Banner ES-TA-3D1 User manual
Section 1 Product Description 3
Section 2 Emergency Stop Switch 4
Requirements
Section 3 Mounting the Control 5
Module
Section 4 Electrical Hookup 6
and Initial Checkout
Section 5 Operating Instructions 10
Section 6 Troubleshooting 13
Section 7 Repairs 15
Section 8 DeviceNet 17
Section 9 Product Specifications 20
Six Input Emergency Stop Monitoring Safety Relay
Model ES-TA-3D1 with DeviceNet™
• Monitors up to six normally-closed emergency stop switch circuits
for a contact failure or wiring fault
• Diverse-redundant input monitoring circuit
• DeviceNet™monitoring of status and diagnostic information
• Auto reset or monitored manual reset
• Two output switching channels for connection to control-reliable
power interrupt circuits
• Designed to comply with standards UL991, EN418, and
EN954-1 (Safety Category 4)
• For use in functional stop category 0 applications per NFPA 79
and EN418
• Plug-in terminal blocks and replaceable circuit boards
• LED indicators for status of all inputs and outputs
• Manual MAC ID Address Switches and LED
• Autobaud
CONTENTS
E-Stop Safety Relay – Model ES-TA-3D1
IMPORTANT NOTICE
Banner Engineering Corp. has made every effort to provide complete application, installation, operation, and maintenance instructions. In addition,
any questions regarding the use or installation of Banner Emergency Stop Monitoring Safety Relay model ES-TA-3D1 should be directed to the
factory applications department at the telephone numbers or address shown on back cover.
The user shall ensure that all machine operators, maintenance personnel, electricians, and supervisors are thoroughly familiar with and understand
all instructions regarding the installation, maintenance, and use of model ES-TA-3D1 Emergency Stop Monitoring Safety Relay, and with the
machinery it controls.
The user and any personnel involved with the installation and use of model ES-TA-3D1 Emergency Stop Monitoring Safety Relay must be thoroughly
familiar with all applicable ANSI/NFPA standards. The standards, listed below, directly address the use of emergency stop systems. Banner
Engineering Corp. makes no claim regarding a specific recommendation of any organization, the accuracy or effectiveness of any information
provided, or the appropriateness of the provided information for a specific application.
The user has the responsibility to ensure that all local, state, and national laws, rules, codes, and regulations relating to the use of this emergency
stop monitoring safety relay in any particular application are satisfied. Extreme care is urged that all legal requirements have been met and that all
installation and maintenance instructions contained in this manual are followed.
U. S. Standards Applicable to Use of Emergency Stop Monitoring Safety Relays
ANSI B11 Standards for Machine Tools “Safety Requirements for the Construction, Care and Use”
Available from: Safety Director
AMT – The Association for Manufacturing Technology
7901 Westpark Drive
McLean, VA 22101-4269
Tel.: 703-827-5266
NFPA79 “Electrical Standard for Industrial Machinery (1997)”
Available from: NationalFire Protection Association
1 Batterymach Park, P.O. Box 9101
Quincy, MA 02269-9101
Tel.: 800-344-3555
ANSI/RIA R15.06 “Safety Requirements for Industrial Robots and Robot Systems”
Available from: Robotic Industries Association
900 Victors Way, P.O. Box 3724
Ann Arbor, MI 48106
Tel.: 734-994-6088
European Standards Applicable to Use of Emergency Stop Monitoring Safety Relays
EN292-1 “Safety of Machinery – Basic Concepts, General Principals for Design
Part 1: Basic Terminology, Methodology”
EN292-2 “Safety of Machinery – Basic Concepts, General Principals for Design
Part 2: Technical Principals and Specifications”
EN60204-1 “Electrical Equipment of Machines: Part 1: General Requirements
Also, request a type “C” standard for your specific machinery.
EN418 Safety of Machinery – Emergency stop equipment functional aspects, principles for design
Available from: Global Engineering Documents
15 Inverness Way East
Englewood, CO 80112-5704
Tel.: 800-854-7179
!
E-Stop Safety Relay – Model ES-TA-3D1
SECTION 1 – Product Description
The purpose of safety relay model ES-TA-3D1 is to increase the control reliability of a
multiple-input Emergency Stop circuit. The ANSI B11.19 standard states:
“Control reliability of electrical, electronic, or pneumatic
systems frequently consists of multiple, independent
parallel or series circuitry or components so arranged
that any single failure . . . either sends a stop
command to the machine tool or prevents a
successive cycle from being initiated.”
As indicated in Figure 3, a typical Emergency Stop switch offers two redundant
switching contacts. In a properly designed machine stop circuit, the opening of either
of the two emergency stop contacts immediately removes electrical power from the
machine control elements which react to stop hazardous machine motion and/or any
other machine hazard. This redundancy of stopping control offered by a two-pole
Emergency Stop switch is the first step towards control reliability. However, failure or
defeat of one of the switch contacts to a short-circuit will go undetected, thereby
removing the redundancy, and leaving the Emergency Stop circuit prone to eventual
failure.
The ES-TA-3D1 safety relay connects up to six Emergency Stop switches to the
machine Emergency Stop control elements. The Emergency Stop switches become the
inputs to the safety relay. The safety relay monitors the condition of both contacts of
each Emergency Stop switch connected to it. The output of the safety relay consists of
two redundant output switching channels, each of which is the series connection of
two force-guided relay contacts (K1 and K2 in Figure 3).
As recommended by the Control Reliability section of ANSI B11.19, outputs of the
ES-TA-3D1 consist of two contacts (K1 and K2). These contacts are mechanically
linked, force-guided contacts, allowing the ES-TA-3D1 to monitor the outputs for
failures. If the safety relay detects failure of any contact of either the input Emergency
Stop switches or the output relays, the safety relay output is disabled and cannot be
reset. The two switching output circuits of the safety relay are rated for up to 250V ac
at up to 4 amps (resistive load).
