Guidance Notes for

ELECTRICAL INTERLOCKING
FOR SAFETY IN
INDUSTRIAL PROCESSES

Addendum: Health and Safety in

Employment Amendment Act 2002
Since this document was published the
Health and Safety in Employment Act 1992
has been amended by legislation which
came into effect from 5 May 2003. While the
technical and general information in this
document remains current, there may be
instances where it does not reflect the
changes contained in the amended Act.
Your local Occupational Safety and Health
Service office can provide further
information or you may call:
Workinfo on 0800 209 020
www.workinfo.govt.nz

Published by
Occupational Safety and Health Service
Department of Labour
Wellington
New Zealand
Issued September 1994
ISBN 0-477-03556-6

CONTENTS
Status and Obligations Under the HSE Act 1992
Introduction

Scope of the book

1. Use of Switches 8
1.1 Switch choice how specifications aid selection 8
1.2 Switch type normally open and normally closed 10
1.3 Switch description the preference for safety 11
2. Types of Switches and Applications 12
2.1 Limit switch with cam 12
2.2 Snap action with over travel 12
2.3 Monitoring normally open and normally closed switches together
2.4 Emergency stop controls 15
2.5 Microswitches 16
2.6 Magnetic switches 17
2.6.1 Electromagnet 17
2.6.2 Permanent magnet 17
2.6.3 Solenoid bolt 18
2.7

Proximity switches 19
2.7.1 Inductive proximity switches 19
2.7.2 Capacitive proximity switches 20
2.7.3 Restricting access of the target 21

2.8

Optical detection systems 21

2.8.1 Infra-red light detection 21
2.8.2 Retroreflective sensor 22
2.8.3 Specular sensor 22
2.8.4 Through-beam sensor 23

2.9

Actuator-operated switches

3. Trapped Key Interlock

25

4. Lockout 26
4.1 Lockout procedures 26
4.2 Power failure release 28
5. Braking Electric Motors 28
5.1 Mechanical braking 28
5.2 Electrical braking 28
5.3 Electrical plugging 28
5.4 Direct current injection 29
5.5 Capacitor braking 29

23

14

6. Programmable Electronic Systems

6.1 Interference 29
6.2 Software 30

29

7. Interlocking Appropriate to the Hazard

References and Acknowledgements
Glossary

31

34

36

Illustrations
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24
Figure 25
Figure 26
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31

An electric circuit 6
Normally-closed switch operated by a rotary cam 7
Spray booth control circuit 7
Detail of an informative switch label 8
IP 54 minimum rating for machine tools 9
Normally open (n.o.) and normally closed (n.c.) 10
Normally closed switch operated by a linear cam 11
Snap action switch with over-travel 12
Actuator movement 13
Contact pusher movement 13
Normally open and normally closed switches on one guard 14
Monitoring switches in two modes. Additional components
may be needed for a working circuit 15
Logic table for the switch monitor unit 15
Monitoring a line under tension 16
Different types of microswitch 17
Magnetic switch operation 18
Time delay circuit using solenoid bolt 18
Operation of an inductive proximity switch 20
Operation of an capacity proximity switch 20
Securing proximity switch with cam 21
Infra-red detection 22
Retroreflective sensor 22
Specular light sensor 23
Through-beam sensor 23
Mobrey safety interlock switch with magnetic actuator 24
The unusual key operates a rotary cam inside each of the openings. Each cam operates
switch contacts. 24
Simple key exchange 25
Key exchange with time delay 26
Lock off safety clasp for six locks 27
Selection of an interlocking system based on AS 4024.1(Int) - 1992 31
Safety interlock switch arrangements Types P, Q interlocking 33

Figure 32 Safety interlock switch arrangements Types R, S interlocking

4 ELECTRICAL INTERLOCKING GUIDANCE NOTES

34

STATUS AND OBLIGATIONS UNDER THE HEALTH AND SAFETY IN

EMPLOYMENT ACT 1992
Electrical Interlocking for Safety in Industrial Processes provides guidance for
equipment owners with responsibility for managing design and fitting electrical
interlocking systems.
It is a presentation of the advantages and snags of various methods of switching
electric current which may be used to control motion to achieve safety. An informed choice based on knowledge of switch operation should be possible when
this booklet is used as a reference.
As part of their obligations under the Health and Safety in Employment Act 1992,
employers using machinery in a place of work are required to perform a hazard
identification and analysis. This hazard analysis will precede an informed decision
about eliminating, or isolating, or minimising the hazards people at work are
exposed to.
The process of interlocking described assumes the presence of a hazard, so the
process is a method for isolating people at work from the hazard or is a method for
minimising the likelihood of the hazard becoming a source of harm.
The Act requires that persons with control of places of work, including a person
who is the owner, lessee, sublessee, or bailee of any plant in a place of work, shall
take all practicable steps to ensure that people in the place of work, and people in
the vicinity of the place of work, are not harmed by any hazard that is or arises in
the place of work.
Electrical Interlocking for Safety in Industrial Processes will help persons with
control of plant and machinery to fit appropriate interlocking systems. Use of the
methods described is one way of fulfilling obligations under the Health and Safety
in Employment Act 1992. It provides examples taken from good practice in
electrical interlocking.
Use of the methods described provides ways of minimising danger. It is not a
prescriptive text, and is not intended to inhibit development.
These guidance notes have only a few allusions to the effects of wear on interlocking systems, and of the necessity for minimising the effects of wear on reliability.
The process of minimising hazards should include identification of causes of wear
which will reduce system reliability, and the institution of a process of test, and
repair or replacement, to keep interlocks working safely.
Standards of work shall comply with provisions of the Electricity Regulations
1993, and codes of practice approved pursuant to the Electricity Act 1992.
Users who develop equivalent or safer interlocking systems than those described
in this guide, should continue their work.

ELECTRICAL INTERLOCKING GUIDANCE NOTES 5

INTRODUCTION
Electric power to drive and control machines is used in every factory. Electricity
powers motors or prime movers. Electricity powers electric and electronic control
systems. All electric circuits consist of a power source, a means of converting
power to energy, and a switch to connect and disconnect power.
Human safety depends on reliable switching, so choosing the right switch for the
job is an essential part of machine design. It is the purpose of this book to provide
advice for owners and designers who make machines safe by reliably interlocking
electric circuits.

Fig. 1 An electric circuit

Scope of the book electric switches affect safety

On many machines, the choice of switch is an important part of reducing hazards.
The dangerous operations of a machine, which an operator has to reach into, must
be automatically guarded. Usually, the position of a guard will result in a switch
breaking or closing a circuit. As the switch detects the physical limit of guard
movement, it is called a limit switch. Its electric circuit is interlocked with the
mechanical function of guard position. Means of interlocking guard position with
machine operation to achieve operator safety will be the main emphasis of this
guide.
Most commonly, contacts are fastened to the plunger of the switch so that they
move with it.
In Fig. 2 a rotary cam which moves with a hinged guard opens switch contacts
when the guard is lifted open. Interlocking is traditionally about separating machine operators from forceful physical contact. When a potential hazard occurs,
for example the movement of parts of a large rotating machine after power is
turned off, the interlocked guards are locked closed. Guards may be opened after
run down is timed out.
In general, switches are used for interlocking either sense position, or sense motion or time. In other specialised uses they sense temperature, or pressure, or
vapours present in the atmosphere.
Interlocking also separates staff from the harmful effects of industrial processes,
especially processes which require the staff member to be close to the operation.
In spray painting booths, an air velocity sensor or Pitot head interlocked with
spray gun operation ensures that spray coating occurs with adequate ventilation,
thus refreshing the air which the painter breathes.
6 ELECTRICAL INTERLOCKING GUIDANCE NOTES

Fig. 2 Normally-closed switch operated by a rotary cam

In other safety-related functions, special detectors monitoring a rise in heat or
pressure, or a fall in fluid level, can change the input signal of an electric circuit,
initiating some event such as starting fire sprinkler pumps, lighting exit signs, or
calling out service staff, but this book will be confined to safety interlocking in
ordinary production. The choice of sensors for connection to alarms which
indicate abnormal conditions is a specialised area outside the scope of this guide.

