Intro to Prosafe Trapped Key chave de segurança

Copyright © Rockwell Automation, Inc. All Rights Reserved.
Introdução para Prosafe Trapped
Key Systems
PEDRO HENRIQUE MELO • TECHNOLOGY CONSULTANT BRAZIL SAFETY • 08•21

Overview
• Trapped Key systems are utilized to force a specific sequence of events in
order to reduce risk
• In this module we will discuss:
– Application example
– Common terminology
– Trapped Key Interlocks – why do we use them
– Prosafe products
– Product coding

Application Example
• Machine has two gates that need to be accessed
– On occasion, both gates will need to be accessed at the same time
• One gate will allow full-body access
• One gate will only allow partial body access (reach in with hands)
• Power must be removed from the hazards prior to opening either gate

Application Example – Video

Common Terminology
• Trapped Key Interlock – also known as key transfer systems
• Primary Key
– Used to start a sequence
• Secondary Key
– Trapped at the start of a sequence, released after primary key is rotated
• Personnel key
– Secondary key to be released and carried by the
person into the hazard
Primary
Key
Secondary
Keys
Primary
Key
Primary
Key
Secondary/
Personnel
Key

Trapped Key Interlocks –
Why Do We Use Them?
• Sequential access, to follow a predetermined sequence of events
– Based on the premise that one key can not be in two places at the same time
– Each product is coded
– Optional personnel key available to ensure that a person entering a cell has control over the
sequence
• Power to products is not required (for mechanical units)
• Stainless steel solution, good for harsh environments
Solenoid Release Unit
Solenoid
Release Unit
3 Way Key
Exchange Unit
1 in 2 out
Bolt Lock
Single Key
Access Lock
Dual Key
Personnel Key
released from
Access lock

Prosafe Products
• Isolation Devices
– Rotary Switches
– Solenoid Release
– Bolt Lock
• Key Exchange Units (also called Key Control Element)
• Guarded Area Access Devices
– Access / Chain Locks
– Slam Locks
– Bolt Lock
• Specialty Devices
– Electronic Timed Delay Unit
– Stopped Motion Unit
– Mini Valve Locks
– Switchgear Adaptors

Isolation Devices
• Rotary Switches
– Used to isolate power. Once power is switched off the
previously trapped key is released for use in the next
step.
– Offered in Single, Dual, Triple and Quad key versions
• Solenoid Release Units
– Used on applications with rundown time controlled by
a PLC. Once safe conditions are reached the
indicator light indicates the key can be removed and
used in the next step of the sequence
– Offered in Single, Dual, Triple and Quad key versions

Key Exchange Unit
• Key Exchange Unit (Key Control Element)
– Used in an interlocking sequence to link together other devices in the Prosafe system
– One to three primary keys
• All must be present to release secondary key(s)
– Up to 24 secondary keys
• Primary key(s) trapped until ALL secondary keys
have been re-inserted, rotated, and trapped

Guarded Area Access Devices
• Guarded Area Access Devices
• Offered in Single, Dual, Triple and Quad key versions
• Available in Mechanical, Electrical, Solenoid versions
– Bolt Lock
• Bolt is extended into recess in a handle or control
element of a switching device and blocks it
• Also used in sliding doors where a recess is present
for the bolt to be extended into
• Note: Bolt lock should not be used on hinged doors
without another safety switch
– Access/Chain Lock
• Access Lock for Loose Fitting Doors
• Chain Lock for Extreme Misalignment of Door
– Slamlock
• Tongue actuator guard locks with trapped key control
Bolt extends in to the
recess blocking the
handle form turning

