GE RSTi-EP Functional Safety Manual
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GE RSTi-EP Functional Safety Manual

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GE
Intelligent Platforms
Programmable Control Products
RSTi-EP Functional
Safety Manual
GFK-2956A
November 2017
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Summary of Contents for GE RSTi-EP

  • Page 1 Intelligent Platforms Programmable Control Products RSTi-EP Functional Safety Manual GFK-2956A November 2017...
  • Page 3 These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met during installation, operation, and maintenance. The information is supplied for informational purposes only, and GE makes no warranty as to the accuracy of the information included herein. Changes, modifications, and/or improvements to equipment and specifications are made periodically and these changes may or may not be reflected herein.
  • Page 4 Contact Information If you purchased this product through an Authorized Channel Partner, please contact the seller directly. General Contact Information Online technical support and http://support.ge-ip.com GlobalCare Additional information http://www.ge-ip.com/ Solution Provider solutionprovider.ip@ge.com Technical Support If you have technical problems that cannot be resolved with the information in this manual, please contact us by telephone or email, or on the web at http://support.ge-ip.com...

  • Page 5: Table Of Contents

    Table of Contents ..............................3 EVISIONS IN THIS ANUAL EP-19 ..........................4 ODULES WITCHABLE BY ..............................5 ENERAL AFETY OTICE 2.1.1 Electrostatic Discharge ............................5 2.1.2 Open Equipment ..............................5 2.1.3 Fusing.................................... 5 2.1.4 Earthing (Functional Earth FE) ........................... 6 2.1.5 Shielding ..................................
  • Page 6 OPERATED NTERLOCK ONTROLLED HUTDOWN WITH ............................61 ANUAL ESET AND MERGENCY 7.12 D CHANNEL AFETY ONITORING WITH UTOMATIC ESET AND ONTROLLED HUTDOWN AND ..................................... 63 MERGENCY 7.13 C ..................................65 ASCADING ................................. 68 EPLACEMENT ARTS RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 7: Revisions In This Manual

    The safety modules of the RSTi-EP system have key features such as emergency-stop circuits and wire-breakage or short-circuit detection.

  • Page 8: Modules Switchable By

    The relay output modules EP-2714 and EP-2814are not safely switchable, therefore they must not switch any safety function. The digital counter module EP-5111 will not be switched since it is supplied via the input current path. RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 9: General Safety Notice

    If a malfunction on a RSTi-EP product cannot be fixed after following the recommended measures (refer to the Chapter, LED Indicators and Troubleshooting), the product in question must be sent back to GE. GE does not assume any liability if the base or electronic module has been tampered with. 2.1.1 Electrostatic Discharge RSTi-EP products can be damaged or destroyed by electrostatic discharge.

  • Page 10: Earthing (Functional Earth Fe)

    A feed-in power supply with secure isolation must be used. 2.1.4 Earthing (Functional Earth FE) Each RSTi-EP I/O module is fitted with an FE spring on the underside which creates an electrical connection to the DIN rail. In order to establish a secure connection, the assembly must be carried out carefully in accordance with the instructions (refer to the Chapter, Error! Reference source not found.).

  • Page 11: Atex Zone 2

    Chapter3. Safety Warning EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2. WHEN IN HAZARDOUS LOCATIONS, TURN OFF POWER BEFORE REPLACING OR WIRING MODULES; AND DO NOT CONNECT OR DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NONHAZARDOUS. 2.3.1 ATEX Zone 2 The module must be mounted in an enclosure certified in accordance with EN60079-15 for use in Zone 2, Group IIC and rated IP54.

  • Page 12: Legal Notice

    2.5 Legal Notice The RSTi-EP series products are CE-compliant in accordance with Directive 2004/108/EC (EMC Directive) and Directive 2006/95/EC (Low Voltage Directive). They also meet the requirements of the ATEX Directive 94/9/EC.

  • Page 13: Safety Function

    A safety-related input circuit together with pulsed inputs is used for detecting broken wires and short circuits. In the RSTi-EP system, three types of EP-19xx modules are available: • EP-1901 (one safe input) •...