Exhaust air

Fan control

Pilot head

Spray gun
air supply

Air speed
sensing
switch

Spray gun
air flow
solenoid

Note: There is no wired link from the fan control

to the spray gun air flow solenoid

Fig. 3 Spray booth control circuit

ELECTRICAL INTERLOCKING GUIDANCE NOTES 7

1. USE OF SWITCHES
1.1 Switch choice how specifications aid selection
Maximum current and maximum voltage to be switched are usually the first
specifications to determine switch choice. Reliable manufacturers publish these
figures in their catalogues, and frequently mould them or stencil them on the body
of the switch. More difficult to find is the minimum voltage required for reliable
operation. This is the wetting voltage, and may exclude the use of mains voltage
switches from extra low voltage safety circuits. Where there is a combination of
factors such as switch contacts prone to oxidation, operating voltages in the extra
low range, that is, less than a few tens of volts, and currents measured in
milliamperes, reliable circuit closure may be impossible to achieve. In this case,
switches with enclosed contacts plated with gold or silver should be used. Switch
vendors should be able to provide data for low voltage switching.
IP67 Ui 500V ~ 600V

IP rating: insulation rating

AC11 Ue 220V~le 2A

AC voltage and current rating

DC11 Ue 220V Le 0,5A

DC voltage and current rating

T10A
F16A

Double insulation; fuse rating 10A slow

fuse rating 16A fast

Fig. 4 Detail of an informative switch label

Switches are chosen for the working environment and should operate predictably
in real life conditions of dirt and wet. International Protection (IP) ratings are
provided by switch manufacturers and consist of two figures following the letters
IP. The first numeral indicates protection of persons against access to dangerous
parts and protection of internal equipment against the ingress of solid foreign
objects. The second numeral indicates protection of internal equipment against
harmful ingress of water. The range is from IP 00, indicating that no special
protection is provided, to IP 68. The digit 6 indicates complete protection against
entry of dust, 8 assures protection against submersion. Test procedures are described fully in AS 1939: 1986 Classification of degrees of protection provided by
enclosures for electrical equipment, which includes a chart for the IP code. IP
rating often indicates a degree of protection for electrical contacts. Around machine tools, where conductive dusts and moisture are likely to be an inevitable part
of their use, switches should be rated at least IP 54 or they should be housed in
such a way that equivalent protection is achieved.

8 ELECTRICAL INTERLOCKING GUIDANCE NOTES

Protection against entry

of dust in sufficient quantity to
interfere with satisfactory
operation of equipment

Protection against entry

splashing and spraying
water from all practicable
directions

Fig. 5 IP 54 Minimum rating for machine tools

Operating levers and cams are not usually rated this way, and must continue to
function in dirty, wet conditions while electric contacts are enclosed. Switch
choice therefore includes consideration of maintenance, to ensure that the means
of operating switches will move freely as required.
When the atmosphere about a switch is explosive, or is not normally explosive but
infrequently explosive, special precautions must be taken. Making or breaking
electrical connections must avoid introducing a source of ignition. When an
employer identifies a hazardous or potentially hazardous area, the employer must
ensure that the switches fitted are safe for the zone.
Switches wired in areas which are explosive, wet or dusty, will only function at
their ratings when the conduits and glands containing wire are fitted and sealed
appropriately. Wiring specifications must therefore include ratings of switches and
also ratings of protective conduits and glands.
Switches are specified for a finite number of operations, about 10,000,000 or so.
Numbers of reliable switch operations will fall drastically as the electrical load is
increased; some manufacturers tables show that while an unloaded switch is good
for over 10,000,000 operations, the expectation of the switch manufacturer is that
when the switch is electrically loaded to switch its full load, reliable operations
will be less than 500,000. This could make replacement essential in less than one
year on a busy, cycling machine, to avoid electrical failure. There are places where
mechanical failure will occur before electrical failure because of debris spoiling
cam operation.
As switch failure is a fact of life, planning an installation to avoid failure to danger
is essential.
Direct current circuits open with more arcing and heat than alternating current
circuits of the same average value. Therefore, de-rating of any a.c. rated switch in
a d.c. circuit is essential to achieve the same reliability. The manufacturer, whose
label illustrates Fig. 4, specifies that d.c. operations be de-rated to 25% of a.c. It
must be emphasised that each switch type will have a distinct specification and
that manufacturers tables must be consulted at the design stage. It may be dangerous to assume that the specification of Fig. 4 applies to all switches. Another
manufacturer supplies tables showing that switch contacts should be aerated to
less than 10%.
For direct current, the characteristics of electrical forces in the circuit are distinct
from alternating current. Electrical switchgear rated and tested to comply to the
specific parameters of each individual application must be installed.
ELECTRICAL INTERLOCKING GUIDANCE NOTES 9

One square inside another shows that there are two separate insulators between the
switch contacts and the operating shaft. This is double insulation of current
carrying parts from the outside.
As peak current through a slow blow fuse may exceed nominal current levels for
some time without blowing the fuse, the options for current limit are to use a
fast-blow fuse to protect the switch contacts, or to de-rate the slow blow fuse as
recommended by the switch manufacturer. Contacts for signal currents of
milliamps will operate safely without fused circuits.
Some manufacturers offer a model with an external shaft for connection to a
hinged guard. The shaft passes inside the body of the switch through a sealed
bearing. The switch end of the shaft is fastened to a rotary cam which operates a
limit switch. The cam housing is therefore rated similarly to the contact housing.

1.2 Switch type normally open and normally closed

Normally closed limit switches are the type most frequently specified for safety
applications, especially where frequent access is needed to some part of a machine
which could cause serious injury. When only one interlocking switch is fitted to a
guard, it should be a normally closed positive break limit switch, unless there are
other compelling reasons.
The normally closed contact configuration is used because it is the simplest and
most effective means of incorporating a switch into an electrical circuit which will
allow failure to a safe condition. This failure to safety or fail safe or no
failure to danger concept is the basis for interlocking in circuit design.

Normally open

Normally closed

Fig. 6 Normally open (n.o.) and normally closed (n.c.)

Normally closed describes the condition of the closed contact set when the
switch is in the unoperated position. In this condition, there is no depression of the
plunger which operates the contacts. The switch will conduct in the unoperated
position and break the circuit when operated.
Similarly, normally open contacts are open in the unoperated position and
closed in the operated position. This is the convention which will be used in this
guide.
While there are common applications which utilise normally open switches in
process control, normally closed is the ususal choice in all stop, emergency stop,
and protection circuits.
10 ELECTRICAL INTERLOCKING GUIDANCE NOTES

Manufacturers who use a different convention will provide catalogues which

cointain a full description of the operating conditions for normally open and
normally closed. Normally open and normally closed. may describe contact
position when an actuator is engaged (see Fig. 26.)
To provide adequate safety from mechanical hazards, the switch used must provide a physical gap across the terminals when the switch is in the open position.
Under no circumstances can a solid state switch be used to provide such
protection.