Bolt Locks
• Bolt Locks – Two primary uses:
– Used as Isolation device / Start Sequence device
• Bolt is extended into recess in a handle or control
element of a switching device and locks it position
• In “safe” position, key can be removed
– Used as Guarded Area Access device
• Only for sliding doors
• Bolt extends into a hole in the frame, locking sliding door
in safe position, then key can be removed
• Frame of door prevents the bolt from extending when the
sliding door is open
• Note: Bolt lock should not be used on hinged doors
without another safety switch
– Note that different versions of the bolt lock allow removing the
key based on the bolt being extended or retracted.
Bolt extends in to the
recess blocking the
handle from turning

Bolt Locks - Considerations
Hazard
• When using a Bolt Lock, care must be taken regarding the
mechanical considerations
• Example: Bolt Lock intended to hold sliding guard closed to
protect user from a hazard unless it is stopped
• What’s wrong with this implementation?
Bad – Bolt extended, key
removed, no protection
from hazard

Bolt Locks - Considerations
Hazard
Hazard
• System must be designed such that it mechanically prevents the bolt from extending when
the guard (or operating device) is NOT protecting a user from the hazard
• Proper implementation shown on the right
Bad – Bolt extended, key removed,
no protection from hazard
Good – When guard is open,
bolt cannot extend, therefore
key cannot be removed
Frame prevents bolt
from extending

Specialty Devices
• Specialty Devices
– Electronic Timed Delay Unit
• Timer output energizes internal solenoid, releasing key.
• Used in applications that required elapsed time before releasing key to allow
access to the hazard
– Stopped Motion Unit
• Stopped motion detection utilizing proximity sensors
• Detects when the hazardous motion has ceased before releasing the key to allow
access to the restricted area
– Mini Valve Locks
• Used to control the opening and closing of process valves in proper sequence
– Switchgear Adaptors
• Used to interlock preparatory switch gear applications
• Can be used to interlock host equipment such as spool valves

Hazard
Prosafe System
Key Free
Key Exchange Unit (2 in, 2 out)
Hazard
Isolation Valve
Bolt Lock
Solenoid
Release
Bolt
Lock
OFF
ON
Access Lock
Rotary Switch
Ca
Ca
Da
Da
Aa
Aa
Aa
Ba
Ba
Aa
Aa
Ba
Ba
Ca
Ca
Ea
Ea
Da
Da
Ea
Ea
Run
Safe
Blank
Blank

Product Coding
• The user must prevent codes from
being duplicated if multiple Prosafe
systems are used within the same
facility
• All codes have two letters when
ordered and are in capitals “AA”.
The actual units will have the first
letter capitalized and the second
letter lowercase, e.g. “Aa”
• Start the sequence with code Aa
and increment through the alphabet,
Ba, Ca, Da, etc. through Za, then
Ab, Bb, etc. through Zz.

Prosafe Builder – Software Simplification Tool
• Prosafe Builder – a software
tool to create a system BOM
– Part of the free ProposalWorks
suite
– Creates the product coding and
catalog numbers so that you
don’t have to

• Ejector key
– Some manufacturers find operators not taking
personnel key with them
– The Ejector Key promotes correct use of key by
the fact that is ejected from code barrel into
operator’s hand
– Ejection force is approximately 20 Newtons
• Replacement code barrels
– Used to replace damaged code barrel
– Easily replaceable with 2 specialty screws
Accessories

Lost, Broken Key, or Damaged Code Barrel?
• Emergency repair kit is the answer
– Kit includes 2 ER coded code barrels and key.
– Kits available ER1– ER9
• Simply replace the lost/broken “B” code barrel as well as the mating “B” code barrel in the
sequence with the ER1 coded barrels and your system is up and running
• Order replacement key or code barrel

Summary
• Trapped Key systems are utilized to force a specific sequence of events in
order to reduce risk
• You should now be able to:
– Explain why trapped key systems
are used
– Give an application example
– Define the common terminology
– Summarize the purpose of each type
of Prosafe product
– Understand the importance of codes
– Explain the purpose of Prosafe Builder
• Next you will complete a short knowledge check

Intro to Prosafe Trapped Key chave de segurança

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