  • Page 14: Sample Design

    With the delay SIL module (EP-1922) switching off can be delayed by a defined time so that, for example, a machine can be shut down in a controlled manner. The delay time can be set in four steps between 0 and 60 seconds (corresponds to stop category 1 as per EN 60204). RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 15: Transition

    Chapter3. System Overview 3.3 Transition Transition Diagram With the delay SIL module (EP-1922) switching off can be delayed by a defined time so that, for example, a machine can be shut down in a controlled manner. The delay time can be set in four steps between 0 and 60 seconds (corresponds to stop category 1 as per EN 60204).
  • Page 16 Chapter3. Configuration Configuration An EP-19xx module can be positioned anywhere in the RSTi-EP station. Each safety segment might include at most 12 switchable modules. Multiple EP-19xx modules and thus safety segments can be set up in a single station. When planning a RSTi-EP station with EP-7641 modules, the following requirements must be met: •...

  • Page 17: Switch-Off Delay Time

    Chapter3. Configuration 4.1 Switch-off Delay Time The turn-off time of a EP-19xx module is 20 ms, caused by the hardware and firmware delay time. The time required until the output voltage even of the last switchable module of a safety segment is below 5 V, can be calculated as follows: Switch off delay [ms] = Turn-off time of a EP-19xx module...
  • Page 18 The safe power-feed module EP-1922 might also be operated without test pulses. This is mandatory whenever an external device producing own test pulses is connected. Test pulses can be enabled or disabled using the DIP-switches at the module. Example of Operation without Test Pulses RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 19: General Technical Data For

    Detailed Descriptions of EP-19xx Modules 5.1 General Technical Data for EP-19xx Type of connection Spring-style 0.14 – 1.5 mm (0.01 – 0.06 in (AWG 26 Single-wired – 16) Line connection cross-section 0.14 – 1.5 mm (0.01 – 0.06 in Fine-wired (AWG 26 –...

  • Page 20: Data Width Of Ep-19Xx Modules

    + CoE Data Width Module Process Data Input Bytes Output Bytes EPXMBE001/ EPXMBE101 EP-1901 EP-1922 EP-1902 The register structure for EPXMBE001/EPXMBE101 refer to the RSTi-EP User Manual (GFK-2958), the section Modbus TCP Network Adapter EPXMBE001/EPXMBE101. ® RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 21: Digital Input Module Ep-1901

    OSSD output it can be forwarded to a PLC or also cascaded to a further RSTi-EP station. Almost all types of output modules will be safely switched-off (SIL3/Ple/Cat. 4) when they are placed within the safety segment (refer to the section, General Contact Information).

  • Page 22: Leds

    Green: Communication over the system bus Status Yellow: Safety circuit 0 OK Yellow: 24 V DC Safe output Green: Feed-in voltage in valid range For error messages, refer to the Chapter, LED Indicators and Troubleshooting. RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 23: Connection Diagrams

    Chapter 7. Detailed Descriptions of EP-19xx Modules 5.3.2 Connection Diagrams EP-1901 Block Diagram EP-1901 GFK-2956A November 2017...

  • Page 24: Specifications Ep-1901

    Overload protection with external fuse Turn-off time < 20 ms Turn-on time < 2 s Auxiliary outputs 2 x 2 Output current max. 10 A (only to support the inputs dedicated inputs) RSTi-EP Functional Safety Manual GFK-2956A...
  • Page 25 Chapter 7. Detailed Descriptions of EP-19xx Modules Diagnosis Module diagnosis Individual channel diagnosis Supply Supply voltage 24 V dc +20%/-15% via system bus External pre-fusing mandatory: super fast, max. 8 A Reverse battery protection Current consumption (I in the power segment of 8 mA the Network Adapter), typ.
  • Page 26 Number of diagnostic bits per channel channel Number of channels Number of similar channels per module Error at channel 0 Error at channel 1 Channel error Error at channel 2 Error at channel 3 Error at channel 4 RSTi-EP Functional Safety Manual GFK-2956A...
  • Page 27 Chapter 7. Detailed Descriptions of EP-19xx Modules Name Bytes Description Default Temperature Error Internal Error Fuse Error Reserved Error byte 3 Communication fault Reserved Reserved Reserved Channel type 0x78 Channel type Reserved Diagnostic bits per Number of diagnostic bits per channel channel Number of channels Number of similar channels per module...
  • Page 28 OSSD switch test failure OSSD voltage too high OSSD Output OSSD voltage too low OSSD overload Reserved Error at channel 9 20-42 Reserved Error at channel 31 Time stamp 43-46 Time stamp [μs] (32 bit) RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 29: Digital Input Module Ep-1902

    OSSD output they can be forwarded to a PLC or also cascaded to a further RSTi-EP station. Almost all types of output modules will be safely switched-off (SIL3/Ple/Cat. 4) when they are placed within the safety segment (refer to the section, General Contact Information).