The ES-TA-3D1 safety relay also provides a selectable (automatic or manual) reset
function.
WARNING. . .
Model ES-TA-3D1
Emergency Stop
Monitoring Safety
Relay is not a point-
of-operation guarding device, as
defined by OSHA regulations. It
is necessary to install point-of-
operation guarding devices, such
as safety light screens and/or
hard guards, to protect personnel
from hazardous machinery.
Failure to install point-of-
operation guards on hazardous
machinery can result in a
dangerous condition which could
lead to serious injury or death.
!
E-Stop Safety Relay – Model ES-TA-3D1
The safety relay has indicators for input power, E-stop inputs, monitor inputs, reset input
and output relay status (see Figure 1). A selector for Auto or Manual Reset is located
under the control panel cover (see page 8 for instructions). See Sections 6 and 7 for
information regarding troubleshooting and repairs.
Figure 1. ES-TA-3D1 status indicators
SECTION 2 – Emergency Stop Switch Requirements
As shown in Figure 3, each Emergency Stop switch must provide two contacts which are
closed when the switches are in the “ready” position. Once activated, the Emergency
Stop switch must open both contacts. The switch may be returned to the closed-contact
position only by a deliberate action (such as twisting, pulling, unlocking, etc.).
Additionally, NFPA79, section 13.2 Emergency Stop Devices specifies the following
switch (“stop control”) requirements:
• Emergency stop pushbuttons shall be located at each operator control station and
at other operating stations where emergency shutdown shall be required.
• Stop and emergency stop pushbuttons shall be continuously operable from all
control and operating stations where located.
• Actuators of emergency stop devices shall be colored RED. The background
immediately around the device actuator shall be colored YELLOW. The actuator of
a pushbutton-operated device shall be of the palm or mushroom-head type.
• The emergency stop actuator shall be either a momentary or self-latching type.
NOTE: Some applications may have additional requirements. The user must refer to all
relevant regulations.
E-Stop Safety Relay – Model ES-TA-3D1
SECTION 3 – Mounting the Control Module
Mount the ES-TA-3D1 E-Stop Safety Relay inside a lockable enclosure which has a
minimum rating of NEMA3 (IP54). The ES-TA-3D1 E-Stop Safety Relay is not
designed for exposed wiring. It is the user’s responsibility to house the safety relay
in an enclosure with NEMA 3 (IEC IP54). For security reasons, the key to the
lockable enclosure should be in the possession of a Qualified Person (see section 5.1,
Security Protocol).
The control module may be mounted onto standard 35 mm DIN rail or may, instead,
be mounted directly to the backplate of the lockable enclosure, using the supplied
hardware. Leave a minimum 1 cm (1/4") gap between the module housing and other
adjacent housings, to allow room for potential board replacement at a later date.
The ES-TA-3D1 E-Stop Safety Relay control module should be configured before
initial checkout and use (see section 4.4 and 4.5).
Dimensions of the safety relay are shown in the diagram below.
115.0 mm
(4.53")
81.0 mm
(3.19")
107.0 mm
(4.21")
97.0 mm
(3.82")
5.0 mm
(0.20")
5.5 mm
(0.22")
Slot for Screws (2)
M3.5 x 0.6 mm
70.0 mm
(2.76")
4.5 mm
(0.18")
6.5 mm
(0.26")
Combo Head (Phillips/Slotted) Screws
M3.5 x 0.6 mm (2) (#6 x .5 equivalent), (supplied)
M3.5 mm washers (2) (#6 equivalent), (supplied)
M3.5 x 0.6 mm nuts (2) (#6 equivalent), (supplied)
Recommended Torque:
16-20 in-lbs on mounting screws
5 in-lbs on terminal screws
Figure 2. ES-TA-3D1 enclosure dimensions
E-Stop Safety Relay – Model ES-TA-3D1
SECTION 4 – Electrical Hookup and Initial Checkout
It is not possible to give exact wiring instructions for a device such as the model
ES-TA-3D1 emergency stop monitoring safety relay which interfaces to a multitude of
machine control configurations. The following guidelines are general in nature.
Model ES-TA-3D1 has no delay function. The output relay contacts open within 25
milliseconds from the time that any emergency stop switch contact opens. This
classifies the ES-TA-3D1 as a functional “Category 0” emergency stop control as
defined by NFPA 79 (National Fire Protection Association Standard for Industrial
Machinery) and EN418 (European Standard: “Safety of Machinery, Emergency Stop
Equipment, Functional Aspects – Principles of Design”).
4.1 Connection of Emergency Stop Switches
Connect the two poles of each Emergency Stop switch as shown in Figure 3. The
switches in Figure 3 are shown in their “ready” position with both contacts closed.
See Product Specifications on page 20 for E-stop Switch Input Requirements.
NOTE: Jumper any unused inputs to simulate an Emergency Stop switch in the
closed-contact position.
4.2 Connection of Reset Switch
The circuit Reset switch can be any mechanical switch, such as a normally open
momentary switch, a two-position key switch, etc. The Reset switch must meet the
requirements listed in the Product Specifications on page 20. The Reset switch
connects between terminals 14 and 34 of the safety relay.
The Reset switch must be located outside and not accessible from the area of
dangerous motion, and must be positioned so that any area of dangerous motion
may be observed by the switch operator during the Reset operation. Any areas not
in full view must use supplemental guarding to detect personnel.
CAUTION . . .
Electrical Hazard
Always disconnect
power from the ES-TA-
3D1 safety relay and all power
from the machine being controlled
before making or removing any
wire connections.
Electrical installation and wiring
must be made by qualified
personnel and must comply with the
NEC (National Electrical Code),
IEC 60204-1 and -2, and all
applicable local standards and
codes.