1.3 Switch description the preference for safety

Most interlocked guards will be fitted with only one switch. When a guard has
only one switch, normally closed positive break is the type of switch which should
be fitted to machinery where frequent access, say once per machine cycle, is
required. When such a switch is opened by the opening of a guard, a cam is arranged to depress its plunger before the guard is opened far enough to allow
access to potentially injurious movement.
Independent of switch orientation, and without relying on the tension of a spring,
even contacts which have become welded or closed by stiction are forced open.
The most serious electrical problem is that the break can be slow enough to put
spurious signals into electronic logic, allowing unwanted operations to occur.
Caution must be exercised, however, when only one limit switch is used. In most
arrangements, removal of the cam, or of the cam and guard, will allow a
normally-closed switch to move to the closed circuit position, allowing machinery
to operate unguarded.

Fig. 7 Normally closed switch operated by a linear cam

ELECTRICAL INTERLOCKING GUIDANCE NOTES 11

2. TYPES OF SWITCHES AND APPLICATIONS

2.1 Limit switch with cam
Normally-closed positive break is probably the most common type in safety
applications and is illustrated in Figs. 2 and 7 in use with both rotary and linear
cams.
Correctly positioned with a positive cam, and wired in the normallyclosed mode, a
normally closed positive break limit switch is the type which will avoid failure to
danger, or be fail safe.
Limit switches can operate in two modes, normally closed and normally open.
In cam-operated interlocking systems, the limit switch must always be installed in
the normally-closed mode, to ensure against both interference with the switch and
failure to danger due to contact fusing or welding, spring failure, mechanical
stiction or seizure.

2.2 Snap action with over-travel

To avoid spurious signals which result from contacts breaking slowly, snap-action
switches are used. These switches have the fast snap action of microswitches,
with mechanical over-travel to force apart contacts which might remain closed in
fault conditions.
Snap action switches are similar in appearance to the normally closed positive
break limit switch used with a cam, but fast opening or closing.
Contacts are held by a sprung contact support (see Fig. 8) and change position
rapidly.
Roller
Actuator

Pivot
Seal
Actuator holding screws
Fastening nut
Acutator spring
Switch body
Screw terminal
Fixed contacts (n.o.set)
Sprung contact support
Conductor
Change over contacts
Fixed contacts (n.c.set)
Conductor
Screw terminal

Cable entry
Cover scew hole

Fig. 8 Snap action switch with over-travel

12 ELECTRICAL INTERLOCKING GUIDANCE NOTES

Fig. 9 gives an idea of the amount of actuator movement for contact change over.
The essential precaution in safety applications is ensuring that camforced
movement is sufficient to open contacts should the spring fail.
Snap action with over-travel is illustrated by showing the rack and pinion pusher
system in Omron D4D limit switches. Other manufacturers achieve equivalent
performance and safety. The rack and pinion pusher system forces the contact
support to the open contacts position should the spring fail.
Shading shows the current paths in Figs. 9 and 10.
Switching
movement

Normal
condition

Contacts
change over

Over travel

Contact pusher
forced up

Fig. 9 Actuator movement

Pinion

Contact
pusher
rack

Actuator
rack

Fig. 10 Contact pusher movement

ELECTRICAL INTERLOCKING GUIDANCE NOTES 13

2.3 Monitoring normally open and normally closed switches together

Normally-closed limit switches should be the first choice for safe interlocking.
They should be wired and positioned so that their contacts can close only when
the guard is closed. When the guard opens, by a mechanical link to the contacts,
the switch contacts open also. Most manufacturers offer normally closed switches
with contacts which close under spring pressure, while a mechanical operation
ensures that contacts part. Wired and positioned to work as intended, the mechanical link from guard to contacts will ensure that normally closed switches cannot
fail to danger. A dangerous occurrence is when switches close by accident or
interference in such a way that potentially harmful motion occurs without isolation
from people near the machine.
Sliding guard closed

Both switches closed

Sliding guard open

Both switches open

Fig. 11 Normally open and normally closed switches on one guard

(For details of switch structure, refer to Fig. 6)
Because it may be easily held closed, or because it may fail to danger, a normally
open switch should not be used alone for safety interlocking with a guard.
There is an application for a normally open switch in Fig. 11, and the normally
closed switch has a guard interlocking function.
The normally open switch has the function of verifying that the guard is correctly
placed. It will only close when the guard closes its contacts.
The normally open switch can also verify that the guard is present. On most
guards, removing completely the cam and guard which allows the normally closed
switch to close, will close the circuit as if the cam was present and correctly
positioned. When there is also a normally open switch wired in series with the
normally closed switch, the absence of a cam or guard and cam will allow the
normally open switch to, open. Thus, the normally open switch will detect the
absence of a cam or guard and cam.
If the normally-open switch fails with contacts closed, that failure will only show
with a check of the switch and not during normal operation. The monitor circuit of
Fig. 12 indicates a possible closed switch by switching off all three lamps during a
fault.
14 ELECTRICAL INTERLOCKING GUIDANCE NOTES

A
Prime
mover
control
circuit

B
Normally open

C
Normally closed

To prime mover
&
Closed guard
& &

SWITCH
MONITOR
UNIT

Normal
&
Guard open

Fig. 12 Monitoring switches in two modes. Additional components may be needed

for a working circuit.
This arrangement is useful to monitor two switches used in opposite modes. The
purpose of the normally-open switch is to monitor correct guard position when
machine design permits the guard to become misaligned, or the actuator roller to
wear excessively. To perform its monitoring function, the normally open switch
cam roller need make only limited contact with the cam. The normally closed
switch cam roller is in contact most of the time. Without the cam closing the
normally open switch, the circuit between prime mover power source and prime
mover cannot be closed. Both switches should be monitored to ensure that the
failure of either switch will be noticed to avoid failure to danger.
The switch monitor unit circuit diagram shows a system of monitoring which
enables indicator lamps to be compared with guard position. A discrepancy indicates a fault requiring repair. To automatically monitor switch operation, the
normal lamp supply could control the contactor supplying the prime mover power
source.

Fig. 13 Logic table for the switch monitor unit

In the logic table of Fig. 13, 1 signifies that control voltage is present or that a
lamp is on. 0 signifies low voltage or that a lamp is off. From the logic table
conditions for fault indication can be read and, if required, a few components
added to the circuit of Fig. 11 to include a fault lamp.
Note that normally open and normally closed describe the condition of the
switch contacts only in their unoperated state. A normally open switch will be
closed only when its actuator is under tension.

2.4 Emergency stop controls

Emergency stop controls should be designed considering the emergency and the
intended action. An emergency stop on a circular saw, for example, is unlikely to
ELECTRICAL INTERLOCKING GUIDANCE NOTES 15

prevent kick back of wood from the saw, but it may stop the blade from turning if
the operator sees that it is loose. Another consideration is that a person caught in a
machine, who is in pain as a result, is unlikely to retain the presence of mind to
find and operate an emergency stop. A designer who hopes that an injured person
will voluntarily use an emergency stop will probably be disappointed. If an emergency stop is fitted, its operation should be involuntary, for example, a pressure
bar in the way of an arm moving into a nip should immediately brake turning
rollers.
It is better to design machinery to prevent access to moving parts than to try and
stop machinery once people are caught in it.