  • Page 30: Leds

    Green: Communication over the system bus Status Yellow: Safety circuit 0 OK Yellow: Safety circuit 1 OK Yellow: 24 V Safe output active Green: Feed-in voltage in valid range For error messages, refer to the Chapter, LED Indicators and Troubleshooting. RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 31: Connection Diagrams

    Process and diagnostic data depend on the network adapter used Data (refer to the table in the section, Data Width of EP-19xx Modules) Interface RSTi-EP I/O communication bus System bus transfer rate 48 Mbps Safety-related data per EN ISO 13849 (Regard the entire safety chain)
  • Page 32 8 mA the Network Adapter), typ. Current consumption (IIN in the respective power 45 mA segment) General data Weight 82 g (2.89 oz) For additional general data, refer to the section, General Contact Information. RSTi-EP Functional Safety Manual GFK-2956A...
  • Page 33 Chapter 7. Detailed Descriptions of EP-19xx Modules Process Data † Byte Description Status Safety input 0 0 - inactive, 1 - active Safety input 1 0 - inactive, 1 - active 0 - inactive, 1 - active Auto Start 0 - inactive, 1 - active Man Start Safety input 0 / channel 1 0 - inactive, 1 - active...
  • Page 34 Input Discrepancy Error Input Pulse Error Safety 0 Input Test Error Reserved Input Discrepancy Error Input Pulse Error Safety 1 Input Test Error Reserved Autostart Reserved Start Key Reserved Input Discrepancy Error Safety 0 Value Reserved RSTi-EP Functional Safety Manual GFK-2956A...
  • Page 35 Chapter 7. Detailed Descriptions of EP-19xx Modules Name Bytes Description Default Input Discrepancy Error Safety 1 Value Reserved SS1 Output Reserved OSSD switch test failure OSSD voltage too high OSSD Output OSSD voltage too low OSSD overload Reserved Error at channel 9 20-42 Reserved Error at channel 31...

  • Page 36: Digital Input Module Ep-1922

    OSSD output they can be forwarded to a PLC or also cascaded to a further RSTi-EP station. The switch-off delay can be set using DIP switches. The undelayed status is displayed with the SS1 output. Almost all types of output modules will be safely switched-off (SIL3/Ple/Cat.

  • Page 37: Leds

    Chapter 7. Detailed Descriptions of EP-19xx Modules The maximum feed-in current in the output current path is 8 A. The module is sending a pulse (< 1 ms) every 100 ms. Caution Risk of material damage - In the case of a maximum power supply of 8 A and a maximum temperature of +140 °F (+60 °C), all wired contacts on the fourth connector must be connected with 1.5 mm²...

  • Page 38: Connection Diagrams

    Chapter 7. Detailed Descriptions of EP-19xx Modules 5.5.2 Connection Diagrams EP-1922 Block Diagram EP-1922 DIP Switch on the EP-1922 RSTi-EP Functional Safety Manual GFK-2956A...
  • Page 39 Chapter 7. Detailed Descriptions of EP-19xx Modules Setting Options for the DIP Switch Caution To ensure the safety functions, regard the following instructions for adjustment: • DIP switches of equal numbers must have identical positions in both rows. • If an external device generating pulses is connected ot a safey input of the EP-1922 module, this input must be operatined in mode “no test pulses”...

  • Page 40: Specifications Ep-1922

    0.5 A, overload behaviour as per IEC 61131-2 excess temperature proof and overload-proof, short circuit proof Overload protection with external fuse Auxiliary outputs 3 x 2 Output current max. 10 A (only to support the inputs dedicated inputs) RSTi-EP Functional Safety Manual GFK-2956A...
  • Page 41 Chapter 7. Detailed Descriptions of EP-19xx Modules Diagnosis Module diagnosis Individual channel diagnosis Supply Supply voltage 20.4V – 28.8V External pre-fusing mandatory: super fast, max. 8 A Reverse battery protection Current consumption from system current path 8 mA Current consumption from input current path I 45 mA General data Weight...
  • Page 42 Number of channels Number of similar channels per module Error at channel 0 Error at channel 1 Error at channel 2 Channel error Error at channel 3 Error at channel 4 Error at channel 5 RSTi-EP Functional Safety Manual GFK-2956A...
  • Page 43 Chapter 7. Detailed Descriptions of EP-19xx Modules Error at channel 6 Error at channel 7 Diagnostic Data Name Bytes Description Default Error at channel 8 Error at channel 9 Channel error Error at channel 10 11-15 Reserved Channel error Reserved 16-23 Channel error Reserved...
  • Page 44 Warning Dangerous contact voltage: • Carry out assembly and wiring work on the RSTi-EP station only when the power supply is disconnected. • Make sure that the place of installation (switch cabinet etc.) has been disconnected from the power supply.