CAUTION . . .
Do Not Use As A Safety
Switch (Interlock) Monitor
The ES-TA-3D1 is not to
be used as a gate or interlocking
switch monitor. The use of input
devices other than Emergency Stop
switches (see section 2) may result
in a reduction in the safety category
as described by EN 954-1.
!
WARNING . . .
Do Not Use Jumpers to
Bypass an E-stop circuit.
!
E-Stop Safety Relay – Model ES-TA-3D1
24V dc
Reset Switch MSC1
Monitor MSC2
Monitor MSC3
Monitor MSC4
Monitor
Master Stop
Control Elements
*Arc Suppressors
(See Warning)
NOTE:
Use jumper wires to make connections to any
unused emergency stop switch or monitor inputs.
Wire to simulate a closed contact.
L2
114 34 19 20
MSC1
MSC2 MSC3 MSC4
40
Internal
Redundant
Safety Relays
K1
K2
ES-TA-3D1
21 2323 22 39
L1
4525 24 6727 26 8929 28
1110 31 30 1312 33 15 3532 16 36 17 37 18 38
Common
ES1
Emergency Stop Switch #1
a
c
b
d
a
c
b
d
a
c
b
d
a
c
b
d
ES2
Emergency Stop Switch #2
ES5
Emergency Stop Switch #5
c
a
c
a
d
b
d
b
ES6
Emergency Stop Switch #6
ES3
Emergency Stop Switch #3 ES4
Emergency Stop Switch #4
+
**
**
Machine
Control
Circuit
Figure 3. General hookup information for model ES-TA-3D1 Emergency Stop Monitoring Safety Relay
WARNING . . . Arc Suppressors
If arc suppressors are used, they MUST be installed as shown across
the load of the master stop control elements (MSC1, MSC2, MSC3
and MSC4). NEVER install suppressors directly across the output
contacts of the ES-TA-3D1 safety relay. It is possible for suppressors to fail as a
short circuit. If installed directly across the output contacts of the safety relay, a
short-circuited suppressor will create an unsafe condition which could result in
serious injury or death.
!
WARNING . . . Intermediate Devices
NEVER wire an intermediate device (for example, a programmable
logic controller - PLC), other than a captive contact (force-guided)
relay, between ES-TA-3D1 outputs and the master stop control
element it switches. To do so sacrifices the control reliability of the control-to-
machine interface, and creates an unsafe condition which could result in serious
injury or death. Whenever a force-guided relay is added as an intermediate
switching device, a normally closed, force-guided monitor contact of that relay
must be connected in series with the monitor contact of the master stop control
element it is switching. (Reference ANSI B11.1 – 1988, Appendix B4)
!
DeviceNet
21 22 23 24 25 26 27
D5 D4 D3 D2 D1
V+ (Red)
CAN_H (white)
Shield
CAN_L (blue)
V- (black)
Figure 4. DeviceNet connections
E-Stop Safety Relay – Model ES-TA-3D1
4.3 Setting the MAC ID Address
In order for the DeviceNet controller to process information from its individual inputs,
each input must have a unique 2-digit address. (For example, two devices on the
same bus network may not both have 26 as their address; however, two devices
within the same factory may have addresses of 26, if they are on separate bus
networks.)
The ES-TA-3D1’s address may be assigned in two ways: locally, using the two rotary
selectors on the front of the module (see Figure 5), or remotely, using the rotary
selectors and the DeviceNet controller. To set the address locally, set the rotary
selectors to a number between 00 and 63 and cycle power to the DeviceNet
connection. To allow the DeviceNet controller to set the address, set the rotary
selectors to a number higher than 63; the address can then be set using the
controller.
The MAC ID LED will be off when the MAC ID address rotary switches match the
current address of the ES-TA-3D1 (as recognized by the DeviceNet controller). If the
addresses do not agree, the LED will flash. (To correct this problem, see DeviceNet
Troubleshooting.) The MAC ID LED will be ON steadily when the MAC ID address
rotary switches are above 63 and the current address of the ES-TA-3D1 (as
recognized by the DeviceNet controller) was set with the MAC ID address rotary
switches above 63.
4.4 Selecting Auto or Manual Reset Mode
The ES-TA-3D1 is switchable between Auto and Manual reset (factory setting is
Manual). When Manual reset is selected, the E-stop relay may be reset only by a
manual Reset switch. When Auto reset is selected, the E-stop relay automatically
resets whenever power is applied to the device, or at the moment when all E-stop and
Monitor inputs become closed. (The manual Reset switch is ignored when Auto reset
is selected.) Regardless of which reset method is selected, the E-stop cannot be
started unless all starting prerequisites have been met (power to the system, and all
E-stop and monitor inputs closed).
To select reset mode, open the module cover and remove the green Reset Mode
selector from the black socket. Reinsert the Reset Mode selector so that the mode
you select (either AUTO or MANUAL, one printed on each side of the Reset Mode
selector) is facing up. (See Figure 6.)
In all cases, the user must ensure that closing the Emergency Stop switch (in Auto
reset) or manually resetting the ES-TA-3D1 does not initiate a restart (per NFPA 79
Section 9.6.3).
Figure 6. Selecting Auto or Manual
Reset
Figure 5. MAC ID address rotary
selectors and LED
E-Stop Safety Relay – Model ES-TA-3D1
4.5 Selecting the Autobaud Feature
The ES-TA-3D1 has an autobaud feature which allows for automatic recognition of the
baud rate on the network into which the ES-TA-3D1 is installed. This convenient
feature automatically matches the ES-TA-3D1 baud rate to the network without
requiring a baud rate configuration step. The autobaud feature is set to ON at the
factory. When the autobaud parameter is set to ON, the baud rate parameter may not
be set via the DeviceNet network. The autobaud parameter may be turned off by
setting the DeviceNet autobaud parameter to OFF (see the EDS file for path
information). When the autobaud parameter is set to OFF, the baud rate parameter
may be set via the DeviceNet network to the desired baud rate.
