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Independent safety zones for conveyor lines

ISD chains of e-stops and rope pulls, with a separate safety input per line
August 11, 2026 by
Ričards Sleņģis
safety zones for conveyor lines
On long conveyor lines the e-stops usually sit in one shared circuit. Press one button and everything stops, and nobody can see which button did it. The RSio block splits the lines into separate zones and reports the status of each device individually.

32

Devices per chain

6

Independent zones per block
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Solution

Each line on its own safety input

Independent safety zones for long conveyor lines, with an ISD chain on each safety input.

Each line on its own input

The e-stops and rope pull of the first line form an ISD chain on one RSio safety input. The second line goes to another input. Each input is its own safety zone.

Devices without ISD join through ISD Connect

The rope pull has no ISD support. The SSA-ISD-TCA T-adapter converts its two NC contacts into an ISD signal, and the switch joins the chain like any other device.

A stop travels two paths

The first line's final switching device sits directly on an RSio safety output - the block stops the line itself. For the second line RSio reports the status to the safety controller over the CIP Safety connection, and the controller stops its own device.

Diagnostics names the device

The ISD protocol runs over the same wiring as the OSSD signals, so every device in the chain stays individually visible. The control system names the button, and the column light shows the state of the zone from a distance.
RSio · Konveijeru zona
Running both lines
SI 1 1. līnija · trošu slēdzis + 3 avārijas pogas OK
SI 2 2. līnija · 4 avārijas pogas OK
SO 1 1. līnijas gala pārslēgšanas ierīce On
CIP 2. līnija · pa drošības kontrolieri On
Ieejas6 Ierīces ķēdēlīdz 32 Izejas2 × 1 A Izejas reakcija5 ms
Statuss: normāls

Paātrināta demonstrācija - reālā sistēmā ierīču statuss ir redzams nepārtraukti vadības sistēmā.

safety zones for conveyor lines

What it changes in daily life

One zone stops, and the device is named

One line stops, not the whole area
Each safety input works on its own. When the first line's chain trips, the second line keeps running.

The device is named, not hunted for
ISD carries a status for every device in the chain, so the control system shows which button or switch opened it.

Less cabling along the line
Chains are built from M12 T-connectors and ready-made cordsets. One input can carry up to 32 devices instead of 32 separate cables back to the cabinet.

The block sits at the line
The IP67 housing of 262 x 74 mm is made for machine mounting. Power and data run over M12 connections, and only the controller takes up cabinet space.

Questions and answers

Frequently asked questions

No. Devices without ISD are brought in through the SSA-ISD-TCA adapter if they have two NC contacts. An input can also carry a single conventional safety device with no chain at all.

RSio works in a CIP Safety system over EtherNet/IP and is configured in Rockwell Automation Studio 5000 using the Banner EDS file. No additional software is needed.

One input carries up to 32 ISD devices, and one block up to 192. The actual reach depends on the cordset lengths between T-connectors, chosen to suit the line layout.
Yes. The housing is IP65 and IP67, rated -25 to +70 °C, and made for machine mounting indoors. Model RSIO-L5-6SI2SO-C uses M12 L-code power and passes through up to 16 A.

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