Cord
released,
spring
retracts

Cord
and
spring
balance

Cord
pulled
plunger
latches

Fig. 14 Monitoring a line under tension

Emergency stop controls have a place at machinery whose operation is frequently
monitored. At a long conveyor, an emergency stop cord may be fitted above the
belt, to provide a means of stopping the belt quickly. An emergency stop circuit
will be fast operating, avoid failure to danger, preferably through a self-monitoring
system, and require a reset of machine control after every operation. The last
condition avoids use of the emergency stop as a handy on-off switch with
consequent increased wear.
The circuit could include normally open switches in a series circuit. A
normally-tensioned pull cord will hold a switch closed, but a slack or broken cord
should open the circuit. Thus, cord tension is monitored.
Emergency stop switches shall not be used for restarting machinery. Use of an
emergency stop shall require a reset operation at the control panel.
Operating means, which may be a taut wire rope, or a bar, or a switch with a large
mushroom-shaped head, shall be a conspicuous red.

2.5 Microswitches
Microswitches are named for the small amount of contact movement which occurs
as they change from open to closed circuit, or as a closed switch opens. They
therefore change from open or from closed very rapidly, free of contact bounce
and consequent unwanted circuit operation. Fast contact movement occurs when
16 ELECTRICAL INTERLOCKING GUIDANCE NOTES

tension in a spring is released quickly, as the switch actuator moves. Integrity of

the spring is therefore an essential requirement for predictable operation
(see Fig. 8).
Actuating
Arm

Pivot
Contact actuator
Slight depression of
the actuating arm
causes contascts to
change over
Screw terminals
Flexible cover

Micro switch

Actuator
Seal
Enclosed Micro switch

MICRO SWITCH

Cable entry

Fig. 15 Different types of microswitch

Should the spring fail or the contacts weld too completely for spring tension to
separate them, contacts will remain closed without warning.
Thus, circuits which are supposed to open will continue to function in the closed
circuit state. This is potentia~lly unsafe in the guard-sensing circuit of a cycling
machine, which relies on a switch opening at every cycle for safety. There is a
place for microswitches on less frequently opened guards, for example, on the
cover of a paper shredder emptied weekly. When microswitches are used with
guards, they should be the kind of switch which has over-travel and linkages to
open stuck contacts (see Fig. 8).

2.6 Magnetic switches

Magnetic switches rely on the change in magnetic field force to move switch
contacts.
2.6.1 Electromagnet
The most common type is reed switches. These are operated by the magnetic field
about a coil through which direct current passes. They are also operable by any
permanent magnet. The most common reed switches only switch milliamperes.
Reed switches do not reliably fail to safety.
2.6.2 Permanent magnet
Magnetic switches used in safety applications most often rely on contacts moved
by a coded permanent magnet. Rating allows switching, for example, 1.3 A at 24
V or 300 mA at 250 V, adequate for many control applications. Contacts close or

ELECTRICAL INTERLOCKING GUIDANCE NOTES 17

change over as the permanent magnet is brought closer. When the permanent
magnet moves away, the contacts change over or open. With no moving parts
exposed, and a degree of protection as high as IP 67, these switches may be
cleaned with high-pressure water and are well suited to use where hygiene is
essential. IP X7 indicates protection against immersion. They are particularly
useful when covers must be removed completely, as the actuator can be fastened
to the cover. They are coded to reduce the likelihood of alternative actuators being
used to make machinery run with guards off. Contacts are de-rated to
approximately 15% of their rated current, to avoid contacts welding closed. A fast
fuse should be wired in series with a magnetic switch to avoid excess current.
For use in safety applications, magnetic switches require a coded magnet for
actuation and should be monitored by a control module to check whether they are
still operable at each switching cycle. If the switch or switches no longer operate,
the module should shut down the machine until repairs are done.
Cable
entry

Target

Contacts open

Magnetic
actuator

Contacts close when

the magnetic actuator
moves close to the switch

Fig. 16 Magnetic switch operation

2.6.3 Solenoid bolt
A solenoid bolt has a shaft or tongue which extends to secure a guard or cover. To
withdraw the bolt, power is switched into a coil and the resulting magnetic force
withdraws the bolt.
Time delay
contact
Entry
interlock

Stop

Start

Locking
solenoid
contact

Power
supply
Time delay

Fig. 17 Time delay circuit using solenoid bolt

18 ELECTRICAL INTERLOCKING GUIDANCE NOTES

Starter

Locking
solenoid

In a typical safety application, a solenoid bolt will be extended by a strong coil

spring while there is no current in its solenoid, or its coil.
In a safety application, a solenoid bolt can be actuated from a timer, or movement
sensor when a cover must remain closed for a specified time or until movement
ceases. For example, an operator can switch off a centrifuge but the bowl continues to spin. The act of switching off a motor can enable a timer or sensor of movement. At the end of the run down period, or when the movement sensor detects
that the bowl has stopped, current is switched to the solenoid bolt which withdraws and allows the lid to be opened.
With the bolt extended the switch can be used to secure a guard until current is
applied to its coil. A timer ending its period closes the solenoid circuit. As the
electric coil is livened, the bolt withdraws under magnetic force, and the guard
may be opened.
In the circuit diagram of Fig. 17, the usual convention of drawing with no power
in the circuit is exchanged for showing how the contacts are arranged with a live
power supply during the timed interval before the time delay contact closes. A
necessary feature is the entry interlock switch, which only allows a start when the
guard is closed.

2.7 Proximity switches

Proximity switches rely on detection of a suitable target, brought close to the
switch. They are fast in action and sometimes well sealed, but security may be
poor, as they respond to a variety of targets which may be different from the
intended one. They operate without the application of any physical force, which
has advantages in production applications, where a controller senses objects
passing a point. High-frequency switching is possible with no effect on the life of
the sensor. Switches are waterproof, and unaffected by vibration or dirt. There are
switches suitable for use in hazardous areas. In safety interlocking applications,
they require some care to avoid failure to danger.
Problems can be experienced with radio interference affecting the operation of
these switches. Switches should be immune from radio interference, or the use of
transmitters, such as cell phones, should be forbidden in the same area.
There are European standards available or becoming available for immunity from
radio frequency interference, and for the use of non-contact safety switches.
For use in safety applications, proximity switches require a coded target for actuation and should be monitored by a control module to check whether they are still
operable at each switching cycle and responding only to wanted signals. If the
switch or switches no longer operate, or respond to interference, the module
should shut down the machine until repairs are done.
A proximity switch used without monitoring its operation would not be
adequately safe for interlocking a guard enclosing a hazard. Failure can be either
open or closed.
2.7.1 Inductive proximity switches
Inductive proximity switches contain an internal oscillator with an amplitude
which reduces in the presence of metal.

ELECTRICAL INTERLOCKING GUIDANCE NOTES 19

Coil

Oscillator

Securing nuts

Amplifier

Relay and
contacts
Cable entry

INDUCTIVE PROXIMITY SWITCH

Metal
target

Coil

Oscillator

Amplifier

Relay and
contacts

Oscillation reduces in the presence of a metal target. Relay contacts change over.

Fig. 18 Operation of an inductive proximity switch

When the change in amplitude is big enough, the switch contacts change over.
There is not usually a restriction on the metal of the target, however, so any piece
of metal which is large enough and close enough will change over the switch
contacts.
Although the diagram shows contacts at the output of the device, the output device
will most likely be a semiconductor or solid state switch without moving parts.
2.7.2 Capacitive proximity switches
A resistor and a capacitor form a resonant circuit where oscillation occurs. When
the value of the capacitor is reduced, by removal of the actuating target, oscillation
ceases. Oscillation, or lack of it, is detected by a circuit within the switch which
will change over the switch contacts. Actuation distance may be changed by
adjustment of a sensitivity control.