To determine if autobaud is set to ON, power (at the DeviceNet power inputs) the
ES-TA-3D1 while it is not connected to the DeviceNet network; the Bus Status
Indicator will flash green, then red, then OFF in a repetitive sequence. If autobaud is
set to OFF, then the Bus Status Indicator will flash green (or red) after the initial
green/red sequence at power up.
4.6 Initial Checkout Procedure
1) IMPORTANT: Ensure that there are no connections at terminals 39/19 and
40/20.
2) Close all E-stop inputs. Ensure all monitoring inputs are closed and that the
Reset input is open. (Refer to Figure 3.)
3) Apply input power to the E-stop relay at terminals 1 and 21. Verify that K1,
K2 and Reset indicators are OFF. Verify that all E-stop and monitor indicators
are ON. (If Auto/Manual Reset selector is set to Auto mode, verify K1, K2
and all E-stop indicators are ON. Reset and all monitor indicators are OFF.)
4) Close the Reset input (if Auto/Manual Reset selector is set to AUTO mode,
go to step 5). Verify that the Reset and K1 LED indicators go ON. K2
indicator should remain OFF. Open the Reset switch and verify that the Reset
indicator is OFF. The K1 and K2 indicators should both be ON at this time. If
the K2 indicator comes ON before the Reset switch is opened, disconnect
the input power and check all wiring. Return to step 2 after the cause of any
problem has been corrected.
5) Activate one Emergency Stop switch (open its contacts). The K1 and K2
indicators should turn OFF, simultaneously. If either indicator does not go
OFF, check the E-stop indicators. (The indicators for the activated Emergency
Stop switch should be OFF, as well as indicators for E-stops with higher
numbers. For example, if E-stop #3 is activated, the indicators for #3, #4, #5,
and #6 should all go OFF simultaneously.) If all E-stop indicators are OK but
either or both K1 and K2 indicators are ON, disconnect the input power and
check all wiring. Return to step 2 after the cause of the problem has been
corrected.
6) Repeat the above checkout procedure for each E-stop switch, individually
(ES1 through ES6).
IMPORTANT . . .
Check Each Switch
Individually
Check ALL Emergency
Stop switches, individually, during
each checkout procedure. When two
or more Emergency Stop switches
are used, each switch must be
individually actuated (engaged), then
re-armed and the ES-TA-3D1 reset.
This allows the ES-TA-3D1 to check
each switch and its wiring to detect
faults.
!
E-Stop Safety Relay – Model ES-TA-3D1
4.7 Connection to the Machine to be Controlled
The hookup diagram (Figure 3) shows a generic connection of the ES-TA-3D1 safety
relay’s two redundant output circuits to master stop control elements MSC1, MSC2,
MSC3 and MSC4. A master stop control element is an electrically powered device,
external to the ES-TA-3D1 safety relay, which stops the machinery being controlled by
immediate removal of electrical power to the machine and (when necessary) by
applying braking to dangerous motion (reference ANSI B11.19, section 5.2: “Stop
Control”). This stopping action must be accomplished by removing power to either
master stop control element.
To satisfy the requirements of Safety Category 4 of prEN 954-1, the master stop
control elements must offer a normally closed, force-guided monitor contact. One
normally closed monitor contact from each master stop control element is wired to
the appropriate terminals on the module (see Figure 3). In operation, if any of the
master stop control elements fails to de-energize, the associated monitor contact will
remain open. As a result, it will not be possible to reset the ES-TA-3D1 safety relay.
NOTE: If less than four MSC elements are controlled by the ES-TA-3D1, jumper the
unused monitor inputs to simulate a closed contact. See NOTICE Regarding
MSC Monitor Hookup, at right.
Apply power to the machine control elements and perform the Periodic Checkout
Procedure (see section 5.2).
SECTION 5 – Operating Instructions
5.1 Security Protocol
The ES-TA-3D1 E-Stop Safety Relay should be mounted inside a lockable enclosure.
For security reasons, the key to the lockable enclosure must be in the possession of a
Qualified Person or Persons. A Qualified Person is a person who, by possession of a
recognized degree or certificate of professional training, or who, by extensive
knowledge, training, and experience, has successfully demonstrated the ability to
solve problems relating to the subject matter and work (ANSI B30.2-1983).
The key to the Reset switch (if the Reset switch, as installed, requires a key) should
be available to a Designated Person or Persons. A Designated Person is one who is
identified and designated in writing, by the employer, as being appropriately trained
and qualified to perform a specified checkout procedure. A machine operator who
meets these requirements may be a Designated Person.
CAUTION . . .
Dangerous Voltage
Before performing the
initial checkout
procedure, make certain all power is
disconnected from the machine to
be controlled. Dangerous voltages
may be present along the ES-TA-
3D1 wiring barriers whenever power
to the machine control elements is
“ON”. Exercise extreme caution
whenever machine control power is
or may be present. Always
disconnect power to the machine
control elements before opening
the enclosure housing of the
ES-TA-3D1.
NOTICE Regarding
MSC Monitor Hookup
It is strongly recommended that one
normally closed auxiliary contact of
each Master Stop Control element
(MSC) be wired as an MSC monitor
contact, as shown in Figure 3. If this is
done, any inconsistency of action
between the MSCs will create a fault
condition, which will prevent the
E-stop relay from resetting.
E-Stop Safety Relay – Model ES-TA-3D1
5.2 Periodic Checkout Requirements
The functioning of the Emergency Stop system (including the ES-TA-3D1 E-Stop
Safety Relay and the guarded machine) must be verified on a regular periodic basis to
ensure proper operation (see also the machine manufacturer’s recommendations).
