch Robust guard locking interlock switch TLS-1 GD G-T27121 TLS-3 GD G-T G-MT G-MT47010 Locking Accessories Standard actuator 440G-A27011 Fully flex actuator 440G-A

5 INPUT DEVICES: Product selection: Primary safeguarding Non-contact interlock switches Non-contact devices are ideal for sliding, hinged or lift-off guard doors. They are especially good for hinged guards with small arc radius due to their increased ability to cope with misalignment when compared to mechanical interlock switches. Non-contact switches aren t subject to mechanical wear because there is no mechanical contact required for operation. IP69K ratings and smooth body profiles make these interlocks ideal for industries such as food and beverage. 18 mm plastic barrel Assured sensing distance LED door indication/ diagnostic Magnetic hold Actuator code type 1) Cable 3 m 10 m Connector 6 inch Pigtail, 8-pin Micro (M12) 18 mm plastic barrel/ 18 mm actuator 15 mm (0.59 in.) Yes Standard Z21S16A Z21S16B Z21S16H Unique Z21U16A Z21U16B Z21U16H 18 mm plastic barrel/ 30 mm actuator 25 mm (0.98 in.) Yes Standard Z21S26A Z21S26B Z21S26H Unique Z21U26A Z21U26B Z21U26H 18 mm stainless steel barrel 18 mm stainless steel barrel/ 18 mm actuator 10 mm (0.39 in.) Yes Standard Z21S17A Z21S17B Z21S17H Unique Z21U17A Z21U17B Z21U17H Plastic rectangular/ rectangular actuator 18 mm (0.71 in.) Yes Standard Z21SS2A Z21SS2B Z21SS2H Unique Z21US2A Z21US2B Z21US2H Plastic rectangular flat pack Integrated latch Safety outputs Contact/ latched Yes 2 Solid state outputs Selectable 20N, 40N or 60N Standard Unique Z21SS- 3PA Z21US- 3PA Z21SS3PB Z21US- 3PB Z21SS3PH Z21US3PH Aux. outputs 1 Solid state output Switching capacity 0.2 A, 24 V DC IP Rating IP 69K * Replace the symbol with 2 (2m), 5 (5m), 10 (10m), 15 (15m), 20 (20m). 1) Uniquely coded switches need to be taught to specific coded actuators. Integrated latch 5

6 INPUT DEVICES: Product selection: Primary Safeguarding Safety limit switches Safety limit switches are effective on sliding interlock guard doors. They offer electrical interlocking of control circuits to the movement of the unit s actuator. Operation of these devices requires physical contact from the actuator. Safety limit switches offer poor tamper resistance when installed isolation, they are generally installed in pairs to offer higher integrity. Housing Safety contacts Auxilliary contacts Contact type Connectivity 440 P-A Plastic Metal 1 N/C 2 N/C 1 N/O 2 N/O Snap acting BBM M20 Roller punger Dome plunger Short lever Adjustable lever 440P-A Compact metal safety limit switches Bottom entry Side entry 440P-ARPS11C 440P-ARP- S11CS 440P-ADP- 1S11C 440P-ADP- 1S11CS 440P-C 22 mm plastic safety limit switches 440P-CRPS11B 440P-CDPS11B 440P-CSLS11B 440P-CALS11B 440P-CRPB12B 440P-CDPS12B 440P-CSLS12B 440P-CALS12B 440P-M 30 mm metal safety limit switches 440P- MRPS11B 440P- MRPB22B 440P-MDPS11B 440P-MSLS11B 440P-MALS11B 440P-MDPB22B 440P-MSLB22B 440P-MALB22B 440 P-C 440 P-M 6