  • Page 45: Dual-Channel Emergency Stop Monitoring

    Chapter 7. Example Applications Example Applications 7.1 Dual-channel Emergency Stop Monitoring Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features • Dual-channel monitoring • Cross-connection detection • Manual reset •...
  • Page 46 Chapter 7. Example Applications EP-1901 EP-2214 Example Application for Dual-channel Emergency Stop Monitoring RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 47: Dual-Channel Light Curtain Monitoring (Aopd Type 4) And Emergency Stop Monitoring

    Chapter 7. Example Applications 7.2 Dual-channel Light Curtain Monitoring (AOPD type 4) and Emergency Stop Monitoring Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features • Dual-channel monitoring •...
  • Page 48 Chapter 7. Example Applications EP-2214 EP-1902 Example Application for Dual-channel Light Curtain Monitoring (AOPD type 4) and Emergency Stop Monitoring RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 49: Dual-Channel Emergency Stop And Cable-Pull Switch Monitoring

    Chapter 7. Example Applications 7.3 Dual-channel Emergency Stop and Cable-pull Switch Monitoring Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features • Dual-channel monitoring • Cross-connection detection • Start buton •...
  • Page 50 Chapter 7. Example Applications EP-1901 EP-2214 Example Application for Dual-channel Emergency Stop and Cable-pull Switch Monitoring RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 51: Dual-Channel Safety Door Monitoring With Automatic Reset And Emergency Stop

    Chapter 7. Example Applications 7.4 Dual-channel Safety Door Monitoring with Automatic Reset and Emergency Stop Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features • Dual-channel monitoring • Cross-connection detection •...
  • Page 52 Chapter 7. Example Applications EP-1901 EP-2214 Example Application for Dual-channel Safety Door Monitoring with Automatic Reset and Emergency Stop RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 53: Safety Mat

    Chapter 7. Example Applications 7.5 Safety Mat Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features • Single-channel monitoring • Cross-connection detection • Wire break detection • Monitoring of external contactors (EDM) Safety sensor/operating Safety mat mechanism...
  • Page 54 Chapter 7. Example Applications EP-1901 EP-2214 Example Application for Safety Mat RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 55: Dual-Channel Two-Hand Monitoring With Automatic Start

    Chapter 7. Example Applications 7.6 Dual-channel Two-hand Monitoring with Automatic Start Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features • Dual-channel monitoring • Cross-connection detection • Automatic reset •...
  • Page 56 Chapter 7. Example Applications EP-1901 EP-2214 Example Application for Dual-channel Two-hand Monitoring with Automatic Start RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 57: Dual-Channel Safety Door Monitoring With Magnetic Switch, Automatic Reset And Emergency Stop

    Chapter 7. Example Applications 7.7 Dual-channel Safety Door Monitoring with Magnetic Switch, Automatic Reset and Emergency Stop Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features • Dual-channel monitoring PDF-M (as per EN 60947-5-3) •...
  • Page 58 Chapter 7. Example Applications EP-1901 EP-2214 Example Application for Dual-channel Safety Door Monitoring with Magnetic Switch, Automatic Reset and Emergency Stop RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 59: Dual - Channel Safety Door Monitoring , Spring - Operated Interlock With Manual Reset And Emergency Stop

    Chapter 7. Example Applications 7.8 Dual-channel Safety Door Monitoring, Spring-operated Interlock with Manual Reset and Emergency Stop Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features • Dual-channel monitoring •...
  • Page 60 Chapter 7. Example Applications EP-1901 EP-2214 Example Application for Dual-channel Emergency Stop Monitoring RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 61: Dual - Channel Safety Door Monitoring , Magnetically Operated Interlock With Manual Reset And Emergency Stop