Procedure:
1) With the machine running, activate one Emergency Stop switch, (open its
contacts). Verify that the machine stops. (The K1 and K2 indicators should turn
OFF, simultaneously. If either indicator does not go OFF, check the E-stop
indicators. The indicators for the activated Emergency Stop switch should be OFF,
as well as indicators for E-stops with higher numbers. For example, if E-stop #3
is activated, the indicators for #3, #4, #5, and #6 should all go OFF
simultaneously.) If all E-stop indicators are OK but either or both K1 and K2
indicators are ON, disconnect the input power and check all wiring. Repeat this
step after the cause of any problem has been corrected.
2) Return the Emergency Stop switch to its closed-contact position. Close and open
the Reset switch (if the controller is in Auto Reset mode, this action is not
necessary). The machine must not start at this point. Initiate the machine startup
procedure (per manufacturer’s instructions). Verify that the machine restarts in
correct sequence.
3) Repeat the above checkout procedure for each E-stop switch, individually (ES1
through ES6).
5.3 Normal Operation
Following are examples of LED status indication and DeviceNet information for typical
ES-TA-3D1 RUN, STOP, and FAULT conditions.
5.3.1 RUN Condition
The following LED status represents a normal run condition, where all E-stop
switches are closed, and the E-stop relay has been reset so that K1 and K2 output
contacts are closed:
ES4
AB
ES3
AB
ES2
AB
ES1
24V
DC
+
PWR
AB ES5
AB ES6
RESET
AB MONITOR
123
K1
K2
4Indicator Key
Indicator "ON"
Indicator "OFF"
Figure 7. Indicator status for normal RUN condition
Operating mode: OK (Go)
E-stop Inputs: All Closed
Monitor Inputs: Mon 1 Open
(NOTE: unused,
jumpered monitor
contacts will not be
listed as open)
Reset Mode: Manual Reset
(or Auto Reset,
depending on selection)
Reset Input: - - - - - -
(or Disabled if in Auto
Reset mode)
K1 Relay: Energized
K2 Relay: Energized
Autobaud: On (or Off, depending on
selection)
Fault Type: No Fault
Action 1: - - - - - -
Action 2: - - - - - -
Action 3: - - - - - -
A normal RUN condition is reported to
DeviceNet as follows:
E-Stop Safety Relay – Model ES-TA-3D1
5.3.2 STOP Condition
If any E-stop switch is actuated during a normal run condition, the output contacts of
K1 and K2 will open. The following LED status illustrates a situation where E-stop
switch ES3 has been actuated:
ES4
AB
ES3
AB
ES2
AB
ES1
24V
DC
+
PWR
AB ES5
AB ES6
RESET
AB MONITOR
123
K1
K2
4Indicator Key
Indicator "ON"
Indicator "OFF"
Figure 8. Indicator status for STOP condition (E-stop switch ES3 is actuated)
ES4
AB
ES3
AB
ES2
AB
ES1
24V
DC
+
PWR
AB ES5
AB ES6
RESET
AB MONITOR
123
K1
K2
4Indicator Key
Indicator "ON"
Indicator "OFF"
Figure 9. Typical indicator status for FAULT condition (contact “B” of E-stop switch
ES4 remains closed upon actuation)
Operating mode: Stop Condition
E-stop Inputs: E-Stop 3 Open
Monitor Inputs: All Closed
Reset Mode: Manual Reset
(or Auto Reset,
depending on selection)
Reset Input: Open (or Disabled if in
Auto Reset mode)
K1 Relay: De-energized
K2 Relay: De-energized
Autobaud: On (or Off, depending on
selection)
Fault Type: No Fault
Action 1: - - - - - -
Action 2: - - - - - -
Action 3: - - - - - -
When the E-stop switch is reset, (ES3 in this example), the indicator lights for ES3,
ES4, ES5, and ES6 will come back ON.
K1 and K2 will close and their LED indicators will come ON:
1) After the Reset switch is closed and then opened (Manual Reset mode) or,
2) Immediately upon resetting ES3 (Auto Reset mode).
5.3.3 FAULT Condition
The following status indication illustrates a typical fault condition in which one switch
contact remains closed when an E-stop switch is actuated. This example illustrates
the situation where contact “B” of switch ES4 fails, closed:
SECTION 7 – Repairs
Board Replacement:
In some cases, it may be possible to repair your module by replacing one or more of
A STOP condition created by actuation of
E-stop switch ES3 is reported to DeviceNet
as follows:
A FAULT condition created by failure of
contact “B” of E-stop switch ES4 is
reported to DeviceNet as follows:
Operating mode: Fault Condition
E-stop Inputs: 4A Open 4B Short
Monitor Inputs: All Closed
Reset Mode: Manual Reset
(or Auto Reset,
depending on selection)
Reset Input: Open (or Disabled if in
Auto Reset mode)
K1 Relay: De-energized
K2 Relay: Energized
Autobaud: On (or Off, depending on
selection)
Fault Type: E-Stop 4 Fault
Action 1: Check E-Stop 4
Action 2: New Relay Board
Action 3: New Comm. Board
E-Stop Safety Relay – Model ES-TA-3D1
Fault Type Cause Recommended Action
E-stop input fault 1 input shorted, 1 input open
Check E-stop inputs
Replace Power Supply PC board
Replace Communication PC board
Replace Interconnection PC board
Reset input fault Shorted input on power up Check Reset input
Replace Power Supply PC board
Replace Communication PC board
Monitor input
fault Open input on power-up
or after stop
Check for open Monitor inputs
Replace Power Supply PC board
Replace Communication PC board
Output relay fault Internal circuit failure Replace Relay PC board
Replace Communication PC board
Power fault No power or power supply
failure
Check power, LED working?