Target Resonant Oscillator

Amplifier
Securing nuts
circuit
CAPACITIVE PROXIMITY SWITCH

Resonant Oscillator
circuit

Amplifier

Relay and
contacts

Relay and
contacts

Oscillation reduces in the presence of a metal target. Relay contacts change over.

Fig. 19 Operation of a capacitive proximity switch

20 ELECTRICAL INTERLOCKING GUIDANCE NOTES

Cable entry

The sensor responds to a variety of solids and liquids such as water, foodstuffs,
glass, wood, metal, paper, and plastic. In a humid atmosphere, a film of water
remaining on the active surface may cause the switch to remain actuated. A
change in humidity may cause unwanted operation of the switch.
Although the diagram shows contacts at the output of the device, the output device
will most likely be a semiconductor or solid state switch without moving parts.
2.7.3 Restricting access of the target
In Fig. 20, the target is embedded in a material of different magnetic permeability
or of different capacitive permittivity. Combinations of material can be obtained
from switch vendors but nylon or other machineable polymer is probably suitable
for a cam, with metal or ferrite for the target. Some caution will be necessary to
ensure that consistent results are obtained if the humidity of the area around the
installation is likely to change.
Hin
ged
gua
rd

Cam

Switch
Target

ard
Fixed gu

Fig. 20 Securing proximity switch with cam

With any proximity device it is essential to test the actual switch in the design
location, because sensitivity, freedom from false triggering and other aspects of
performance vary widely between manufacturers and models of switch.

2.8 Optical detection systems

Optical systems require a transmitter and a receiver. Photoelectric sensors interlocked with machine control systems have particular application for the protection
of personnel where mechanical guards are impractical or severely impede access
to the machine.
A light source transmits light. The receiver detects light from the source, and
controls relay contacts. Light from the source is reflected back into the receiver, or
shines directly to through beam sensors, with a change in the strength of received
light changing position of relay contacts controlled by the sensor. Infra-red
detectors are receivers only of light.
2.8.1 Infra-red light detection
A change in infra-red light, or radiant heat, should be detected as a person moves
in front of an infrared light sensor.

ELECTRICAL INTERLOCKING GUIDANCE NOTES 21

They also detect other sources of heat, such as central heating, and the area under
surveillance is not easily defined. Operation is too unpredictable for safety
applications.

Source

Infra-red

Receiver

Fig. 21 Infra-red detection

2.8.2 Retroreflective sensor
Light is reflected from a retroreflector into the light receiver. Interruption of the
light beam results in a change of position of relay contacts controlled by the
receiver. In a safety system configuration, transmitter and receiver are housed
together, with the receiver monitoring light reflected from a mirror. A
retroreflective sensor will detect objects which are not themselves reflectors, by
detecting an absence of reflected light.

Modulated infra-red

Transmitter infra-red

Reflector

Fig. 22 Retroreflective sensor

2.8.3 Specular sensor
Usually for a shorter range than the retroreflective type sensor, specular-type
sensors require a sufficiently reflective target, preferably bright or shiny, to reflect
light back into the receiver. Operation is too unpredictable for safety applications.

22 ELECTRICAL INTERLOCKING GUIDANCE NOTES

Modulated infra-red

Transmitter )top) and receiver

Reflective target

Fig. 23 Specular light sensor

2.8.4 Through beam sensor
Generally of longer range than retroreflective or specular sensors, through-beam
sensors are found in production and in safety applications. Objects must be large
enough to adequately block light from reaching the receiver. Information concerning the range and detection capabilities of optical systems will be available from
vendors.
Light source and light receiver are usually housed separately. Throughbeam sensors for safety systems should meet a test of high performance, such as BS 6491:
Electro-sensitive safety systems for industrial machines.
Only through-beam sensors or certified retroreflective sensors are recommended
for protecting personnel near industrial machines.

Transmitter

Receiver

Fig. 24 Through-beam sensor

2.9 Actuator-operated switches

When switches are used to detect the presence of a cover, the cover may include a
key to close a switch, only when the cover is on. The key is an actuator with an
unusual shape which will open the switch as it is withdrawn. An unusual shape for
the key is essential for the security of this system. The key actuator may work by
turning a cam as it is withdrawn, or it may be a magnet of unusual shape.

ELECTRICAL INTERLOCKING GUIDANCE NOTES 23

MOBREY MAGNETIC SAFETY SWITCH

Rivets

Actuating
assembly
T-shaped
magnet
Bar magnet

Rivets

Pivot

Switch
contacts

Pivoting
assembly

Terminals

T-shaped
magnet

Mounting
holes

Cable entry

Fig. 25 Mobrey safety interlock switch with magnetic actuator

Actuator-operated switches are useful where a guard or cover must be removed
from a machine completely to allow cleaning or adjustment.

Actuator

Key entry

INTERLOCK SWITCH

Fig. 26 The unusual key operates a rotary cam inside each of the openings. Each
cam operates switch contacts.

24 ELECTRICAL INTERLOCKING GUIDANCE NOTES

3. TRAPPED KEY INTERLOCK

Access to hazardous areas requires the use of a key. The access key is only available from a retaining clamp when defined conditions have been met. Commonly,
the access sequence is that the trapped key turns off an electrical supply to a
hazard, the key is withdrawn, then the key is used to unlock a mechanical guard.

Power control

Key

BASIC KEY EXCHANGE SYSTEM

The key can only be withdrawn from
the power control in the off position,
or withdrawn from the guard when it
is locked closed.

Fig. 27 Simple key exchange

Start up requires operations to be reversed. Until the guard is closed, and the bolt
home, the key cannot be released to turn on power. When machines are big
enough to have multiple opening guards, the key controlling electrical supply can
be secured in a key exchange unit while the other keys are held in multiple guards.
When machine parts continue to move after power is turned off, motionsensing or
time delay can be added to secure guards until machinery stops.
Trapped key systems are usually made for rugged environments where high security is needed, but where cam-operated limit switches would fail early around
wool processing machinery, for example.
Keys are usually too big to fit conveniently in a pocket, so are likely to stay with
the machine.

ELECTRICAL INTERLOCKING GUIDANCE NOTES 25

C
Power control

C
Guard

C
C

A
B

C
Guard

KEY EXCHANGE SYSTEM WITH

TIME DELAY
Key A can only be withdrawn from the
power control in the off position.

C
Guard

Key B can only be withdrawn from the time

delay when the run down period is ended.
Key C can only be freed from the key
exchange unit after the insertion of Key B.
Keys C are the only keys which open the
guard.
Keys C can only be freed from the guards
when they are closed.

C
Guard

Machine

Fig. 28 Key exchange with time delay

4. LOCKOUT
4.1 Lockout procedures
When access to machinery requires shut down, that is opening of power sources
for maintenance or tool changes, there may be periods while service personnel are
out of sight of other people in the plant. Any of the others may have some reason
for turning on the machine. The result may be mutilation or death for the person
performing service.
Strict lockout procedures need to be formulated and enforced by owners of machinery. All staff need to be aware of lockout procedures. Wherever possible,
power connections should be designed so that plugs can be disconnected or fuses
removed.
Lockout or tagout places control in the hands of the person doing the service. No
other person shall be able to restart machinery while the maintenance person is at
work on it. Every person who performs maintenance should have a named lock
and key. A locking tag and methods of fitting should be available for every
machine.
26 ELECTRICAL INTERLOCKING GUIDANCE NOTES

Isolators appear to have opened circuits when the handle turns. An unpleasant, and
maybe fatal, surprise awaits staff if the handle turns without opening contacts.
Isolators shall have indicators to show the position of the moving contacts. If the
handle is an indicator, it cannot indicate the open position unless the moving
contacts are in the open position. The indicator shall not indicate OFF unless the
contacts open. The fault is obvious and appropriate precautions must be taken.
A necessary addition to electrical lockout is reducing energy in the machine to
zero from all sources. Thus, electrical lockout must include locking off power to
prime movers, not only control circuits. This includes, for a.c. motors, locking off
all three phases. Shut down shall include sensors and machine parts controlled by
them, so all potentially moving parts in the section have zero energy and cannot
move unexpectedly.