7 INPUT DEVICES: Product selection: Complementary measures Emergency pullwire switches Emergency Pullwire switches can provide continuous emergency stop access for up to 125m with machinery such as conveyor systems. They are capable of detecting wire pull or wire breakage, this is a requirement of the relevant machine safety standards. The design of the wire system makes installation of the product quicker than any other system on the market. Type System length Safety contacts Auxiliary contacts M20 Lifeline 3 Cable actuated emergency stop 30 m Lifeline 4 Lifeline 4 stainless steel Cable & pushbutton actuated Emergency Stop Cable & pushbutton actuated emergency stop 75 m 75 to 125 m 2 N/C 2 N/O 440E-D N/C 1 N/O 440E-D N/C 440E-D N/C 2 N/O 440E-L N/C 1 N/O 440E-L N/C 440E-L N/C 2 N/O 440E-L N/C 1 N/O 440E-L N/C 440E-L m 2 N/C 2 N/O 440E-L22BNSM Accessories Installation kit comprises of 1 tensioner, 2 rope grips, rope and quantity of eyebolts Lifeline 3 and 4 Lifeline 4 stainless steel Length [m] 5 440E-A E-A E-A E-A E-A E-A E-A E-A E-A E-A E-A E-A E-A E-A13200 Note: switches not included. Enabling switches The enabling switches allow for personnel access to the hazardous areas of the machine during operation. The 3 position switches are ideal for maintenance, set-up or teaching activities that occur in close proximity of the equipment. An optional E-Stop or jog button can be included on the device. Main contacts: 3 position switches Monitoring contacts Jog contacts Emergency stop contacts 2 N/C 1 N/C 1 N/O 2 N/C Conduit entry For enabling switch Mounting bracket Single actuator Single safety switch plus enabling switch 440J-N21TNPM M20 440J-N21TNPM - NP 440J-A00N 440J-A01N 440J-A02N 440J-N21TNPM - NE 7

8 INPUT DEVICES: Product selection: Complementary measures Emergency stop operators All emergency stop operators are designed to incorporate direct opening action principle according to IEC This principle ensures that the contacts are mechanical forced open when the emergency stop operator is actuated. The E-Stop reliability is further improved with use of the self monitoring contact block (SMCB), if the SCMB becomes detached from the operator that safety contacts will open mm emergency stop operators components Type Size [mm] Markings Trigger action, twist-to-release Trigger action, ronis key lock M20 Plastic Metal Plastic Metal FP-MT34 800FM-MT34 Emergency stop operator, non-illuminated FP-MT44 800FM-MT44 800FP-MK44 800FM-LM44 EMO Laser engraved 800FP-MT44LE 800FM-MT44LE FP-MT64 800FM-MT64 Emergency stop operator, illuminated FP-LM44 800FM-LM44 Contact block / LED module Type Contact type Package quantity Voltage N/O 800F-X10 Contact block N/C F-X01 Self-monitoring 800F-X01S Integrated LED Module (RED) V AC/DC 800F-N3R 240 V AC 800F-N7R 22.5mm emergency stop operators complete Type Complete unit, emergency stop operator, non-illuminated Size (mm) 40 Contact type Trigger action, twist-to-release N/O N/C Plastic 1 800FP-MT44PX (Self-Monitoring) 800FP-MT44PX11S FP-MT44PX11 8