Replace Relay PC board
Replace Communication PC board
Auto Reset fault Missing selector card or
Internal circuit failure
Check missing Auto Reset selector card
Replace Power Supply PC board
Replace Communication PC board
The ES-TA-3D1 E-Stop Safety Relay also features a self-contained provision for
troubleshooting; indicator LEDs on the front of the module provide clues to possible
faults. If the circuit is working properly, the Power LED should be ON, and the individual
indicator lights for each Emergency Stop switch input should remain ON.
If one of the Emergency Stop switches connected to the circuit has been activated, its
indicator on the front panel of the module will go OFF; in addition, each indicator to
the right of it, on the panel, will also go OFF. (For example, if switch #4 has been
activated, the indicators for switches 4, 5, and 6 will be OFF).
To reset, start by verifying that the problem prompting the E-stop procedure has been
corrected. The E-stop switch indicator, and all those to the right of it on the control
module front panel, should go ON. Then activate the Reset switch connected to the
ES-TA-3D1 E-Stop Safety Relay, and reset the E-stop switch indicated by the first LED
to be OFF, reading from left to right on the control panel. (For example, if switch #4
has been activated, the indicators for switches 4, 5, and 6 will be OFF; start by
resetting switch #4.) Verify that all monitor indicators are ON. (If one of the monitor
inputs is open, its indicator will go OFF; in addition, each monitor indicator to the
right of it will also go OFF. For example, if monitor 2 is open, the indicators for
monitor 2, 3 and 4 will be OFF.)
If any of the E-stop switch indicators remain OFF, repeat this step with the next E-stop
switch indicator (again, the first/left-most unlit LED on the front of the module
control panel).
NOTE: After a successful reset, both of the K1/K2 indicators should be ON. If not, the
control module has an internal fault and should be returned to the factory for repair.
SECTION 6 — Troubleshooting
Use indicator LEDs on E-stop relay to diagnose fault type (see Section 5.3). Use your
DeviceNet Manager as a troubleshooting aid. Also, see the most current Electronic
Data Sheet (EDS) file; it assigns a number to a specific text string that will be helpful
in troubleshooting problems.
6.1 General E-stop Relay Faults
E-Stop Safety Relay – Model ES-TA-3D1
6.2 E-stop Relay Faults Specific to DeviceNet
ES-TA-3D1
Network Status Indicator Description Recommended Action
Green ON Steady On line, connected/allocated to master No action required.
Green Flashing
On line, not connected/allocated to
master;
If autobaud is ON, address and baud
rate ok
1) Connect/allocate the device to the master.
2) Check that all connectors and wiring are correct and tightly connected.
3) Check that the overall network is functional by connecting to some other
device on the same DeviceNet network.
4) If autobaud is turned OFF, set the autobaud parameter (offline) to ON or set
the MAC ID switches to a value known not to be in use and offline try to
connect at 125K (factory default), then 250K, then 500K baud until
successful. If unsuccessful, repeat step 2.
Red ON Steady Critical network fault or
duplicate node address detected
1) Check to ensure that no other device on the network has the
same MAC ID (network address). Each DeviceNet device must have a
unique MAC ID. Use the MAC ID address switches (set at 00 to 63) or set
the MAC ID over the network by setting MAC ID parameter to the desired
value (the MAC ID switches must be set to 64 or higher to allow setting of
the MAC ID via the network).
2) If autobaud is turned OFF, check that the configured baud rate matches the
baud rate of the network.
3) Ensure that the DeviceNet network is properly terminated and grounded
per DeviceNet specifications.
4) Check for insufficient network power supply.
Red Flashing Connection timeout or no power to
ES-TA-3D1
1) Check input power to the ES-TA-3D1.
2) Check DeviceNet I/O connection time out expected packet rate (EPR)
parameter setting and/or problem with DeviceNet master.
OFF No network power or off line 1) Check the DeviceNet connector(s) for proper supply voltage and wiring for
loose or incorrect connections.
Green/Red/OFF Autobaud detecting network baud rate.
1) Check that all connectors and wiring are correct and tightly connected.
2) Check that the overall network is functional by connecting/allocating to
some other device on the same DeviceNet network.
3) Create repetitive network communication to some other device on the
same DeviceNet network. This will allow detection of the baud rate.
ES-TA-3D1
MAC ID Indicator Description Recommended Action
ON Steady MAC ID address is controlled by the
master. No action required.
Flashing
The address indicated by the MAC ID
switches does not match the current
address. This indicates that the switch
setting has been changed with the
device on. This is normal if the user is
in the process of changing the
address.
1) If switches have been changed, return the switches to the correct address
(the indicator will stop flashing).
2) If trying to change the address, complete the address change procedure.
OFF MAC ID address is controlled by the
MAC ID switches. No action required.
E-Stop Safety Relay – Model ES-TA-3D1
Figure 10. Gently pry up each of the
three wiring barriers.
Figure 11. Remove the module cover.
Figure 12. Gently push the sides of the
module outward
Replacement Circuit Boards Model No. Part No.
Replacement power supply and relay board ESD-PST-1 54991
Replacement communication board with DeviceNet ESD-AB-1D 54992
Replacement interconnection board ESD-IB-1 54993
Replacement Reset Mode Selector ESD-JB-1 54994
2) Remove the module cover by placing the blade of a small flat-blade screwdriver
in the slot located at either end of the cover, and gently prying the cover open
(Figure 11). The cover is not hinged; it will come completely off.
3) Gently push the sides of the module housing outward (at the top corners) to
dislodge the four locking tabs (on the two circuit boards) from the slots on the
sides of the housing (Figure 12). Pull the assembly of the three circuit boards
straight out of the module housing.
4) Disconnect the circuit boards from one another (Figure 15).
its boards. See the chart below for the proper replacements and the installation
instructions that follow.