    Chapter 7. Example Applications 7.9 Dual-channel Safety Door Monitoring, Magnetically Operated Interlock with Manual Reset and Emergency Stop Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features • Dual-channel monitoring •...
  • Page 62 Chapter 7. Example Applications EP-1901 EP-2214 EP-1214 Example Application for Dual-channel Safety Door Monitoring, Magnetically Operated Interlock with Manual Reset, Stop and Emergency Stop RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 63: Dual-Channel Safety Door Monitoring With Proximity Sensors, Automatic Reset And Emergency Stop

    Chapter 7. Example Applications 7.10 Dual-channel Safety Door Monitoring with Proximity Sensors, Automatic Reset and Emergency Stop Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features • Dual-channel monitoring •...
  • Page 64 Chapter 7. Example Applications EP-1901 EP-2214 Example Application for Dual-channel Safety Door Monitoring with Proximity Detectors, Automatic Reset and Emergency Stop RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 65: Dual-Channel Safety Door Monitoring, Spring-Operated Interlock, Controlled Shutdown With Manual Reset And Emergency Stop

    Chapter 7. Example Applications 7.11 Dual-channel Safety Door Monitoring, Spring-operated Interlock, Controlled Shutdown with Manual Reset and Emergency Stop Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features •...
  • Page 66 Chapter 7. Example Applications EP-1901 EP-2214 Example Application for Dual-channel Safety Door Monitoring, Spring-operated Interlock, Controlled Shutdown with Manual Reset and Emergency Stop RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 67: Dual-Channel Safety Door Monitoring With Automatic Reset And Controlled Shutdown And Emergency Stop

    Chapter 7. Example Applications 7.12 Dual-channel Safety Door Monitoring with Automatic Reset and Controlled Shutdown and Emergency Stop Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Stop category EN 60204-1 Features • Dual-channel monitoring •...
  • Page 68 Chapter 7. Example Applications EP-1902 EP-2214 Example Application for Dual-channel Safety Door Monitoring with Automatic Reset and Controlled Shutdown and Emergency Stop RSTi-EP Functional Safety Manual GFK-2956A...

  • Page 69: Cascading

    Chapter 7. Example Applications 7.13 Cascading Achievable safety rating Cat. 4 DIN EN ISO 13849-1 DIN EN ISO 13849-1 SIL3 IEC 62061/61508 Notes A shielded cable installation is necessary if the safely switched-off line (24 V OSSD on 4.2) runs outside the switch cabinet. Note: All example applications shown are proposals without warranty.
  • Page 70 LED Indicators and Troubleshooting Attention In the event of a malfunction occurring on a RSTi-EP station, carry out the following recommended measures. If the malfunction cannot be fixed, send the affected product to GE (refer to the section, General Contact Information).
  • Page 71 – Perform a cold start within 24 hours. If the error has not been fixed, send the module to GE for a technical examination. – Interruption in one of the two – Check safety circuit for interruptions if an...

  • Page 72: Replacement Parts

    Accessories and Replacement Parts Order No. Designation Purpose EP-8100 Swivel marker Pivoting holder for module markers EP-8101 Paper labels for swivel markers Can be printed with laser printers EP-8301 Termination kit Set with two end brackets and one end plate High Density Connector signal connectors for EP-8360 High density connector kit...
  • Page 73 Appendix A. Checklist for Use of EP-19xx Modules Appendix A Checklist for Use of EP-19xx Modules Checklist for use of EP-19xx Modules Sheet 1/3: Planning Equipment type / equipment ID Version: HW/FW Date: Reviewer 1: Reviewer 2: Notes: Requirement (mandatory) Remark The corresponding manual was consulted during planning.
  • Page 74 The safety module(s) was(were) installed in a switch cabinet (IP 54). All conductor cross-sections meet the guidelines. Date / Signature of Reviewer 1: Date / Signature of Reviewer 2: RSTi-EP Functional Safety Manual GFK-2956A...
  • Page 75 Appendix A. Checklist for Use of EP-19xx Modules Checklist for use of EP-19xx Modules Sheet 3/3: Commissioning and configuration Equipment type / equipment ID Version: HW/FW Date: Reviewer 1: Reviewer 2: Notes: Requirement (mandatory) Remark During commissioning, the intentional starting up of potentially hazardous processes is only possible while looking into the danger zone at the same time.
  • Page 76 1-800-433-2682 1-434-978-5100 www.ge-ip.com GFK-2956A...

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