9 INPUT DEVICES: Product selection: Complementary measures Enclosed emergency stop operator Type 1-Hole emergency stop station, plastic Size (mm) 40 Contact type Trigger action, twist-to-release Trigger action, ronis key lock N/O N/C PG knockouts Metric knockouts PG knockouts Metric knockouts 1 800F-1YP1 800F-1YM1 800F-1YP4 800F-1YM F-1YP2 800F-1YM2 800F-1YP5 800F-1YM5 30 mm NEMA emergency stop operators Type Emergency stop operator, non-illuminated, full voltage Contact type Trigger action, twist-to-release N/O NC (late break) Type 4/13 Type 4/4X/ T-FXT6D4 800H-FRXT6D T-FXT6A1 800H-FRXT6A1 Type Lamp type Voltage N/O Contact type N/C (late break) Trigger action, twist-to-release Type 4/13 Type 4/4X/13 Emergency stop operator, illuminated, full voltage Incandescent 24 V AC/DC T-FXTQ24RA1 800H-FRXTQ24RA1 120 V AC T-FXTQH10RA1 800H-FRXTQH10RA1 LED 24 V AC/DC T-FXTQH24RA1 800H-FRXTQH24RA1 Emergency stop operator, illuminated, transformer Incandescent LED 120 V AC T-FXTP16RA1 800H-FRXTP126RA1 240 V AC T-FXTP26RA1 800H-FRXTP26RA1 120 V AC T-FXTPH16RA1 800H-FRXTPH16RA1 240 V AC T-FXTPH26RA1 800H-FRXTPH26RA1 In addition to what is shown here, NHP have an extensive range of emergency stop operators plus complimentary pushbuttons and indication lights to suit safety applications. 9

10 SAFETY RELAY DEVICE: Product selection: GSR Safety relays GSR safety relay system can be used to monitor the following input devices: Mechanical interlock switches Emergency pullwire switches Non-contact interlock switches Enabling switches Safety limit switches Safety mats Emergency stop operators Safety light curtains / laser scanners The GSR modules can be used as standalone devices or expanded using their single wire safety connection. This makes the GSR range perfect for any application of up to 8 safety functions and 3 individual safe zones. Relay type No. of inputs Inputs Immediate safety outputs 2 N/O Time delay Immediate auxiliary outputs Power supply Dual input 1 N/C, 2 N/C, 440R-D22R2 2 dual-channel 1 S.S 24 V DC Dual Input solid state output (DIS) OSSD, safety mat 2 S.S 440R-D22S2 Single input (SI) 1 N/C, 2 N/C, 2 N/O 440R-S12R2 1 dual-channel 1 S.S 24 V DC Compatible input (CI) OSSD, safety mat 3 N/O 440R-S13R2 Gaurdlocking proximity (GLP) 1 dual-channel 2 N/C, OSSD 2 S.S 1 S.S 24 V DC 440R-GL2S2P Expansion module (EM) 2 PNP 4 N/O 1 S.S 24 V DC 440R-EM4R2 Expansion module time delayed (EMD) 1 single-wire safety 100 ms 300 s on or off delay 100 ms 20 s jog 1 S.S 24 V DC 440R-EM4R2D OUTPUT/SWITCHING DEVICE: Product selection: Safety control relays Contacts Contact rating Coil voltage DPDT 2-pole 8 A 24 V DC 700-HPS2Z24 Accessories Screw terminal socket 700-HN123 Safety contactors Rated operational current (A) Ratings for switching 3-Phase kw (50Hz) Aux. contacts AC-3 AC-1 400/415 V N/O N/C * S-C09 14BC S-C12 14BC S-C16 14BC S-C23 14BC S-C30 14BC / S-C37 14BC S-C43 14BC S-C60 14BC S-C72 14BC S-C85 14BC * Must insert coil voltage code where dots are shown, coils in next table. 10

11 Coil voltage codes: AC Volts HZ R K V D VA T G DC Volts S-C09 C43 DC, with diode DJ 100S-C09 C43 DC, electronic, with diode EJ 100S-C60 C80 DC, with diode DQ DJ DY DD NHP SAFETY REFERENCE GUIDE Safety with Integrity INTEGRATED SAFETY SOLUTIONS AT YOUR DOORSTEP SAFETY nhp-nz.com Sales 0800 NHP NHP To register for NHP s Safety Reference Guide simply scan the QR code or visit: nhp.com.au Sales 1300 NHP NHP To stay up to date with the latest in safety, register today for the NHP Safety Reference Guide! The guide comes complete with: Glossary of safety terminology Safety interlock technology Wiring diagram examples Technical information on our range of safety products White papers Safety functional application notes 11

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