Fig. 29 Lock off safety clasp for six locks

Where the isolation point for machinery is distant in a large and complex operation, a written isolation procedure protocol is required. The isolation of
fully-automated machinery can be very difficult, because often power must remain
on the control system, which could prevent the main supply to a motor control
centre from being disconnected. In this case, a written protocol for equipment
isolation would be required. Writing and enforcing the protocol would be the
responsibility of the company management. Appropriate wording would be:
Senior management enforces strict and severe penalties for not following
lockout procedures and applies the rules to everybody in the company.
Contractors on this site are bound by the same conditions.
With zero energy where electromagnetic brakes are fitted, there shall be a procedure to prevent movement of any part of the machine where the brake force is
removed.
Fuse removal to open circuits without locking off controllers has the disadvantage
that fuses are easily replaced components with the ability to liven circuits. Fuse
removal to open circuits without locking off controllers effectively removes
control from the service personnel working on the machine.
Means shall be provided to remove hydraulic or pneumatic pressure which may
cause an accident if it can cause movement. Hydraulic or pneumatic lockout
includes relieving pressure to tank or to atmosphere.
Means shall be provided to secure machine parts of significant weight, and loads
within the machine. Raised weights, such as platens, must be chocked if they
cannot be lowered.
When the machine is in the zero energy state it can be worked on.

ELECTRICAL INTERLOCKING GUIDANCE NOTES 27

Every person who works on or in the machine adds a lock to the tagout, and
pockets the key.
The advantage of named locks is that owners of securing locks are easily
identified as maintenance is completed.

4.2 Power failure release

Should power failure to the machine occur, a potentially dangerous situation arises
when power is restored if the machine automatically restarts. The potentially
dangerous situation would be most obvious if a circular saw started unexpectedly.
The Electricity Regulations 1993 require the fitting of switches which open when
power supply ceases.
A power failure release device incorporated into the mains circuit shall be fitted to
all machinery where unexpected starts would cause a hazard. The device will
prohibit latching of the mains circuit if mains power is not present, and delatch the
mains circuit if power fails during operation. The device will not indicate the
ON position while power is not present.

5. BRAKING ELECTRIC MOTORS

5.1 Mechanical braking
Mechanical braking uses a friction device, such as pads, in contact with discs or
brake shoes expanding against brake drums. The usual arrangement is that the
brake is held off by the application of power from the motor circuit. When the
motor power turns off, the brake is applied and the motor stops by the application
of the brake. Brake force is usually applied by the retraction of springs.

5.2 Electrical braking

Electrical braking either changes the electric field of the motor to stop motion, or
dissipates the rotational energy of the motor in a load which is specially connected
for the purpose.

5.3 Electrical plugging

Electrical plugging for three-phase motors consists of swapping two leads. Plugging is reversing the supply connections to the motor while it is running in the first
direction, in order to obtain its rotation in the other direction. This applies reverse
torque to the motor which stops rotation with, however, a large temperature rise.
The rotation of the motor shaft must be sensed to ensure that current is disconnected when rotation stops. If reverse power is applied continuously, the motor
will start to turn in the opposite direction. Usually a direct-on-line reversing starter
is used for this duty. Squirrel cage motors are used for plugging, and also starting
and inching.

28 ELECTRICAL INTERLOCKING GUIDANCE NOTES

5.4 Direct current injection

Direct current injection consists of disconnecting power from the stator winding,
and connecting d.c. to set up a~stationary field. The braking effect is small at high
motor speeds unless high currents are applied. Direct current is disconnected after
a time delay, but reversal of the motor cannot take place.
Direct current shunt motors may be used for starting, plugging and inching, and
for dynamic braking. Series motors may be used for the same purposes.

5.5 Capacitor braking

Capacitor braking connects capacitors across the motor terminals when the power
supply to an induction motor is opened. The capacitors force the motor to run as
an induction generator, with its power dissipating into the capacitors. The motor
terminals are then short-circuited and magnetic braking occurs. Capacitor braking
followed by simultaneous magnetic and direct current injection braking may be
applied when load inertia is very high.

6. PROGRAMME ELECTRONIC SYSTEMS

Programmable electronic systems provide automation for industrial processes to
enable machinery to perform repetitive tasks with more consistency and sometimes in more dangerous conditions than a human operator
A design document should be available for any programmable electronically
controlled, automated industrial process or machine. It should clearly describe the
operating environment, features designed and tested for the operating
environment, circuit design features, and programme design.
The operating environment may include the presence of hazardous atmospheres,
potential rises in signals earths, vibration where the controller or some of its
modules are to be mounted, dust, corrosive atmospheres, extremes of temperature
and extremes of humidity. Possibly harmful features should be listed to enable
assessment, and then removal, isolation, or minimisation of their effects to occur
during design and installation, and where adverse effects remain present, to allow
for their presence by programmed maintenance or other monitoring during the life
of the installation.

6.1 Interference
There are several sources of interference with programme operation which may
cause unexpected operation.
Signals from a radio frequency transmitter may interfere with programme operation so that parameters such as distance or load are read wrongly. In these circumstances, operation of a lifting machine where load and distance are monitored
continuously could vary from the designers intention, possibly causing a hazard
to the operator and other people nearby.
Electrical interference in a circuit may raise signal levels higher than wanted, so
injecting spurious signals into logic. When electrical interference breaks through
into voltage supply lines, momentary rises in voltage can exceed maximum
component ratings, causing failure of integrated circuits and other components.
ELECTRICAL INTERLOCKING GUIDANCE NOTES 29

There are various options for defeating mains-borne interference, for example,
applying suppression at source, or supplying the controller from a different power
supply from the circuit in which the signals arise, or fitting an interference filter at
the mains input of the programmable logic controller.
Users should be aware of sources of radiated and electrical interference and ensure
that equipment vendors are also aware of conditions at the installation at the time
of placing orders. There should be a list of potential sources of energy which may
interfere with control systems. Sources may include electric fields around lift
motor cables, energy radiated from welding machines, energy reaching the mains
from semiconductor switching devices, radiant energy from electromagnetic
heating systems, energy radiated by control and communication transmitters.
Design documents should list interference sources, and measurements, and assessments of whether the interference is likely to be significant.
Users should also be aware of features of the New Zealand electricity supply
system such as frequency variation, the presence of harmonics, and the use of
audio frequencies for signalling. Vendors should be able to assess how their
equipment will perform in adverse conditions and advise on fitting control measures such as mains filters or radio frequency shielding.
Static electricity, which may be generated as easily as walking across synthetic
floor coverings, may be discharged into electronic circuits, causing semiconductor
components to break down partially. Failure may then occur at some later time,
perhaps after a series of intermittent faults.