Removing the Circuit Boards
1) Remove the three wiring barriers (leaving the wires connected to them, if
possible) by gently prying each barrier up and off, using a flat-blade screwdriver
(Figure 10).
E-Stop Safety Relay – Model ES-TA-3D1
Installing the Replacement Circuit Boards
1) The boards install in reverse order: first connect all three circuit boards
together.
2) Align the board edges with the slots on the module walls (use the slots
which are closest to the vented module walls). Slide the three-board
assembly into the module. Apply pressure on the top edge of the boards
until the locking tabs on the boards engage the slots on the housing.
Squeeze the sides of the housing to fully engage the tabs into their slots
(Figure 13).
3) Replace the module cover by positioning the windows of the cover over the
LEDs of the two circuit boards and engaging one of the locking tabs on the
cover with the mating slot on the module side wall. Push down the opposite
end of the cover until its locking tab aligns with its slot. Squeeze the sides of
the housing to fully engage the tabs into their slots.
4) Remount the module and replace the wiring barriers by pushing them down
into their receptacles. Take care to match the terminal labels on the wiring
barriers with the terminal labels on the board headers.
If it ever becomes necessary to return an ES-TA-3D1 to the factory, please do the
following:
1) Contact the Banner Factory Application Engineering Group at the address or at
the numbers listed at the bottom of page 20. They will attempt to troubleshoot
the system from your description of the problem. If they conclude that a
component is defective, they will issue an RMA (Return Merchandise
Authorization) number for your paperwork, and give you the proper shipping
address.
2) Pack the ES-TA-3D1 carefully. Damage which occurs in return shipping is not
covered by warranty.
Figure 13. Pull the three-circuit board
assembly from the housing.
Figure 14. Three-circuit board assembly.
Figure 15. Disconnect the circuit boards from one
another.
E-Stop Safety Relay – Model ES-TA-3D1
SECTION 8 – DeviceNet
8.1 Information Communicated to DeviceNet
Module Status OK (GO)
Power-Up
Stop Condition
Fault
E-Stop Inputs Status All Closed
E-Stop X Open (Where X is 1, 2, 3, 4, 5, or 6. Only one open
input is reported at a time.)
Fault (Input number and status of both circuits for that input,
i.e. 1A Open, 1B short)
Monitor Inputs Status All Closed
Monitor X Open (Where X is 1, 2, 3, or 4. Only one open
input is reported at a time.)
Reset Mode Auto Reset or Manual Reset*
Reset Input Status Open, Closed or Disabled (Reset Input is disabled in Auto
Reset mode)
Output Relay Status K1 Energized or De-energized
K2 Energized or De-energized
Diagnostic Information Fault Type
Troubleshooting Suggestions
Autobaud ON* or OFF
* Factory setting
WARNING . . .
For Information
Monitoring Only
DeviceNet™ information
must be used for non-safety
monitoring purposes, only. NEVER
use the DeviceNet™data to control a
safety-related function. To do so
creates an unsafe condition which
could lead to serious injury or death.
!
8.2 DeviceNet Specifications
Bus Status Indicator
A bi-colored (red/green) LED visible on the control module indicates network status:
Green Steady On line, connected/allocated to master
Flashing On line, not connected/allocated to master; if Autobaud is
ON, address and baud rate ok
Red Steady Critical network fault or duplicate node address detected
Flashing Connection timeout or no power to light screen
Green/Red OFF No network power or off line
Green/Red/OFF Flashing Autobaud detecting network baud rate
Sequentially
Power Requirements 11 to 25V dc; 80 mA (supplied by DeviceNet network)
Device Type 131 (Safety Relay Module)
Connection Types Supported Explicit Message, Poll, COS (Change of State)
Network Address 0-63 (Manual switches or Network configured)
Baud Rate Supported Autobaud or Network configured (125K, 250K, 500K)
Factory setting is Autobaud ON.
EDS File Part Number 52243
EDS File Name 131_1_1.eds
Bit Map Icon File Name 131.bmp
NOTE: EDS and Bitmap files on 3.5" floppy disk supplied with
controller (part number 52243). For custom EDS files or Bitmap
files contact Banner Applications Department
Product Code 1 (6-Input E-stop Relay)
Vendor Code 12 (Banner Engineering Corp.)
E-Stop Safety Relay – Model ES-TA-3D1
8.3 POLL & COS I/O Assembly Instances
Device I/O assemblies consist of:
• Poll: One product specific input assembly containing operating mode, status of
E-stop inputs, status of Monitor inputs, status of Reset Mode, status of
Reset input, status of output relays (K1 and K2), autobaud setting and Fault
type.
• COS: One product specific input assembly containing the operating mode only.
8.4 I/O Assemblies Data Attribute Format
Assembly instance 1 is used as the response data for the Poll command. Produced
connection size of 4 bytes. Consumed connection size of 0 bytes.
Assembly instance 2 is used as the response data for the COS command. A COS
command is issued in response to a change in the E-stop relay operating mode.
Produced connection size of 1 byte. Consumed connection size of 0 bytes.
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0E-stop Inputs Operating Mode
1Reset
Mode
Invalid
Reset
Mode
Reset
Input
Invalid
Reset
Input K1 Relay
Invalid K1 Relay
State K2 Relay
Invalid K2 Relay
State
2Reserved Autobaud Reserved Monitor
Input
Invalid
Monitor
Input 4 Monitor
Input 3 Monitor
Input 2 Monitor
Input 1
3Reserved Reserved Reserved Fault Type
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0E-stop Inputs Operating Mode
E-Stop Safety Relay – Model ES-TA-3D1
8.5 Additional Information Available through Explicit Messaging
Autobaud Setting:
1 byte message, 0 = OFF, 1 = ON. See EDS file for path information.
Factory setting is ON.
