Remotely actuated, circuit testing emergency stop apparatus and method

1. An Emergency Stop (E-stop) Switch, comprising:

a. a first relay governing a first control circuit in the E-stop switch; and

b. a second relay governing a second control circuit in the E-stop switch;

wherein transferring energization from the first control circuit to the second control circuit, and vice-versa, allows testing of the deenergized first and second relays and control circuits while:

maintaining electrical operation of equipment served by the E-stop switch; and

maintaining manual actuation capability of the E-stop switch to open the first and the second control circuits, resulting in shut down of the equipment served by the E-stop switch.

2. The E-stop switch of claim 1 , further allowing testing, in a deenergized state, of all equipment power source control contactors associated with emergency stop capability of the equipment for a failed switch, a fused contact, an inadvertent power source, or a ground.

3. The E-stop switch of claim 1 , wherein each relay is any device capable of activating change in an electric circuit in response to a change affecting the device.

4. The E-stop switch of claim 1 , wherein each relay includes at least one coil and at least one associated contact.

5. The E-stop switch of claim 1 , wherein each relay includes at least one motor and at least one associated contact.

6. The E-stop switch of claim 1 , wherein transferring energization is governed by a Programmable Logic Controller (PLC).

7. The E-stop switch of claim 1 , wherein manual actuation of the E-stop switch separates a first contact, or first set of contacts, of each relay such a distance from a second contact, or second set of contacts, of the respective relay, that each relay is incapable of maintaining or achieving a closed, state to, thereby, maintain or allow electrical operation of the equipment served by the E-stop switch.

8. The E-stop switch of claim 1 , wherein manual actuation of the E-stop switch physically moves a coil and contactors within the E-stop switch such a distance that each relay is incapable of maintaining or achieving a closed state, resulting in shut down of the equipment served by the E-stop switch.

9. The E-stop switch of claim 1 , wherein all circuit devices controlling power to the equipment can be tested while maintaining electrical operation of the equipment served by the E-stop switch.

10. The E-stop switch of claim 1 , wherein manual actuation of the E-stop switch mechanically moves contactors of the first and the second relays, within the E-stop switch, such a distance that the contactors are incapable of maintaining or achieving a closed state, regardless of an energization state of any coils governing the contactors, resulting in shut down of the equipment served by the E-stop switch.

11. An Emergency Stop (E-stop) Switch, comprising:

a. a first relay governing a first control circuit in the E-stop switch; and

b. a second relay governing a second control circuit in the E-stop switch;

wherein:

one of the first or the second relay is closed to energize the respective control circuit, thereby maintaining electrical operation of equipment served by the E-stop switch;

the other of the first or the second relay is open to de-energize the respective control circuit, thereby allowing testing of the respective control circuit during uninterrupted electrical operation of the equipment served by the E-stop switch; and

manual actuation of the E-stop switch de-activates electrical operation of the equipment served by the E-stop switch by opening contacts included in each of the first and the second control circuits to open all equipment power source control contactors governing electrical operation of the equipment.

12. A method for testing an Emergency Stop (E-stop) Switch, comprising the steps of:

a. transferring energization from a first control circuit to a second control circuit to maintain electrical operation of equipment served by the E-stop switch before, during, and after the transfer;

b. testing the first control circuit;

c. transferring energization from the second control circuit to the first control circuit to maintain electrical operation of equipment served by the E-stop switch before, during, and after the transfer; and

d. testing the second control circuit, wherein all control circuitry and all equipment power source control contactors associated with emergency stop capability of the equipment is tested in a deenergized state during testing of the first and the second control circuits.

13. A method for testing control circuitry of electrically operated equipment served by an Emergency Stop (E-stop) switch, comprising the steps of:

a. transferring energization from a first control circuit to a second control circuit to maintain electrical operation of the equipment before, during, and after the transfer;

b. testing the control circuitry for a failed switch, a fused contact, an inadvertent power source, or a ground;

c. transferring energization from the second control circuit to the first control circuit to maintain electrical operation of the equipment before, during, and after the transfer; and

d. further testing the control circuitry for a failed switch, a fused contact, an inadvertent power source, or a ground, wherein manual actuation of the E-stop switch deactivates the equipment by opening contacts governed by the first and the second control circuits.

14. A computer-readable medium that configures a computer system to perform a method for testing an Emergency Stop (E-stop) Switch, the method comprising the steps of:

a. transferring energization from a first control circuit to a second control circuit to maintain electrical operation of equipment served by the E-stop switch before, during, and after the transfer;

b. testing the first control circuit;

c. transferring energization from the second control circuit to the first control circuit to maintain electrical operation of equipment served by the E-stop switch before, during, and after the transfer; and

d. testing the second control circuit, wherein all control circuitry and all equipment power source control contactors associated with emergency stop capability of the equipment is tested in a deenergized state during testing of the first and the second control circuits.

15. A computer-readable medium that configures a computer system to perform a method for testing control circuitry of electrically operated equipment served by an Emergency Stop (E-stop) switch, the method comprising the steps of:

a. transferring energization from a first control circuit to a second control circuit to maintain electrical operation of the equipment before, during, and after the transfer;

b. testing the control circuitry for a failed switch, a fused contact, an inadvertent power source, or a ground;

c. transferring energization from the second control circuit to the first control circuit to maintain electrical operation of the equipment before, during, and after the transfer; and

d. further testing the control circuitry for a failed switch, a fused contact, an inadvertent power source, or a ground, wherein manual actuation of the E-stop switch deactivates the equipment by opening contacts governed by the first and the second control circuits.

16. An Emergency Stop (E-stop) Switch, comprising:

a first control circuit including at least one coil controlling at least one set of contacts; and

a second control circuit including at least one coil controlling at least one set of contacts; wherein:

one of the first or the second control circuits is energized to maintain electrical operation of equipment served by the E-stop switch;

the other of the first or the second control circuits is de-energized, allowing testing of the respective control circuit during uninterrupted electrical operation of the equipment; and

manual actuation of the E-stop switch physically moves all of the coils and all of the sets of contacts such a distance that all of the sets of contacts are opened and incapable of maintaining or achieving a closed state, regardless of an energization state of any of the coils, resulting in shut down of the equipment served by the E-stop switch.

17. An Emergency Stop (E-stop) Switch, comprising a plurality of control circuits, each including at least one contactor, wherein:

energizing any one of the control circuits allows energization and operation of equipment served by the E-stop switch and testing of remaining, deenergized control circuits during operation of the equipment;

transferring energization between the plurality of control circuits allows continued energization and operation of the equipment and allows testing of all of the control circuits when placed in a deenergized state; and

manual actuation of the E-stop switch deenergizes all of the control circuits, resulting in shut down of the equipment.