6.2 Software
Programmes can allow dangerous operation in unexpected ways, due to the assumptions on which they are written. For example, if low levels of hydraulic fluid
in a machine call an instruction to hold controls at their present state, the machine
may continue to run even if a guard is opened.
The hold controls instruction has priority over the result of guard open, which
would normally be a stop instruction, perhaps because the programmer did not
anticipate that the machine could run low on hydraulic fluid during operation.
There are two ways of improving safety when a machine is under programme
control. The first is to wire the safety precautions in the traditional way, that is
with limit switches at the guards wired to the control circuits of prime movers.
Wiring of safety interlocks for emergency stops and other critical safeguards
should be in a circuit outside the computer or programmable logic controller. The
limit switches can be two-pole types with contacts to switch the control circuits,
and a second contact set for signalling purposes. Signal contacts can be used for
connection to the computer or programmable logic controller. Programmable logic
controller operation follows operation of the safety circuit. Hard-wired safety
circuits should be the method used with one-off controller systems.
In the second and more expensive system, independent programmers prepare code
for two different controllers. This method is used for largescale automated process
control, or for mass-produced machines, such as press brakes sold with dedicated
controllers.
Outputs are continuously compared while the machine operates. The comparator
circuit shuts down the machine if it detects a difference between the outputs of the
30 ELECTRICAL INTERLOCKING GUIDANCE NOTES

programmable logic controllers. The comparator circuit is a watchdog, and can

detect software differences (that is differences in programme outputs), and differences in hardware outputs. Thus, failures affecting only one programmable logic
controller can cause the machine to stop. The advantage of using different computers is that common mode failure, that is when the same fault affects both
computers together to generate identical but faulty outputs, has a reduced
probability of occurring.
The watchdog will not necessarily distinguish between a hardware and a software
fault, but can stop machinery when it detects a discrepancy.
Control systems should shut down without failure to danger when supply power is
lost or goes below safe limits; the operating system memory or user programme
memory is corrupted; the operating system responds incorrectly.

7. INTERLOCKING APPROPRIATE TO THE HAZARD

Fig. 30 shows a graphical assessment of the degree of hazard presented by machinery to users. It is based on Appendix B of AS 4024.1 (Int) - 1992 Safeguarding of machinery, Part 1: General Principles. Using this method requires knowledge which will be added to with experience. There will be some degree of subjectivity in using the method, but describing the hazard has the advantage of
concentrating the minds of those assessing hazards of machinery.
Scale A
Fatal

Scale C
Assess
ment 3

Inevitable

Amputation
of a limb

Probable

R
Amputation of
a hand or foot

Scale B

ent 1
essm
s
s
A
Ass
essm
ent 2
Amputation of
a finger or toe

Potential severity
of injury

Possible

1 30 10

days days day hr min min min or less

Remotely
possible
Potential severity
of injury

Fig. 30 Selection of an interlocking system based on AS 4024 (Int) 1992

ELECTRICAL INTERLOCKING GUIDANCE NOTES 31

In this way the experience of machinery users, who have suffered from too easy
access, can be applied in the-design of interlocking systems. This design method
requires an assessment of the hazard at the opening to potentially dangerous parts
of the machine, assuming that the interlock has failed.
There are three factors to measure, which are:
(a) Severity;
(b) Frequency; and
(c) Probability.
Measurement of potential severity requires a knowledge of the accident record for
similar machinery and the fate of those who were caught in it. The assessor will
have to observe the operation of the machinery and decide on its likelihood of
piercing, crushing, shearing, or amputating anyone with the misfortune to get
caught. Generally, if it looks potentially injurious, someone has probably been
caught in a similar mechanism and was hurt or killed.
Frequency of approach is measurable in terms of duties.
(a) Does product have to be lifted from the mould by hand every time the
platen opens?
(b) When does the attendant free the line if a bottle jams under the filling
head?
(c) How many times an hour does the stacking robot drop product which the
attendant is supposed to clear?
It is almost guaranteed that if people can clean a machine without turning it off, or
reach through moving parts to a grease nipple, or follow blindly when a supervisor
teaches poor work habits, they will do so. Probability is less a matter of measuring
what is sensible, and more a matter of imagining the worst case of an operator
hurrying to fill an order and clean up before the end of the shift. Probability is not
simply a matter of imagining that only the interlock fails, but also of assessing
what people who work with machinery, with perhaps a limited understanding of
what it does and how it works and of the meaning of terms like force and
power, are likely to do when a fault appears in addition to failure of the
interlock.
An example of interlocking selection is given in Fig. 30, where the loss of a finger
or toe is probable if the interlock fails. Probability is the likelihood of injury
occurring, and is the area where there is most likely to be disagreement.
There is an expectation that people working with machinery will be always objective and unhurried, and careful, but even these paragons have lapses. As the
operator is required to approach the hazard once per hour, Type R guard operated
power interlocking is appropriate for the initial assessment. Other considerations,
such as experience of users, or technical considerations including the supply of
adequately rated safety interlock switches, may result in sorde adjustment of the
rating. (Assessment 1.)
Two other examples should help to demonstrate use of the system, which assumes
continued use of the machine after the interlock fails.
In the second case, the amputation of a hand at a chain transmission is remotely
possible, with a frequency of approach less than once per five days. Type P interlocking is therefore the first choice. (Assessment 2.)
32 ELECTRICAL INTERLOCKING GUIDANCE NOTES

Power
source

Guard door
TYPE P
Single control
system
interlocking

Machine
contactor

Safety interlock switch

Power
source

Guard door
TYPE Q
Duel control
system
interlocking
without cross
monitoring

Machine
contactors

Safety interlock switches

Channel 1
Channel 2

Fig. 31 Safety interlock switch arrangements Types P, Q interlocking

In the third case, at an injection moulding machine, should the press platen close
while the operator is between the press platen and the fixed part of the mould
removing product, fatal injuries are probable.
Frequency of approach is once per 10 minutes. Interlocking system selection from
Fig. 30 shows that type S is appropriate, that is with guard locking interlocking or
dual control system interlocking with cross monitoring. This level of safety is
illustrated in Fig. 32 (Assessment 3).
Adoption of a systematic approach to hazards of interlocking failure will only
have a value if records are kept in a way in which information can be readily
brought up to date.