Diagnostic Information:
See EDS file for details regarding Fault Type and Troubleshooting suggestion information.
E-Stop Inputs
0: All E-Stops are closed.
1: E-Stop 1 is open.
2: E-Stop 2 is open.
3: E-Stop 3 is open.
4: E-Stop 4 is open.
5: E-Stop 5 is open.
6: E-Stop 6 is open.
7: E-Stop 1A is open, 1B is short.
8: E-Stop 1A is short, 1B is open.
9: E-Stop 2A is open, 1B is short.
10: E-Stop 2A is short, 1B is open.
11: E-Stop 3A is open, 1B is short.
12: E-Stop 3A is short, 1B is open.
13: E-Stop 4A is open, 1B is short.
14: E-Stop 4A is short, 1B is open.
15: E-Stop 5A is open, 1B is short.
16: E-Stop 5A is short, 1B is open.
17: E-Stop 6A is open, 1B is short.
18: E-Stop 6A is short, 1B is open.
19: E-Stop status is unknown.
Operating Mode
0: Power-Up
1: OK (Go)
2: Stop Condition
3: Fault
4: Operating mode is unknown.
Reset Mode Invalid
0: The reset mode is known.
1: The reset mode is unknown.
Reset Mode
0: The reset mode is manual.
1: The reset mode is automatic.
Reset Input Invalid
0: The status of the reset input is known.
1: The status of the reset input is
unknown/disabled.
Reset Input
0: The reset input is open.
1: The reset input is closed.
K1 Relay Invalid
0: The state of the K1 relay is known.
1: The state of the K1 relay is unknown.
K1 Relay State
0: The K1 relay is OFF.
1: The K1 relay is ON.
K2 Relay Invalid
0: The state of the K2 relay is known.
1: The state of the K2 relay is unknown.
K2 Relay State
0: The K1 relay is OFF.
1: The K1 relay is ON.
Autobaud
0: Autobaud is OFF.
1: Autobaud is ON.
Monitor Input Invalid
0: The Monitor input status is known.
1: The Monitor input status is unknown.
Monitor Input 1
0: Monitor input 1 is open.
1: Monitor input 1 is closed.
Monitor Input 2
0: Monitor input 2 is open.
1: Monitor input 2 is closed.
Monitor Input 3
0: Monitor input 3 is open.
1: Monitor input 3 is closed.
Monitor Input 4
0: Monitor input 4 is open.
1: Monitor input 4 is closed.
Fault Type
0: No Fault
1: E-Stop 1 Fault
2: E-Stop 2 Fault
3: E-Stop 3 Fault
4: E-Stop 4 Fault
5: E-Stop 5 Fault
6: E-Stop 6 Fault
7: Reset Input Fault
8: Monitor 1 Fault
9: Monitor 2 Fault
10: Reserved
11: Monitor 3 Fault
12: Reserved
13: Reserved
14: Reserved
15: Monitor 4 Fault
16: Reserved
17: Reserved
18: Reserved
19: Reserved
20: Reserved
21: Reserved
22: Reserved
23: Output Fault
24: Power Fault
25: Auto Reset Fault
26: The Fault type is unknown
E-Stop Safety Relay – Model ES-TA-3D1
WARRANTY: Banner Engineering Corporation warrants its products to be free from defects for one year. Banner Engineering Corporation
will repair or replace, free of charge, any product of its manufacture found to be defective at the time it is returned to the factory during the
warranty period. This warranty does not cover damage or liability for the improper application of Banner products. This warranty is in lieu
of any other warranty either expressed or implied.
Replacement Circuit Boards
Description Model No. Part No.
Replacement power supply and relay board ESD-PST-1 54991
Replacement communication board with DeviceNet ESD-AB-1D 54992
Replacement interconnection board ESD-IB-1 54993
Replacement Reset Mode Selector ESD-JB-1 54994
Supply Protection Circuitry
Dimensions See diagram, page 10
Protected against transient voltages and reverse polarity
Output Configuration Outputs (K1 and K2): two redundant (i. e. total of four) safety relay (forced-guided) contacts
Contact ratings:
Maximum voltage: 250V ac or 250V dc
Maximum current: 4A ac or dc (resistive load)
Maximum power: 1000VA, 20 watts
Mechanical life: 10,000,000 operations
Electrical life: 100,000 at full resistive load
NOTE: Transient suppression is recommended when switching inductive loads. Install suppressors across
load. Never install suppressors across output contacts (see Warning on page 5).
Output Response Time 25 milliseconds maximum
Status Indicators 20 green LED indicators:
Power ON ES1-A ES2-B ES4-A ES5-B Monitor-1 Monitor-4
K1 energized ES1-B ES3-A ES4-B ES6-A Monitor-2 Reset
K2 energized ES2-A ES3-B ES5-A ES6-B Monitor-3
1 Bi-color red/green LED indicator for Bus Status
1 Amber LED Indicator for MAC ID
Input Requirements Emergency stop switch must have two normally closed contacts each capable of switching 20 to 150mA
@ 12 to 18V dc.
Reset switch must have one normally open contact capable of switching 20 to 150mA @ 12 to 18V dc.
Master Stop Control (MSC) Element monitor contacts must be capable of switching 20 to 250 mA @ 12 to 18V dc
Enclosure Size: See Figure 2, page 5
Material: polycarbonate. Rated NEMA 1, IEC IP20
Mounting Mounts to standard 35 mm DIN rail track. Safety relay must be installed inside an enclosure rated NEMA 3,
IEC IP54, or better.
Vibration Resistance 10 to 55Hz @ .35mm displacement per IEC 68-2-6
Operating Temperature 0 to 50°C ( 32 to 122°F)
Supply Voltage and Current 24V dc ±15% at 450mA maximum; 10% maximum ripple
SECTION 9 – Product Specifications