ELECTRICAL INTERLOCKING GUIDANCE NOTES 33

Guard door

Power
source

TYPE R
Guard operated
power
interlocking
Safety interlock switch

Guard door
TYPE S
Guard locking
interlocking

Power
source
Machine
contactor

Safety interlock switch

TYPE S
Duel control
system
interlocking
with cross
monitoring

Guard door

Power
source
Monitored
contactors

Safety interlock switches

Channel 1
Channel 2
Cross monitoring circuit

Fig. 32 Safety interlock switch arrangements Types R, S interlocking

34 ELECTRICAL INTERLOCKING GUIDANCE NOTES

REFERENCES AND ACKNOWLEDGEMENTS

Alger, Philip L. Induction Machines. Gordon and Breach Scientific
Publishers Inc. 440 Park Avenue South, New York, 1951.
AS 1939: 1986 Classification of degrees of protection provided by
enclosures for electrical equipment.
AS 3858: 1990 Low voltage switchpear and controlgear Circuit breakers.
Constructional and performance requirements.
AS 4024.1(Int) 1992 Safeguarding of machinery: Part 1 General Principles.
BS 6491 Electro-sensitive Safety Systems for Industrial Machines.
Coker, A. J., revised by Philip Chapman. Electric Motors Questions and
Answers. Second edition. Butterworth and Co (Publishers) Ltd, 1976.
Connor, R A W. Fuses for the protection of electronic equipment. The
construction, characteristics and design considerations of fuses. Wireless
World. January, 1978.
Electricity Act 1992.
Electricity Regulations 1993.
Health and Safety in Employment Act 1992.
IEC 127-2: 1989 Miniature fuses. Part 2: Cartridge fuse links.
IEC 801 Electromagnetic compatibility for industrial process measurement and
control equipment.
IEC 947 Low Voltage Switchpear and Controlgear.
Kraus and Naimer (NZ) Limited. An Explanation of IEC 947 in Respect to Main
and Emergency Switches, Maintenance Switches and Switch Disconnectors.
Mobrey Magnetic Safety Switch. Ronald Trist and Co. Ltd. Bath Road, Slough,
Bucks, England.
Omron Electronics Pty Ltd. Omron Catalogue. 2nd edition. Cat No. X0 E5-2.
Rapp, Frank J. and Brooks, Barrie E. Machinery Lockout Procedures.
International Union UAW, 1989.
SafeBook Machine Guard Interlocking Theory and Practice. Guardmaster Ltd,
1992.
Schmersal Safety Switches Series AZ 15 and AZ 16. K. A. Schmersal GmbH and
Co, 1987.
Schmersal Proximity Switches. K A Schmersal GmbH and Co, 1986.
Specifiers Guide for Limit and Enclosed Switches. Micro Switch a Honeywell
Division. Catalog 40, Issue 12, October 1991.
Wall, T.F. Three-phase motors theory and operation. Newnes, 1952.
Wray, Tony. The everyday risks of playing safe. New Scientist, 8 September 1988,
pp 61-65.

ELECTRICAL INTERLOCKING GUIDANCE NOTES 35

GLOSSARY
Actuator: Part of a switch which is moved by an outside force.
Alternating current: Electric current which, over time, varies regularly
in amplitude and sign.
Ampere: One ampere is that constant current which, if present in each of two
parallel conductors of infinite length and one metre apart in empty space,
causes each conductor to experience a force of 2 x 10-7 newtons per metre of
length.
Amplitude: Size or quantity.
Atmosphere: Air and its contents. Pneumatic systems exhaust to atmosphere.
Average value: Equivalent value of steady direct current which will heat a
resistor. The amplitude of d.c. may change, for example following rectification
of a.c., but the sign will always be the same.
Belt conveyor: Moving continuous flexible carrier of goods.
Breaking: Opening an electric circuit.
Capacitor: Device for storing electric charge on metal plates separated by an
insulating medium.
Chocked: Secured from movement by mechanical stops.
Closing: Completing the current path of an electric circuit.
Coil: Insulated wire wound about a former to carry current and produce an electric
field.
Contactor: Device which closes one or more electric circuits.
Contacts: Parts of a switch which open and close to control the flow of current.
Current: Flow of energy through an electrical conductor.
Direct current: Current which flows in only one direction.
Direct-on-line: Switching the supply directly on to the motor. There may be an
upper power limit specified for motors which may be started this way.
Electric: Charged with electricity.
Electrical: Powered by electricity.
Electricity: Phenomena caused by electric charge, which causes bodies carrying
like charges to repel each other, while bodies carrying opposite charges attract
each other. Electric charge is caused by an excess of electrons for negative
charge, or a deficit of electrons for positive charge.
Electronic: Circuit where small amounts of current are used to control much
larger currents.
Energy: Work done when the point of application of a force moves.
Extra low voltage: Any voltage normally exceeding 32 volts a.c. or 115 volts d.c.
Fast blow fuse: Usually a cartridge fuse which operates at 1.2 times the nominal
current.
Ferrite: Ceramic magnetic oxides which have magnetic properties. They are
insulators.
36 ELECTRICAL INTERLOCKING GUIDANCE NOTES

Hazard: An activity, arrangement, circumstance, event, occurrence, phenomenon,

process, situation, or substance (whether arising or caused within or outside a
place of work) that is an actual or potential cause or source of harm.
Humid: Damp.
Hydraulic: Using oil under pressure as a means of doing work.
Inching: Predetermined movement of machinery for each actuation of a control.
Inductive: Causing magnetic flux by passage of current through a conductor.
Infrared: Heat radiation within the range 400 nm to 4000 nm. nm = nanometres
= 10-9 metres
Ingress: Entrance to an enclosed space.
Input of an electric circuit: The part of a circuit which receives a control signal.
It may include filters to restrict amplitude and frequency of the signals
received.
Integrity: Design for predictable operation.
Interlocking: Means of restricting operation of machinery by control circuits.
International Protection (JP) ratings: Degree of protection provided by
enclosures for electrical equipment. AS 1939-1986 provides a statement for use
in New Zealand.
Limit switch: Switch which detects the limit of movement.
Livened: Connected to a source of electric current.
Logic: System of determining output signals from combinations of input signals.
Machineable polymer: Substance made from long chain molecules which can
have its shape altered by turning or tapping.
Magnetic permeability: Property of a substance which determines how easily it
will form a magnetic flux.
Milliamperes: Thousandths of amperes. 1 mA = 10-3 A
Monitoring: Verification of the operation of a circuit. When operation is different
from that expected, protective measures are switched into operation.
Normally closed: Switch contacts which are closed when the switch actuator is
under no pressure.
Normally open: Switch contacts which are open when the switch actuator is
under no pressure.
Nylon: Long chain polymer.
Oscillator Circuit which produces a signal regularly varying in amplitude over
time.
Oxidation: Formation of an insulating layer of metallic oxide.
Permeability: Property of a substance which determines how easily it will form a
magnetic flux.
Permittivity: Value of the insulating medium between plates of a capacitor in
determining quantity of charge held.
Pitot head: Means of reading air velocity by sensing pressure differences.
Platen: Part of a press which moves under pressure to form a product.
ELECTRICAL INTERLOCKING GUIDANCE NOTES 37

Plunger: Switch part which moves when the actuator causes it to.
Pneumatic: Using air under pressure as a means of doing work.
Power: Rate at which work is done or electrical energy is converted into work.
Pressure: Force per unit area.
Prime movers: An engine, motor, or other appliance which provides mechanical
energy derived from steam, water, wind, gas, gaseous products, compressed air,
the combustion of fuel, or any other source.
Programmable logic controller: An electronic device which continuously
accepts inputs from field devices and sensors and controls outputs, in
accordance with an internal programme. Device which accepts a series of
programming steps to perform logical functions.
Pull cord: Cord which operates a latching switch to stop motion.
Reflective target: Object which reflects sufficient light to allow a receiver to
determine whether a target is present or absent.
Resistor: Circuit element which dissipates heat.
Resonant: Oscillation at a specific frequency.
Retroreflector: Reflector using glass or plastic prisms to return light to a receiver
Slow blow fuse: Fuse which allows current flow in excess of the nominal value to
continue. As much as 10 times the nominal value for a few milliseconds.
Solenoid: Electric coil whose flux causes movement of a ferromagnetic core.
Specular: Reflective, especially from a metal surface.
Spurious: Unwanted and likely to cause unwanted operation.
Squirrel cage: Rotor named for its shape.
Starting: Means of connecting an electric motor to a circuit. Considerations are:
starting current; starting torque; inertia of rotor; control electronics required;
possibility of braking.
Stiction: Force holding electric contacts together.
Surveillance: Review of operation of machinery.
Switch: Device by which a small amount of force, which may be mechanical or
electrical, is used to allow the flow of a much larger force, for example, electric
current, into a circuit.
Tank: Receiver for hydraulic oil.
Temperature: Measure of the hotness or coldness of a body.
Torque: Force tending to rotate the body on which it acts.
Velocity sensor: Device which senses speed of an object or fluid.
Voltage: Potential difference between two points in a circuit.
Welded: Connection of two solids by the liquefaction, followed by solidification
of material which joins them.

38 ELECTRICAL INTERLOCKING GUIDANCE NOTES